Ricon B156 User manual

B156/B220
SERVICE MANUAL
002350MIU

B156/B220
SERVICE MANUAL

B156/B220
SERVICE MANUAL
002350MIU

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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
repair or modify Ricoh equipment risk persona
l
injury, damage to property or loss of warrant
y
p
rotection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
B156 DSc424 LD124c Aficio 3224C C2410
B220 DSc432 LD132c Aficio 3232C C3210e
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 05/2005 Original Printing

Trademarks
Microsoft®, Windows®, and MS-DOS®are registered trademarks of Microsoft
Corporation in the United States and /or other countries.
PostScript®is a registered trademark of Adobe Systems, Incorporated.
PCL®is a registered trademark of Hewlett-Packard Company.
Ethernet®is a registered trademark of Xerox Corporation.
PowerPC®is a registered trademark of International Business Machines
Corporation.
Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights involved
with those marks.
Symbols and Abbreviations
This manual uses several symbols.
Symbol What it means
Refer to section number
See Core Tech Manual for details
Screw
Connector
E-ring
Clip ring
Long Edge Feed (LEF)Short Edge Feed (SEF)

SM i B156/B220
B156/B220
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 POWER REQUIREMENTS ..............................................................1-2
1.1.4 SPACE REQUIREMENTS................................................................1-2
1.2 COPIER (B156/B220)................................................................................1-3
1.2.1 POWER SOCKETS FOR PERIPHERALS .......................................1-3
1.2.2 INSTALLATION FLOW CHART .......................................................1-4
1.2.3 ACCESSORY CHECK......................................................................1-5
1.2.4 INSTALLATION PROCEDURE ........................................................1-6
1.3 PAPER TRAY UNIT (B456).....................................................................1-13
1.3.1 ACCESSORY CHECK....................................................................1-13
1.3.2 INSTALLATION PROCEDURE ......................................................1-13
1.4 LCT (B457)..............................................................................................1-17
1.4.1 ACCESSORY CHECK....................................................................1-17
1.4.2 INSTALLATION PROCEDURE ......................................................1-17
1.5 AUTO REVERSE DOCUMENT FEEDER (B810)....................................1-21
1.5.1 ACCESSORY CHECK....................................................................1-21
1.5.2 INSTALLATION PROCEDURE ......................................................1-21
1.6 INTERCHANGE UNIT (B481) .................................................................1-24
1.6.1 ACCESSORY CHECK....................................................................1-24
1.6.2 INSTALLATION PROCEDURE ......................................................1-25
1.7 1 BIN TRAY UNIT (B480)........................................................................1-26
1.7.1 ACCESSORY CHECK....................................................................1-26
1.7.2 INSTALLATION PROCEDURE ......................................................1-27
1.8 SHIFT TRAY (B510)................................................................................1-30
1.8.1 ACCESSORY CHECK....................................................................1-30
1.8.2 INSTALLATION PROCEDURE ......................................................1-30
1.9 BY-PASS FEED UNIT (B490) .................................................................1-33
1.9.1 ACCESSORY CHECK....................................................................1-33
1.9.2 INSTALLATION PROCEDURE ......................................................1-33
1.10 DUPLEX UNIT (B509) ...........................................................................1-35
1.10.1 ACCESSORY CHECK..................................................................1-35
1.10.2 INSTALLATION PROCEDURE ....................................................1-36
1.11 BRIDGE UNIT (B482)............................................................................1-38
1.11.1 ACCESSORY CHECK..................................................................1-38
1.11.2 INSTALLATION PROCEDURE ....................................................1-38
1.12 1000-SHEET FINISHER (B408) ............................................................1-42
1.12.1 ACCESSORY CHECK..................................................................1-42

