Ricoh A109 User manual

SERVICE MANUAL
PN: RCSM5006
A109
RICOH GROUP COMPANIES

SERVICE MANUAL
A109
RICOH GROUP COMPANIES
®
®

A109
FIELD SERVICE
MANUAL
PN: RCFM5006

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Corporation and its member companies.
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PERMISSION OF RICOH CORPORATION.
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used in this document are trademarks, registered trademarks or the property of their
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the benefit of such companies. No such use, or the use of any trade name, or web
site is intended to convey endorsement or other affiliation with Ricoh products.
2000 RICOH Corporation. All rights reserved.

The Field Service Manual contains information
regarding service techniques, procedures, processes
and spare parts of office equipment distributed by
Ricoh Corporation. Users of this manual should be
either service trained or certified by successfully
completing a Ricoh Technical Training Program.
Untrained and uncertified users utilizing information
contained in this service manual to repair or modify
Ricoh equipment risk personal injury, damage to
property or loss of warranty protection.
RicohCorporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A109 - NC5006 SC106
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*4/94 Original Printing
1 7/94 Revised Pages
2 6/96 Reprint
3 9/98 Reprint

Table of Contents
1. SPECIFICATIONS
1. SPECIFICATIONS...............................................................1-1
2. COMPONENT LAYOUT & DESCRIPTIONS
1. MECHANICAL COMPONENT LAYOUT ...........................2-1
2. DRIVE LAYOUT .................................................................2-3
3. AIR FLOW ........................................................................... 2-5
4. ELECTRICAL COMPONENT DESCRIPTIONS ................. 2-6
3. INSTALLATION
1. INSTALLATION REQUIREMENTS ....................................3-1
1.1 ENVIRONMENT............................................................................3-1
1.2 MACHINE LEVEL .........................................................................3-1
1.3 MINIMUM SPACE REQUIREMENTS .........................................3-2
1.4 POWER REQUIREMENTS ..........................................................3-3
2. COPIER INSTALLATION....................................................3-4
2.1 ACCESSORY CHECK..................................................................3-4
2.1.1 Copier ........................................................................................................3-4
2.1.2 Optional Table............................................................................................3-4
2.2 COPIER SEPARATION ..............................................................3-5
2.3 COPIER INSTALLATION PROCEDURE .....................................3-6
2.4 PAPER SIZE CHANGE ..............................................................3-23
2.5 OPTIONAL HOLDER (A702) INSTALLATION ...........................3-25
2.6 KEY COUNTER INSTALLATION ..............................................3-27
2.7 UPPER AND LOWER HEATER
INSTALLATION (OPTIONS).......................................................3-28
4. SERVICE TABLES
1. SERVICE REMARKS.......................................................... 4-1
1.1 GENERAL CAUTION....................................................................4-1
FSM i A109

1.2 DRUM ...........................................................................................4-1
1.3 TRANSFER BELT UNIT ...............................................................4-2
1.4 SCANNER UNIT...........................................................................4-3
1.5 LASER UNIT.................................................................................4-3
1.6 CHARGE CORONA......................................................................4-4
1.7 DEVELOPMENT...........................................................................4-4
1.8 DRUM CLEANING........................................................................4-5
1.9 TRANSFER BELT CLEANING.....................................................4-6
1.10 FUSING UNIT.............................................................................4-6
1.11 PAPER FEED .............................................................................4-7
1.12 TRANSFER ROLLER UNIT........................................................4-7
1.13 FILTER........................................................................................4-7
1.14 USED TONER.............................................................................4-7
2. SERVICE PROGRAM MODE ............................................ 4-8
2.1 SERVICE PROGRAM MODE OPERATION ...............................4-8
2.1.1 Service Program Access Procedure..........................................................4-8
2.1.2 To Exit SP Mode........................................................................................4-8
2.1.3 To Return To The Index Menu...................................................................4-9
2.1.4 Change The Menu Screen.........................................................................4-9
2.1.5 Access to "Copy in SP Mode"....................................................................4-9
2.1.6 To Input Data...........................................................................................4-10
2.1.7 To Clear The Counter..............................................................................4-10
2.2 SERVICE PROGRAM MODE TABLE ........................................4-11
2.2.1 Sp Adjustment..........................................................................................4-11
2.2.2 SP Test Mode.........................................................................................4-17
2.2.3 SP Data Output........................................................................................4-21
2.2.4 Special Features......................................................................................4-23
2.2.5 Jam/SC Counter ......................................................................................4-29
2.2.6 Operation Counter ...................................................................................4-30
2.2.7 Counter Clear...........................................................................................4-32
A109 ii FSM

