Ricoh B202 User manual

B202/B178/B180
SERVICE MANUAL
002366MIU

B202/B178/B180
SERVICE MANUAL

B202/B178/B180
SERVICE MANUAL
002366MIU

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2005 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
B202 DSc428 LD328c Aficio 3228C C2824
B178 DSc435 LD335c Aficio 3235C C3528
B180 DSc445 LD345c Aficio 3245C C4535
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 06/2005 Original Printing

SM i B202/B178/B180
B202/B178/B180
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

B202/B178/B180 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 SCANNER ACCESSIBILITY OPTION............................................1-48
INSTALLATION REQUIREMENTS.....................................................1-48
ACCESSARY CHECK ........................................................................1-49
INSTALLATION PROCEDURE ..........................................................1-50
1.5.10 KEY COUNTER HOLDER............................................................1-55
1.5.11 ANTI-CONDENSATION HEATER................................................1-57
1.5.12 ANTI-CONDENSATION HEATER................................................1-59
1.5.13 ANTI-CONDENSATION HEATER
(SCANNER ACCESSIBILITY OPTION) .......................................1-61
1.6 PRINTER OPTIONS................................................................................1-64
1.6.1 OVERVIEW ....................................................................................1-64
I/F Card Slot........................................................................................1-64
SD Card Slot.......................................................................................1-64
1.6.2 POSTSCRIPT 3..............................................................................1-65
1.6.3 FILE FORMAT CONVERTER ........................................................1-66
1.6.4 IEEE 1394 (FIREWIRE)..................................................................1-67
Installation Procedure .........................................................................1-67
UP Mode Settings for IEEE 1394........................................................1-68
SP Mode Settings for IEEE 1394........................................................1-68
1.6.5 IEEE 1284 ......................................................................................1-69
Installation Procedure .........................................................................1-69
1.6.6 IEEE 802.11B (WIRELESS LAN) ...................................................1-70
Installation Procedure .........................................................................1-70
UP Mode Settings for Wireless LAN ...................................................1-72
SP MODE SETTINGS FOR IEEE 802.11B WIRELESS LAN .............1-73
1.6.7 BLUETOOTH..................................................................................1-74
1.6.8 DATA OVERWRITE SECURITY UNIT (B735) ...............................1-75
ACCESSORY CHECK........................................................................1-75
Seal Check And Removal ...................................................................1-75
Installation Procedure .........................................................................1-76
1.6.9 CHECK ALL CONNECTIONS ........................................................1-77
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 SETTINGS.................................................................................................2-1
New Unit Set.........................................................................................2-1
PM Counter Reset ................................................................................2-1
2.2 PM TABLES ..............................................................................................2-2
2.3 OTHERS ...................................................................................................2-4
Rev. 11/2005

SM iii B202/B178/B180
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
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 .......................................................................................3-12
3.3 DUPLEX INVERTER UNIT......................................................................3-14
3.3.1 TOP COVER ..................................................................................3-14
3.3.2 DUPLEX CONTROL BOARD .........................................................3-14
3.3.3 DUPLEX INVERTER MOTOR 1.....................................................3-15
3.3.4 DUPLEX INVERTER MOTOR 2 AND SWITCH .............................3-16
3.3.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR..................3-16
3.3.6 EXIT SENSOR 1 AND 2 .................................................................3-16
3.4 DUPLEX FEED UNIT ..............................................................................3-17
3.4.1 DUPLEX DRIVE BOARD................................................................3-17
3.4.2 DUPLEX FEED MOTOR ................................................................3-17
3.4.3 DUPLEX FEED SENSOR...............................................................3-18
3.5 EXTERIOR COVERS ..............................................................................3-19
3.5.1 REAR, FRONT, AND RIGHT SIDES ..............................................3-19
3.5.2 LEFT SIDE .....................................................................................3-21
3.5.3 OPERATION PANEL AND SCANNER COVERS...........................3-22
3.6 SCANNER UNIT......................................................................................3-23
3.6.1 EXPOSURE GLASS.......................................................................3-23
3.6.2 ORIGINAL LENGTH/WIDTH SENSOR ..........................................3-23
3.6.3 SENSOR BOARD UNIT (SBU).......................................................3-24
When reassembling ............................................................................3-24
3.6.4 EXPOSURE LAMP STABILIZER ...................................................3-26
3.6.5 XENON LAMP ................................................................................3-26
3.6.6 SCANNER POWER SUPPLY UNIT (PSU) ....................................3-28
3.6.7 SCANNER MOTOR........................................................................3-28