B156/B220 ii SM
1.12.2 INSTALLATION PROCEDURE ....................................................1-43
1.13 500-SHEET FINISHER (B458) ..............................................................1-46
1.13.1 ACCESSORY CHECK..................................................................1-46
1.13.2 INSTALLATION PROCEDURE ....................................................1-47
1.14 PLATEN COVER INSTALLATION ........................................................1-49
1.15 PRINTER OPTIONS..............................................................................1-50
1.15.1 POSTSCRIPT 3 (B769) ................................................................1-50
1.15.2 FILE FORMAT CONVERTER (B609)...........................................1-51
1.15.3 IEEE1394 INTERFACE (B581) ....................................................1-52
UP Mode Settings for IEEE 1394........................................................1-53
SP Mode Settings for IEEE 1394........................................................1-53
1.15.4 IEEE 1284 (B679).........................................................................1-54
Installation Procedure .........................................................................1-54
1.15.5 IEEE802.11B (G813) ....................................................................1-55
UP Mode Settings for Wireless LAN ...................................................1-57
SP Mode Settings for IEEE 802.11b Wireless LAN ............................1-58
1.15.6 BLUETOOTH (B736) ....................................................................1-59
1.15.7 CHECKING THE CONNECTIONS ...............................................1-60
1.16 DATA OVERWRITE SECURITY UNIT (B735) ......................................1-61
ACCESSORY CHECK........................................................................1-61
Seal Check and Removal ...................................................................1-61
Installation Procedure .........................................................................1-62
1.17 KEY COUNTER INSTALLATION ..........................................................1-64
1.18 ANTI-CONDENSATION HEATER.........................................................1-66
1.19 TRAY HEATER .....................................................................................1-68
1.20 TRAY HEATER (OPTIONAL PAPER TRAY UNIT) ...............................1-70
1.21 TRAY HEATER (OPTIONAL LCT) ........................................................1-72
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 MAIN UNIT ................................................................................................2-1
2.1.1 OVERVIEW ......................................................................................2-1
2.1.2 WASTE TONER BOTTLES ..............................................................2-2
2.1.3 PM TABLE........................................................................................2-3
2.2 OPTIONAL UNIT PM TABLE ....................................................................2-6
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 SPECIAL TOOLS ......................................................................................3-1
3.2 FILTERS....................................................................................................3-1
3.3 SCANNER UNIT........................................................................................3-2
3.3.1 EXPOSURE GLASS.........................................................................3-2
3.3.2 APS SENSORS................................................................................3-2
3.3.3 LENS BLOCK ASSEMBLY...............................................................3-3
3.3.4 EXPOSURE LAMP STABILIZER .....................................................3-5

