Text preview for : 41641990-Ricoh-B202-B178-B180-3228C-3235-3245-Service-Manual.pdf part of Ricoh Aficio B202/B178/B180 Also known as: Ricoh Aficio 3228C, 3235C, or 3245C; Savin C2824, C3528, or C4535; Lanier LD328c, LD335c, or LD345c; Gestetner DSc428, DSc435. DSc445.
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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.
WARNING
The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection. Ricoh Corporation
LEGEND
PRODUCT CODE B202 B178 B180 GESTETNER DSc428 DSc435 DSc445 COMPANY LANIER RICOH LD328c Aficio 3228C LD335c Aficio 3235C LD345c Aficio 3245C SAVIN C2824 C3528 C4535
DOCUMENTATION HISTORY
REV. NO. * DATE 06/2005 COMMENTS Original Printing
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
SM i B202/B178/B180
Rev. 06/2006
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 Before You Begin The Procedure .......................................................1-75 Accessory Check ................................................................................1-75 Seal Check And Removal ...................................................................1-76 Installation Procedure .........................................................................1-77 1.6.9 CHECK ALL CONNECTIONS ........................................................1-79
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
B202/B178/B180
ii
SM
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
SM iii B202/B178/B180
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
B202/B178/B180 iv SM
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
SM v B202/B178/B180
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
B202/B178/B180 vi SM
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
SM vii B202/B178/B180
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
B202/B178/B180 viii SM
Picture Element (Dot Position) Correction ..........................................6-28 Scan Line Correction ..........................................................................6-28 Image Separation................................................................................6-28 ACS (Auto Color Select) .....................................................................6-29 Scanner Gamma Correction (RGB Gamma Correction) .....................6-30 Filtering ...............................................................................................6-31 ADS (Auto Image Density Selection) ..................................................6-31 Color Conversion ................................................................................6-32 Main Scan Magnification.....................................................................6-33 Printer Gamma Correction ..................................................................6-34 Error Diffusion .....................................................................................6-36 IPU Board Test ...................................................................................6-36 6.5 IMAGE DATA PATH................................................................................6-37 Copier Application...............................................................................6-37 Printer Application...............................................................................6-37 Scanner Application (1 bit/8 bits) ........................................................6-37 Fax Application (Transmission/Reception)..........................................6-37 6.6 LASER EXPOSURE................................................................................6-38 6.6.1 OVERVIEW ....................................................................................6-38 6.6.2 OPTICAL PATH..............................................................................6-39 6.6.3 LASER SYNCHRONIZING DETECTOR ........................................6-40 Overview.............................................................................................6-40 Main Scan Start Detection ..................................................................6-40 Clock Frequency Adjustment ..............................................................6-40 6.6.4 DUAL BEAM WRITING ..................................................................6-41 Dual Beam Mechanism.......................................................................6-41 Laser Beam Pitch Change Mechanism...............................................6-41 Printing Mode and Black LD Unit Position ..........................................6-42 6.6.5 LD SAFETY SWITCH .....................................................................6-43 Front and Upper Left Cover Switch.....................................................6-43 Error Messages ..................................................................................6-44 6.6.6 AUTOMATIC LINE POSITION ADJUSTMENT ..............................6-45 Overview.............................................................................................6-45 Summary of Each Adjustment ............................................................6-46 Adjustment Conditions ........................................................................6-47 Main Scan Skew Adjustment ..............................................................6-48 6.6.7 DIFFERENCES IN THE COPY AND PRINTER MODES ...............6-48 6.7 PHOTOCONDUCTOR UNIT ...................................................................6-49 6.7.1 OVERVIEW ....................................................................................6-49 6.7.2 DRIVE.............................................................................................6-50 6.7.3 DRUM GEAR POSITION SENSORS .............................................6-51 Mechanism .........................................................................................6-51 Initialization Process and SC Codes ...................................................6-52 6.7.4 DRUM CHARGE AND QUENCHING .............................................6-53 6.7.5 DRUM CLEANING..........................................................................6-54 6.7.6 WASTE TONER COLLECTION .....................................................6-55 Waste Toner Path ...............................................................................6-55 Waste Toner Vibrator..........................................................................6-56 6.7.7 WASTE TONER BOTTLE FULL DETECTION ...............................6-57
SM ix B202/B178/B180
