Ricoh A229 User manual

SERVICE MANUAL
PN: RCSMA229
A229
RICOH GROUP COMPANIES

i
SM A229
TABLE OF CONTENTS
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION..........................................1-1
1.1 SPECIFICATIONS.................................................................................... 1-1
1.1.1 COPIER ENGINE............................................................................. 1-1
1.1.2 ADF.................................................................................................. 1-4
1.2 MACHINE CONFIGURATION .................................................................. 1-5
1.3 MECHANICAL COMPONENT LAYOUT................................................... 1-6
1.3.1 COPIER ENGINE............................................................................. 1-6
1.3.2 ADF.................................................................................................. 1-8
1.4 PAPER PATH........................................................................................... 1-9
1.5 COPY PROCESS................................................................................... 1-10
1.6 DRIVE LAYOUT...................................................................................... 1-12
1.6.1 COPIER ENGINE........................................................................... 1-12
1.6.2 ADF................................................................................................ 1-13
1.7 ELECTRICAL COMPONENT DESCRIPTION........................................ 1-14
1.7.1 COPIER ENGINE........................................................................... 1-14
1.7.2 ADF................................................................................................ 1-21
DETAILED DESCRIPTIONS
2. DETAILED DESCRIPTIONS..........................................................2-1
2.1 DOCUMENT FEEDER.............................................................................. 2-1
2.1.1 PICK-UP ROLLER RELEASE MECHANISM................................... 2-1
2.1.2 BOTTOM PLATE LIFT MECHANISM.............................................. 2-2
2.1.3 PICK-UP AND SEPARATION MECHANISM................................... 2-3
2.1.4 ORIGINAL FEED MECHANISM....................................................... 2-4
2.1.5 ORIGINAL FEED DRIVE MECHANISM........................................... 2-5
Original Feed Start............................................................................... 2-5
Original Feed........................................................................................ 2-5
2.1.6 ORIGINAL SIZE DETECTION......................................................... 2-6
2.1.7 ORIGINAL TRANSPORT MECHANISM.......................................... 2-7
2.1.8 ORIGINAL SKEW CORRECTION MECHANISM............................. 2-8
2.1.9 ORIGINAL INVERSION AND FEED-OUT MECHANISM................. 2-9
General Operation................................................................................ 2-9
Original Inversion Mechanism............................................................ 2-10
Original Exit Mechanism (Single-Sided Original Mode)...................... 2-11
Original Exit Mechanism (Double-Sided Original Mode).................... 2-12
2.1.10 JAM CONDITIONS ...................................................................... 2-13
2.1.11 TIMING CHARTS......................................................................... 2-14
A4 Sideways: One-Sided Original (Three Pages).............................. 2-14
A3: Two-Sided Original (One Page)................................................... 2-15
2.2 SCANNING............................................................................................. 2-16

iiA229 SM
2.2.1 OVERVIEW.................................................................................... 2-16
2.2.2 SCANNER DRIVE.......................................................................... 2-17
2.2.3 ORIGINAL SIZE DETECTION IN BOOK MODE............................ 2-18
2.3 IMAGE PROCESSING............................................................................ 2-20
2.3.1 OVERVIEW.................................................................................... 2-20
2.3.2 SBU................................................................................................ 2-21
2.3.3 AUTO IMAGE DENSITY (ADS) ..................................................... 2-22
2.3.4 IPU (IMAGE PROCESSING UNIT)................................................ 2-23
Overview............................................................................................ 2-23
2.3.5 IMAGE PROCESSING STEPS AND RELATED SP MODES........ 2-24
2.3.6 AUTO SHADING............................................................................ 2-30
Black level correction ......................................................................... 2-30
White level correction......................................................................... 2-30
2.3.7 TEXT/PHOTO AREA SEPARATION ............................................. 2-31
Edge Determination ........................................................................... 2-31
Dot Screen Determination.................................................................. 2-32
Final Evaluation.................................................................................. 2-32
2.3.8 BACKGROUND ERASE................................................................ 2-33
2.3.9 INDEPENDENT DOT ERASE........................................................ 2-34
2.3.10 FILTERING, MAIN SCAN MAGNIFICATION/REDUCTION......... 2-36
Overview............................................................................................ 2-36
Filtering .............................................................................................. 2-36
Main scan magnification/reduction..................................................... 2-37
2.3.11 GAMMA (γ) CORRECTION.......................................................... 2-38
2.3.12 GRADATION PROCESSING....................................................... 2-38
Error Diffusion and Dithering.............................................................. 2-39
Grayscale Processing ........................................................................ 2-39
2.3.13 LINE WIDTH CORRECTION....................................................... 2-40
2.3.14 COMPRESSION AND STORAGE............................................... 2-41
Circuit................................................................................................. 2-41
Compression...................................................................................... 2-42
Image Rotation................................................................................... 2-42
2.4 LASER EXPOSURE ............................................................................... 2-43
2.4.1 OVERVIEW.................................................................................... 2-43
2.4.2 OPTICAL PATH............................................................................. 2-44
2.4.3 AUTO POWER CONTROL............................................................ 2-45
2.4.4 DUAL BEAM WRITING.................................................................. 2-46
2.4.5 LASER BEAM PITCH CHANGE MECHANISM............................. 2-47
2.4.6 LD SAFETY SWITCHES................................................................ 2-48
2.5 DRUM UNIT............................................................................................ 2-49
2.5.1 PROCESS CONTROL................................................................... 2-49
Overview............................................................................................ 2-49
Drum potential sensor calibration....................................................... 2-50
VSG adjustment................................................................................. 2-50
VG Adjustment................................................................................... 2-51
LD power adjustment ......................................................................... 2-52
VREF Update..................................................................................... 2-53
2.5.2 DRUM UNIT COMPONENTS ........................................................ 2-54
2.5.3 DRIVE MECHANISM..................................................................... 2-55