SM iii B156/B220
3.3.5 SCANNER LAMP .............................................................................3-5
3.3.6 SCANNER I/O BOARD.....................................................................3-8
3.3.7 SCANNER MOTOR..........................................................................3-8
3.3.8 FRONT SCANNER WIRE ................................................................3-8
3.3.9 REAR SCANNER WIRE.................................................................3-11
3.4 LASER UNIT ...........................................................................................3-13
3.4.1 CAUTION DECAL LOCATION .......................................................3-13
3.4.2 LASER UNIT ..................................................................................3-14
Adjusting for Image Skew ...................................................................3-16
D-Phase Adjustment ...........................................................................3-17
Laser Beam Pitch Adjustment.............................................................3-18
3.4.3 POLYGONAL MIRROR MOTOR AND LSD ...................................3-19
3.5 DEVELOPMENT UNIT ............................................................................3-20
3.6 PHOTOCONDUCTOR UNIT (PCU) ........................................................3-21
3.6.1 PCU ASSEMBLY............................................................................3-21
3.6.2 WASTE TONER BOTTLES ............................................................3-24
3.6.3 CHARGE CORONA UNIT, GRID, WIRE, AND CLEANER.............3-25
3.6.4 CHARGE CORONA WIRE CLEANER MOTOR .............................3-27
3.6.5 OPC BELT CLEANING UNIT .........................................................3-27
3.6.6 IMAGE TRANSFER BELT CLEANING UNIT .................................3-27
3.7 PAPER TRANSFER UNIT.......................................................................3-28
3.7.1 VERTICAL TRANSPORT UNIT......................................................3-28
3.7.2 TRANSFER ROLLER .....................................................................3-28
3.8 FUSING/PAPER EXIT.............................................................................3-29
3.8.1 FUSING UNIT.................................................................................3-29
3.8.2 OIL SUPPLY UNIT .........................................................................3-29
3.8.3 OIL SUPPLY PAD ..........................................................................3-30
3.8.4 CLEANING ROLLER AND FUSING SPONGE ROLLER ...............3-30
3.8.5 OILING ROLLER AND OIL SUPPLY ROLLER ..............................3-31
3.8.6 FUSING LAMPS.............................................................................3-32
When installing the fusing lamps ........................................................3-32
3.8.7 FUSING INNER UNIT.....................................................................3-33
3.8.8 PRESSURE ROLLER THERMOFUSE...........................................3-33
3.8.9 HOT ROLLER STRIPPERS ...........................................................3-34
3.8.10 FUSING BELT UNIT AND PRESSURE ROLLER UNIT ...............3-34
3.8.11 PRESSURE ROLLER, PRESSURE ROLLER GEAR,
AND CLEANING ROLLER ..........................................................3-35
3.8.12 PRESSURE ROLLER THERMISTOR ..........................................3-36
3.8.13 OIL ABSORBERS.........................................................................3-37
3.8.14 FUSING ENTRANCE AND TRANSFER BELT SENSORS ..........3-38
3.8.15 PAPER EXIT/OVERFLOW SENSORS.........................................3-39
3.9 PAPER FEED AND TRANSPORT ..........................................................3-41
3.9.1 FEED ROLLER AND FRICTION PAD ............................................3-41
3.9.2 REGISTRATION SENSOR.............................................................3-42
3.9.3 PAPER FEED SENSOR 1..............................................................3-45
3.9.4 PAPER NEAR-END SENSORS .....................................................3-45
3.9.5 PAPER FEED SENSOR 2..............................................................3-46
3.9.6 PAPER END SENSOR 1................................................................3-47
3.9.7 PAPER END SENSOR 2................................................................3-47

B156/B220 iv SM
3.10 ELECTRICAL COMPONENTS..............................................................3-48
3.10.1 EXHAUST FAN AND I/O BOARD.................................................3-48
3.10.2 BICU BOARD AND CONTROLLER BOARD................................3-49
3.10.3 HDD..............................................................................................3-50
3.10.4 HIGH VOLTAGE SUPPLY BOARD ..............................................3-51
3.10.5 POWER SUPPLY UNIT................................................................3-52
3.11 DRIVE UNITS........................................................................................3-53
3.11.1 DEVELOPMENT CLUTCHES ......................................................3-53
K Development Units ..........................................................................3-53
C, Y and M Development Units...........................................................3-53
3.11.2 DEVELOPMENT MOTORS..........................................................3-54
3.11.3 MAIN MOTOR ..............................................................................3-54
3.11.4 PCU GEAR BOX ..........................................................................3-55
3.11.5 FUSING UNIT MOTOR ................................................................3-55
3.11.6 PAPER FEED CLUTCH 1 ............................................................3-56
3.11.7 PAPER FEED MOTOR.................................................................3-56
3.11.8 PAPER FEED CLUTCH 2 ............................................................3-57
3.11.9 REGISTRATION CLUTCH ...........................................................3-57
3.11.10 OIL PUMP ..................................................................................3-58
3.12 COPY ADJUSTMENT ...........................................................................3-59
3.12.1 PRINTING ....................................................................................3-59
Registration - Leading Edge/Side-to-Side...........................................3-59
Blank Margin.......................................................................................3-60
Main Scan Magnification.....................................................................3-60
3.12.2 SCANNING...................................................................................3-61
Scanner Sub-Scan Magnification........................................................3-61
Scanner Leading Edge and Side-to-Side Registration........................3-61
Main Scan Dot Position Correction .....................................................3-62
3.12.3 ARDF IMAGE ADJUSTMENT ......................................................3-63
ARDF Side-to-Side and Leading Edge Registration ...........................3-63
ARDF Skew Adjustment .....................................................................3-64
3.13 COLOR ADJUSTMENT.........................................................................3-65
3.13.1 AUTO COLOR CALIBRATION (ACC) ..........................................3-65
3.13.2 PRINTER GAMMA CORRECTION ..............................................3-66
Copy Mode .........................................................................................3-66
Printer Mode .......................................................................................3-70
3.14 SCANNER WHITE LEVEL ADJUSTMENT ...........................................3-72
White Level Check ..............................................................................3-72
White Level Adjustment ......................................................................3-72
3.15 TOUCH SCREEN CALIBRATION .........................................................3-75
3.16 CHECKING THE BREAKER SWITCH ..................................................3-76
3.16.1 BREAKER ....................................................................................3-76
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL.........................................................................................4-1
4.1.1 SERVICE CALL CONDITIONS ........................................................4-1