2.3 SENSOR/SWITCH/SIGNAL DATA CHECK
(INPUT MODE) ..........................................................................4-33
2.3.1 Input Check Mode Table .........................................................................4-34
2.4 ELECTRICAL COMPONENT CHECK
(OUTPUT MODE) ......................................................................4-36
2.4.1 Output Check Mode Table.......................................................................4-38
2.5 SP MODES AFTER REPLACEMENT
AND CLEANING.........................................................................4-41
2.6 MEMORY ALL CLEAR PROCEDURE .......................................4-42
3. USER TOOLS MENU........................................................4-43
3.1 USER TOOLS ACCESS PROCDURE 1 .................................4-43
3.2 USER TOOLS ACCESS PROCEDURE 2 .................................4-44
4. TEST POINTS / DIP SWITCHES / LED’S ........................4-45
4.1 MAIN CONTROL BOARD...........................................................4-45
4.1.1 Test Points...............................................................................................4-45
4.1.2 DIP Switches............................................................................................4-45
4.1.3 LED’s .......................................................................................................4-45
4.2 IPU BOARD ................................................................................4-46
4.2.1 Dip Switches............................................................................................4-46
4.2.2 LED’s .......................................................................................................4-46
5. PREVENTIVE MAINTENANCE SCHEDULE ................... 4-47
5.1 PM TABLE ..................................................................................4-47
5.REPLACEMENT & ADJUSTMENT
1. COLOR BALANCE ADJUSTMENT ..................................5-1
2. COPY IMAGE ADJUSTMENT
-PRINTING/SCANNING.......................................................5-5
2.1 PRINTING ...................................................................................5-5
2.1.1 Registration And Adjustment ...................................................................5-7
2.1.2 Blank Margin Adjustment .........................................................................5-8
2.2 SCANNING ................................................................................5-10
3. EXTERIOR AND INNER COVERS...................................5-12
FSM iii A109

3.1 EXTERIOR COVER REMOVAL.................................................5-12
3.1.1 Front Door................................................................................................5-12
3.1.2 Upper Rear Cover....................................................................................5-13
3.1.3 Upper Left Cover......................................................................................5-13
3.1.4 Lower Rear Cover....................................................................................5-13
3.1.5 Lower Left Cover......................................................................................5-13
3.1.6 Right Front Door ......................................................................................5-14
3.1.7 Upper Right Cover...................................................................................5-14
3.1.8 Lower Front Cover...................................................................................5-14
3.1.9 Top Cover................................................................................................5-15
3.2 INNER COVER REMOVAL .......................................................5-16
3.2.1 Right Inner Cover.....................................................................................5-16
3.2.2 Total Counter Cover ................................................................................5-16
3.2.3 Lower Left Inner Cover ...........................................................................5-16
3.2.4 Upper Left Inner Cover ...........................................................................5-16
4. SCANNER UNIT................................................................5-17
4.1 EXPOSURE GLASS REMOVAL ................................................5-17
4.2 EXPOSURE LAMP REPLACEMENT.........................................5-18
4.3 OPTICS THERMOSWITCH REPLACEMENT............................5-19
4.4 SCANNER CONTROL BOARD REPLACEMENT......................5-20
4.5 LENS UNIT (CCD BOARD) REPLACEMENT............................5-21
4.6 ORIGINAL LENGTH SENSOR (1) REPLACEMENT .................5-22
4.7 ORIGINAL WIDTH SENSOR AND ORIGINAL
LENGTH SENSOR (2) REPLACEMENT ...................................5-23
4.8 SCANNER MOTOR REPLACEMENT........................................5-24
4.9 SCANNER DRIVE BELT REPLACEMENT ................................5-26
4.10 SCANNER HOME POSITION SENSOR/SCANNER
MOTOR DRIVE BOARD/LAMP REGULATOR
BOARD/SCANNER UNIT LIFT SENSOR
REPLACEMENT.......................................................................5-27
4.11 SCANNER WIRE REPLACEMENT .........................................5-28
5. LASER UNIT .................................................................... 5-33
5.1 WARNING...................................................................................5-33
A109 iv FSM