B202/B178/B180 iv SM
3.6.8 FRONT SCANNER WIRE ..............................................................3-29
3.6.9 REAR SCANNER WIRE.................................................................3-32
3.6.10 TOUCH PANEL POSITION ADJUSTMENT .................................3-35
3.7 LASER OPTICS ......................................................................................3-36
3.7.1 CAUTION DECAL LOCATIONS.....................................................3-36
3.7.2 LASER OPTICS HOUSING UNIT ..................................................3-37
Adjustments after Replacing the Laser Optics Housing Unit...............3-43
3.7.3 POLYGON MIRROR MOTOR ........................................................3-44
3.7.4 POLYGON MIRROR MOTOR DRIVE BOARD ..............................3-45
3.7.5 LASER SYNCHRONIZING DETECTOR BOARDS ........................3-45
3.8 PCU AND DEVELOPMENT UNIT ...........................................................3-46
3.9 PAPER FEED..........................................................................................3-47
3.9.1 PICK-UP, FEED, AND SEPARATION ROLLERS ..........................3-47
Tray 1 and Tray 2 ...............................................................................3-47
By-pass Tray.......................................................................................3-47
3.9.2 PAPER WIDTH DETECTION BOARD ...........................................3-49
3.9.3 VERTICAL TRANSPORT SENSOR ...............................................3-50
3.9.4 RIGHT DOOR UNIT .......................................................................3-50
3.9.5 REGISTRATION SENSOR AND RELAY SENSORS .....................3-51
3.9.6 PAPER FEED CLUTCHES.............................................................3-51
3.9.7 BY-PASS FEED CLUTCH ..............................................................3-52
3.9.8 TRAY LIFT MOTOR .......................................................................3-52
3.9.9 PAPER FEED MOTOR...................................................................3-53
3.10 TRANSFER AND PAPER TRANSPORT UNIT .....................................3-54
3.10.1 TRANSFER UNIT .........................................................................3-54
3.10.2 TRANSFER BELT CLEANING UNIT............................................3-55
3.10.3 CLEANING BLADE AND CLEANING ROLLER ...........................3-56
3.10.4 TRANSFER BELT ........................................................................3-58
When you reinstall the transfer belt ....................................................3-59
3.10.5 TRANSFER UNIT DRIVE MOTOR...............................................3-60
3.11 ID SENSORS ........................................................................................3-61
3.12 FUSING.................................................................................................3-62
3.12.1 FUSING UNIT...............................................................................3-62
3.12.2 UPPER COVER............................................................................3-63
3.12.3 THERMOSTAT AND HEATING ROLLER THERMISTOR............3-64
3.12.4 PRESSURE ROLLER THERMISTOR AND FUSE .......................3-65
Reassembling .....................................................................................3-65
3.12.5 HEATING ROLLER LAMP AND PRESSURE ROLLER LAMP ....3-66
3.12.6 FUSING BELT UNIT.....................................................................3-67
3.12.7 HOT ROLLER AND HEATING ROLLER ......................................3-68
Reassembling .....................................................................................3-68
3.12.8 UPPER PAPER GUIDE PLATE AND STRIPPER PAWLS...........3-69
3.12.9 LOWER PAPER GUIDE PLATE AND STRIPPER PAWLS..........3-70
3.12.10 CLEANING ROLLER AND OIL SUPPLY ROLLER ....................3-71
3.12.11 PRESSURE ROLLER.................................................................3-72
Reassembling .....................................................................................3-72
3.12.12 DRIVE GEAR .............................................................................3-72
3.12.13 FUSING UNIT FAN.....................................................................3-73
3.12.14 PAPER EXIT ..............................................................................3-74