SM v B156/B220
4.1.2 SC TABLE ........................................................................................4-2
4.2 SELF-DIAGNOSTIC MODE ....................................................................4-20
4.2.1 OVERVIEW ....................................................................................4-20
4.2.2 DETAILED SELF-DIAGNOSTICS ..................................................4-21
4.3 IMAGE TEST MODE ...............................................................................4-22
4.3.1 OVERVIEW ....................................................................................4-22
4.3.2 VPU TEST ......................................................................................4-22
SP4-907-1: VPU Test Pattern: R ........................................................4-22
SP4-907-2: VPU Test Pattern: G ........................................................4-22
SP4-907-3: VPU Test Pattern: B ........................................................4-22
4.3.3 IPU TEST .......................................................................................4-22
4.3.4 GAVD TEST ...................................................................................4-22
4.4 ELECTRICAL COMPONENT DEFECTS ................................................4-23
4.4.1 SENSORS ......................................................................................4-23
4.4.2 SWITCHES.....................................................................................4-25
4.4.3 BLOWN FUSE CONDITIONS ........................................................4-25
4.5 CHECK POINTS FOR IMAGE PROBLEMS AT REGULAR INTERVALS ..4-26
4.6 SKEWED, TRAPEZOID, AND PARALLELOGRAM IMAGES..................4-27
4.6.1 SKEWED IMAGES .........................................................................4-27
4.6.2 TRAPEZOID IMAGES ....................................................................4-27
4.6.3 PARALLELOGRAM IMAGES .........................................................4-28
4.6.4 CHECKING THE IMAGE WITH THE TRIMMING PATTERN .........4-29
4.6.5 CORRECTING THE IMAGES ........................................................4-30
Flowchart ............................................................................................4-30
Action..................................................................................................4-31
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1
Starting the SP mode............................................................................5-1
Quitting the SP mode............................................................................5-1
SP Mode Touch Screen........................................................................5-2
Copy Window for Test Printing .............................................................5-3
Working on SP Mode Menus ................................................................5-3
Service Mode Lock/Unlock ...................................................................5-4
5.1.2 SP MODE TABLE.............................................................................5-5
SP1-XXX: (Feed) ..................................................................................5-5
SP2-XXX: (Drum)..................................................................................5-9
SP3-XXX: (Process) ...........................................................................5-17
SP4-XXX: (Scanner) ...........................................................................5-20
SP5-XXX: (Mode) ...............................................................................5-28
SP6-XXX: (Peripherals) ......................................................................5-53
SP7-XXX: (Data Log)..........................................................................5-56
SP8-XXX: (Data Log2)........................................................................5-66
5.1.3 TEST PATTERN PRINTING (SP5-955-1) ....................................5-100
5.1.4 INPUT CHECK .............................................................................5-101

