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Ž Ž
Ž

A230/A231/A232
SERVICE MANUAL
RICOH GROUP COMPANIES PN: RCSMA232
Ž

RICOH GROUP COMPANIES
Ž
Ž

A230/A231/A232
SERVICE MANUAL
A230/A231/A232
SERVICE MANUAL

PN: RCSMA232
WARNING
The 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.

Ricoh Corporation
Rev. 5/15/99

LEGEND

PRODUCT COMPANY
CODE
GESTETNER RICOH SAVIN
A230 3235s Aficio 340 9935D
A231 3235 Aficio 350 9935DP
A232 3245 Aficio 450 9945P

DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 5/98 Original Printing
1 6/98 ..Revised pages
2 1/99 G909/G912 Addition
3 5/99 A695 Addition
A230/A231/A232
TABLE OF CONTENTS

1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS .................................................................................... 1-1
1.2 PAPER EXIT TRAY SELECTION............................................................. 1-5
1.3 MACHINE CONFIGURATION .................................................................. 1-6
1.3.1 SYSTEM COMPONENTS ............................................................... 1-6
1.3.2 INSTALLABLE OPTION TABLE ...................................................... 1-8
Copier options ...................................................................................... 1-8
Fax options .......................................................................................... 1-8
1.4 MECHANICAL COMPONENT LAYOUT................................................... 1-9
1.5 PAPER PATH ......................................................................................... 1-11
1.6 ELECTRICAL COMPONENT DESCRIPTIONS...................................... 1-12
1.7 DRIVE LAYOUT ..................................................................................... 1-15
1.8 COPY PROCESS ................................................................................... 1-16
1.8.1 OVERVIEW ................................................................................... 1-16
1.9 BOARD STRUCTURE ............................................................................ 1-18
1.9.1 BLOCK DIAGRAM ......................................................................... 1-18
1.9.2 DESCRIPTIONS ............................................................................ 1-19

2. DETAILED SECTION DESCRIPTIONS....................................... 2-1
2.1 SCANNING............................................................................................... 2-1
2.1.1 OVERVIEW ..................................................................................... 2-1
2.1.2 SCANNER DRIVE ........................................................................... 2-2
2.1.3 ORIGINAL SIZE DETECTION IN PLATEN MODE .......................... 2-3
2.2 IMAGE PROCESSING ............................................................................. 2-5
2.2.1 OVERVIEW ..................................................................................... 2-5
2.2.2 SBU ................................................................................................. 2-6
2.2.3 AUTO IMAGE DENSITY (ADS) ....................................................... 2-7
2.2.4 IPU (IMAGE PROCESSING UNIT).................................................. 2-8
Overview .............................................................................................. 2-8
Image processing path......................................................................... 2-9
SP modes for each image process .................................................... 2-10
Auto shading ...................................................................................... 2-12
Background erase .............................................................................. 2-12
Independent dot erase ....................................................................... 2-13
Filtering, main scan magnification/reduction ...................................... 2-14
Gamma () correction......................................................................... 2-15
Gradation processing ......................................................................... 2-15
2.2.5 MEMORY BLOCK.......................................................................... 2-18
Binary picture processing mode ......................................................... 2-19
Grayscale processing mode............................................................... 2-20
2.2.6 FCI (FINE CHARACTER IMAGE).................................................. 2-21
2.3 LASER EXPOSURE ............................................................................... 2-22

SM i A230/A231/A232
2.3.1 OVERVIEW ................................................................................... 2-22
2.3.2 OPTICAL PATH ............................................................................. 2-23
2.3.3 AUTO POWER CONTROL (APS) ................................................. 2-24
2.3.4 DUAL BEAM WRITING.................................................................. 2-25
2.3.5 LASER BEAM PITCH CHANGE MECHANISM ............................. 2-26
2.3.6 LD SAFETY SWITCHES ............................................................... 2-27
2.4 PHOTOCONDUCTOR UNIT (PCU)........................................................ 2-28
2.4.1 OVERVIEW ................................................................................... 2-28
2.4.2 DRIVE MECHANISM ..................................................................... 2-29
2.5 DRUM CHARGE..................................................................................... 2-30
2.5.1 OVERVIEW ................................................................................... 2-30
2.5.2 CHARGE ROLLER VOLTAGE CORRECTION ............................. 2-31
Correction for environmental conditions............................................. 2-31
Correction for paper width and thickness (bypass tray only) .............. 2-32
2.5.3 ID SENSOR PATTERN PRODUCTION TIMING ........................... 2-33
2.5.4 DRUM CHARGE ROLLER CLEANING ......................................... 2-33
2.6 DEVELOPMENT..................................................................................... 2-34
2.6.1 OVERVIEW ................................................................................... 2-34
2.6.2 DRIVE MECHANISM ..................................................................... 2-35
2.6.3 DEVELOPER MIXING ................................................................... 2-36
2.6.4 DEVELOPMENT BIAS................................................................... 2-37
Correction for paper width and thickness (bypass tray only) .............. 2-37
2.6.5 TONER SUPPLY ........................................................................... 2-38
Toner bottle replenishment mechanism ............................................. 2-38
Toner supply mechanism ................................................................... 2-39
2.6.6 TONER DENSITY CONTROL ....................................................... 2-40
Overview ............................................................................................ 2-40
Toner density control flow chart ......................................................... 2-40
Sensor control mode .......................................................................... 2-41
Image Pixel Count Control Mode. ...................................................... 2-42
2.6.7 TONER NEAR END/END DETECTION......................................... 2-43
Toner near end/end detection flow chart............................................ 2-43
2.6.8 TONER END RECOVERY............................................................. 2-45
Toner end recovery flow chart............................................................ 2-45
2.6.9 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS .......... 2-46
2.7 DRUM CLEANING AND TONER RECYCLING...................................... 2-47
2.7.1 DRUM CLEANING......................................................................... 2-47
2.7.2 TONER RECYCLING .................................................................... 2-48
2.8 PAPER FEED ......................................................................................... 2-49
2.8.1 OVERVIEW ................................................................................... 2-49
2.8.2 PAPER FEED DRIVE MECHANISM ............................................. 2-50
2.8.3 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM 2-51
2.8.4 PAPER LIFT MECHANISM............................................................ 2-52
2.8.5 PAPER END DETECTION............................................................. 2-54
2.8.6 PAPER REGISTRATION............................................................... 2-55
2.8.7 PAPER FEED AND JAM TIMING .................................................. 2-56
2.9 IMAGE TRANSFER AND PAPER SEPARATION .................................. 2-57
2.9.1 OVERVIEW ................................................................................... 2-57
2.9.2 BELT DRIVE MECHANISM ........................................................... 2-58

