Gestetner B147 User manual

B147/B149/B190
SERVICE MANUAL
001892MIUMIU
RICOH GROUP COMPANIES

B147/B149/B190
SERVICE MANUAL
RICOH GROUP COMPANIES
®
®

B147/B149/B190
SERVICE MANUAL
001892MIU

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2004 RICOH Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
p
rocesses and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
r
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual to
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rotection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
B147 DSc332 LD232c Aficio 2232C C3224
B149 DSc338 LD238c Aficio 2238C C3828
B190 DSc328 LD228c Aficio 2228C C2820
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 01/2004 Original Printing
1 09/2004 B190 Addition

SM i B147/B149/B190
B147/B149/B190
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION............................................................................ 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1
1.1.1 ENVIRONMENT ...............................................................................1-1
1.1.2 MACHINE LEVEL .............................................................................1-1
1.1.3 MACHINE SPACE REQUIREMENT.................................................1-2
1.1.4 POWER REQUIREMENTS ..............................................................1-2
1.2 OPTIONAL UNIT COMBINATIONS ..........................................................1-3
1.2.1 MACHINE OPTIONS ........................................................................1-3
1.2.2 CONTROLLER OPTIONS ................................................................1-3
1.3 COPIER.....................................................................................................1-4
1.3.1 POWER SOCKETS FOR PERIPHERALS .......................................1-4
1.3.2 INSTALLATION FLOW CHART .......................................................1-5
1.4 MACHINE INSTALLATION........................................................................1-6
1.4.1 COPIER............................................................................................1-6
Accessory Check ..................................................................................1-6
Installation Procedure ...........................................................................1-7
Settings Relevant to Contract .............................................................1-11
1.4.2 MOVING MACHINE........................................................................1-12
1.4.3 TRANSPORTING MACHINE..........................................................1-13
1.5 OPTIONAL UNIT .....................................................................................1-15
1.5.1 ONE-TRAY PAPER FEED UNIT ....................................................1-15
Accessory Check ................................................................................1-15
Installation Procedure .........................................................................1-16
1.5.2 TWO-TRAY PAPER FEED UNIT....................................................1-19
Accessory Check ................................................................................1-19
Installation Procedure .........................................................................1-20
1.5.3 LARGE CAPACITY TRAY ..............................................................1-23
Accessory Check ................................................................................1-23
Installation Procedure .........................................................................1-24
1.5.4 AUTO REVERSE DOCUMENT FEEDER ......................................1-27
Accessory Check ................................................................................1-27
Installation Procedure .........................................................................1-27
1.5.5 TWO-TRAY FINISHER...................................................................1-30
Accessory Check ................................................................................1-30
Installation Procedure .........................................................................1-30
1.5.6 PUNCH UNIT .................................................................................1-33
Accessory Check ................................................................................1-33
Installation Procedure .........................................................................1-34
1.5.7 MULTI-BIN OUTPUT TRAY ...........................................................1-37
Accessories Check List.......................................................................1-37

B147/B149/B190 ii SM
Installing the Multi-Bin Output Tray.....................................................1-38
1.5.8 BOOKLET FINISHER .....................................................................1-39
Accessory Check ................................................................................1-39
Adjusting the Height............................................................................1-40
Main Body...........................................................................................1-41
Optional Punch Unit ............................................................................1-44
1.5.9 PRINTER SCANNER UNIT (FOR ASIA MODEL ONLY)................1-48
Accessory Check ................................................................................1-48
Installation Procedure .........................................................................1-48
1.5.10 POSTSCRIPT 3............................................................................1-51
1.5.11 256 MB MEMORY ........................................................................1-52
1.5.12 FILE FORMAT CONVERTER ......................................................1-53
1.5.13 IEEE 1394 (FIREWIRE)................................................................1-54
Installation Procedure .........................................................................1-54
UP Mode Settings for IEEE 1394........................................................1-55
SP Mode Settings for IEEE 1394........................................................1-55
1.5.14 USB 2.0 ........................................................................................1-56
Installation Procedure .........................................................................1-56
USB SP Settings.................................................................................1-57
1.5.15 IEEE 802.11B (WIRELESS LAN) .................................................1-58
Installation Procedure .........................................................................1-58
UP Mode Settings for Wireless LAN ...................................................1-60
SP MODE SETTINGS FOR IEEE 802.11B WIRELESS LAN.........................1-61
1.5.16 BLUETOOTH................................................................................1-62
1.5.17 CHECK ALL CONNECTIONS ......................................................1-64
1.5.18 KEY COUNTER HOLDER............................................................1-65
1.5.19 ANTI-CONDENSATION HEATER................................................1-67
1.5.20 ANTI-CONDENSATION HEATER................................................1-69
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 SETTINGS.................................................................................................2-1
New Unit Set.........................................................................................2-1
Counter Reset.......................................................................................2-1
2.2 PM TABLES ..............................................................................................2-2
2.3 OTHERS ...................................................................................................2-5
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 SPECIAL TOOLS ................................................................................3-1
3.2 IMAGE ADJUSTMENT..............................................................................3-2
3.2.1 SCANNING.......................................................................................3-2
Scanner sub-scan magnification...........................................................3-2
Scanner leading edge and side-to-side registration..............................3-2
Main scan dot position correction .........................................................3-3