6.8 DEVELOPMENT .....................................................................................6-58 6.8.1 OVERVIEW ....................................................................................6-58 6.8.2 DRIVE.............................................................................................6-59 6.8.3 DEVELOPER AGITATION .............................................................6-60 6.8.4 DEVELOPMENT BIAS ...................................................................6-61 6.8.5 TONER SUPPLY MECHANISM .....................................................6-62 Overview.............................................................................................6-62 Toner Agitation and Attraction ............................................................6-62 Air Flow and Toner Flow .....................................................................6-63 Toner Near End Detection ..................................................................6-63 Toner Transport ..................................................................................6-64 6.8.6 TONER CARTRIDGE DETECTION ...............................................6-65 6.9 PAPER FEED..........................................................................................6-66 6.9.1 OVERVIEW ....................................................................................6-66 6.9.2 DRIVE TRAY 1, TRAY 2, AND BY-PASS TRAY .........................6-67 6.9.3 PAPER LIFT TRAYS 1 & 2..........................................................6-68 6.9.4 PAPER SIZE DETECTION TRAYS 1 & 2....................................6-69 6.9.5 PAPER HEIGHT DETECTION TRAYS 1 & 2 ..............................6-70 6.9.6 PAPER END DETECTION TRAYS 1 & 2 ....................................6-70 6.9.7 REGISTRATION.............................................................................6-71 6.9.8 PAPER FEED LINE SPEED...........................................................6-72 6.9.9 GRIP ROLLER RELEASE MECHANISM .......................................6-73 6.10 DUPLEX UNIT.......................................................................................6-74 6.10.1 OVERVIEW ..................................................................................6-74 6.10.2 DUPLEX OPERATION .................................................................6-75 Up to A4/LT (81/2" x 11") LEF ............................................................6-75 Larger than A4/LT (81/2" x 11") LEF...................................................6-75 6.10.3 DUPLEX INVERTER UNIT...........................................................6-76 6.10.4 FEED TO EXTERNAL EXIT TRAY (NON-DUPLEX MODE) ........6-77 6.10.5 FEED TO DUPLEX FEED UNIT ...................................................6-78 6.10.6 FEED TO TWO-TRAY FINISHER AND BOOKLET FINISHER ....6-79 With Optional One-Tray Paper Feed Unit ...........................................6-79 With Optional LCT or Two-Tray Paper Feed Unit ...............................6-79 6.10.7 DUPLEX FEED UNIT ...................................................................6-80 Drive ...................................................................................................6-80 Feed-in and feed-out...........................................................................6-80 6.11 IMAGE TRANSFER AND PAPER SEPARATION .................................6-81 6.11.1 OVERVIEW ..................................................................................6-81 6.11.2 TRANSFER BELT DRIVE ............................................................6-82 Drive Motor .........................................................................................6-82 Transfer belt speed control .................................................................6-83 Transfer belt mark sensor ...................................................................6-84 6.11.3 TRANSFER CURRENT................................................................6-85 6.11.4 TRANSFER BELT CLEANING .....................................................6-86 6.11.5 TRANSFER BELT CONTACT ......................................................6-87 Mechanism .........................................................................................6-87 Transfer Belt Sensor ...........................................................................6-88 Copier ACS.........................................................................................6-88 Printer ACS.........................................................................................6-89
B202/B178/B180 x SM
6.12 FUSING .................................................................................................6-90 6.12.1 OVERVIEW ..................................................................................6-90 6.12.2 FUSING UNIT DRIVE...................................................................6-91 Belt and Rollers ..................................................................................6-91 Fusing Clutch......................................................................................6-91 6.12.3 FUSING TEMPERATURE CONTROL..........................................6-92 Fusing Temperatures..........................................................................6-92 Temperature Corrections ....................................................................6-93 Overheat Protection ............................................................................6-93 6.12.4 ENERGY SAVER MODES ...........................................................6-94 Overview.............................................................................................6-94 Panel Off Mode ...................................................................................6-95 Auto Off Mode.....................................................................................6-96 6.13 PAPER EXIT .........................................................................................6-97 6.13.1 OVERVIEW ..................................................................................6-97 6.13.2 PAPER OVERFLOW DETECTION ..............................................6-98 6.14 PRINTER FUNCTIONS .........................................................................6-99 6.14.1 OVERVIEW ..................................................................................6-99 6.14.2 HARD DISK ................................................................................6-101 Overview...........................................................................................6-101 Data Transfer....................................................................................6-101 