5.2 OPTICAL HOUSING UNIT REPLACEMENT ............................5-34
5.3 LD UNIT AND POLYGON MOTOR REPLACEMENT................5-36
5.4 LASER SYNCHRONIZING DETECTOR
BOARD REPLACEMENT ..........................................................5-37
5.5 POLYGON MOTOR DRIVE BOARD
REPLACEMENT...............................................................................5-38
6. PAPER FEED SECTION...................................................5-39
6.1 PICK-UP/PAPER FEED/SEPARATION
ROLLER REPLACEMENT..........................................................5-39
6.2 PAPER FEED CLUTCH, PICK-UP AND SEPARATION ROLLER
SOLENOID REPLACEMENT (1ST, 2ND
AND 3RD FEED UNIT)...............................................................5-40
6.3 PAPER FEED MOTOR REPLACEMENT...................................5-44
6.4 TRAY LIFT MOTOR (1ST, 2ND, AND 3RD) REPLACEMENT ..5-45
6.5 BY-PASS FEED TABLE .............................................................5-46
6.5.1 Pick-up, Paper Feed & Separation Roller Replacement..........................5-46
6.6 BY-PASS PAPER WIDTH SENSOR AND
BY-PASS PAPER LENGTH SENSOR
REPLACEMENT .......................................................................5-47
6.7 BY-PASS FEED CLUTCH AND BY-PASS PICK-UP
SOLENOID..................................................................................5-48
6.8 REGISTRATION SENSOR REPLACEMENT.............................5-49
6.9 REGISTRATION CLUTCH REPLACEMENT.............................5-50
6.10 1ST PAPER TRAY PAPER SIZE SWITCH,
2ND AND 3RD TRAY SET SWITCH
REPLACEMENT.......................................................................5-51
6.11 REGISTRATION BUCKLE ADJUSTMENT .............................5-52
7. DRUM UNIT.......................................................................5-53
7.1 DRUM UNIT REMOVAL AND OPC DRUM
REPLACEMENT .......................................................................5-53
7.2 INSTALLING A NEW DRUM ......................................................5-57
7.3 CLEANING BLADE REPLACEMENT.........................................5-60
7.4 CLEANING BRUSH REPLACEMENT........................................5-61
7.5 BIAS ROLLER BLADE REPLACEMENT ...................................5-62
7.6 CHARGE WIRE REPLACEMENT..............................................5-63
7.7 PRE-CLEANING CORONA WIRE
REPLACEMENT.........................................................................5-64
FSM v A109

7.8 DRUM MOTOR REPLACEMENT...............................................5-65
7.9 USED TONER TANK REMOVAL ..............................................5-66
8. DEVELOPMENT SECTION ..............................................5-67
8.1 DEVELOPER COLLECTION ....................................................5-67
8.2 DEVELOPER INSTALLATION ..................................................5-69
8.3 TONER DENSITY SENSOR REPLACEMENT ........................5-73
8.4 DEVELOPMENT ROLLER ASSEMBLY
REPLACEMENT.........................................................................5-74
8.5 DUAL MIXING ROLLER REPLACEMENT
(FOR ALL COLORS) ................................................................5-76
8.6 BLACK SLEEVE MOTOR REPLACEMENT...............................5-77
8.7 COLOR SLEEVE MOTOR REPLACEMENT..............................5-78
8.8 BLACK DEVELOPMENT DRIVE
MOTOR REPLACEMENT...........................................................5-80
8.9 COLOR DEVELOPMENT DRIVE
MOTOR REPLACEMENT...........................................................5-81
9. TRANSFER BELT SECTION............................................ 5-82
9.1 TRANSFER BELT REPLACEMENT...........................................5-82
9.2 TRANSFER BELT POSITION CLUTCH
AND TRANSFER BELT POSITION SENSOR
REPLACEMENT.........................................................................5-84
10. TRANSFER ROLLER UNIT............................................5-85
10.1 TRANSFER ROLLER UNIT REMOVAL...................................5-85
10.2 TRANSFER ROLLER BLADE REPLACEMENT......................5-86
10.3 PAPER DISCHARGE PLATE REPLACEMENT.......................5-87
10.4 TRANSFER ROLLER REPLACEMENT...................................5-88
11. TRANSFER BELT CLEANING UNIT .............................5-89
11.1 TRANSFER BELT CLEANING BLADE
REPLACEMENT.......................................................................5-89
11.2 CLEANING BLADE SOLENOID REPLACEMENT...................5-90
11.3 TRANSFER BELT CLEANING ENTRANCE SEAL
SOLENOID REPLACEMENT ...................................................5-91
12. LUBRICANT UNIT...........................................................5-92
12.1 LUBRICANT BRUSH AND LUBRICANT BAR
REPLACEMENT.......................................................................5-92
A109 vi FSM