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SM A229
2.5.4 DRUM CHARGE............................................................................ 2-56
Overview............................................................................................ 2-56
Charge Corona Wire Cleaning Mechanism........................................ 2-57
2.5.5 DRUM CLEANING AND TONER RECYCLING............................. 2-58
Overview............................................................................................ 2-58
Drive Mechanism................................................................................ 2-59
Cleaning Blade Pressure Mechanism and Side-to-Side Movement... 2-60
Toner Recycling and Waste Toner Collection Mechanism................. 2-61
2.5.6 OTHERS........................................................................................ 2-64
Air Flow Around the Drum.................................................................. 2-64
Pick-off Mechanism............................................................................ 2-65
Quenching.......................................................................................... 2-66
2.6 DEVELOPMENT AND TONER SUPPLY................................................ 2-67
2.6.1 OVERVIEW.................................................................................... 2-67
2.6.2 DEVELOPMENT MECHANISM..................................................... 2-68
2.6.3 DRIVE MECHANISM..................................................................... 2-69
2.6.4 CROSSMIXING.............................................................................. 2-70
2.6.5 DEVELOPMENT BIAS................................................................... 2-71
2.6.6 TONER SUPPLY ........................................................................... 2-72
Toner Bottle Mechanism .................................................................... 2-72
Toner Supply Mechanism................................................................... 2-73
Toner End Detection .......................................................................... 2-74
2.6.7 TONER DENSITY CONTROL ....................................................... 2-75
Overview............................................................................................ 2-75
Sensor control mode.......................................................................... 2-75
Image pixel count control ................................................................... 2-76
2.6.8 TONER END DETECTION............................................................ 2-77
Toner Near End.................................................................................. 2-77
Toner End .......................................................................................... 2-77
2.6.9 TONER END RECOVERY............................................................. 2-77
2.6.10 ABNORMAL TD SENSOR CONDITIONS.................................... 2-78
2.7 IMAGE TRANSFER AND PAPER SEPARATION .................................. 2-79
2.7.1 OVERVIEW.................................................................................... 2-79
2.7.2 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM... 2-80
2.7.3 TRANSFER BELT UNIT LIFT MECHANISM................................. 2-82
2.7.4 PAPER TRANSPORTATION AND BELT DRIVE MECHANISM... 2-83
2.7.5 TRANSFER BELT CLEANING MECHANISM................................ 2-84
2.7.6 TONER COLLECTION MECHANISM............................................ 2-85
2.8 PAPER FEED......................................................................................... 2-86
2.8.1 OVERVIEW.................................................................................... 2-86
2.8.2 DRIVE MECHANISM..................................................................... 2-87
2.8.3 TRAY POSITIONING MECHANISM – TRAYS 1 AND 2................ 2-88
2.8.4 PAPER LIFT MECHANISM - TRAYS 1 AND 2.............................. 2-89
2.8.5 PICK-UP AND FEED MECHANISM – TRAYS 1 TO 3................... 2-91
Overview............................................................................................ 2-91
Pick-up and Feed............................................................................... 2-92
Separation Roller Release Mechanism.............................................. 2-93
Paper Skew Prevention Mechanism................................................... 2-94
2.8.6 VERTICAL TRANSPORT MECHANISM........................................ 2-95

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2.8.7 PAPER REGISTRATION............................................................... 2-96
Overview............................................................................................ 2-96
Registration Drive Mechanism............................................................ 2-97
Guide Plate Release Mechanism....................................................... 2-98
2.8.8 PAPER NEAR-END/END DETECTION – TRAYS 1 TO 3............. 2-99
Near-end Detection............................................................................ 2-99
End Detection..................................................................................... 2-99
2.8.9 PAPER SIZE DETECTION – TRAY 2.......................................... 2-100
2.8.10 BUILT IN LCT ............................................................................ 2-101
Paper Tray Lift Mechanism .............................................................. 2-101
Tray Lock Mechanism...................................................................... 2-102
2.8.11 BY-PASS FEED TABLE............................................................. 2-103
Feed Mechanism/Paper End Detection............................................ 2-103
Table Open/Close Detection............................................................ 2-104
Paper Size Detection ....................................................................... 2-105
2.8.12 TANDEM FEED TRAY............................................................... 2-106
Overview.......................................................................................... 2-106
Side Fence Drive Mechanism........................................................... 2-107
Rear Fence Drive Mechanism.......................................................... 2-108
Tray Lock Mechanism...................................................................... 2-109
Tray Lifting and Lowering Mechanism.............................................. 2-109
2.9 IMAGE FUSING.................................................................................... 2-110
2.9.1 OVERVIEW.................................................................................. 2-110
2.9.2 FUSING ENTRANCE GUIDE ...................................................... 2-111
2.9.3 FUSING DRIVE MECHANISM..................................................... 2-112
2.9.4 FUSING LAMP CONTROL.......................................................... 2-113
2.10 PAPER EXIT/DUPLEX........................................................................ 2-114
2.10.1 OVERVIEW................................................................................ 2-114
2.10.2 PAPER EXIT MECHANISM....................................................... 2-115
2.10.3 DUPLEX DRIVE MECHANISM.................................................. 2-116
2.10.4 INVERTER................................................................................. 2-117
Feed-in and Jogging ........................................................................ 2-117
Feed-out........................................................................................... 2-118
2.10.5 DUPLEX TRAY FEED MECHANISM......................................... 2-119
2.10.6 BASIC DUPLEX FEED OPERATION ........................................ 2-120
Up to A4 / Letter lengthwise............................................................. 2-120
Longer than A4 / Letter lengthwise................................................... 2-123
2.11 ENERGY SAVER MODES.................................................................. 2-126
2.11.1 OVERVIEW................................................................................ 2-126
2.11.2 ENERGY SAVER MODE........................................................... 2-127
Entering energy saver mode............................................................ 2-127
What happens in energy saver mode............................................... 2-127
Return to stand-by mode.................................................................. 2-127
2.11.3 LOW POWER MODE................................................................. 2-128
Entering low power mode................................................................. 2-128
What happens in low power mode ................................................... 2-128
Return to stand-by mode.................................................................. 2-128

