Aficio B135, B138 Service Manual
RICOH GROUP COMPANIES
B135/B138
SERVICE MANUAL
001903MIU
SERVICE MANUAL
B135/B138
®
®
RICOH GROUP COMPANIES
B135/B138
SERVICE MANUAL
001903MIU
A
f
r
It is the reader's responsibility when discussing the information contained
within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH CORPORATION.
ll product names, domain names or product illustrations, including
desktop images, used in this document are trademarks, registered
trademarks or the property of their respective companies.
They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use o
any trade name, or web site is intended to convey endorsement or othe
affiliation with Ricoh products.
2004 RICOH Corporation. All rights reserved.
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WARNING
The Service Manual contains information
regarding service techniques, procedures,
rocesses and spare parts of office equipmen
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
information contained in this service manual to
repair or modify Ricoh equipment risk persona
injury, damage to property or loss of warranty
rotection.
Ricoh Corporation
Rev. 07/2004
LEGEND
PRODUCT CODE COMPANY
B135/B182* DSm635 LD135 Aficio 2035e 4035e
B138/B183* DSm645 LD145 Aficio 2045e 4045e
* Machines pre-configured with the Printer/Scanner option (B654) will use the
B182/B183 product codes.
GESTETNER LANIER RICOH SAVIN
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
2/2004 Original Printing
B135/B138
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION PROCEDURE.................................................... 1-1
1.1 INSTALLATION REQUIREMENTS ...........................................................1-1
1.1.1 ENVIRONMENT ...............................................................................1-2
1.1.2 MACHINE LEVEL.............................................................................1-2
1.1.3 MINIMUM SPACE REQUIREMENTS...............................................1-3
1.1.4 POWER REQUIREMENTS ..............................................................1-5
1.2 INSTALLATION FLOW CHART ................................................................1-6
1.3 MAIN MACHINE INSTALLATION..............................................................1-7
1.3.1 ACCESSORY CHECK......................................................................1-7
1.3.2 INSTALLATION PROCEDURE ........................................................1-8
Development Unit and PCU..................................................................1-9
Toner Bottle ........................................................................................1-12
Paper Trays ........................................................................................ 1-13
Initialize TD Sensor and Developer.....................................................1-15
Set Paper Size for Paper Trays ..........................................................1-16
Electrical Total Counter.......................................................................1-17
HDD Caution Decal.............................................................................1-17
Exposure Glass Cleaner ..................................................................... 1-17
1.4 PAPER TRAY UNIT INSTALLATION (B542) ..........................................1-18
1.4.1 ACCESSORY CHECK....................................................................1-18
1.4.2 PAPER TRAY UNIT INSTALLATION PROCEDURE .....................1-19
1.5 1-BIN TRAY UNIT INSTALLATION (B544) .............................................1-23
1.5.1 ACCESSORY CHECK....................................................................1-23
1.5.2 1-BIN TRAY INSTALLATION PROCEDURE..................................1-24
1.6 BRIDGE UNIT INSTALLATION (B538) ...................................................1-30
1.6.1 ACCESSORY CHECK....................................................................1-30
1.6.2 BRIDGE UNIT INSTALLATION PROCEDURE .............................. 1-31
1.7 TWO-TRAY FINISHER INSTALLATION (B545)......................................1-33
1.7.1 ACCESSORY CHECK....................................................................1-33
1.7.2 TWO-TRAY FINISHER INSTALLATION PROCEDURE.................1-34
1.8 PUNCH UNIT INSTALLATION ................................................................1-37
1.8.1 ACCESSORY CHECK....................................................................1-37
1.8.2 PUNCH UNIT INSTALLATION PROCEDURE ............................... 1-38
1.9 ARDF INSTALLATION (B541).................................................................1-41
1.9.1 ACCESSORY CHECK....................................................................1-41
1.9.2 ARDF INSTALLATION PROCEDURE............................................1-41
1.9.3 ARDF SKEW ADJUSTMENT ......................................................... 1-44
1.10 LCT INSTALLATION (B543)..................................................................1-45
1.10.1 ACCESSORY CHECK..................................................................1-45
1.10.2 LCT INSTALLATION PROCEDURE.............................................1-46
SM i B135/B138
1.11 PLATEN COVER INSTALLATION (G329) ............................................1-48