B156/B220 vi SM
Main Machine Input Check (SP5-803) ..............................................5-101
Table 1: Tray 1 and 2 Paper Size .....................................................5-104
Table 2: By-pass Tray Paper Size ....................................................5-104
Table 3: Optional Paper Tray Unit Paper Size ..................................5-104
Table 4: Optional Paper Tray Unit Paper Near End..........................5-104
ARDF Input Check (SP6-007)...........................................................5-105
Finisher Input Check (SP6-117)........................................................5-106
5.1.5 OUTPUT CHECK .........................................................................5-107
Main Machine Output Check (SP5-804) ...........................................5-107
ARDF Output Check (SP6-008)........................................................5-110
Finisher Output Check (SP6-118).....................................................5-110
5.1.6 SMC DATA LISTS (SP5-990).......................................................5-111
5.1.7 ORIGINAL JAM HISTORY DISPLAY ...........................................5-111
Total Count .......................................................................................5-111
Details on the Most Recent Jams .....................................................5-111
5.1.8 COPY JAM HISTORY DISPLAY ..................................................5-112
Total Count .......................................................................................5-112
Details on the Most Recent Jams .....................................................5-112
5.1.9 MEMORY ALL CLEAR (SP5-801) ................................................5-113
Using an SD card..............................................................................5-113
Without Using a Flash Memory Card ................................................5-114
5.2 PRINTER SERVICE MODE ..................................................................5-115
5.2.1 SERVICE MODE TABLE..............................................................5-115
Service Table Key.............................................................................5-115
5.2.2 SP MODES RELATED TO THE PRINTER CONTROLLER .........5-117
5.3 SCANNER SERVICE MODE.................................................................5-118
5.3.1 SCANNER PROGRAM MODE TABLE.........................................5-118
SP1-XXX (System and Others).........................................................5-118
SP2-XXX (Scanning-image quality) ..................................................5-118
5.3.2 APS OUTPUT DISPLAY (SP4-301) .............................................5-119
5.4 PROGRAM DOWNLOAD......................................................................5-120
5.4.1 FIRMWARE ..................................................................................5-120
5.4.2 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-122
Uploading NVRAM Data (SP5-824)..................................................5-122
Downloading NVRAM Data (SP5-825) .............................................5-123
5.5 SOFTWARE RESET .............................................................................5-124
5.6 SYSTEM SETTINGS AND COPY SETTING RESET............................5-124
5.6.1 SYSTEM SETTING RESET .........................................................5-124
5.6.2 COPIER SETTING RESET ..........................................................5-125
5.7 USER TOOLS .......................................................................................5-126
5.7.1 HOW TO ENTER USER TOOLS..................................................5-126
UP Mode Initial Screen: User Tools/Counter Display........................5-126
System Settings................................................................................5-126
Copier/Document Server Features ...................................................5-126
Printer, Facsimile, Scanner Settings.................................................5-126
Inquiry ...............................................................................................5-126
Counter .............................................................................................5-127
5.8 DIP SWITCHES.....................................................................................5-127
5.9 SD CARD APPLICATION MOVE ..........................................................5-128