SM iii B147/B149/B190
3.2.2 ARDF................................................................................................3-4
ARDF side-to-side and leading edge registration .................................3-4
3.2.3 REGISTRATION...............................................................................3-5
Image Area ...........................................................................................3-5
Leading Edge........................................................................................3-5
Side to Side ..........................................................................................3-5
Adjustment Standard ............................................................................3-5
Paper Registration Standard.................................................................3-5
Adjustment Procedure ..........................................................................3-6
3.2.4 COLOR REGISTRATION .................................................................3-6
Line Position Adjustment ......................................................................3-6
Adjustment of Line Speed for Thick Paper............................................3-6
3.2.5 PRINTER GAMMA CORRECTION ..................................................3-7
Copy Mode ...........................................................................................3-7
Printer Mode .......................................................................................3-11
3.3 DUPLEX INVERTER UNIT......................................................................3-13
3.3.1 TOP COVER ..................................................................................3-13
3.3.2 DUPLEX CONTROL BOARD .........................................................3-13
3.3.3 DUPLEX INVERTER MOTOR 1.....................................................3-14
3.3.4 DUPLEX INVERTER MOTOR 2 AND SWITCH .............................3-15
3.3.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR..................3-15
3.3.6 EXIT SENSOR 1 AND 2 .................................................................3-15
3.4 DUPLEX FEED UNIT ..............................................................................3-16
3.4.1 DUPLEX DRIVE BOARD................................................................3-16
3.4.2 DUPLEX FEED MOTOR ................................................................3-16
3.4.3 DUPLEX FEED SENSOR...............................................................3-17
3.5 EXTERIOR COVERS ..............................................................................3-18
3.5.1 REAR, FRONT, AND RIGHT SIDES ..............................................3-18
3.5.2 LEFT SIDE .....................................................................................3-20
3.5.3 OPERATION PANEL AND SCANNER COVERS...........................3-21
3.6 SCANNER UNIT......................................................................................3-22
3.6.1 EXPOSURE GLASS.......................................................................3-22
3.6.2 ORIGINAL LENGTH/WIDTH SENSOR ..........................................3-22
3.6.3 SENSOR BOARD UNIT (SBU).......................................................3-23
3.6.4 EXPOSURE LAMP STABILIZER ...................................................3-24
3.6.5 XENON LAMP ................................................................................3-24
3.6.6 SCANNER POWER SUPPLY UNIT (PSU) ....................................3-25
3.6.7 SCANNER MOTOR........................................................................3-25
3.6.8 FRONT SCANNER WIRE ..............................................................3-26
3.6.9 REAR SCANNER WIRE.................................................................3-29
3.6.10 TOUCH PANEL POSITION ADJUSTMENT .................................3-32
3.7 LASER OPTICS ......................................................................................3-33
3.7.1 CAUTION DECAL LOCATIONS.....................................................3-33
3.7.2 LASER OPTICS HOUSING UNIT ..................................................3-34
Adjustments after Replacing the Laser Optics Housing Unit...............3-39
3.7.3 POLYGON MIRROR MOTOR ........................................................3-40
3.7.4 LASER SYNCHRONIZING DETECTOR BOARDS ........................3-40
3.8 PCU AND DEVELOPMENT UNIT ...........................................................3-41