1.12 BOOKLET FINISHER INSTALLATION (B546)......................................1-49
1.12.1 ACCESSORY CHECK..................................................................1-49
1.12.2 BOOKLET FINISHER INSTALLATION PROCEDURE.................1-50
1.13 1000 SHEET FINISHER (B408) ............................................................1-55
1.13.1 ACCESSORY CHECK..................................................................1-55
1.13.2 1000 SHEET FINISHER INSTALLATION PROCEDURE.............1-56
1.14 FILE FORMAT CONVERTER B519-17.................................................1-59
1.14.1 ACCESSORY CHECK..................................................................1-59
1.14.2 INSTALLATION PROCEDURE .................................................... 1-59
1.14.3 CHECK ALL CONNECTIONS ...................................................... 1-60
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE SCHEDULE............................... 2-1
2.1 PM TABLE................................................................................................. 2-1
REPLACEMENT AND REPLACEMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 SPECIAL TOOLS AND LUBRICANTS ................................................3-2
3.1.1 SPECIAL TOOLS .............................................................................3-2
3.1.2 LUBRICANTS...................................................................................3-2
3.2 LASER UNIT .............................................................................................3-3
3.2.1 CAUTION DECAL LOCATIONS.......................................................3-3
3.2.2 LASER UNIT ....................................................................................3-4
3.3 PHOTOCONDUCTOR UNIT (PCU) ..........................................................3-6
3.3.1 PCU ..................................................................................................3-6
3.3.2 DRUM...............................................................................................3-7
3.3.3 PICK-OFF PAWLS ...........................................................................3-9
Pick-off pawl position adjustment.......................................................... 3-9
3.3.4 CHARGE ROLLER AND CLEANING ROLLER..............................3-10
3.3.5 DRUM CLEANING BLADE 2..........................................................3-11
3.3.6 DRUM CLEANING BLADE 1..........................................................3-12
3.4 FUSING UNIT..........................................................................................3-13
3.4.1 FUSING UNIT REMOVAL ..............................................................3-13
3.4.2 FUSING UNIT SIDE FAN ...............................................................3-14
3.4.3 FUSING UNIT CORNER FAN ........................................................3-16
3.5 PAPER FEED..........................................................................................3-17
3.5.1 IDLE ROLLER DUST BLADE.........................................................3-17
3.5.2 REGISTRATION ROLLER DUST BLADE ...................................... 3-18
3.6 PRINTED CIRCUIT BOARDS .................................................................3-19
3.6.1 IOB .................................................................................................3-19
IOB DIP Switch Settings (SW101) ......................................................3-20
3.7 HARD DISK, CONTROLLER BOARD.....................................................3-21
B135/B138 ii SM
Rev. 07/2004
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL CONDITIONS .................................................................4-1
4.1.1 SUMMARY .......................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS .............................................................4-2
4.2 ELECTRICAL COMPONENT DEFECTS ................................................4-20
4.2.1 SENSORS ......................................................................................4-20
4.2.2 SWITCHES.....................................................................................4-21
4.3 BLOWN FUSE CONDITIONS .................................................................4-21
4.4 LEDS .......................................................................................................4-22
4.5 TEST POINTS .........................................................................................4-22
4.6 READING SC 740/741 DETAILS FROM LED2… ............................. …..4-23
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE TABLES.....................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATION.....................................5-1
5.1.2 SERVICE TABLE KEY .....................................................................5-4
5.1.3 SERVICE TABLES ...........................................................................5-5
SP1-xxx: Feed ......................................................................................5-5
SP2-xxx: Drum......................................................................................5-9
SP3-xxx: Process................................................................................5-19
