Ricoh K-C3 User manual

©Ricoh Company, Ltd.
January 18th, 2006
Subject to change
Model K-C3
Machine Code:
(B245/B276/B277/B268/B269)
SERVICE MANUAL

B245/B276/B277/B268/B269 Service Manual 18-Jan-06
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Table of Contents
Table of Contents................................................................................................................... i
Read This First ..................................................................................................................... 1
Safety Notices and Symbols & Abbreviations.................................................................... 1
Important Safety Notices ...........................................................................................1
Laser Safety ..................................................................................................................2
Symbols and Abbreviations............................................................................................... 2
Installation............................................................................................................................. 3
Installation Requirements..................................................................................................3
Environment ..................................................................................................................3
Machine Level ...............................................................................................................4
Minimum Space Requirements......................................................................................4
Power Requirements .....................................................................................................4
Copier Installation .............................................................................................................5
Power Sockets for Peripherals ......................................................................................5
Accessory Check...........................................................................................................5
Installation Procedure ....................................................................................................6
Platen Cover Installation .................................................................................................10
Accessory Check.........................................................................................................10
Installation Procedure ..................................................................................................10
ARDF Installation ............................................................................................................ 11
Accessory Check......................................................................................................... 11
Installation Procedure ..................................................................................................12
ADF Installation...............................................................................................................15
Accessory Check.........................................................................................................15
Installation Procedure ..................................................................................................16
Two-tray Paper Tray Unit Installation ..............................................................................19
Accessory Check.........................................................................................................19
Installation Procedure ..................................................................................................19
One-tray Paper Tray Unit Installation ..............................................................................24
Accessory Check.........................................................................................................24
Installation Procedure ..................................................................................................24
One-Bin Tray Installation .................................................................................................28
Accessory Check.........................................................................................................28
Installation Procedure ..................................................................................................28

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Anti-condensation Heater Installation..............................................................................31
Tray Heaters ...................................................................................................................32
Upper Tray Heater ....................................................................................................... 32
Lower Tray Heater (Two-tray Model Only) ................................................................... 34
Tray Heaters For The Optional Paper Feed Units ....................................................... 35
Key Counter Installation ..................................................................................................39
GDI Expansion ................................................................................................................42
Accessory Check.........................................................................................................42
Installing Expansion Component ................................................................................. 42
Installing Panels and Keys ..............................................................................................44
Preventive Maintenance .....................................................................................................45
PM Tables .......................................................................................................................45
How to Reset the PM Counter......................................................................................... 47
Replacement and Adjustment ............................................................................................. 49
General Cautions ............................................................................................................49
PCU (Photoconductor Unit) ......................................................................................... 49
Transfer Roller ............................................................................................................. 49
Scanner Unit................................................................................................................ 49
Laser Unit ....................................................................................................................50
Fusing Unit ..................................................................................................................50
Paper Feed.................................................................................................................. 50
Special Tools and Lubricants...........................................................................................51
Exterior Covers & Operation Panel .................................................................................52
Rear Cover ..................................................................................................................52
Rear Lower Cover (Two-tray Models Only)..................................................................52
Copy Tray ....................................................................................................................53
Upper Covers ..............................................................................................................53
Left Cover ....................................................................................................................54
Front Cover..................................................................................................................54
Front Right Cover ........................................................................................................55
Right Rear Cover.........................................................................................................55
Right Door (Duplex Unit (B269/B277)) ........................................................................56
By-pass Tray................................................................................................................ 56
Left Lower Cover (Two-tray Models Only) ...................................................................57
Right Lower Cover (Two-tray Models Only) ................................................................. 57
Platen Cover Sensor ...................................................................................................58