6.14.3 PRINT DATA PROCESSING .....................................................6-102 RPCS Driver .....................................................................................6-102 PCL5e/PCL6c Driver.........................................................................6-102 PS3 Driver ........................................................................................6-103 CMS (Color Management System) ...................................................6-103 Gray Correction ................................................................................6-103 BG/UCR (Black Generation/Under Color Removal)..........................6-103 Gamma Correction............................................................................6-103 Toner Limitation ................................................................................6-104 Dither Processing and ROP/RIP .......................................................6-104 6.14.4 CONTROLLER FUNCTIONS .....................................................6-105 Sample Print .....................................................................................6-105 Locked Print......................................................................................6-105 6.14.5 JOB SPOOLING .........................................................................6-106 Related SP Modes ............................................................................6-106 Paper Source Selection ....................................................................6-107 Auto Continue ...................................................................................6-108 Paper Output Tray ............................................................................6-109 Stapling.............................................................................................6-109 Punching...........................................................................................6-110 6.15 FILE FORMAT CONVERTER (MLB)...................................................6-111 6.16 DATA OVERWRITE SECURITY UNIT (B735) ....................................6-112 6.16.1 AUTO ERASE MEMORY ...........................................................6-112 Types of Data Overwritten and Not Overwritten ...............................6-112 Overwrite timing ................................................................................6-112
SM
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B202/B178/B180
SPECIFICATIONS
SPECIFICATIONS............................................................................. 7-1
1. GENERAL SPECIFICATIONS.....................................................................7-1 1.1 BASIC..................................................................................................7-1 1.2 PRINTER.............................................................................................7-4 1.3 SCANNER ...........................................................................................7-5 2. SUPPORTED PAPER SIZES......................................................................7-6 2.1 PAPER FEED......................................................................................7-6 2.2 PAPER EXIT .......................................................................................7-7 PLATEN/ARDF ORIGINAL SIZE DETECTION ....................................7-8 3. SOFTWARE ACCESSORIES .....................................................................7-9 3.1 PRINTER DRIVERS ............................................................................7-9 3.2 UTILITY SOFTWARE ........................................................................7-10 SCANNER ..........................................................................................7-10 Scanner Drivers ..................................................................................7-10 Scanner Utilities ..................................................................................7-10 4. MACHINE CONFIGURATION ...................................................................7-11 5. OPTIONAL EQUIPMENT ..........................................................................7-13 5.1 ARDF.................................................................................................7-13 5.2 ONE-TRAY PAPER FEED UNIT .......................................................7-14 5.3 TWO-TRAY PAPER FEED UNIT ......................................................7-14 5.4 2000-SHEET LARGE CAPACITY TRAY ...........................................7-14 5.5 TWO-TRAY FINISHER & PUNCH UNIT ...........................................7-15 5.6 BOOKLET FINISHER ........................................................................7-16 5.7 MULTI-BIN OUTPUT TRAY ..............................................................7-16 5.8 SCANNER ACCESSIBILITY OPTION...............................................7-17
PUNCH KIT B377
SEE SECTION B377 FOR DETAILED TABLE OF CONTENTS
TWO-TRAY PAPER FEED B598
SEE SECTION B598 FOR DETAILED TABLE OF CONTENTS
TWO-TRAY FINISHER B599
SEE SECTION B599 FOR DETAILED TABLE OF CONTENTS
LARGE CAPACITY TRAY B600
SEE SECTION B600 FOR DETAILED TABLE OF CONTENTS
ONE-TRAY PAPER FEED UNIT B601
SEE SECTION B601 FOR DETAILED TABLE OF CONTENTS
B202/B178/B180
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BOOKLET FINISHER B602
SEE SECTION B602 FOR DETAILED TABLE OF CONTENTS
FAX OPTION TYPE 3245 B712
SEE SECTION B712 FOR DETAILED TABLE OF CONTENTS
SM
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B202/B178/B180
IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. 4. The copier drives some of its components when it completes the warm-up period. Be careful to keep hands away from the mechanical and electrical components as the copier starts operation. 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. Immediately wash eyes with plenty of water. If unsuccessful, get medical attention. OBSERVANCE OF ELECTRICAL SAFETY STANDARDS The copier and its peripherals must be serviced by a customer service representative who has completed the training course on those models.
CAUTION
1. The NVRAM module installed on the controller has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations. 2. The optional fax and memory expansion units contain lithium batteries, which can explode if replaced incorrectly. Replace only with the same or an equivalent type recommended by the manufacturer. Do not recharge or burn the batteries. Used batteries must be handled in accordance with local regulations.