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SM A229
2.11.4 AUTO OFF MODE..................................................................... 2-129
Off Mode (Sleep Mode).................................................................... 2-129
Weekly Timer Off Mode ................................................................... 2-130
2.11.5 SUMMARY................................................................................. 2-131
INSTALLATION
3. INSTALLATION PROCEDURE...................................................3-1
3.1 INSTALLATION REQUIREMENTS .......................................................... 3-1
3.1.1 ENVIRONMENT .............................................................................. 3-1
3.1.2 MACHINE LEVEL............................................................................ 3-1
3.1.3 MINIMUM SPACE REQUIREMENTS.............................................. 3-2
3.1.4 POWER REQUIREMENTS.............................................................. 3-2
3.2 COPIER (A229)........................................................................................ 3-3
3.2.1 ACCESSORY CHECK..................................................................... 3-3
3.2.2 INSTALLATION PROCEDURE........................................................ 3-4
3.3 PAPER SIZE CHANGE .......................................................................... 3-13
3.3.1 550-SHEET PAPER TRAY (TRAY 2)............................................ 3-13
3.3.2 1,500-SHEET PAPER TRAY (TRAY 3)......................................... 3-14
3.3.3 TANDEM FEED TRAY PAPER SIZE CHANGE (TRAY 1) ............ 3-16
3.3.4 OPTIONAL LCT............................................................................. 3-19
3.3.5 CHANGING THE UNIVERSAL TRAY PAPER SIZE...................... 3-20
3.4 LCT (8).................................................................................................... 3-21
3.4.1 ACCESSORY CHECK................................................................... 3-21
INSTALLATION PROCEDURE.......................................................... 3-22
3.5 3,000-SHEET FINISHER (A697)............................................................ 3-27
3.5.1 ACCESSORY CHECK................................................................... 3-27
3.5.2 INSTALLATION PROCEDURE...................................................... 3-28
3.6 PUNCH UNIT INSTALLATION (A812).................................................... 3-31
3.6.1 ACCESSORY CHECK................................................................... 3-31
3.6.2 PUNCH UNIT INSTALLATION ...................................................... 3-32
3.7 OUTPUT TRAY (A814)........................................................................... 3-35
3.7.1 ACESSORY CHECK ..................................................................... 3-35
3.7.2 OUTPUT TRAY INSTALLATION PROCEDURE ........................... 3-36
3.8 KEY COUNTER INSTALLATION ........................................................... 3-37
SERVICE TABLES
4. SERVICE TABLES......................................................................4-1
4.1 GENERAL CAUTIONS............................................................................. 4-1
4.1.1 DRUM.............................................................................................. 4-1
4.1.2 DRUM UNIT..................................................................................... 4-1
4.1.3 TRANSFER BELT UNIT .................................................................. 4-2
4.1.4 SCANNER UNIT.............................................................................. 4-2
4.1.5 LASER UNIT.................................................................................... 4-2
4.1.6 CHARGE CORONA......................................................................... 4-3
4.1.7 DEVELOPMENT.............................................................................. 4-3
Rev.12/15/98

viA229 SM
4.1.8 CLEANING....................................................................................... 4-4
4.1.9 FUSING UNIT.................................................................................. 4-4
4.1.10 PAPER FEED ................................................................................ 4-4
4.1.11 USED TONER ............................................................................... 4-4
4.2 SERVICE PROGRAM MODE................................................................... 4-5
4.2.1 SERVICE PROGRAM MODE OPERATION.................................... 4-5
Service Program Access Procedure .................................................... 4-5
Accessing Copy Mode from within an SP Mode................................... 4-7
Selecting the Program Number............................................................ 4-8
Inputting a Value or Setting for an SP Mode........................................ 4-9
4.2.2 SERVICE PROGRAM MODE TABLES ......................................... 4-10
4.2.3 TEST PATTERN PRINTING (SP2-902)......................................... 4-51
Test Pattern Table (SP2-902-2: Test Pattern Printing – IPU)............. 4-51
Test Pattern Table (SP2-902-3: Test Pattern Printing – Printing)....... 4-51
4.2.4 INPUT CHECK............................................................................... 4-52
Main Machine Input Check (SP5-803) ............................................... 4-52
ADF Input Check (SP5-007)............................................................... 4-56
4.2.5 OUTPUT CHECK........................................................................... 4-57
Main Machine Output Check (SP5-804)............................................. 4-57
ADF Output Check (SP5-008)............................................................ 4-58
4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS)............. 4-58
4.2.7 MEMORY ALL CLEAR (SP5-801) ................................................. 4-59
4.2.8 SOFTWARE RESET...................................................................... 4-60
4.2.9 SYSTEM SETTING AND COPY SETTING (UP MODE) RESET... 4-60
System Setting Reset......................................................................... 4-60
Copy Features Reset ......................................................................... 4-60
4.3 PROGRAM DOWNLOAD ....................................................................... 4-61
Downloading to the SBICU................................................................. 4-61
Download from SBICU to Flash Memory Card................................... 4-63
4.4 USER PROGRAM MODE....................................................................... 4-64
4.4.1 HOW TO ENTER AND EXIT UP MODE........................................ 4-64
4.4.2 UP MODE TABLE.......................................................................... 4-64
System Setting Table......................................................................... 4-64
Copy Features Table.......................................................................... 4-65
4.4.3 IMAGE QUALITY SETTING BY UP MODE ................................... 4-67
Text mode.......................................................................................... 4-67
Text/Photo Mode................................................................................ 4-69
Photo Mode........................................................................................ 4-70
Pale Mode.......................................................................................... 4-71
Generation Mode ............................................................................... 4-72
4.5 TEST POINTS/DIP SWITCHES/LEDS................................................... 4-73
4.5.1 DIP SWITCHES............................................................................. 4-73
4.5.2 TEST POINTS ............................................................................... 4-73
4.5.3 FUSES........................................................................................... 4-74
4.5.4 VARIABLE RESISTORS................................................................ 4-74
4.5.5 LEDS.............................................................................................. 4-75
4.6 SPECIAL TOOLS AND LUBRICANTS.................................................... 4-75
4.6.1 SPECIAL TOOLS........................................................................... 4-75
4.6.2 LUBRICANTS................................................................................ 4-75