A230/A231/A232 ii SM
2.9.3 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM.. 2-58
2.9.4 TRANSFER BELT UNIT CONTACT MECHANISM ....................... 2-60
2.9.5 TRANSFER BELT CHARGE ......................................................... 2-61
Overview ............................................................................................ 2-61
Correction for paper width and thickness ........................................... 2-62
Currents applied to leading edge and image areas............................ 2-62
2.9.6 TRANSFER BELT CLEANING MECHANISM................................ 2-63
2.10 IMAGE FUSING AND PAPER EXIT ..................................................... 2-64
2.10.1 OVERVIEW ................................................................................. 2-64
2.10.2 FUSING DRIVE AND RELEASE MECHANISM........................... 2-65
2.10.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM .................... 2-66
2.10.4 PRESSURE ROLLER.................................................................. 2-67
2.10.5 CLEANING MECHANISM............................................................ 2-67
2.10.6 FUSING TEMPERATURE CONTROL......................................... 2-68
Temperature Control .......................................................................... 2-68
Fusing Idling....................................................................................... 2-68
2.10.7 OVERHEAT PROTECTION......................................................... 2-69
2.11 ENERGY SAVER MODES ................................................................... 2-70
2.11.1 OVERVIEW ................................................................................. 2-70
2.11.2 ENERGY SAVER MODE ............................................................. 2-71
Entering the energy saver mode ........................................................ 2-71
What happens in energy saver mode................................................. 2-71
Return to stand-by mode.................................................................... 2-71
2.11.3 LOW POWER MODE .................................................................. 2-72
Entering the low power mode............................................................. 2-72
What happens in low power mode ..................................................... 2-72
Return to stand-by mode.................................................................... 2-72
2.11.4 AUTO OFF MODE ....................................................................... 2-73
Entering auto off mode....................................................................... 2-73
What happens in auto off mode ......................................................... 2-73
Returning to stand-by mode ............................................................... 2-73
2.11.5 NIGHT MODE .............................................................................. 2-74
Entering night stand-by and night modes........................................... 2-74
What happens in night stand-by and night modes ............................. 2-74
Returning to stand-by mode ............................................................... 2-75

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.............................................................. 3-3
3.2 INSTALLATION FLOW CHART................................................................ 3-4
3.3 COPIER INSTALLATION.......................................................................... 3-5
3.3.1 ACCESSORY CHECK ..................................................................... 3-5
3.3.2 INSTALLATION PROCEDURE........................................................ 3-6
3.4 PAPER TRAY UNIT INSTALLATION ..................................................... 3-12
3.4.1 ACCESSORY CHECK ................................................................... 3-12
3.4.2 INSTALLATION PROCEDURE...................................................... 3-13