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Scanner Unit ...................................................................................................................59
Exposure Glass/DF Exposure Glass ...........................................................................59
Lens Block ................................................................................................................... 59
Lamp Stabilizer Board And Exposure Lamp ................................................................ 61
Original Width/Length Sensor......................................................................................61
Scanner Motor .............................................................................................................63
Scanner Home Position Sensor...................................................................................64
Adjusting Scanner Positions ........................................................................................65
Laser Unit........................................................................................................................ 69
Location Of Caution Decal........................................................................................... 69
Toner Shield Glass ......................................................................................................69
Laser Unit ....................................................................................................................70
LD Unit.........................................................................................................................70
Polygonal Mirror Motor ................................................................................................71
Laser Unit Alignment Adjustment.................................................................................72
PCU Section....................................................................................................................74
PCU.............................................................................................................................74
Pick-off Pawls and Toner Density Sensor .................................................................... 75
OPC Drum ................................................................................................................... 76
Charge Roller and Cleaning Brush .............................................................................. 77
Cleaning Blade ............................................................................................................78
Developer ....................................................................................................................79
After Replacement or Adjustment ................................................................................80
Toner Supply Motor ......................................................................................................... 81
Paper Feed Section ........................................................................................................82
Paper Feed Roller .......................................................................................................82
Friction Pad .................................................................................................................83
Paper End Sensor .......................................................................................................83
Exit Sensor ..................................................................................................................84
By-Pass Feed Roller and Paper End Sensor............................................................... 85
Registration Roller .......................................................................................................86
By-Pass Paper Size Switch ......................................................................................... 87
Registration Clutch ......................................................................................................88
Registration Sensor .....................................................................................................88
Upper Paper Feed Clutch and By-Pass Feed Clutch .................................................. 89
Relay Clutch ................................................................................................................89

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Relay Sensor ...............................................................................................................90
Lower Paper Feed Clutch (Two-tray Models Only) ...................................................... 90
Vertical Transport Sensor (Two-tray Models Only) ......................................................91
Paper Size Switch .......................................................................................................91
Image Transfer ................................................................................................................ 92
Image Transfer Roller .................................................................................................. 92
Image Density Sensor .................................................................................................93
Fusing ............................................................................................................................. 94
Fusing Unit ..................................................................................................................94
Thermistor ...................................................................................................................94
Fusing Lamps ..............................................................................................................95
Hot Roller Stripper Pawls.............................................................................................96
Hot Roller.....................................................................................................................96
Thermostat ..................................................................................................................97
Pressure Roller and Bushings ..................................................................................... 97
NIP Band Width Adjustment ........................................................................................98
Cleaning Roller ............................................................................................................99
Duplex Unit (Duplex Models B269/B277 Only).............................................................. 100
Duplex Exit Sensor .................................................................................................... 100
Duplex Entrance Sensor............................................................................................ 100
Duplex Inverter Sensor.............................................................................................. 101
Duplex Transport Motor ............................................................................................. 102
Duplex Inverter Motor ................................................................................................102
Duplex Control Board ................................................................................................ 103
Other Replacements .....................................................................................................104
Quenching Lamp .......................................................................................................104
High-Voltage Power Supply Board ............................................................................ 104
BICU (Base-Engine Image Control Unit) ................................................................... 105
Main Motor.................................................................................................................105
Rear Exhaust Fan (B269/B277 Only) ........................................................................ 106
Left Exhaust Fan ....................................................................................................... 107
PSU (Power Supply Unit) ..........................................................................................107
Gearbox.....................................................................................................................108
Copy Adjustments Printing/Scanning .............................................................................111
Printing .......................................................................................................................111
Scanning.................................................................................................................... 113

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ADF Image Adjustment.............................................................................................. 115
Troubleshooting ................................................................................................................ 117
Service Call Conditions ................................................................................................. 117
Summary ................................................................................................................... 117
SC Code Descriptions ............................................................................................... 117
Electrical Component Defects .......................................................................................128
Sensors .....................................................................................................................128
Switches ....................................................................................................................129
Blown Fuse Conditions .................................................................................................131
LED Display ..................................................................................................................132
BICU.......................................................................................................................... 132
Service Tables .................................................................................................................. 133
Service Program Mode ................................................................................................. 133
How to Enter the SP Mode ........................................................................................ 133
SP Mode Tables ............................................................................................................ 135
SP1-XXX (Feed)........................................................................................................135
SP2-XXX (Drum) .......................................................................................................137
SP4-XXX (Scanner)................................................................................................... 141
SP5-XXX (Mode) .......................................................................................................146
SP6-XXX (Peripherals) .............................................................................................. 148
SP7-XXX (Data Log).................................................................................................. 149
SP8-XXX (History).....................................................................................................153
SP9-XXX (Etc.)..........................................................................................................156
Using SP Modes ........................................................................................................... 157
Adjusting Registration and Magnification................................................................... 157
ID Sensor Error Analysis (SP 2221)........................................................................... 158
Display APS Data (SP 4301 1) .................................................................................. 158
Memory Clear ............................................................................................................159
Input Check (SP 5803) ..............................................................................................161
Output Check (SP 5804)............................................................................................163
Serial Number Input (SP 5811) .................................................................................. 165
NVRAM Data Upload/Download (SP 5824/5825) ...................................................... 165
Firmware Update Procedure...................................................................................... 167
Test Pattern Print (SP 5902 1) ................................................................................... 170
Paper Jam Counters (SP 7504)................................................................................. 172
SMC Print (SP 5990) .................................................................................................172