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SM A229
4.7 PREVENTIVE MAINTENANCE TABLE.................................................. 4-76
REPLACEMENT AND ADJUSTMENT
5. REPLACEMENT AND ADJUSTMENT........................................5-1
5.1 EXTERIOR ............................................................................................... 5-1
5.1.1 FRONT ............................................................................................ 5-1
Front Door............................................................................................ 5-1
5.1.2 RIGHT.............................................................................................. 5-2
Paper Feed Cover................................................................................ 5-2
Upper Right Cover ............................................................................... 5-2
Lower Right Cover ............................................................................... 5-2
5.1.3 LEFT................................................................................................ 5-3
Upper Left Cover.................................................................................. 5-3
Lower Left Cover.................................................................................. 5-3
5.1.4 REAR............................................................................................... 5-4
Upper Rear Cover................................................................................ 5-4
Lower Rear Cover................................................................................ 5-4
5.2 DOCUMENT FEEDER.............................................................................. 5-5
5.2.1 COVER REMOVAL.......................................................................... 5-5
5.2.2 FEED UNIT REMOVAL AND SEPARATION ROLLER
REPLACEMENT........................................................................................ 5-7
5.2.3 FEED BELT REPLACEMENT.......................................................... 5-8
5.2.4 PICK-UP ROLLER REPLACEMENT............................................... 5-9
5.2.5 SENSOR REPLACEMENT............................................................ 5-10
Entrance and Registration Sensors.................................................... 5-10
Width Sensor...................................................................................... 5-11
Exit Sensor and Inverter Sensor ........................................................ 5-12
5.2.6 TRANSPORT BELT REPLACEMENT........................................... 5-13
5.3 SCANNER UNIT..................................................................................... 5-14
5.3.1 EXPOSURE GLASS...................................................................... 5-14
5.3.2 OPERATION PANEL..................................................................... 5-15
5.3.3 LENS BLOCK ................................................................................ 5-16
5.3.4 ORIGINAL SIZE SENSORS .......................................................... 5-17
5.3.5 EXPOSURE LAMP........................................................................ 5-18
5.3.6 SCANNER H.P SENSOR .............................................................. 5-19
5.3.7 SCANNER MOTOR/SCANNER MOTOR DRIVE BOARD............. 5-20
Scanner Motor.................................................................................... 5-20
Scanner Motor Drive Board................................................................ 5-20
5.3.8 SCANNER WIRES......................................................................... 5-21
Rear Scanner Drive Wire................................................................... 5-24
Front Scanner Drive Wire................................................................... 5-25
Reinstallation...................................................................................... 5-26
5.3.9 OPTICS DUST FILTER ................................................................. 5-28
5.4 LASER UNIT........................................................................................... 5-29
5.4.1 CAUTION DECAL LOCATIONS.................................................... 5-29
Rev.12/15/98

viiiA229 SM
5.4.1 CAUTION DECAL LOCATIONS.................................................... 5-29
5.4.2 LD UNIT REPLACEMENT ............................................................. 5-30
5.4.3 LASER BEAM PITCH ADJUSTMENT ........................................... 5-31
5.4.4 POLYGON MIRROR MOTOR REPLACEMENT............................ 5-33
5.4.5 LASER SYNCHRONIZATION DETECTOR REPLACEMENT ....... 5-34
5.5 DRUM UNIT............................................................................................ 5-35
5.5.1 DRUM UNIT REMOVAL AND DRUM REPLACEMENT ................ 5-35
5.5.2 QUENCHING LAMP REPLACEMENT........................................... 5-36
5.5.3 GRID PLATE/CHARGE CORONA WIRE/WIRE CLEANER
REPLACEMENT............................................................................ 5-37
5.5.4 DRUM ENTRANCE SEAL AND DRUM POTENTIAL SENSOR
REPLACEMENT............................................................................ 5-39
5.5.5 CLEANING BLADE REPLACEMENT............................................ 5-40
5.5.6 CLEANING BRUSH REPLACEMENT ........................................... 5-41
5.5.7 PICK-OFF PAWL REPLACEMENT ............................................... 5-42
5.5.8 OZONE FILTER REPLACEMENT................................................. 5-43
5.5.9 DRUM MOTOR REPLACEMENT.................................................. 5-44
5.5.10 TONER OUTPUT AND RECYCLING PUMP UNIT
REPLACEMENT.......................................................................... 5-45
5.5.11 AIR PUMP AND TONER COLLECTION MOTOR
REPLACEMENT.......................................................................... 5-46
5.6 DEVELOPMENT AND TONER SUPPLY................................................ 5-47
5.6.1 DEVELOPMENT UNIT REMOVAL................................................ 5-47
5.6.2 DEVELOPMENT AND AIR DUST FILTER REPLACEMENT......... 5-49
5.6.3 DEVELOPER REPLACEMENT ..................................................... 5-50
5.6.4 DEVELOPMENT ENTRANCE, FRONT,
AND REAR SIDE SEALS .............................................................. 5-52
5.6.5 TONER DENSITY SENSOR REPLACEMENT.............................. 5-53
5.6.6 TONER END SENSOR REPLACEMENT...................................... 5-54
6.6.7 DEVELOPMENT MOTOR REPLACEMENT.................................. 5-54
5.7 TRANSFER BELT UNIT ......................................................................... 5-55
5.7.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION.................... 5-55
Removal............................................................................................. 5-55
Installation.......................................................................................... 5-55
5.7.2 TRANSFER BELT REPLACEMENT.............................................. 5-57
5.7.3 BIAS ROLLER CLEANING BLADE REPLACEMENT.................... 5-59
5.8 PAPER FEED......................................................................................... 5-60
5.8.1 PAPER TRAY UNIT REMOVAL..................................................... 5-60
5.8.2 PAPER TRAY REMOVAL.............................................................. 5-61
Tandem Tray Removal....................................................................... 5-61
Universal Tray/Built-in LCT Removal ................................................. 5-62
5.8.3 PAPER FEED ROLLER REPLACEMENT ..................................... 5-63
5.8.4 TANDEM REAR FENCE DRIVE BELT REMOVAL........................ 5-64
5.8.5 TANDEM SIDE FENCE MOTOR REMOVAL................................. 5-66
5.8.6 3RD TRAY PAPER SENSOR REMOVAL...................................... 5-67
5.8.7 3RD TRAY LIFT WIRE REMOVAL................................................ 5-68
5.8.8 PAPER FEED CLUTCH/RELAY CLUTCH REMOVAL.................. 5-70
5.8.9 BY-PASS FEED TABLE REMOVAL.............................................. 5-73
5.8.10 BY-PASS FEED ROLLER REPLACEMENT................................ 5-74