SM vii B156/B220
Overview...........................................................................................5-129
Move Exec ........................................................................................5-129
Undo Exec ........................................................................................5-129
5.10 USING THE DEBUG LOG...................................................................5-130
5.10.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG .........5-130
5.10.2 RETRIEVING THE DEBUG LOG FROM THE HDD ...................5-133
5.10.3 RECORDING ERRORS MANUALLY .........................................5-134
5.10.4 NEW DEBUG LOG CODES .......................................................5-135
SP5857-015 Copy SD Card-to-SD Card: Any Desired Key .............5-135
SP5857-016 Create a File on HDD to Store a Log ..........................5-135
SP5857-017 Create a File on SD Card to Store a Log ....................5-135
DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1
6.1.1 MECHANICAL COMPONENTS........................................................6-1
6.1.2 PAPER PATH...................................................................................6-2
6.1.3 DRIVE COMPONENTS ....................................................................6-3
Layout ...................................................................................................6-3
Drive Power Path..................................................................................6-4
6.1.4 ELECTRICAL COMPONENTS.........................................................6-5
Scanner Unit .........................................................................................6-5
Image Transfer .....................................................................................6-6
Paper Path............................................................................................6-7
Development Units................................................................................6-8
Boards ..................................................................................................6-9
6.2 BOARD STRUCTURE.............................................................................6-10
6.2.1 BLOCK DIAGRAM..........................................................................6-10
6.2.2 CONTROLLER ...............................................................................6-12
6.3 COPY PROCESS....................................................................................6-14
6.4 PROCESS CONTROL ............................................................................6-16
6.4.1 OVERVIEW ....................................................................................6-16
6.4.2 PROCESS CONTROL STEPS .......................................................6-16
Six Steps.............................................................................................6-16
When is Process Control Done?.........................................................6-16
Supplementary Information on Process Control .................................6-17
6.5 SCANNING..............................................................................................6-19
6.5.1 OVERVIEW ....................................................................................6-19
6.5.2 SCANNER DRIVE ..........................................................................6-20
Book Mode..........................................................................................6-20
ARDF Mode ........................................................................................6-20
6.5.3 ORIGINAL SIZE DETECTION........................................................6-21
6.6 IMAGE PROCESSING ............................................................................6-23
6.6.1 OVERVIEW ....................................................................................6-23
6.6.2 SBU BLOCK DIAGRAM .................................................................6-24
Signal Processing ...............................................................................6-24
A/D Conversion...................................................................................6-24

B156/B220 viii SM
White Level Correction........................................................................6-24
Others .................................................................................................6-24
Black Level Correction ........................................................................6-25
VPU Test Mode ..................................................................................6-25
6.6.3 IMAGE PROCESSING ...................................................................6-26
Shading Correction .............................................................................6-26
Picture Element (Dot Position) Correction ..........................................6-26
Scan Line Correction ..........................................................................6-26
Scanner Gamma Correction (RGB Gamma Correction) .....................6-27
Filtering ...............................................................................................6-27
ADS (Auto Image Density Selection) ..................................................6-27
Image Separation................................................................................6-28
ACS (Auto Color Selection) ................................................................6-28
Color Conversion ................................................................................6-29
Main Scan Magnification.....................................................................6-29
Printer Gamma Correction ..................................................................6-30
Error Diffusion.....................................................................................6-32
6.7 PHOTOCONDUCTOR UNIT (PCU) ........................................................6-33
6.7.1 OVERVIEW ....................................................................................6-33
6.7.2 CHARGE CORONA UNIT ..............................................................6-34
Power Supply......................................................................................6-34
Grid and Wire Cleaning.......................................................................6-34
Quenching ..........................................................................................6-35
6.7.3 OPC BELT DRIVE ..........................................................................6-36
6.7.4 OPC BELT CLEANING UNIT .........................................................6-36
Bottle Detection ..................................................................................6-36
Waste Toner Collection.......................................................................6-37
Drive ...................................................................................................6-37
6.7.5 IMAGE TRANSFER BELT UNIT ....................................................6-38
Drive ...................................................................................................6-38
Belt Mark Detection.............................................................................6-38
Transfer Roller ....................................................................................6-39
6.7.6 IMAGE TRANSFER BELT CLEANING UNIT .................................6-40
Image Transfer Belt Cleaning .............................................................6-40
Waste Toner Collection.......................................................................6-40
Set Switch and Full Sensor.................................................................6-40
Contact Mechanism ............................................................................6-41
Power Supply......................................................................................6-42
Drive ...................................................................................................6-42
6.8 LASER EXPOSURE................................................................................6-43
6.8.1 OVERVIEW ....................................................................................6-43
6.8.2 POLYGON MIRROR MOTOR UNIT...............................................6-44
Speed .................................................................................................6-44
6.8.3 SYNCHRONIZATION DETECTOR ................................................6-44
6.8.4 LD UNIT..........................................................................................6-44
6.8.5 LD SAFETY SWITCH .....................................................................6-45
Front Door...........................................................................................6-45
Circuit..................................................................................................6-45
Operation Panel Display and Switch Mechanism ...............................6-46