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Original Jam History Display (SP 7508)..................................................................... 173
ADF APS Sensor Output Display (SP 6901).............................................................. 174
Detailed Section Descriptions ...........................................................................................175
Overview .......................................................................................................................175
Component Layout ....................................................................................................175
Paper Path................................................................................................................. 176
Drive Layout ..............................................................................................................177
Board Structure .............................................................................................................178
Block Diagram ...........................................................................................................178
BICU (Base Engine and Image Control Unit)............................................................. 178
SBU (Sensor Board Unit)...........................................................................................179
Copy Process Overview ................................................................................................ 180
Scanning .......................................................................................................................182
Overview....................................................................................................................182
Scanner Drive............................................................................................................ 183
Original Size Detection in Platen Mode ..................................................................... 184
Image Processing .........................................................................................................186
Overview....................................................................................................................186
SBU (Sensor Board Unit)...........................................................................................187
IPU (Image Processing Unit) ..................................................................................... 188
Video Control Unit (VCU)........................................................................................... 199
Laser Exposure .............................................................................................................200
Overview....................................................................................................................200
Auto Power Control (APC)......................................................................................... 201
LD Safety Switch .......................................................................................................202
Photoconductor Unit (PCU)........................................................................................... 203
Overview....................................................................................................................203
Drive ..........................................................................................................................204
Drum Charge.................................................................................................................205
Overview....................................................................................................................205
Charge Roller Voltage Correction .............................................................................. 206
ID Sensor Pattern Production Timing ........................................................................ 207
Drum Charge Roller Cleaning.................................................................................... 207
Development .................................................................................................................208
Overview....................................................................................................................208
Drive ..........................................................................................................................209

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Developer Mixing.......................................................................................................209
Development Bias ..................................................................................................... 210
Toner Supply.............................................................................................................. 211
Toner Supply Mechanism .......................................................................................... 212
Toner Density Control ................................................................................................ 212
Toner Supply in Abnormal Sensor Conditions............................................................ 216
Toner Near End/End Detection and Recovery ........................................................... 216
Drum Cleaning and Toner Recycling ............................................................................. 218
Drum Cleaning...........................................................................................................218
Toner Recycling ......................................................................................................... 219
Paper Feed ...................................................................................................................220
Overview....................................................................................................................220
Paper Feed Drive Mechanism ................................................................................... 221
Paper Feed and Separation Mechanism ................................................................... 221
Paper Lift Mechanism ................................................................................................ 222
Paper End Detection .................................................................................................222
Paper Size Detection................................................................................................. 223
Side Fences............................................................................................................... 225
Paper Registration..................................................................................................... 225
Image Transfer and Paper Separation .......................................................................... 227
Overview....................................................................................................................227
Image Transfer Current Timing .................................................................................. 228
Transfer Roller Cleaning............................................................................................ 228
Paper Separation Mechanism ...................................................................................229
Image Fusing and Paper Exit ........................................................................................ 230
Overview....................................................................................................................230
Fusing Unit Drive and Release Mechanism............................................................... 231
Fusing Entrance Guide Shift...................................................................................... 232
Pressure Roller..........................................................................................................233
Fusing Temperature Control ...................................................................................... 233
Overheat Protection................................................................................................... 235
Duplex Unit....................................................................................................................237
Overall .......................................................................................................................237
Drive Mechanism.......................................................................................................238
Basic operation.......................................................................................................... 238
Feed In and Exit Mechanism ..................................................................................... 241