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SM A229
5.8.11 BY-PASS PAPER SIZE BOARD REPLACEMENT...................... 5-75
5.8.12 BY-PASS FEED MOTOR/CLUTCH REMOVAL........................... 5-77
5.8.13 REGISTRATION MOTOR REMOVAL ......................................... 5-78
5.8.14 PAPER DUST REMOVER REMOVAL......................................... 5-79
5.8.15 REGISTRATION SENSOR REMOVAL........................................ 5-80
5.8.16 COPIER FEED UNIT REMOVAL................................................. 5-81
5.9 FUSING UNIT......................................................................................... 5-83
5.9.1 FUSING UNIT REMOVAL.............................................................. 5-83
5.9.2 FUSING THERMISTOR AND FUSING THERMOFUSE
REPLACEMENT............................................................................. 5-84
Fusing Thermistor Replacement ........................................................ 5-84
Fusing Thermofuse Replacement ...................................................... 5-84
5.9.3 FUSING LAMP REPLACEMENT................................................... 5-85
5.9.4 HOT ROLLER REPLACEMENT .................................................... 5-87
5.9.5 PRESSURE ROLLER AND BEARING REPLACEMENT............... 5-89
5.9.6 HOT ROLLER STRIPPER PAWL REPLACEMENT ...................... 5-90
5.9.7 FUSING PRESSURE ADJUSTMENT............................................ 5-91
5.9.8 OIL SUPPLY/CLEANING ROLLER REPLACEMENT.................... 5-92
5.9.9 PRESSURE ROLLER CLEANING ROLLER REPLACEMENT...... 5-93
5.10 PAPER EXIT/DUPLEX UNIT................................................................ 5-94
5.10.1 EXIT SENSOR/FUSING EXIT SENSOR ..................................... 5-94
5.10.2 JOGGER MOTOR........................................................................ 5-95
5.10.3 DUPLEX ENTRANCE SENSOR.................................................. 5-95
5.10.4 DUPLEX TRANSPORT/DUPLEX FEED CLUTCHES.................. 5-96
5.10.5 DUPLEX TRANSPORT SENSOR 1............................................. 5-96
5.10.6 DUPLEX TRANSPORT SENSORS 2 & 3.................................... 5-97
5.10.7 JOGGER HP SENSOR................................................................ 5-98
5.11 BOARDS AND OTHER ITEMS............................................................. 5-99
5.11.1 SBICU BOARD ............................................................................ 5-99
5.11.2 HARD DISK DRIVE.................................................................... 5-100
5.11.3 I/O BOARD ................................................................................ 5-101
5.11.4 PSU............................................................................................ 5-102
5.11.5 PAPER FEED CONTROL BOARD (PFC).................................. 5-102
5.12 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING................... 5-103
5.12.1 PRINTING.................................................................................. 5-103
Registration - Leading Edge............................................................. 5-103
Registration – Side-to-Side .............................................................. 5-103
Blank Margin.................................................................................... 5-105
5.12.2 PARALLELOGRAM IMAGE ADJUSTMENT.............................. 5-106
5.12.3 SCANNING................................................................................ 5-108
Registration: Platen Mode................................................................ 5-108
Magnification.................................................................................... 5-108
5.12.4 ADF IMAGE ADJUSTMENT ...................................................... 5-109
Registration...................................................................................... 5-109
5.13 TOUCH SCREEN CALIBRATION ...................................................... 5-110