SM v B202/B178/B180
3.13 ELECTRICAL COMPONENTS..............................................................3-75
3.13.1 MOVING THE CONTROLLER BOX OUT OF THE WAY .............3-75
3.13.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C,
B OUT OF THE WAY ...................................................................3-76
3.13.3 CONTROLLER, IPU, AND BCU ...................................................3-76
3.13.4 HDD..............................................................................................3-78
When reassembling the HDD .............................................................3-78
3.13.5 NVRAM REPLACEMENT PROCEDURE .....................................3-79
NVRAM on the BCU ...........................................................................3-79
NVRAM on the Controller ...................................................................3-80
3.13.6 REMOVING THE HIGH VOLTAGE SUPPLY BOARD - C, B .......3-81
3.13.7 SUB POWER SUPPLY UNIT .......................................................3-81
3.13.8 PSU ..............................................................................................3-82
3.13.9 DRIVER BOARD ..........................................................................3-82
3.14 DRIVE UNIT ..........................................................................................3-83
3.14.1 REGISTRATION CLUTCH ...........................................................3-83
3.14.2 DEVELOPMENT CLUTCHES ......................................................3-83
3.14.3 DEVELOPMENT MOTOR - CMY .................................................3-84
3.14.4 DRUM DRIVE MOTOR - CMY AND DRUM DRIVE MOTOR - K ....3-86
3.14.5 DEVELOPMENT DRIVE MOTOR - K...........................................3-87
3.15 TONER SUPPLY UNIT .........................................................................3-88
M Toner Supply Unit ...........................................................................3-88
C and Y Toner Supply Units ...............................................................3-92
K Toner Supply Unit............................................................................3-93
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 ...........................................................................4-8
4.2.1 VPU TEST MODE ............................................................................4-8
SP4-907-1 VPU Test Pattern: R ...........................................................4-8
SP4-907-2 VPU Test Pattern: G ...........................................................4-8
SP4-907-3 VPU Test Pattern: B ...........................................................4-8
4.2.2 IPU TEST MODE..............................................................................4-8
SP4-904-1 Register Access..................................................................4-8
SP4-904-2 Image Path .........................................................................4-8
4.3 SERVICE CALL CONDITIONS ...............................................................4-10
4.3.1 SUMMARY .....................................................................................4-10
SC Code Classification .......................................................................4-11
4.4 SC TABLE ...............................................................................................4-12
4.5 TROUBLESHOOTING GUIDE 1 .............................................................4-51
4.5.1 IMAGE QUALITY............................................................................4-51
Work-flow............................................................................................4-51
4.6 TROUBLESHOOTING GUIDE 2 .............................................................4-53

B202/B178/B180 vi SM
4.6.1 IMAGE QUALITY............................................................................4-53
Detailed Explanation ...........................................................................4-57
Copy Image processing ......................................................................4-62
4.6.2 COLOR SHIFT ...............................................................................4-64
Adjustment Standard: Max. 150 mm..................................................4-66
How to measure the gap between color lines .....................................4-72
4.6.3 COLOR SHIFT AFTER TRANSFER UNIT REPLACEMENT .........4-74
Check the color shift level ...................................................................4-74
Fusing/ Registration Roller Speed Adjustment ...................................4-74
4.6.4 BLACK OVER PRINT .....................................................................4-77
Black Over Print Disabled ...................................................................4-77
Black Over Print Enabled....................................................................4-77
4.7 ELECTRICAL COMPONENT DEFECTS ................................................4-78
4.7.1 SENSORS ......................................................................................4-78
4.8 BLOWN FUSE CONDITIONS .................................................................4-80
4.9 LEDS (BCU) ............................................................................................4-80
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 ............................................................................5-4
Service Mode Lock/Unlock ...................................................................5-5
5.1.3 REMARKS........................................................................................5-6
Display on the Control Panel Screen ....................................................5-6
Others ...................................................................................................5-7
5.2 COPY SERVICE MODE............................................................................5-8
5.2.1 SERVICE MODE TABLE..................................................................5-8
SP1-XXX (Feed) ...................................................................................5-8
SP2-XXX (Drum).................................................................................5-19
SP3-XXX (Process) ............................................................................5-35
SP4-XXX (Scanner) ............................................................................5-45
SP5-XXX (Mode) ................................................................................5-55
SP6-XXX (Peripherals) .......................................................................5-83
SP7-XXX (Data Log)...........................................................................5-86
SP8-xxx: Data Log2 ............................................................................5-97
5.2.2 INPUT CHECK TABLE .................................................................5-134
ARDF Input Check: SP6-007 ............................................................5-136
Table 1: Paper Height Sensor...........................................................5-137
Table 2: Paper Size Switch (Tray 2) .................................................5-137
Table 3: Paper Size (By-pass Table) ................................................5-137