SM iii A230/A231/A232
3.5 INTERCHANGE UNIT INSTALLATION .................................................. 3-17
3.5.1 ACCESSORY CHECK ................................................................... 3-17
3.5.2 INSTALLATION PROCEDURE...................................................... 3-18
3.6 1-BIN TRAY UNIT INSTALLATION ........................................................ 3-22
3.6.1 ACCESSORY CHECK ................................................................... 3-22
3.6.2 INSTALLATION PROCEDURE...................................................... 3-23
3.7 BRIDGE UNIT INSTALLATION .............................................................. 3-28
3.7.1 ACCESSORY CHECK ................................................................... 3-28
3.7.2 INSTALLATION PROCEDURE...................................................... 3-29
3.8 AUTO REVERSE DOCUMENT FEEDER INSTALLATION .................... 3-31
3.8.1 ACCESSORY CHECK ................................................................... 3-31
3.8.2 INSTALLATION PROCEDURE...................................................... 3-32
3.9 DUPLEX UNIT INSTALLATION.............................................................. 3-34
3.9.1 ACCESSORY CHECK ................................................................... 3-34
3.9.2 INSTALLATION PROCEDURE...................................................... 3-35
3.10 BY-PASS FEED UNIT INSTALLATION ................................................ 3-39
3.10.1 ACCESSORY CHECK ................................................................. 3-39
3.10.2 INSTALLATION PROCEDURE.................................................... 3-39
3.11 LCT INSTALLATION............................................................................. 3-41
3.11.1 ACCESSORY CHECK ................................................................. 3-41
3.11.2 INSTALLATION PROCEDURE.................................................... 3-42
3.12 1,000-SHEET FINISHER INSTALLATION............................................ 3-44
3.12.1 ACCESSORY CHECK ................................................................. 3-44
3.12.2 INSTALLATION PROCEDURE.................................................... 3-45
3.13 3,000-SHEET FINISHER INSTALLATION............................................ 3-48
3.13.1 ACCESSORY CHECK ................................................................. 3-48
3.13.2 INSTALLATION PROCEDURE.................................................... 3-49
3.14 PUNCH UNIT INSTALLATION ............................................................. 3-52
3.14.1 ACCESSORY CHECK ................................................................. 3-52
3.14.2 INSTALLATION PROCEDURE.................................................... 3-53
3.15 PLATEN COVER INSTALLATION........................................................ 3-56
3.16 IMAGE ENHACEMENT KIT (HDD) INSTALLATION ............................ 3-57
3.16.1 ACCESSORY CHECK ................................................................. 3-57
3.16.2 INSTALLATION PROCEDURE.................................................... 3-58
3.17 ELECTRIC SORT KIT INSTALLATION ................................................ 3-60
3.18 KEY COUNTER INSTALLATION ......................................................... 3-61
3.19 ANTI-CONDENSATION HEATER ........................................................ 3-63
3.20 TRAY HEATER..................................................................................... 3-65
3.21 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) .............................. 3-66

4. SERVICE TABLES ...................................................................... 4-1
4.1 GENERAL CAUTIONS ............................................................................. 4-1
4.1.1 DRUM .............................................................................................. 4-1
4.1.2 TRANSFER BELT UNIT .................................................................. 4-2
4.1.3 SCANNER UNIT .............................................................................. 4-2
4.1.4 LASER UNIT.................................................................................... 4-2
4.1.5 CHARGE ROLLER .......................................................................... 4-3
4.1.6 DEVELOPMENT.............................................................................. 4-3
4.1.7 FUSING UNIT .................................................................................. 4-3

A230/A231/A232 iv SM
4.1.8 PAPER FEED .................................................................................. 4-4
4.1.9 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 .................................. 4-6
Selecting the Program Number ............................................................ 4-6
Inputting a Value or Setting for an SP Mode ........................................ 4-6
4.2.2 SERVICE PROGRAM MODE TABLES ........................................... 4-7
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 (SP6-007) .............................................................. 4-55
4.2.5 OUTPUT CHECK........................................................................... 4-56
Main Machine Output Check (SP5-804)............................................. 4-56
ADF Output Check (SP6-008)............................................................ 4-57
4.2.6 SYSTEM PARAMETER AND DATA LISTS (SMC LISTS)............. 4-57
4.2.7 NIP BAND WIDTH ADJUSTMENT (SP1-109) ............................... 4-58
4.2.8 MEMORY ALL CLEAR (SP5-801) ................................................. 4-59
4.2.9 SOFTWARE RESET...................................................................... 4-60
4.2.10 SYSTEM SETTING AND COPY SETTING (UP MODE) RESET. 4-60
System Setting Reset......................................................................... 4-60
Copy Setting Reset ............................................................................ 4-60
4.3 PROGRAM DOWNLOAD ....................................................................... 4-61
Downloading to the BICU................................................................... 4-61
Download from BICU to Flash Memory Card ..................................... 4-63
4.4 USER PROGRAM MODE....................................................................... 4-65
4.4.1 HOW TO ENTER AND EXIT UP MODE ........................................ 4-65
4.4.2 UP MODE TABLE.......................................................................... 4-65
System Setting Table ......................................................................... 4-65
Copy Setting Table............................................................................. 4-66
4.5 TEST POINTS/DIP SWITCHES/LEDS ................................................... 4-67
4.5.1 DIP SWITCHES ............................................................................. 4-67
4.5.2 TEST POINTS ............................................................................... 4-67
4.5.3 LEDS ............................................................................................. 4-68
4.6 SPECIAL TOOLS AND LUBRICANTS ................................................... 4-68
4.6.1 SPECIAL TOOLS........................................................................... 4-68
4.6.2 LUBRICANTS ................................................................................ 4-68

5. PREVENTIVE MAINTENANCE SCHEDULE............................... 5-1
5.1 PM TABLE ................................................................................................ 5-1

6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 SCANNER UNIT....................................................................................... 6-1
6.1.1 EXPOSURE GLASS ........................................................................ 6-1
6.1.2 SCANNER EXTERIOR/OPERATION PANEL ................................. 6-2
6.1.3 LENS BLOCK/SBU ASSEMBLY...................................................... 6-3