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A229 SM
TROUBLESHOOTING
6. TROUBLESHOOTING ................................................................. 6-1
6.1 SERVICE CALL CONDITIONS .................................................................6-1
6.1.1 SUMMARY.......................................................................................6-1
6.1.2 SC CODE DESCRIPTIONS .............................................................6-2
6.2 ELECTRICAL COMPONENT DEFECTS.................................................6-29
6.2.1 SENSORS......................................................................................6-29
6.2.2 SWITCHES.....................................................................................6-33
6.3 BLOWN FUSE CONDITIONS .................................................................6-34
6.4 FIRMWARE HISTORY............................................................................6-35
FINISHER A697
1. OVERALL MACHINE INFORMATION......................................... 7-1
1.1 SPECIFICATIONS.....................................................................................7-1
1.2 MECHANICAL COMPONENT LAYOUT ...................................................7-3
1.3 ELECTRICAL COMPONENT LAYOUT.....................................................7-4
1.4 ELECTRICAL COMPONENT DESCRIPTION...........................................7-5
1.5 DRIVE LAYOUT........................................................................................7-7
2. DETAILED DESCRIPTIONS........................................................ 7-8
2.1 TRAY AND STAPLER JUNCTION GATE MECHANISM ..........................7-8
Upper tray mode...................................................................................7-8
Sort/stack mode....................................................................................7-8
Staple mode..........................................................................................7-8
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM..............................7-9
Vertical Paper Alignment ......................................................................7-9
Horizontal Paper Alignment..................................................................7-9
2.3 STAPLER UNIT MOVEMENT MECHANISM ..........................................7-10
Side-to-side:........................................................................................7-10
Rotation: .............................................................................................7-10
2.4 STAPLER................................................................................................7-11
2.5 FEED-OUT MECHANISM .......................................................................7-12
2.6 SHIFT TRAY UP/DOWN MECHANISM ..................................................7-13
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM............................................7-14
2.8 PUNCH UNIT DRIVE MECHANISM........................................................7-15
2.9 PUNCH WASTE COLLECTION MECHNISM..........................................7-16
2.10 JAM CONDITIONS................................................................................7-17
2.11 TIMING CHARTS ..................................................................................7-18
2.11.1 A4 SIDEWAYS (2 SHEETS): NORMAL
AND PUNCH MODE ......................................................................7-18
2.11.2 A4 SIDEWAYS (2 SHEETS): SORT/STACK AND PUNCH
MODE..........................................................................................7-19
2.11.3 A4 SIDEWAYS (2 SHEETS): STAPLE AND PUNCH MODE
........................................................................................................7-20
Rev. 05/2000

xi
SM A229
3. SERVICE TABLES....................................................................7-21
3.1 DIP SWITCHES...................................................................................... 7-21
3.2 TEST POINTS........................................................................................ 7-21
3.3 LED......................................................................................................... 7-21
3.4 VARIABLE RESISTORS......................................................................... 7-21
3.5 FUSES.................................................................................................... 7-21
4. REPLACEMENT AND ADJUSTMENT......................................7-22
4.1 COVER REPLACEMENT....................................................................... 7-22
Rear Cover......................................................................................... 7-22
Upper Left Cover................................................................................ 7-22
Upper Cover....................................................................................... 7-22
Front Door.......................................................................................... 7-22
Left Front Cover................................................................................. 7-22
Shift Tray............................................................................................ 7-23
Lower Left Cover................................................................................ 7-23
Right Cover........................................................................................ 7-23
Front Shift Tray Cover........................................................................ 7-23
Rear Shift Tray Cover ........................................................................ 7-23
4.2 POSITIONING ROLLER REPLACEMENT............................................. 7-24
4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT .................................. 7-25
4.4 SENSOR REPLACEMNT....................................................................... 7-26
4.4.1 STACK HEIGHT SENSOR 1 AND 2.............................................. 7-26
4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR....................... 7-27
Upper Tray Paper Limit Sensor.......................................................... 7-27
Upper Tray Exit Sensor...................................................................... 7-27
4.4.3 SHIFT TRAY EXIT SENSOR......................................................... 7-28
4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSOR.......... 7-29
Entrance Sensor ................................................................................ 7-29
Stapler Tray Entrance Sensor............................................................ 7-29
4.4.5 STAPLER ROTATION HP SENSOR............................................. 7-30
4.5 STAPLER REMOVAL............................................................................. 7-31
4.6 PUNCH POSITION ADJUSTMENT........................................................ 7-32
Right to left......................................................................................... 7-32
Front to rear ....................................................................................... 7-32
4.7 STACK FEED-OUT MOTOR SPEED ADJUSTMENT............................ 7-33
4.8 ROM HISTORY ...................................................................................... 7-34
LARGE CAPACITY TRAY A698
1. OVERALL MACHINE INFORMATION........................................8-1
1.1 SPECIFICATIONS.................................................................................... 8-1
1.2 MECHANICAL COMPONENT LAYOUT................................................... 8-2
1.3 ELECTRICAL COMPONENT LAYOUT.................................................... 8-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS........................................ 8-4
1.5 DRIVE LAYOUT ....................................................................................... 8-5
Rev. 07/99

xii
A229 SM
2.1 PAPER FEED MECHANISM.................................................................... 8-6
2.2 TRAY LIFT MECHANISM......................................................................... 8-7
Tray lifting conditions ........................................................................... 8-7
Tray lowering conditions ...................................................................... 8-7
2.3 PAPER STACK HEIGHT DETECTION..................................................... 8-9
3. SERVICE TABLES....................................................................8-10
3.1 TEST POINTS........................................................................................ 8-10
4. REPLACEMENT AND ADJUSTMENT......................................8-11
4.1 COVER REMOVAL ................................................................................ 8-11
Tray Cover ......................................................................................... 8-11
Right Cover....................................................................................... 8-11
Front Cover........................................................................................ 8-11
Upper Rear Cover.............................................................................. 8-11
Lower Rear Cover.............................................................................. 8-12
Feed Unit Cover................................................................................. 8-12
4.2 ROLLER REPLACEMENT...................................................................... 8-13
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ............ 8-13
Pick-up Roller..................................................................................... 8-13
Paper Feed Roller.............................................................................. 8-13
Separation Roller ............................................................................... 8-13
4.3 PAPER END SENSOR REPLACEMENT............................................... 8-14
4.4 PAPER FEED SENSOR REPLACEMENT............................................. 8-15
4.5 PAPER POSITION SENSOR REPLACEMENT...................................... 8-16
4.6 PICK-UP SOLENOID REPLACEMENT.................................................. 8-17
4.7 LIFT MOTOR REPLACEMENT .............................................................. 8-18
4.8 SIDE FENCE POSITION CHANGE........................................................ 8-19
COPIER CONNECTOR KIT A808
1. OVERVIEW .................................................................................9-1
1.1 FUNCTION LIST....................................................................................... 9-2
1.2 SPECIFICATIONS.................................................................................... 9-5
2. DETAILED DESCRIPTIONS .......................................................9-6
2.1 BASIC OPERATION................................................................................. 9-6
2.1.1 NO SORT AND NO STAPLE MODE............................................... 9-6
2.1.2 SORT, STAPLE MODE ................................................................... 9-7
2.1.3 OPERATION AT IRREGULAR CONDITIONS................................. 9-8
3. INSTALLATION PROCEDURE...................................................9-9
4. SERVICE TABLES....................................................................9-12
4.1 GENERAL CAUTIONS........................................................................... 9-12
4.2 SERVICE PROGRAM MODE................................................................. 9-12
4.3 USER PROGRAM MODE....................................................................... 9-13
Rev. 2/15/99