B147/B149/B190 iv SM
3.9 PAPER FEED..........................................................................................3-42
3.9.1 PICK-UP, FEED, AND SEPARATION ROLLERS ..........................3-42
Tray 1 and Tray 2 ...............................................................................3-42
By-pass Tray.......................................................................................3-42
3.9.2 PAPER WIDTH DETECTION BOARD ...........................................3-43
3.9.3 VERTICAL TRANSPORT SENSOR ...............................................3-44
3.9.4 RIGHT DOOR UNIT .......................................................................3-44
3.9.5 REGISTRATION SENSOR AND RELAY SENSORS .....................3-45
3.9.6 PAPER FEED CLUTCHES.............................................................3-45
3.9.7 BY-PASS FEED CLUTCH ..............................................................3-46
3.9.8 TRAY LIFT MOTOR .......................................................................3-46
3.9.9 PAPER FEED MOTOR...................................................................3-47
3.10 TRANSFER AND PAPER TRANSPORT UNIT .....................................3-48
3.10.1 TRANSFER UNIT .........................................................................3-48
3.10.2 TRANSFER BELT CLEANING UNIT............................................3-49
3.10.3 CLEANING BLADE AND CLEANING ROLLER ...........................3-50
3.10.4 TRANSFER BELT ........................................................................3-52
3.10.5 TRANSFER UNIT DRIVE MOTOR...............................................3-54
3.11 ID SENSORS ........................................................................................3-55
3.12 FUSING.................................................................................................3-56
3.12.1 FUSING UNIT...............................................................................3-56
3.12.2 OIL SUPPLY UNIT AND UPPER COVER....................................3-57
3.12.3 CLEANING UNIT..........................................................................3-58
3.12.4 HEATING ROLLER LAMP............................................................3-59
3.12.5 FUSING BELT UNIT.....................................................................3-60
3.12.6 HOT ROLLER...............................................................................3-61
3.12.7 HEATING ROLLER ......................................................................3-61
3.12.8 PAPER GUIDE PLATES AND STRIPPER PAWLS......................3-62
3.12.9 THERMISTOR AND FUSE...........................................................3-63
3.12.10 PRESSURE ROLLER FUSING LAMP .......................................3-64
3.12.11 PRESSURE ROLLER.................................................................3-65
3.12.12 FUSING UNIT FAN.....................................................................3-67
3.12.13 WASTE OIL BOTTLE .................................................................3-68
3.12.14 PAPER EXIT ..............................................................................3-68
3.13 ELECTRICAL COMPONENTS..............................................................3-69
3.13.1 MOVING THE CONTROLLER BOX OUT OF THE WAY .............3-69
3.13.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C,
B OUT OF THE WAY ...................................................................3-70
3.13.3 CONTROLLER, IPU, AND BCU ...................................................3-70
3.13.4 HDD..............................................................................................3-72
3.13.5 NVRAM REPLACEMENT PROCEDURE .....................................3-72
NVRAM on BCU .................................................................................3-72
NVRAM on Controller .........................................................................3-73
3.13.6 REMOVING THE HIGH VOLTAGE SUPPLY BOARD - C, B .......3-74
3.13.7 SUB POWER SUPPLY UNIT .......................................................3-74
3.13.8 PSU ..............................................................................................3-75
3.13.9 DRIVER BOARD ..........................................................................3-75

SM v B147/B149/B190
3.14 DRIVE UNIT ..........................................................................................3-76
3.14.1 REGISTRATION CLUTCH ...........................................................3-76
3.14.2 DEVELOPMENT CLUTCHES ......................................................3-76
3.14.3 DEVELOPMENT MOTOR - CMY .................................................3-77
3.14.4 DRUM DRIVE MOTOR - CMY AND DRUM DRIVE MOTOR - K .3-79
3.14.5 DEVELOPMENT DRIVE MOTOR - K...........................................3-80
3.15 TONER SUPPLY UNIT .........................................................................3-81
M Toner Supply Unit ...........................................................................3-81
C and Y Toner Supply Units ...............................................................3-85
K Toner Supply Unit............................................................................3-86
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 PROCESS CONTROL ERROR CONDITIONS .........................................4-1
4.1.1 DEVELOPER INITIALIZATION RESULT .........................................4-1
4.1.2 PROCESS CONTROL SELF-CHECK RESULT...............................4-3
4.1.3 LINE POSITION ADJUSTMENT RESULT .......................................4-4
4.2 SCANNER TEST MODE ...........................................................................4-7
4.2.1 VPU TEST MODE ............................................................................4-7
SP4-907-1 VPU Test Pattern: R ..........................................................4-7
SP4-907-2 VPU Test Pattern: G ..........................................................4-7
SP4-907-3 VPU Test Pattern: B ..........................................................4-7
4.2.2 IPU TEST MODE..............................................................................4-7
SP4-904-1 Register Write/Read Check Result ....................................4-7
SP4-904-2 Image Path Check Result ..................................................4-7
4.3 SERVICE CALL CONDITIONS .................................................................4-9
4.3.1 SUMMARY .......................................................................................4-9
SC Code Classification .......................................................................4-10
4.4 SC TABLE ...............................................................................................4-11
4.5 TROUBLESHOOTING GUIDE ................................................................4-55
4.5.1 IMAGE QUALITY............................................................................4-55
Work-flow............................................................................................4-55
4.6 TROUBLESHOOTING GUIDE ................................................................4-57
4.6.1 IMAGE QUALITY............................................................................4-57
Detailed Explanation ...........................................................................4-61
Copy Image processing ......................................................................4-66
4.6.2 COLOR SHIFT ...............................................................................4-68
Adjustment Standard: Max. 150 mm..................................................4-70
How to measure the gap between color lines .....................................4-76
4.6.3 COLOR SHIFT AFTER TRANSFER UNIT REPLACEMENT .........4-78
Check the color shift level ...................................................................4-78
Fusing/ Registration Roller Speed Adjustment ...................................4-78
4.6.4 BLACK OVER PRINT .....................................................................4-81
Black Over Print Disabled ...................................................................4-81
Black Over Print Enabled....................................................................4-81
4.7 ELECTRICAL COMPONENT DEFECTS ................................................4-82
4.7.1 SENSORS ......................................................................................4-82