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Energy Saver Modes of Basic Machines....................................................................... 242
Overview....................................................................................................................242
AOF ...........................................................................................................................243
Timers........................................................................................................................ 243
Recovery ...................................................................................................................243
Energy Saver Modes of GDI Machines ......................................................................... 244
Overview....................................................................................................................244
AOF ...........................................................................................................................245
Timers........................................................................................................................ 245
Recovery ...................................................................................................................245
Specifications.................................................................................................................... 246
General Specifications .................................................................................................. 246
Supported Paper Sizes ................................................................................................. 249
Original Size Detection .............................................................................................. 249
Paper Feed and Exit.................................................................................................. 251
Machine Configuration .................................................................................................. 253
Optional Equipment.......................................................................................................255
ARDF.........................................................................................................................255
ADF ...........................................................................................................................255
One-Tray Paper Tray Unit.......................................................................................... 256
Two-Tray Paper Tray Unit.......................................................................................... 256
One-Bin Tray ............................................................................................................. 256

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Read This First
Safety Notices and Symbols & Abbreviations
Important Safety Notices
Prevention of Physical Injury
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the power cord is unplugged.
2. The wall outlet should be near the copier and easily accessible.
3. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. If a job has started before the copier completes the warm-up or initializing
period, keep hands away from the mechanical and electrical components
because the starts making copies as soon as the warm-up period is
completed.
5. The inside and the metal parts of the fusing unit become extremely hot
while the copier is operating. Be careful to avoid touching those
components with your bare hands.
Health Safety Conditions
Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it
may cause temporary eye discomfort. Try to remove with eye drops or flush with water as
first aid. If unsuccessful, get medical attention.
Observance of Electrical Safety Standards
The copier and its peripherals must be installed and maintained by a customer service
representative who has completed the training course on those models.
Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite
suddenly when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.

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Laser Safety
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based
optical units in the field. The optical housing unit can only be repaired in a factory or at a
location with the requisite equipment. The laser subsystem is replaceable in the field by a
qualified Customer Engineer. The laser chassis is not repairable in the field. Customer
engineers are therefore directed to return all chassis and laser subsystems to the factory or
service depot when replacement of the optical subsystem is required.
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
Warning for Laser Unit
WARNING: Turn off the main switch before attempting any of the procedures in the
Laser Unit section. Laser beams can seriously damage your eyes.
CAUTION MARKING:
Symbols and Abbreviations
This manual uses several symbols and abbreviations. The meaning of those symbols and
abbreviations are as follows:
See or Refer to
Clip ring
Screw
Connector
SEF Short Edge Feed
LEF Long Edge Feed

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Installation
Installation Requirements
Before installing options, please do the following:
If there is a printer option in the machine, print out all data in the printer buffer.
Turn off the main switch and disconnect the power cord, the telephone line,
and the network cable.
Environment
–Temperature and Humidity Chart–
Temperature Range: 10C to 32C (50F to 89.6F)
Humidity Range: 15% to 80% RH
Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight)
Ventilation: 3 times/hr/person or more
Ambient Dust: Less than 0.075 mg/m3 (2.0 x 10-6 oz/yd3)
Avoid areas exposed to sudden temperature changes:
1) Areas directly exposed to cool air from an air conditioner.
2) Areas directly exposed to heat from a heater.
Do not place the machine in areas where it can get exposed to corrosive gases.
Do not install the machine at any location over 2,000 m (6,500 ft.) above sea level.
Place the machine on a strong and level base. (Inclination on any side should be no
more than 5 mm.)
Do not place the machine where it is subjected to strong vibrations.