xiii
SM A229
4.3.1 UNIQUE UP................................................................................... 9-13
4.3.2 UP MODE TABLE.......................................................................... 9-13
System Setting Table......................................................................... 9-13
Copy Features Table.......................................................................... 9-15
5. TROUBLESHOOTING............................................................... 9-17
NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912
1. OVERALL MACHINE INFORMATION...................................... 10-1
1.1 SPECIFICATIONS.................................................................................. 10-1
1.2 COMPONENT LAYOUT......................................................................... 10-2
1.2.1 MECHANICAL COMPONENT LAYOUT........................................ 10-2
1.2.2 DRIVE LAYOUT............................................................................. 10-3
1.3 ELECTRICAL COMPONENT DESCRIPTIONS...................................... 10-4
2. DETAILED DESCRIPTIONS ..................................................... 10-6
2.1 BASIC OPERATION............................................................................... 10-6
Proof Tray .......................................................................................... 10-6
Bridge Unit ......................................................................................... 10-6
Trays.................................................................................................. 10-6
2.2 PROOF TRAY SENSORS...................................................................... 10-7
2.2.1 PAPER SENSOR........................................................................... 10-7
2.2.2 PAPER OVERFLOW SENSOR..................................................... 10-7
2.3 TRAY SENSORS.................................................................................... 10-8
2.3.1 PAPER SENSOR........................................................................... 10-8
2.3.2 PAPER OVERFLOW SENSOR..................................................... 10-8
2.3.3 TRAY EXIT SENSOR .................................................................... 10-8
2.4 TIMING CHART AND MISFEED DETECTION....................................... 10-9
3. INSTALLATION PROCEDURE............................................... 10-11
3.1 MAILBOX (G909).................................................................................. 10-11
3.1.1 ACCESSORY CHECK................................................................. 10-11
3.1.2 REQUIREMENT OPTIONS FOR MAIN MACHINE ..................... 10-11
3.1.3 INSTALLATION PROCEDURE.................................................... 10-12
1.2 BRIDGE UNIT FOR MAILBOX (G912)................................................. 10-15
1.2.1 ACCESSORY CHECK................................................................. 10-15
1.2.2 INSTALLATION PROCEDURE.................................................... 10-16
4. REPLACEMENT AND ADJUSTMENT.................................... 10-21
4.1 PROOF TRAY UNIT............................................................................. 10-21
4.1.1 PROOF TRAY SENSOR AND PAPER
OVERFLOW SENSORS............................................................... 10-21
4.1.2 PROOF TRANSPORT UNIT........................................................ 10-21
4.2 TRAY UNIT........................................................................................... 10-22
4.2.1 TRAYS......................................................................................... 10-22
4.2.2 PAPER SENSOR, PAPER OVERFLOW SENSOR,
AND TRAY EXIT SENSOR.......................................................... 10-23
Rev. 4/5/99

xiv
A229 SM
Paper Overflow Sensor.................................................................... 10-23
Paper Sensor................................................................................... 10-23
Tray Exit Sensor (above the 1st tray, and in the 3rd, 6th,
and 9th trays)................................................................................... 10-23
4.2.3 MAIN CONTROL BOARD............................................................ 10-24
4.2.4 TRAY EXIT SENSOR ADJUSTMENT......................................... 10-25
5. SERVICE TABLES.................................................................. 10-27
5.1 DIP SWITCHES/VRIABLE RESISTORS/LEDS.................................... 10-27
5.1.1 DIP SWITCHES........................................................................... 10-27
5.1.2 VARIABLE RESISTORS.............................................................. 10-28
5.1.3 LEDS ........................................................................................... 10-28
Rev. 4/5/99

OVERALL MACHINE INFORMATION
COPIER CONNECTOR KIT A808
DETAILED DESCRIPTIONS
NINE-TRAY MAILBOX AND BRIDGE UNIT G909/G912
INSTALLATION
SERVICE TABLES
REPLACEMENT AND ADJUSTMENT
TROUBLESHOOTING
FINISHER A697
LARGE CAPACITY TRAY A698
TAB
POSITION 2 TAB
POSITION 1
TAB
POSITION 3
4
TAB
POSITION 8 TAB
POSITION 7
Rev. 4/5/99