B147/B149/B190 vi SM
4.8 BLOWN FUSE CONDITIONS .................................................................4-84
4.9 LEDS (BCU) ............................................................................................4-84
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...........5-1
Entering SP Mode.................................................................................5-1
Exiting SP Mode ...................................................................................5-1
5.1.2 TYPES OF SP MODES ....................................................................5-2
SP Mode Button Summary ...................................................................5-3
Switching Between SP Mode and Copy Mode for Test Printing ...........5-4
Selecting the Program Number.............................................................5-4
Exiting Service Mode ............................................................................5-5
5.1.3 REMARKS........................................................................................5-5
Display on the Control Panel Screen ....................................................5-5
Others ...................................................................................................5-6
5.2 COPY SERVICE MODE............................................................................5-7
5.2.1 SERVICE MODE TABLE..................................................................5-7
SP1-XXX (Feed) ...................................................................................5-7
SP2-XXX (Drum).................................................................................5-15
SP3-XXX (Process) ............................................................................5-27
SP4-XXX (Scanner) ............................................................................5-35
SP5-XXX (Mode) ................................................................................5-42
SP6-XXX (Peripherals) .......................................................................5-64
SP7-XXX (Data Log)...........................................................................5-67
SP8-xxx: Data Log2 ............................................................................5-78
5.2.2 INPUT CHECK TABLE .................................................................5-114
ARDF Input Check: SP6-007 ............................................................5-116
Table 1: Paper Height Sensor...........................................................5-117
Table 2: Paper Size Switch (Tray 2) .................................................5-117
Table 3: Paper Size (By-pass Table) ................................................5-117
Table 4: Original Size Detection .......................................................5-118
5.2.3 OUTPUT CHECK TABLE .............................................................5-119
5.2.4 TEST PATTERN (SP5-997) .........................................................5-123
5.3 PRINTER SERVICE MODE ..................................................................5-124
SP1-XXX (Service Mode) .................................................................5-124
5.4 SCANNER SP MODE ...........................................................................5-126
SP1-xxx (System and Others) ..........................................................5-126
SP2-XXX (Scanning-image quality) ..................................................5-127
5.5 REBOOT / SYSTEM SETTING RESET ................................................5-137
5.5.1 SOFTWARE RESET ....................................................................5-137
5.5.2 SYSTEM SETTINGS AND COPY SETTING RESET ...................5-137
System Setting Reset .......................................................................5-137
Copier Setting Reset.........................................................................5-138
5.6 FIRMWARE UPDATE ...........................................................................5-139
5.6.1 TYPE OF FIRMWARE..................................................................5-139