SM v A230/A231/A232
6.1.4 ORIGINAL SIZE SENSORS ............................................................ 6-4
6.1.5 EXPOSURE LAMP .......................................................................... 6-5
6.1.6 SCANNER H.P SENSOR/PLATEN COVER SENSOR.................... 6-6
6.1.7 SCANNER MOTOR ......................................................................... 6-7
6.1.8 SIB/LAMP STABILIZER................................................................... 6-8
6.1.9 SCANNER WIRE ............................................................................. 6-9
6.1.10 SCANNER UNIT POSITIONING ADJUSTMENT......................... 6-12
6.2 LASER UNIT........................................................................................... 6-14
6.2.1 CAUTION DECAL LOCATIONS .................................................... 6-14
6.2.2 LASER UNIT.................................................................................. 6-15
6.2.3 POLYGON MIRROR MOTOR ....................................................... 6-16
6.2.4 LASER SYNCHRONIZATION DETECTOR ................................... 6-17
6.2.5 LD UNIT ......................................................................................... 6-17
Laser beam pitch adjustment ............................................................. 6-18
6.3 PHOTOCONDUCTOR UNIT (PCU)........................................................ 6-19
6.3.1 PCU ............................................................................................... 6-19
6.3.2 DRUM ............................................................................................ 6-20
6.3.3 PICK-OFF PAWLS......................................................................... 6-21
6.3.4 CHARGE ROLLER/CHARGE ROLLER CLEANING PAD ............. 6-22
6.3.5 DRUM CLEANING BLADE ............................................................ 6-23
6.3.6 ID SENSOR ................................................................................... 6-23
6.4 DEVELOPMENT..................................................................................... 6-24
6.4.1 DEVELOPMENT UNIT .................................................................. 6-24
6.4.2 DEVELOPMENT FILTER .............................................................. 6-25
6.4.3 DEVELOPMENT ROLLER ............................................................ 6-25
6.4.4 DEVELOPER ................................................................................. 6-26
6.4.5 TD SENSOR .................................................................................. 6-27
6.5 TRANSFER UNIT ................................................................................... 6-28
6.5.1 TRANSFER BELT UNIT ................................................................ 6-28
6.5.2 TRANSFER BELT.......................................................................... 6-29
6.5.3 TRANSFER BELT CLEANING BLADE/TONER OVERFLOW
SENSOR........................................................................................ 6-30
Transfer Belt Cleaning Blade ............................................................. 6-30
Toner Overflow Sensor ...................................................................... 6-30
6.5.4 RIGHT COVER .............................................................................. 6-31
6.6 PAPER FEED ......................................................................................... 6-32
6.6.1 PICK-UP, SEPARATION, AND FEED ROLLERS.......................... 6-32
6.6.2 LOWER RIGHT COVER/LOWER REAR COVER ......................... 6-32
6.6.3 RELAY/UPPER PAPER FEED/LOWER PAPER FEED
CLUTCHES ................................................................................... 6-33
6.6.4 UPPER PAPER FEED UNIT.......................................................... 6-34
6.6.5 LOWER PAPER FEED UNIT......................................................... 6-35
6.6.6 PAPER END/PAPER HEIGHT/RELAY SENSORS ....................... 6-36
6.6.7 REGISTRATION SENSOR ............................................................ 6-37
6.7 FUSING .................................................................................................. 6-39
6.7.1 FUSING UNIT ................................................................................ 6-39
6.7.2 HOT ROLLER STRIPPERS AND FUSING LAMP ......................... 6-40
6.7.3 THERMISTOR AND THERMOFUSE............................................. 6-41
6.7.4 CLEANING ROLLER ..................................................................... 6-42

A230/A231/A232 vi SM
6.7.5 HOT ROLLER AND PRESSURE ROLLER ................................... 6-43
6.8 DRIVE AREA .......................................................................................... 6-44
6.8.1 REGISTRATION CLUTCH AND TRANSFER BELT CLUTCH ...... 6-44
6.8.2 MAIN MOTOR................................................................................ 6-45
6.8.3 TONER BOTTLE MOTOR ............................................................. 6-46
6.9 PCBS ...................................................................................................... 6-47
6.9.1 POWER PACK............................................................................... 6-47
6.9.2 I/O BOARD .................................................................................... 6-47
6.9.3 BICU BOARD................................................................................. 6-48
6.9.4 PSU ............................................................................................... 6-49
6.10 HARD DISK .......................................................................................... 6-50
6.11 COPY ADJUSTMENTS: PRINTING/SCANNING ................................. 6-51
6.11.1 PRINTING.................................................................................... 6-51
Registration - Leading Edge/Side-to-Side .......................................... 6-51
Blank Margin ...................................................................................... 6-52
Main Scan Magnification .................................................................... 6-52
Parallelogram Image Adjustment ....................................................... 6-53
6.11.2 SCANNING .................................................................................. 6-54
Registration: Platen Mode.................................................................. 6-54
Magnification ...................................................................................... 6-54
Scanner Skew Image Adjustment ...................................................... 6-55
6.11.3 ADF IMAGE ADJUSTMENT ........................................................ 6-56
Registration ........................................................................................ 6-56