PARTS CATALOG
PN: RCPCA229
A229
RICOH GROUP COMPANIES

A229 PARTS LOCATION AND LIST
Location of Unit....................................................................... 2
1. Exterior 1 (A229)................................................................. 14
2. Exterior 2 (A229)................................................................. 16
3. Operation Panel (A229) ...................................................... 18
4. DF Exterior (A229).............................................................. 20
5. Original Feed 1 (A229)........................................................ 22
6. Original Feed 2 (A229)........................................................ 24
7. Original Feed 3 (A229)........................................................ 26
8. Original Transport (A229) ................................................... 28
9. Original Exit 1 (A229).......................................................... 30
10. Original Exit 2 (A229).......................................................... 32
11. DF Drive Section 1 (A229).................................................. 34
12. DF Drive Section 2 (A229).................................................. 36
13. DF Frame Section (A229)................................................... 38
14. Optics Section 1 (A229)...................................................... 40
15. Optics Section 2 (A229)...................................................... 42
16. Optics Section 3 (A229)...................................................... 44
17. Optics Section 4 (A229)...................................................... 46
18. Laser Unit (A229)................................................................ 48
19. By-pass Feed Unit (A229)................................................... 50
20. Tandem Tray 1 (A229)....................................................... 52
21. Tandem Tray 2 (A229)........................................................ 54
22. Universal Tray (A229)......................................................... 56
23. LCT Tray 1 (A229).............................................................. 58
24. LCT Tray 2 (A229).............................................................. 60
25. Paper Feed Unit 1 (A229)................................................... 62
26. Paper Feed Unit 2 (A229)................................................... 64
27. Paper Feed Unit 3 (A229)................................................... 66
28. Vertical Transport (A229) .................................................... 68
29. Paper Registration 1 (A229)................................................ 70
30. Paper Registration 2 (A229)................................................ 72
31. Paper Registration 3 (A229)................................................ 74
32. Toner Bottle Holder (A229).................................................. 76
33. Toner Hopper Section (A229).............................................. 78
34. Development Unit 1 (A229)................................................. 80
35. Development Unit 2 (A229)................................................. 82
36. PCU 1 (A229)...................................................................... 84
37. PCU 2 (A229)...................................................................... 86
38. PCU 3 (A229)...................................................................... 88
39. PCU 4 (A229)...................................................................... 90
40. Transfer Belt Unit 1 (A229).................................................. 92
41. Transfer Belt Unit 2 (A229).................................................. 94
42. Fusing Unit 1 (A229)............................................................ 96
43. Fusing Unit 2 (A229)............................................................ 98
44. Fusing Unit 3 (A229)............................................................100
45. Paper Exit Unit 1 (A229)......................................................102
46. Paper Exit Unit 2 (A229)......................................................104
47. Paper Exit Unit 3 (A229)......................................................106
48. Inverter/Duplex Unit 1 (A229)..............................................108
49. Inverter/Duplex Unit 2 (A229)..............................................110
50. Inverter/Duplex Unit 3 (A229)..............................................112
51. Inverter/Duplex Unit 4 (A229)..............................................114
52. Inverter/Duplex Unit 5 (A229)..............................................116
53. Drive Section 1 (A229) ........................................................118
54. Drive Section 2 (A229) ........................................................120
55. Drive Section 3 (A229) ........................................................122
A229 PARTS CATALOG
TABLE OF CONTENTS

Rev. 4/99
56. Drive Section 4 (A229)........................................................124
57. Drive Section 5 (A229)........................................................126
58. Electrical Section 1 (A229)..................................................128
59. Electrical Section 2 (A229)..................................................130
60. Electrical Section 3 (A229)..................................................132
61. Frame Section 1 (A229)......................................................134
62. Frame Section 2 (A229)......................................................136
63. Frame Section 3 (A229)......................................................138
64. Option Exit Tray (A814).......................................................140
65. Key Counter unit (A674)......................................................142
66. I/O Board (A229).................................................................144
67. SBICU Board (A229)...........................................................148
68. Decal And Document (A229) ..............................................156
69. Special Tools (A229)...........................................................160
A229 PARTS INDEX
Parts Index............................................................................... 2
LARGE CAPACITY TRAY A698 PARTS LOCATION AND LIST
1. Exterior (A698)..................................................................... 2
2. Tray Drive Section (A698).................................................... 4
3. Paper Feed Section 1 (A698)............................................... 6
4. Paper Feed Section 2 (A698)............................................... 8
5. Electrical Section (A698)...................................................... 10
6. Frame Section (A698).......................................................... 12
7. Decal And Document (A698) ............................................... 14
LARGE CAPACITY TRAY A698 PARTS INDEX
Parts Index............................................................................... 2
FINISHER A697 PARTS LOCATION AND LIST
LOCATION OF UNIT................................................................ 2
1. EXTERIOR (A697).............................................................. 6
2. STAPLE TRANSPORT 1 (A697) ........................................ 8
3. STAPLE TRANSPORT 2 (A697) ........................................ 10
4. STAPLE TRAY 1 (A697)..................................................... 12
5. STAPLE TRAY 2 (A697)..................................................... 14
6. STAPLER UNIT (A697)...................................................... 16
7. TRANSPORT SECTION 1 (A697)...................................... 18
8. TRANSPORT SECTION 2 (A697)...................................... 20
9. PUNCH UNIT (A697).......................................................... 22
10. PAPER EXIT SECTION 1 (A697)....................................... 24
11. PAPER EXIT SECTION 2 (A697)....................................... 26
12. FRAME SECTION (A697) .................................................. 28
13. DRIVE SECTION (A697).................................................... 30
14. ELECTRICAL SECTION (A697)......................................... 32
15. DECAL AND DOCUMENT (A697)...................................... 34
FINISHER A697 PARTS INDEX
PARTS INDEX.......................................................................... 2
PRINTER CONTROL UNIT A852 PARTS LOCATION AND LIST
1. PRINTER CONTROL (A852)................................................ 2
2. PRINTER CONTROL BOARD (A852).................................. 4
3. ACCESSORIES (A852)........................................................ 6
PRINTER CONTROL UNIT A852 PARTS INDEX
PARTS INDEX.......................................................................... 2
MAILBOX & BRIDGE UNIT G909/G912 PARTS LOCATION AND LIST
1. MAILBOX 1......................................................................... 2
2. MAILBOX 2......................................................................... 4
3. MAILBOX 3......................................................................... 6
4. MAILBOX 4......................................................................... 8
5. MAILBOX 5.........................................................................10
6. MAILBOX 6.........................................................................12
7. BRIDGE UNIT..................................................................... 14
MAILBOX & BRIDGE UNIT G909/G912 PARTS INDEX
PARTS INDEX........................................................................ 2