12.2 LUBRICANT BRUSH CLUTCH REPLACEMENT....................5-93
13. FUSING UNIT..................................................................5-94
13.1 FUSING UNIT REMOVAL ........................................................5-94
13.2 CLEANING ROLLER AND SCRAPER
REPLACEMENT.......................................................................5-95
13.3 OIL SUPPLY PAD REPLACEMENT.........................................5-96
13.4 FUSING THERMISTOR REPLACEMENT ...............................5-97
13.5 OIL BLADE REPLACEMENT ...................................................5-98
13.6 FUSING LAMP AND FUSING THERMOFUSE
REPLACEMENT.......................................................................5-99
13.7 HOT ROLLER REPLACEMENT.............................................5-100
13.8 PRESSURE ROLLER LAMP REPLACEMENT......................5-102
13.9 PRESSURE ROLLER REPLACEMENT ................................5-103
13.10 PRESSURE ROLLER THERMISTOR
REPLACEMENT...................................................................5-104
13.11 TRANSPORT MOTOR REPLACEMENT.............................5-105
13.12 FUSING PRESSURE (NIP BAND WIDTH)
CONFIRMATION...................................................................5-106
14. OTHERS........................................................................ 5-107
14.1 MAIN CONTROL BOARD REPLACEMENT .........................5-107
14.2 DEVELOPMENT FILTER AND DEVELOPMENT OZONE
FILTER REPLACEMENT........................................................5-108
14.3 FILTER REPLACEMENT (DEVELOPMENT EXHAUST,
CHARGE INLET FAN, FUSING EXHAUST
OZONE, OPTICSCOOLING FAN AND
INNER COOLING FAN)..........................................................5-109
14.4 TONER TANK AGITATOR REPLACEMENT.........................5-110
14.5 PAPER TRANSPORT BELT REPLACEMENT ......................5-111
14.6 POINT ACCURACY ADJUSTMENT.......................................5-112
6. TROUBLESHOOTING
1. SERVICE CALL CONDITIONS........................................... 6-1
1.1 SUMMARY....................................................................................6-1
1.2 SCANNING...................................................................................6-3
1.3 PRINTING.....................................................................................6-6
FSM vii A109

1.4 DEVELOPMENT...........................................................................6-8
1.5 AROUND THE DRUM ................................................................6-12
1.6 TRANSFER BELT / ROLLER .....................................................6-14
1.7 PAPER FEED .............................................................................6-16
1.8 FUSING.......................................................................................6-17
1.9 COMMUNICATION.....................................................................6-20
1.10 OPTIONAL EQUIPMENTS.......................................................6-23
1.11 OTHERS...................................................................................6-24
2. BLOWN FUSE CONDITIONS........................................... 6-25
3. COPY QUALITY................................................................6-26
3.1 SP402 ADJUSTMENT................................................................6-26
3.2 ROUGH SOLID IMAGE SURFACE & POOR
COLOR REPRODUCTION IN 4C MODE..................................6-26
3.3 SCATTERED TONER AROUND SOLID IMAGE
AREAIN1C MODE ......................................................................6-27
3.4 YELLOW/BROWN BACKGROUND DURING LONG RUNS......6-27
3.5 FIRE FLY SPOTS.......................................................................6-27
7. DUAL JOB FEEDER
1. SPECIFICATIONS...............................................................7-1
2. COMPONENT LAYOUT...................................................... 7-3
2.1 MECHANICAL COMPONENT LAYOUT ....................................7-3
3. ELECTRICAL COMPONENT DESCRIPTION.................... 7-4
4. INSTALLATION................................................................... 7-6
4.1 ACCESSORY CHECK..................................................................7-6
4.2 INSTALLATION PROCEDURE ...................................................7-7
5. SERVICE TABLES............................................................7-12
5.1 DIP SWITCHES AND SWITCHES .............................................7-12
5.2 VARIABLE RESISTORS.............................................................7-13
5.3 LEDs ...........................................................................................7-13
5.4 FUSEs.........................................................................................7-13
6. REPLACEMENTS AND ADJUSTMENTS........................ 7-14
Rev. 11/8/96
A109 viii FSM