7. TROUBLESHOOTING................................................................. 7-1
7.1 SERVICE CALL CONDITIONS................................................................. 7-1
7.1.1 SUMMARY....................................................................................... 7-1
7.1.2 SC CODE DESCRIPTIONS............................................................. 7-2
7.2 ELECTRICAL COMPONENT DEFECTS................................................ 7-24
7.2.1 SENSORS ..................................................................................... 7-24
7.2.2 SWITCHES .................................................................................... 7-25
7.3 BLOWN FUSE CONDITIONS................................................................. 7-26

SM vii A230/A231/A232
PAPER TRAY UNIT A682

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 DESCRIPTION .......................................... 8-4
1.5 DRIVE LAYOUT ....................................................................................... 8-5

2. DETAILED DESCRIPTIONS ....................................................... 8-6
2.1 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM ........... 8-6
2.2 PAPER LIFT MECHANISM ...................................................................... 8-7
2.3 PAPER END DETECTION ....................................................................... 8-9
2.4 PAPER HEIGHT DETECTION ............................................................... 8-10

3. SERVICE TABLES .................................................................... 8-11
3.1 DIP SWITCHES...................................................................................... 8-11
3.2 TEST POINTS ........................................................................................ 8-11
3.3 SWITCHES............................................................................................. 8-11
3.4 FUSES.................................................................................................... 8-11

4. REPLACEMENT AND ADJUSTMENT...................................... 8-12
4.1 COVER REPLACEMENT ....................................................................... 8-12
Right Cover ........................................................................................ 8-12
Rear 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 TRAY MOTOR REPLACEMENT ............................................................ 8-14
4.4 PAPER FEED AND RELAY CLUTCH REPLACEMENT......................... 8-15
4.5 PAPER FEED UNIT REPLACEMENT .................................................... 8-16
Upper Paper Feed Unit ...................................................................... 8-17
Lower Paper Feed Unit ...................................................................... 8-17
4.6 PAPER END, TRAY LIFT, AND RELAY SENSOR
REPLACEMENT ..................................................................................... 8-18
Paper End Sensor.............................................................................. 8-18
Tray Lift Sensor.................................................................................. 8-18
Relay Sensor...................................................................................... 8-18

LCT (A683)

1. OVERALL MACHINE INFORMATION ........................................ 9-1
1.1 SPECIFICATIONS .................................................................................... 9-1
1.2 MECHANICAL COMPONENT LAYOUT................................................... 9-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................... 9-3

A230/A231/A232 viii SM
1.4 ELECTRICAL COMPONENT DESCRIPTION .......................................... 9-4
1.5 DRIVE LAYOUT ....................................................................................... 9-5

2. DETAILED DESCRIPTIONS ....................................................... 9-6
2.1 PAPER FEED MECHANISM .................................................................... 9-6
2.2 TRAY LIFT AND PAPER HEIGHT DETECTION MECHANISM ............... 9-7
Tray lifting conditions ........................................................................... 9-7
Tray lowering conditions ...................................................................... 9-7
2.3 TRAY UNIT SLIDE MECHANISM............................................................. 9-8

3. SERVICE TABLES ...................................................................... 9-9
3.1 DIP SWITCHES........................................................................................ 9-9
3.2 TEST POINTS .......................................................................................... 9-9
3.3 SWITCHES............................................................................................... 9-9
3.4 FUSES...................................................................................................... 9-9

4. REPLACEMENT AND ADJUSTMENT...................................... 9-10
4.1 COVER REPLACEMENT ....................................................................... 9-10
Tray Cover ......................................................................................... 9-10
Front Cover ........................................................................................ 9-10
Rear Cover......................................................................................... 9-10
Right Lower Cover ............................................................................. 9-10
Upper Cover....................................................................................... 9-10
4.2 ROLLER REPLACEMENT...................................................................... 9-11
4.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ............ 9-11
Pick-up Roller..................................................................................... 9-11
Paper Feed Roller .............................................................................. 9-11
Separation Roller ............................................................................... 9-11
4.3 TRAY LIFT AND PAPER END SENSOR REPLACEMENT.................... 9-12
Tray Lift Sensor.................................................................................. 9-12
Paper End Sensor.............................................................................. 9-12
4.4 RELAY SENSOR REPLACEMENT ........................................................ 9-13
4.5 SIDE FENCE POSITION CHANGE ........................................................ 9-14

BY-PASS A689

1 OVERALL MACHINE INFORMATION ....................................... 10-1
1.1 SPECIFICATIONS .................................................................................. 10-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 10-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 10-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 10-3

2 DETAILED DESCRIPTIONS ...................................................... 10-4
2.1 BASIC OPERATION............................................................................... 10-4
2.2 PAPER SIZE DETECTION ..................................................................... 10-5