SM vii B202/B178/B180
Table 4: Original Size Detection .......................................................5-138
5.2.3 OUTPUT CHECK TABLE .............................................................5-139
5.2.4 TEST PATTERN (SP5-997) .........................................................5-143
5.3 PRINTER SERVICE MODE ..................................................................5-144
SP1-XXX (Service Mode) .................................................................5-144
5.4 SCANNER SP MODE ...........................................................................5-146
SP1-xxx (System and Others) ..........................................................5-146
SP2-XXX (Scanning-image quality) ..................................................5-146
5.5 REBOOT/SYSTEM SETTING RESET ..................................................5-147
5.5.1 SOFTWARE RESET ....................................................................5-147
5.5.2 SYSTEM SETTINGS AND COPY SETTING RESET ...................5-147
System Setting Reset .......................................................................5-147
Copier Setting Reset.........................................................................5-148
5.6 FIRMWARE UPDATE ...........................................................................5-149
5.6.1 TYPE OF FIRMWARE..................................................................5-149
5.6.1 BEFORE YOU BEGIN ..................................................................5-150
5.6.2 UPDATING FIRMWARE...............................................................5-151
5.6.3 UPDATING THE LCDC FOR THE OPERATION PANEL.............5-154
5.6.4 DOWNLOADING STAMP DATA ..................................................5-155
5.6.5 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-156
Uploading Content of NVRAM to an SD card ...................................5-156
Downloading an SD Card to NVRAM................................................5-156
5.6.6 INSTALLING ANOTHER LANGUAGE .........................................5-157
5.6.7 HANDLING FIRMWARE UPDATE ERRORS...............................5-160
5.7 SD CARD APPLI MOVE........................................................................5-161
5.7.1 OVERVIEW ..................................................................................5-161
5.7.2 MOVE EXEC ................................................................................5-162
5.7.3 UNDO EXEC ................................................................................5-163
5.8 CONTROLLER SELF-DIAGNOSTICS ..................................................5-164
5.8.1 OVERVIEW ..................................................................................5-164
5.8.2 DETAILED SELF-DIAGNOSTICS ................................................5-165
5.9 USING THE DEBUG LOG.....................................................................5-166
5.9.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG ...........5-166
5.9.2 RETRIEVING THE DEBUG LOG FROM THE HDD .....................5-169
5.9.3 RECORDING ERRORS MANUALLY ...........................................5-170
5.9.4 NEW DEBUG LOG CODES .........................................................5-171
SP5857-015 Copy SD Card-to-SD Card: Any Desired Key .............5-171
SP5857-016 Create a File on HDD to Store a Log ..........................5-171
SP5857-017 Create a File on SD Card to Store a Log ....................5-171
5.10 DIP SWITCHES...................................................................................5-172
Controller Board................................................................................5-172
BCU Board........................................................................................5-172
DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1
6.1.1 COMPONENT LAYOUT ...................................................................6-1

B202/B178/B180 viii SM
6.1.2 PAPER PATH...................................................................................6-2
6.1.3 DRIVE LAYOUT ...............................................................................6-3
6.1.4 BOARD STRUCTURE......................................................................6-4
Overview...............................................................................................6-4
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
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