SP4-xxx: Scanner ...............................................................................5-20
SP5-xxx: Mode ...................................................................................5-29
SP6-xxx: Peripherals ..........................................................................5-49
SP7-xxx: Data Log..............................................................................5-51
SP8-xxx: Data Log2............................................................................5-59
5.1.4 NIP BANDWIDTH ADJUSTMENT: SP1-109 ..................................5-96
5.1.5 TEST PATTERN PRINTING: SP2-902...........................................5-97
Test Pattern Table (SP2-902-2: IPU Test Print)..................................5-97
Test Pattern Table: SP2-902-3 Printing Test Patterns........................5-98
5.1.6 INPUT CHECK ............................................................................... 5-99
Main Machine Input Check: SP5-803..................................................5-99
ARDF Input Check: SP6-007 ............................................................5-103
5.1.7 OUTPUT CHECK .........................................................................5-104
Main Machine Output Check: SP5-804.............................................5-104
ARDF Output Check: SP6-008) ........................................................5-106
5.1.8 SMC PRINT OUT LISTS: SP5-990...............................................5-106
5.1.9 MEMORY CLEAR: SP5-801.........................................................5-107
5.1.10 SYSTEM SETTINGS AND COPY SETTING RESET ................. 5-109
5.2 SOFTWARE DOWNLOAD ....................................................................5-111
5.2.1 SOFTWARE DOWNLOAD RECOVERY PROCEDURE ..............5-112
5.3 UPLOADING/DOWNLOADING NVRAM DATA.....................................5-113
5.3.1 UPLOADING NVRAM DATA (SP5-824).......................................5-113
5.3.2 DOWNLOADING NVRAM DATA (SP5-825) ................................5-113
5.4 SELF-DIAGNOSTIC MODE ..................................................................5-114
SM iii B135/B138
5.4.1 SELF-DIAGNOSTIC MODE AT POWER ON ............................... 5-114
5.4.2 DETAILED SELF-DIAGNOSTIC MODE .......................................5-115
5.5 USER PROGRAM MODE ..................................................................... 5-117
5.5.1 HOW TO USE UP MODE.............................................................5-117
5.6 DIP SWITCHES.....................................................................................5-120
5.7 USING THE DEBUG LOG..................................................................... 5-121
5.7.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG ........... 5-121
5.7.2 RETRIEVING THE DEBUG LOG FROM THE HDD.....................5-125
5.7.3 RECORDING ERRORS MANUALLY ...........................................5-125
Rev. 07/2004
DETAILED DESCRIPTIONS
6. DETAILED SECTIOIN DESCRIPTIONS ...................................... 6-1
6.1 BOARD STRUCTURE............................................................................... 6-2
6.1.1 BLOCK DIAGRAM............................................................................6-2
6.1.2 CONTROLLER .................................................................................6-4
6.2 IMAGE PROCESSING ..............................................................................6-7
6.2.1 OVERVIEW ......................................................................................6-7
6.2.2 SBU (SENSOR BOARD UNIT).........................................................6-8
6.2.3 AUTO IMAGE DENSITY (ADS)........................................................6-9
6.2.4 IPU (IMAGE PROCESSING UNIT).................................................6-10
Overview.............................................................................................6-10
6.2.5 IMAGE PROCESSING MODES .....................................................6-11
6.2.6 SUMMARY OF IMAGE PROCESSING FUNCTIONS ....................6-13
6.2.7 IMAGE PROCESSING STEPS AND RELATED SP MODES.........6-14
Text Mode...........................................................................................6-14
Text/Photo Mode ................................................................................6-15
Photo Mode ........................................................................................6-16
Pale (Low-Density Mode)....................................................................6-17
Generation Copy Mode.......................................................................6-18
6.2.8 PRE-FILTERING ............................................................................6-19
6.2.9 BACKGROUND ERASE.................................................................6-20
6.2.10 INDEPENDENT DOT ERASE ...................................................... 6-21
6.2.11 LINE WIDTH CORRECTION........................................................6-22
6.2.12 FILTERING...................................................................................6-23
Interactive SP Codes ..........................................................................6-23
Text Mode MTF Filter..........................................................................6-27