3 REPLACEMENT AND ADJUSTMENT....................................... 10-6

SM ix A230/A231/A232
3.1 COVER REPLACEMENT ....................................................................... 10-6
Rear Cover......................................................................................... 10-6
Front Cover ........................................................................................ 10-6
Hinge Cover ....................................................................................... 10-6
Upper Cover....................................................................................... 10-6
3.2 PAPER FEED AND PICK-UP ROLLER REPLACEMENT ...................... 10-7
Paper Feed Roller .............................................................................. 10-7
Pick-up Roller..................................................................................... 10-7
3.3 SEPARATION ROLLER REPLACEMENT.............................................. 10-8
3.4 PAPER END SENSOR AND PICK-UP SOLENOID
REPLACEMENT ..................................................................................... 10-9
Paper End Sensor.............................................................................. 10-9
Pick-up Solenoid ................................................................................ 10-9
3.5 PAPER SIZE SENSOR BOARD REPLACEMENT ............................... 10-10
3.6 BY-PASS TABLE REMOVAL ............................................................... 10-11
3.7 PAPER FEED CLUTCH REPLACEMENT............................................ 10-12

1-BIN TRAY A684

1. OVERALL MACHINE INFORMATION ...................................... 11-1
1.1 SPECIFICATIONS .................................................................................. 11-1
1.2 MECHANICAL COMPONENT AND DRIVE LAYOUT ............................ 11-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 11-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 11-3

2. DETAILED DESCRIPTIONS ..................................................... 11-4
2.1 BASIC OPERATION............................................................................... 11-4

3. REPLACEMENT AND ADJUSTMENT...................................... 11-5
3.1 COVER REMOVAL ................................................................................ 11-5
Front Cover ........................................................................................ 11-5
Upper Cover....................................................................................... 11-5
Rear Cover......................................................................................... 11-5
3.2 PAPER SENSOR REPLACEMENT........................................................ 11-6
3.3 ENTRANCE AND PAPER LIMIT SENSOR REPLACEMENT ................ 11-7
Paper Limit Sensor............................................................................. 11-7
Entrance Sensor ................................................................................ 11-7

AUTO DOCUMENT FEEDER A680

1. OVERALL MACHINE INFORMATION ...................................... 12-1
1.1 SPECIFICATIONS .................................................................................. 12-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 12-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 12-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 12-4
1.5 DRIVE LAYOUT ..................................................................................... 12-6

A230/A231/A232 x SM
2. DETAILED DESCRIPTION........................................................ 12-7
2.1 ORIGINAL FEED-IN PREPARATION MECHANISM.............................. 12-7
Original Stopper Release (top diagram):............................................ 12-7
Pick-up Roller Release (bottom diagram): ......................................... 12-7
2.2 PICK-UP AND SEPARATION MECHANISM.......................................... 12-8
2.3 ORIGINAL FEED MECHANISM ............................................................. 12-9
2.4 ORIGINAL FEED DRIVE MECHANISM ............................................... 12-10
Original Feed Start ........................................................................... 12-10
Original Feed.................................................................................... 12-10
2.5 ORIGINAL SIZE DETECTION .............................................................. 12-11
2.6 ORIGINAL TRANSPORT MECHANISM............................................... 12-12
2.7 ORIGINAL SKEW CORRECTION MECHANISM ................................. 12-13
2.8 ORIGINAL INVERSION AND FEED-OUT MECHANISM ..................... 12-14
2.8.1 GENERAL OPERATION.............................................................. 12-14
2.8.2 ORIGINAL INVERSION MECHANISM ........................................ 12-15
2.8.3 ORIGINAL EXIT MECHANISM
(SINGLE-SIDED ORIGINAL MODE) ........................................... 12-16
2.8.4 ORIGINAL EXIT MECHANISM
(DOUBLE-SIDED ORIGINAL MODE).......................................... 12-17
2.9 STAMP ................................................................................................. 12-18
2.10 JAM CONDITIONS ............................................................................. 12-19
2.11 TIMING CHARTS ............................................................................... 12-20
2.11.1 A4 SIDEWAYS: ONE-SIDED ORIGINAL
(3 ORIGINALS).......................................................................... 12-20
2.11.2 A4 SIDEWAYS: TWO-SIDED ORIGINAL
(2 ORIGINALS).......................................................................... 12-21

3. SERVICE TABLES .................................................................. 12-22
3.1 DIP SWITCHES.................................................................................... 12-22
3.2 TEST POINTS ...................................................................................... 12-22
3.3 VARIABLE RESISTORS....................................................................... 12-22
3.4 FUSES.................................................................................................. 12-22

4. REPLACEMENT AND ADJUSTMENT.................................... 12-23
4.1 COVER REPLACEMENT ..................................................................... 12-23
Front Cover Removal ....................................................................... 12-23
Rear Cover Removal........................................................................ 12-23
Left Cover Removal ......................................................................... 12-23
Upper Exit Cover Removal............................................................... 12-23
Original Tray Removal ..................................................................... 12-23
Upper Cover Removal...................................................................... 12-23
4.2 FEED UNIT REMOVAL AND SEPARATION ROLLER
REPLACEMENT ................................................................................... 12-24
4.3 FEED BELT REPLACEMENT .............................................................. 12-25
4.4 SENSOR REPLACEMENT................................................................... 12-26
4.4.1 ORIGINAL SET, ORIGINAL WIDTH AND
REGISTRATION SENSORS ....................................................... 12-26
Original Set Sensor .......................................................................... 12-26