6.1 TRANSPORT BELT REPLACEMENT ......................................7-14
6.2 ORIGINAL TABLE / ORIGINAL GUIDE REMOVAL ................7-16
6.3 FEED ROLLER REPLACEMENT .............................................7-18
6.4 SEPARATION BELT REPLACEMENT.......................................7-19
6.5 FEED-OUT MOTOR (FEED-OUT UNIT) REMOVAL.................7-21
6.6 INVERTER SOLENOID REMOVAL AND
ADJUSTMENT............................................................................7-23
6.7 BELT DRIVE MOTOR REPLACEMENT ....................................7-24
6.8 FEED-IN CLUTCH (FEED-IN UNIT) REMOVAL........................7-27
6.9 STOPPER SOLENOID REPLACEMENT...................................7-29
6.10 VERTICAL REGISTRATION ADJUSTMENT...........................7-30
6.10.1 One Sided Original Mode.......................................................................7-30
6.10.2 Two Sided Original Mode.......................................................................7-31
6.10.3 Combine 2 Originals Mode ....................................................................7-32
6.11 SIDE TO SIDE REGISTRATION ADJUSTMENT.....................7-33
6.12 MOTOR SPEED ADJUSTMENT..............................................7-34
8. SORTER
1. OVERALL MACHINE INFORMATION ............................... 8-1
1.1 SPECIFICATIONS........................................................................8-1
1.2 COMPONENT LAYOUT ...............................................................8-2
1.2.1 Mechanical Components ...........................................................................8-2
1.2.2 Electrical Components...............................................................................8-3
1.3 ELECTRICAL COMPONENT DESCRIPTIONS ...........................8-4
1.4 DRIVE LAYOUT............................................................................8-5
2. INSTALLATION................................................................... 8-6
2.1 ACCESSORY CHECK..................................................................8-6
2.2 INSTALLATION PROCEDURE ....................................................8-7
3. SERVICE TABLES............................................................8-13
3.1 TEST POINT...............................................................................8-13
3.2 LEDs ...........................................................................................8-13
3.3 DIP SWITCH...............................................................................8-13
3.4 VARIABLE RESISTORS.............................................................8-13
Rev. 7/94
FSM ix A109

4. REPLACEMENT AND ADJUSTMENT.............................8-14
4.1 SORTER MOTOR, SPONGE ROLLER, AND INLET SENSOR
REPLACEMENT.........................................................................8-14
4.2 JAM SENSOR REPLACEMENT.................................................8-15
4.3 VERTICAL DRIVE ROLLER TIMING BELT
ADJUSTMENT............................................................................8-16
4.4 SORTER MOTOR SPEED ADJUSTMENT................................8-16
9.DISPLAY EDITOR
1. SPECIFICATIONS...............................................................9-1
2. INSTALLATION................................................................... 9-2
2.1 ACCESSORY CHECK..................................................................9-2
2.2 INSTALLATION PROCEDURE ....................................................9-3
10. FILM PROJECTOR UNIT
1. SPECIFICATION...............................................................10-1
2. ELECTRICAL COMPONENT LAYOUT AND
DESCRIPTIONS................................................................ 10-2
3. INSTALLATION................................................................. 10-3
3.1 ACCESSORY CHECK................................................................10-3
3.2 INSTALLATION PROCEDURE ..................................................10-4
CONTROLLER INTERFACE KIT TYPE-A
BULLETINS
Rev. 3/20/96
A109 x FSM

IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the copier power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers
off or open while the main switch is turned on, keep hands away from
electrified or mechanically driven components.
5. If the hot roller temperature is low when the main switch is turned on, the
copier starts process control self check automatically. Keep hands away
from the mechanical and the electrical components to avoid any injury.
6. If the start key is pressed before the copier completes the warm-up
period (Start key starts blinking red and green alternatively), keep hands
away from the mechanical and the electrical components as the copier
starts making copies as soon as the warm-up period is completed.
7. The inside and the metal parts of the fusing unit become extremely hot
while the copier is operating. Be careful to avoid touching those
components with your bare hands.
HEALTH SAFETY CONDITIONS
1. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get
medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
2. The RAM board on the main control board has a lithium battery which
can explode if replaced incorrectly. Replace the battery only with an
identical one. The manufacturer recommends replacing the entire RAM
board. Do not recharge or burn this battery. Used batteries must be
handled in accordance with local regulations.

1993 By Ricoh Company Ltd. All rights reserved
FSM a A109