SM vii B147/B149/B190
5.6.1 BEFORE YOU BEGIN… ..............................................................5-140
5.6.2 UPDATING FIRMWARE...............................................................5-140
5.6.3 VERIFYING A SUCCESSFUL UPDATE ......................................5-147
5.6.4 UPDATING THE LCDC FOR THE OPERATION PANEL.............5-150
5.6.5 DOWNLOADING STAMP DATA ..................................................5-151
5.6.6 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-152
Uploading Content of NVRAM to an SD card ...................................5-152
Downloading an SD Card to NVRAM................................................5-152
5.6.7 INSTALLING ANOTHER LANGUAGE .........................................5-153
5.6.8 HANDLING FIRMWARE UPDATE ERRORS...............................5-156
5.7 SD CARD APPLI MOVE........................................................................5-157
5.7.1 OVERVIEW ..................................................................................5-157
5.7.2 MOVE EXEC ................................................................................5-158
5.7.3 UNDO EXEC ................................................................................5-159
5.8 CONTROLLER SELF-DIAGNOSTICS ..................................................5-160
5.8.1 OVERVIEW ..................................................................................5-160
5.8.2 DETAILED SELF-DIAGNOSTICS ................................................5-161
5.9 USER PROGRAM MODE .....................................................................5-162
5.9.1 MENU ...........................................................................................5-162
5.9.2 DISPLAY ......................................................................................5-166
Selecting Menu .................................................................................5-166
Inquiry ...............................................................................................5-166
5.10 DIP SWITCHES...................................................................................5-167
Controller Board................................................................................5-167
BCU Board........................................................................................5-167
DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1
6.1.1 COMPONENT LAYOUT ...................................................................6-1
6.1.2 PAPER PATH...................................................................................6-2
6.1.3 DRIVE LAYOUT ...............................................................................6-3
6.1.4 BOARD STRUCTURE......................................................................6-4
Overview...............................................................................................6-4
Descriptions ..........................................................................................6-5
6.1.5 PRINTING PROCESS ......................................................................6-6
6.2 PROCESS CONTROL ..............................................................................6-8
6.2.1 OVERVIEW ......................................................................................6-8
6.2.2 POTENTIAL CONTROL ...................................................................6-8
Overview...............................................................................................6-8
Process Control Self Check ..................................................................6-9
6.2.3 PROCESS CONTROL SELF CHECK PROCEDURE ....................6-10
Step 1: VSG Adjustment .....................................................................6-10
Step 2: ID Sensor Solid Pattern Generation .......................................6-11
Step 3: Sensor Pattern Detection .......................................................6-11
Step 4: Toner Amount Calculation ......................................................6-11
Step 5: VD, VB, VL Selection and VREF Adjustment .........................6-12
Rev. 06/2004

B147/B149/B190 viii SM
Step 6: ID Sensor Highlight Pattern Generation .................................6-13
Step 7: Sensor Pattern Density Detection...........................................6-13
Step 8: VL (LD Power) Selection ........................................................6-13
6.2.4 VREF COMPENSATION DURING A PRINT JOB..........................6-14
Highlight Pattern .................................................................................6-14
Adjustment Process ............................................................................6-14
6.2.5 TONER SUPPLY CONTROL .........................................................6-15
Overview.............................................................................................6-15
Toner Supply Control Modes ..............................................................6-15
6.2.6 TONER NEAR END/TONER END DETECTION............................6-16
Introduction .........................................................................................6-16
Toner Near End Detection 1 ...............................................................6-17
Toner Near End Detection 2 ...............................................................6-17
Toner End Detection ...........................................................................6-18
Toner End Recovery ...........................................................................6-18
6.2.7 DEVELOPER INITIALIZATION ......................................................6-19
6.3 SCANNING..............................................................................................6-20
6.3.1 OVERVIEW ....................................................................................6-20
6.3.2 SCANNER DRIVE ..........................................................................6-21
6.3.3 ORIGINAL SIZE DETECTION........................................................6-22
6.3.4 ANTI-CONDENSATION HEATER..................................................6-23
6.4 IMAGE PROCESSING ............................................................................6-24
6.4.1 OVERVIEW ....................................................................................6-24
6.4.2 SBU BLOCK DIAGRAM .................................................................6-25
Signal Processing ...............................................................................6-25
A/D Conversion...................................................................................6-25
White Level Correction........................................................................6-25
Others .................................................................................................6-25
Black Level Correction ........................................................................6-26
Adjustments ........................................................................................6-26
VPU Test Mode ..................................................................................6-26
6.4.3 IPU BLOCK DIAGRAM...................................................................6-27
Shading Correction .............................................................................6-27
Picture Element (Dot Position) Correction ..........................................6-28
Scan Line Correction ..........................................................................6-28
Image Separation................................................................................6-28
ACS (Auto Color Select) .....................................................................6-29
Scanner Gamma Correction (RGB Gamma Correction) .....................6-30
Filtering ...............................................................................................6-31
ADS (Auto Image Density Selection) ..................................................6-31
Color Conversion ................................................................................6-32
Main Scan Magnification.....................................................................6-33
Printer Gamma Correction ..................................................................6-34
Error Diffusion.....................................................................................6-36
IPU Board Test ...................................................................................6-36
6.5 IMAGE DATA PATH................................................................................6-37
Copier Application...............................................................................6-37
Printer Application...............................................................................6-37
Scanner Application (1 bit/8 bits) ........................................................6-37