SM xi A230/A231/A232
Original Width Sensor ...................................................................... 12-26
Registration Sensor.......................................................................... 12-26
4.4.2 ENTRANCE SENSOR ................................................................. 12-27
4.4.3 EXIT SENSOR AND INVERTER SENSOR ................................. 12-28
Exit Sensor....................................................................................... 12-28
Inverter Sensor................................................................................. 12-28
4.5 TRANSPORT BELT REPLACEMENT .................................................. 12-29
4.6 SIDE-TO-SIDE REGISTRATION ADJUSTMENT................................. 12-30
SP Mode .......................................................................................... 12-30
Original Table Position ..................................................................... 12-30

INTERCHANGE UNIT A690

1. OVERALL MACHINE INFORMATION ...................................... 13-1
1.1 SPECIFICATIONS .................................................................................. 13-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 13-2
1.3 DRIVE LAYOUT ..................................................................................... 13-3

2. DETAILED DESCRIPTION........................................................ 13-4
2.1 JUNCTION GATE MECHANISM ............................................................ 13-4
To the Exit Tray or Bridge Unit
(for the Upper Tray, Left Tray, or Finisher)......................................... 13-4
To the 1-bin Tray................................................................................ 13-4
To the Duplex Unit ............................................................................. 13-4

3. REPLACEMENT AND ADJUSTMENT...................................... 13-5
3.1 EXIT SENSOR (COPIER) REPLACEMENT........................................... 13-5

DUPLEX A687

1. OVERALL MACHINE INFORMATION ...................................... 14-1
1.1 SPECIFICATIONS .................................................................................. 14-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 14-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 14-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 14-4
1.5 DRIVE LAYOUT ..................................................................................... 14-5

2. DETAILED DESCRIPTIONS ..................................................... 14-6
2.1 BASIC OPERATION............................................................................... 14-6
Larger than A4 lengthwise/LT lengthwise .......................................... 14-6
Up to A4 lengthwise/LT lengthwise .................................................... 14-7
2.2 FEED IN AND EXIT MECHANISM ......................................................... 14-8
Feed-in............................................................................................... 14-8
Inversion and Exit............................................................................... 14-8

3. REPLACEMENT AND ADJUSTMENT...................................... 14-9

A230/A231/A232 xii SM
3.1 COVER REMOVAL ................................................................................ 14-9
3.2 ENTRANCE SENSOR REPLACEMENT .............................................. 14-10
3.3 EXIT SENSOR REPLACEMENT.......................................................... 14-11

BRIDGE UNIT A688

1. OVERALL MACHINE INFORMATION ...................................... 15-1
1.1 SPECIFICATIONS .................................................................................. 15-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 15-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 15-3
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 15-3
1.5 DRIVE LAYOUT ..................................................................................... 15-4

2. DETAILED DESCRIPTION........................................................ 15-5
2.1 JUNCTION GATE MECHANISM ............................................................ 15-5

3. REPLACEMENT AND ADJUSTMENT...................................... 15-6
3.1 EXIT SENSOR REPLACEMENT............................................................ 15-6

1,000-SHEET FINISHER A681

1. OVERALL MACHINE INFORMATION ...................................... 16-1
1.1 SPECIFICATIONS .................................................................................. 16-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 16-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 16-3
1.4 ELECTRICAL COMPONENT DESCRIPTIONS...................................... 16-4
1.5 DRIVE LAYOUT ..................................................................................... 16-6

2. DETAILED DESCRIPTIONS ..................................................... 16-7
2.1 JUNCTION GATE MECHANISM ............................................................ 16-7
Staple mode ....................................................................................... 16-7
No staple mode .................................................................................. 16-7
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ........................... 16-8
2.3 EXIT GUIDE PLATE OPEN/CLOSE MECHANISM ................................ 16-9
2.4 STAPLER ............................................................................................. 16-10
2.5 FEED OUT MECHANISM..................................................................... 16-11
2.6 SHIFT TRAY UP/DOWN MECHANISM................................................ 16-12
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM ......................................... 16-13
2.8 JAM CONDITIONS ............................................................................... 16-14
2.9 TIMING CHARTS ................................................................................. 16-15
2.9.1 NO STAPLE MODE (A4 SIDEWAYS, 3 SHEETS/2SETS).......... 16-15
2.9.2 STAPLE MODE (A4 SIDEWAYS, 2 SHEETS/2 SETS) ............... 16-16

3. SERVICE TABLE .................................................................... 16-17
3.1 DIP SWITCH TABLE ............................................................................ 16-17
3.2 TEST POINTS ...................................................................................... 16-17

SM xiii A230/A231/A232
3.3 FUSES.................................................................................................. 16-17