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, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations. 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
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.
WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
WARNING
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Optics Housing Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:
CAUTION- CLASS 3B LASER RADIATION WHEN OPEN AVOID EXPOSURE TO THE BEAM VORSICHT- LASERSTRAHLUNG KLASSE 3B WENN ABDECKUNG GEOFFNET NICHT DEM STRAHL AUSSETZEN
CAUTION VORSICHT
CAUTION- CLASS 3B LASER RADIATION WHEN OPEN AVOID EXPOSURE TO THE BEAM VORSICHT- LASERSTRAHLUNG KLASSE 3B WENN ABDECKUNG GEOFFNET NICHT DEM STRAHL AUSSETZEN
CAUTION VORSICHT
>PS<
>PS<
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
Short Edge Feed (SEF)
Long Edge Feed (LEF)
B712 FAX OPTION TYPE 3245 PREVENTIVE MAINTENANCE TWO-TRAY PAPER FEED B598
LARGE CAPACITY TRAY B600
TWO-TRAY FINISHER B599 BOOKLET FINISHER B602 PUNCH KIT B377
ONE-TRAY PAPER FEED UNIT B601
TAB POSITION 8
TAB POSITION 7
SPECIFICATIONS
TAB POSITION 6
DETAILED DESCRIPTIONS
TAB POSITION 5
SERVICE TABLES
TAB POSITION 4
TROUBLESHOOTING
TAB POSITION 3
REPLACEMENT AND ADJUSTMENT
TAB POSITION 2
TAB POSITION 1
INSTALLATION
INSTALLATION
INSTALLATION REQUIREMENTS
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
Ambient Humidity (%RH) 80% 70%
Recommended conditions: 15 to 25°C 30 to 70 %RH
54%
30%
15%
B178I901.WMF
10°C
15°C
30°C 32°C
1. Temperature Range: 2. Humidity Range: 3. Ambient Illumination: 4. Ventilation:
10°C to 32°C (50°F to 89.6°F) 15% to 80% RH Less than 1,500 lux (do not expose to direct sunlight) 3 times/hr/person or more
5. Do not exposed the machine to the following: 1) Cool air from an air conditioner 2) Heat from a heater 6. Do not install the machine in areas that are exposed to corrosive gas. 7. Install the machine at locations lower than 2,500 m (8,200 ft.) above sea level. 8. Install the machine on a strong, level base. (Inclination on any side must be no more than 5 mm.) 9. Do not install the machine in areas that get strong vibrations.
1.1.2 MACHINE LEVEL
Front to back: Within 5 mm (0.2") Right to left: Within 5 mm (0.2")
SM
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B202/B178/B180/
Installation
1. INSTALLATION
INSTALLATION REQUIREMENTS
1.1.3 MACHINE SPACE REQUIREMENT
Install the machine near the power source, with the clearance as shown. [B]
[A]
[C]
[D]
B178I902.WMF
A: Over 100 mm (3.9") B: Over 100 mm (3.9") C: Over 550 mm (22") D: Over 75 mm (3.0")
1.1.4 POWER REQUIREMENTS
CAUTION
1. Insert the plug firmly in the outlet. 2. Do not use an outlet extension plug or cord. 3. Ground the machine. 1. Input voltage level: 120 V, 60 Hz: More than 10 A 220 V ~ 240 V, 50 Hz/60 Hz: More than 6 A 2. Permissible voltage fluctuation: ±10 % 3. Do not put things on the power cord.
B202/B178/B180
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SM
OPTIONAL UNIT COMBINATIONS
1.2.1 MACHINE OPTIONS
No. 1 2 3 4 5 6 7 8 9 10 11 Options 1-tray paper feed unit 2-tray paper feed unit Large capacity tray Platen cover ARDF Multi-bin output tray Two-tray finisher Punch kit (3 types) Booklet finisher Punch unit (4 types) Scanner accessibility option Remarks One from the three One from the two One from No. 6, No. 7, and No. 9 One from No. 6, No. 7, and No. 9 No. 7 required; One of the three types One from No. 6, No. 7, and No. 9 No. 9 required; One of the four types
Italic: Child options (Child options require a parent option.)
1.2.2 CONTROLLER OPTIONS
No. 12 13 14 15 16 17 18 Options IEEE 1394 IEEE 802.11b IEEE 1284 Bluetooth PostScript 3 File Format Converter Data overwrite security unit Remarks One from the four
Italic: Child options (Child options require a parent option.)