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Machine Level
Front to back: Within 5 mm (0.2") of level
Right to left: Within 5 mm (0.2") of level
Minimum Space Requirements
Place the copier near the power source, providing clearance as shown:
A (front): 750 mm (30")
B (left): 150 mm (6")
C (rear): 50 mm (2")
D (right): 250 mm (10")
The recommended 750 mm front space is sufficient to allow the paper tray to be pulled out.
Additional front space is required to allow operators to stand at the front of the machine.
Power Requirements
Make sure that the wall outlet is near the machine and easily accessible. After.
completing installation, make sure the plug fits firmly into the outlet.
Avoid multi-wiring.
Be sure to ground the machine
Input voltage:
North and South America, Taiwan: 110 – 120 V, 60 Hz, 12 A
Europe, Asia: 220 – 240 V, 50/60 Hz, 7 A

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Copier Installation
Power Sockets for Peripherals
Make sure to plug the cables into the correct sockets.
[A]: Socket for ADF/ARDF (Rated voltage output max. DC24 V)
[B]: Socket for paper tray unit (Rated voltage output max. DC24 V)
Accessory Check
Check that you have the accessories in this list.
Basic Machines
No. Description Q’ty
1 NECR-English /Multi-language (-17, -27,-19, -29) 1
2 EU Safety Sheet (-27, -22,-24, -26) 1
3 Laser Decal (-27, -22,-24, -26, -19, -28, -29) 1
4 Model Name Plate (-22,-29) 1
GDI Machines
No. Description Q’ty
1 NECR-English /Multi-language (-19, -29) 1
2 Laser Decal (-19, -29) 1
3 Model Name Plate (-19, -29) 1
4 Operating Instructions (-19, -29) 1
5 General Setting Guide (-19, -29) 1
6 Copy Reference (-19, -29) 1

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No. Description Q’ty
7 Printer/Scanner Reference (-19, -29) 1
8 Network Reference (-19, -29) 1
9 Quick Guide Copy Edition (-19, -29) 1
10 Quick Guide Printer/Scanner Edition (-19, -29) 1
11 Manual for this machine (-19, -29) 1
12 Safety Information (-19, -29) 1
Installation Procedure
Unplug the machine power cord before starting the following procedure.
1. Remove filament tape and other padding.
2. Open the front door and remove the toner bottle holder [A]

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3. Open the right door [B], and remove the PCU (photoconductor unit) [C].
4. Separate the PCU into the upper part and the lower part ( x 5).
5. Put a sheet of paper on a level surface and place the upper part on it.
This prevents foreign material from getting on the sleeve rollers

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6. Distribute a pack of developer [D] to all openings equally.
Do not spill the developer on the gears [E]. If you have spilled it, remove the
developer by using a magnet or magnetized screwdriver.
Do not turn the gear [E] too much. The developer may spill.
7. Reassemble the PCU and reinstall it.
8. Shake the toner bottle [F] several times. (Do not remove the bottle cap [G] before
you shake the bottle.)
9. Remove the bottle cap [G] and install the bottle on the holder. (Do not touch the
inner cap [H].)
10. Set the holder (with the toner bottle) in the machine.

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11. Pull out the paper tray [I] and turn the paper size dial to the appropriate size.
Adjust the positions of the end and side guides.
To move the side guides, release the green lock on the rear side guide.
12. Install the optional ARDF, ADF, or platen cover.
13. Plug in the main power cord and turn on the main switch.
14. Activate the SP mode and execute "Devlpr Initialize" (SP 2214 1).
15. Wait until the message "Completed" shows (about 45 seconds).
16. Activate the User Tools and select the menu "Language."
17. Specify a language. This language is used for the operation panel.
18. Load the paper in the paper tray and make a full size copy, and make sure the
side-to-side and leading edge registrations are correct.

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Platen Cover Installation
Accessory Check
Check that you have the accessories indicated below.
No. Description Q’ty
1 Stepped Screw 2
Installation Procedure
Unplug the machine power cord before starting the following procedure.
Install the platen cover ( x 2).

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ARDF Installation
Accessory Check
Check the quantity and condition of the accessories against the following list.
No. Description Q’ty
1 Scale Guide 1
2 DF Exposure Glass 1
3 Stud Screw 2
4 Knob Screw 2
5 Original Size Decal 2
6 Screwdriver Tool 1
7 Attention Decal—Top Cover 1
8 Stamp Cartridge 1
9 Installation Procedure 1