4. REPLACEMENT AND ADJUSTMENT.................................... 16-18
4.1 COVER REMOVAL .............................................................................. 16-18
Front Door........................................................................................ 16-18
Front Cover ...................................................................................... 16-18
Rear Cover....................................................................................... 16-18
Upper Cover..................................................................................... 16-18
Lower Left Cover.............................................................................. 16-19
Front Shift Tray Cover...................................................................... 16-19
Rear Shift Tray Cover ...................................................................... 16-19
Shift Tray.......................................................................................... 16-19
4.2 ENTRANCE SENSOR REPLACEMENT .............................................. 16-20
4.3 EXIT SENSOR REPLACEMENT.......................................................... 16-21
4.4 STACK HEIGHT SENSOR REPLACEMENT ....................................... 16-22
4.5 POSITIONING ROLLER REPLACEMENT ........................................... 16-23
4.6 STAPLER REPLACEMENT.................................................................. 16-24

3,000-SHEET FINISHER A697

1. OVERALL MACHINE INFORMATION ...................................... 17-1
1.1 SPECIFICATIONS .................................................................................. 17-1
1.2 MECHANICAL COMPONENT LAYOUT................................................. 17-3
1.3 ELECTRICAL COMPONENT LAYOUT .................................................. 17-4
1.4 ELECTRICAL COMPONENT DESCRIPTION ........................................ 17-5
1.5 DRIVE LAYOUT ..................................................................................... 17-7

2. DETAILED DESCRIPTIONS ..................................................... 17-8
2.1 TRAY AND STAPLER JUNCTION GATE MECHANISM........................ 17-8
Normal mode...................................................................................... 17-8
Sort/stack mode ................................................................................. 17-8
Staple mode ....................................................................................... 17-8
2.2 JOGGER UNIT PAPER POSITIONING MECHANISM ........................... 17-9
Vertical Paper Alignment.................................................................... 17-9
Horizontal Paper Alignment ............................................................... 17-9
2.3 STAPLER UNIT MOVEMENT MECHANISM........................................ 17-10
Side-to-side: ..................................................................................... 17-10
Rotation:........................................................................................... 17-10
2.4 STAPLER ............................................................................................. 17-11
2.5 FEED-OUT MECHANISM..................................................................... 17-12
2.6 SHIFT TRAY UP/DOWN MECHANISM................................................ 17-13
2.7 SHIFT TRAY SIDE-TO-SIDE MECHANISM ......................................... 17-14
2.8 PUNCH UNIT DRIVE MECHANISM ..................................................... 17-15
2.9 PUNCH WASTE COLLECTION MECHNISM ....................................... 17-16
2.10 JAM CONDITIONS ............................................................................. 17-17
2.11 TIMING CHARTS ............................................................................... 17-18
2.11.1 A4 SIDEWAYS (2 SHEETS): NORMAL AND
PUNCH MODE........................................................................... 17-18

A230/A231/A232 xiv SM
Rev. 08/98
2.11.2 A4 SIDEWAYS (2 SHEETS): SORT/STACK AND
PUNCH MODE ............................................................................17-19
2.11.3 A4 SIDEWAYS (2 SHEETS): STAPLE AND
PUNCH MODE ............................................................................17-20

3. SERVICE TABLES ................................................................... 17-21
3.1 DIP SWITCHES .....................................................................................17-21
3.2 TEST POINTS........................................................................................17-21
3.3 LED ........................................................................................................17-21
3.4 VARIABLE RESISTORS ........................................................................17-21
3.5 FUSES ...................................................................................................17-21

4. REPLACEMENT AND ADJUSTMENT..................................... 17-22
4.1 COVER REPLACEMENT.......................................................................17-22
Rear Cover ........................................................................................17-22
Upper Left Cover ...............................................................................17-22
Upper Cover ......................................................................................17-22
Front Door .........................................................................................17-22
Left Front Cover.................................................................................17-22
Shift Tray ...........................................................................................17-23
Lower Left Cover ...............................................................................17-23
Right Cover........................................................................................17-23
Front Shift Tray Cover .......................................................................17-23
Rear Shift Tray Cover........................................................................17-23
4.2 POSITIONING ROLLER REPLACEMENT ............................................17-24
4.3 ALIGNMENT BRUSH ROLLER REPLACEMENT .................................17-25
4.4 SENSOR REPLACEMNT.......................................................................17-26
4.4.1 STACK HEIGHT SENSOR 1 AND 2 .............................................17-26
4.4.2 UPPER TRAY PAPER LIMIT AND EXIT SENSOR ......................17-27
Upper Tray Paper Limit Sensor .........................................................17-27
Upper Tray Exit Sensor .....................................................................17-27
4.4.3 SHIFT TRAY EXIT SENSOR ........................................................17-28
4.4.4 ENTRANCE AND STAPLER TRAY ENTRANCE SENSOR .........17-29
Entrance Sensor................................................................................17-29
Stapler Tray Entrance Sensor ...........................................................17-29
4.4.5 STAPLER ROTATION HP SENSOR ............................................17-30
4.5 STAPLER REMOVAL ............................................................................17-31
4.6 PUNCH POSITION ADJUSTMENT .......................................................17-32
Right to left ........................................................................................17-32
Front to rear.......................................................................................17-32
4.7 STACK FEED-OUT MOTOR SPEED ADJUSTMENT ...........................17-33

SM xv A230/A231/A232
Rev. 08/98

TM TM
SWAPBOXTM AND SWAPFTLTM INSTALLATION MANUAL

1. INTRODUCTION ........................................................................ 18-1
1.1 PRECAUTIONS