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Installation
1.2 OPTIONAL UNIT COMBINATIONS
COPIER
1.3 COPIER
1.3.1 POWER SOCKETS FOR PERIPHERALS
CAUTION
Rating voltage for peripherals. Make sure to plug the cables into the correct sockets. 1. ARDF Rating voltage output connector for accessory Max. DC24V 2. Duplex unit Rating voltage output connector for accessory Max. DC24V
3. Finisher Rating voltage output connector for accessory Max. DC24V
B178I903.WMF
B202/B178/B180
1-4
SM
COPIER
This flow chart shows the installation procedures.
Start A Unpack the copier. Scanner accessbility option The paper feed unit or LCT installed? Yes Place the copier on the paper feed unit or LCT, and install it. No Select the language. The controller options installed? Set the date and time. Install the copier.
Yes Install the scanner accessbility option. No
Yes Install the controller options. No Install the platen cover or ARDF.
Perform ACC.
Check magnification and registration. The two-tray finisher or booklet finisher installed? Yes Adjust the operation panel display if necessary.
The punch unit installed?
Specify the settings relevant to the contract (see section 1.4.1).
Yes Install the punch unit. No No Install the finisher. End
A
B178I904.WMF
You need the optional paper tray unit or the LCT if you want to install the finisher. A punch unit is for to the two-tray finisher or the booklet finisher.
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B202/B178/B180/
Installation
1.3.2 INSTALLATION FLOW CHART
MACHINE INSTALLATION
1.4 MACHINE INSTALLATION
1.4.1 COPIER
CAUTION
Make sure that the transfer belt is in its correct position before you move the machine. Otherwise, the transfer belt and the black PCU can be damaged.
Accessory Check
Check the quantity and condition of these accessories. Description Q'ty 1. Operating InstructionsSystem Setting................................1 2. Operating ManualCopy Reference ....................................1 3. Operating ManualPrinter Reference ..................................1 4. CD-ROMPrinter/Scanner Driver.........................................1 5. CD-ROMOperating Instructions .........................................1 6. Ferrite Core .........................................................................1 7. Paper Size Decal .................................................................1 8. Model Name Decal ..............................................................1 9. Operation Panel Indication Decal ........................................1 10. Energy Star Sticker............................................................1 11. DecalInkjet Caution..........................................................1 12. DecalCopy Prohibition .....................................................1 14. External Tray .....................................................................1 15. Power Cord........................................................................1 16. TonerBlack ......................................................................1 17. TonerMagenta .................................................................1 18. TonerCyan .......................................................................1 19. TonerYellow.....................................................................1 20. Exposure Glass Cleaning Cloth .........................................1 21. Cloth Holder.......................................................................1 22. NECR ................................................................................1
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SM
MACHINE INSTALLATION
CAUTION
Remove the tape from the development units (see step 2) before you turn the main switch on. The development units can be severely damaged if you do not remove the tape. Put the copier on the paper tray unit or the LCT first if you will install an optional paper tray unit or the optional LCT at the same time. Then install the copier and other options. NOTE: Keep the shipping retainers after you install the machine. You may need them in the future if you transport the machine to another location.
[A]
B178I501.WMF
B178I502.WMF
1. Remove the tape and padding on the copier. 2. Remove the pin [A]. NOTE: Keep the pin. You may need it if you want to transport the machine ( 1.4.3). 3. Remove all tapes from the four development units. 4. Turn the transfer belt release lever clockwise.
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B202/B178/B180/
Installation
Installation Procedure
MACHINE INSTALLATION
5. Shake the toner cartridge five or six times. 6. Install the toner cartridges to the copier. 7. Check that the hooks [A] hold the cartridge correctly.
[A]
B178I506.WMF
[B] 8. Install the external tray [B].
B178I507.WMF
9. Attach the cloth holder [C] to the left side of the scanner unit. 10. Put the contract glass cleaning cloth [D] in the holder. [D]
[C]
B178I508.WMF
B202/B178/B180
1-8
SM
MACHINE INSTALLATION
11. Attach the duplex inverter guide [A]. 12. Attach the guide cover [B].
Installation
[B] [A]
B178I509.WMF
13. Attach the correct model name decal [C] to the front cover with the cover [D]. 14. Pull each paper tray out. Then adjust the side guides and end guide to match the paper size. NOTE: To move the side guides, first pull out the tray fully. Then push down the green lock at the rear insid