Text/Photo, Photo Mode Filter ............................................................ 6-28
Pale, Generation Mode Filter ..............................................................6-29
Photo Mode Smoothing for Dithering..................................................6-30
Photo Mode Grayscale .......................................................................6-30
Photo Mode Image Quality .................................................................6-31
6.2.13 OTHERS.......................................................................................6-32
Vertical Black Line Correction.............................................................6-32
Density Settings..................................................................................6-32
ADS Level...........................................................................................6-33
6.2.14 PRACTICAL APPLICATION OF SP MODES ...............................6-34
Solving Problems................................................................................6-34
B135/B138 iv SM
Recommended Settings for MTF Filters .............................................6-35
6.3 PHOTOCONDUCTOR UNIT (PCU) ........................................................6-37
6.3.1 OVERVIEW ....................................................................................6-37
6.3.2 DRUM CLEANING..........................................................................6-38
6.4 DRUM CHARGE .....................................................................................6-39
6.4.1 CORRECTION FOR PAPER WIDTH AND THICKNESS ...............6-39
6.4.2 DEVELOPMENT BIAS ...................................................................6-40
Mechanism .........................................................................................6-40
Correction for paper width and thickness (by-pass tray only) .............6-40
6.5 PAPER FEED..........................................................................................6-41
6.5.1 PAPER REGISTRATION................................................................6-41
6.6 IMAGE FUSING AND PAPER EXIT........................................................6-42
6.6.1 CLEANING MECHANISM ..............................................................6-42
6.6.2 HOT ROLLER STRIPPER CLEANING...........................................6-43
6.6.3 FUSING TEMPERATURE CONTROL............................................6-45
Temperature Control...........................................................................6-46
Fusing Idling Temperature .................................................................. 6-47
6.6.4 CPM DOWN FOR THICK PAPER..................................................6-48
6.6.5 COOLING AND OVERHEAT PROTECTION .................................6-49
6.6.6 TONER SCATTER PREVENTION .................................................6-50
Rev. 07/2004
SPECIFICATIONS
SPECIFICATIONS............................................................................. 7-1
1. GENERAL SPECIFICATIONS.....................................................................7-1
2. MACHINE CONFIGURATION.....................................................................7-3
3. OPTIONAL EQUIPMENT ............................................................................7-5
AUTO REVERSE DOCUMENT FEEDER B541
SEE SECTION B541 FOR DETAILED TABLE OF CONTENTS
PAPER TRAY UNIT B542
SEE SECTION B542 FOR DETAILED TABLE OF CONTENTS
LARGE CAPACITY TRAY B543
SEE SECTION B543 FOR DETAILED TABLE OF CONTENTS
BRIDGE UNIT B538
SEE SECTION B538 FOR DETAILED TABLE OF CONTENTS
1 BIN TRAY B544
SEE SECTION B544 FOR DETAILED TABLE OF CONTENTS
SM v B135/B138
Rev. 07/2004
1,000 SHEET FINISHER B408
SEE SECTION B408 FOR DETAILED TABLE OF CONTENTS
TWO-TRAY FINISHER B545
SEE SECTION B545 FOR DETAILED TABLE OF CONTENTS
BOOKLET FINISHER B546
SEE SECTION B546 FOR DETAILED TABLE OF CONTENTS
PRINTER/SCANNER CONTROLLER B654
SEE SECTION B654 FOR DETAILED TABLE OF CONTENTS
FAX UNIT B653
SEE SECTION B653 FOR DETAILED TABLE OF CONTENTS
INTERNET FAX IFAX
SEE SECTION IFAX FOR DETAILED TABLE OF CONTENTS
DATAOVERWRITESECURITY UNIT B692/B694
SEE SECTION B692/B694 FOR DETAILED TABLE OF CONTENTS
B135/B138 vi SM
IIMPORTANT 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. Note that some components of the copier and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. If 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.
5. If the Start key is pressed before the copier completes the warm-up period
(the Start key starts blinking red and green alternatively), keep hands away
from the mechanical and the electrical components as the copier starts
making copies as soon as the warm-up period is completed.
6. 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
1. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. Toner and developer are non-toxic, but if you get either of them in your eyes
by accident, it may cause temporary eye discomfort. Try to remove with eye
drops or flush with water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the system control board 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.
1. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
Do not incinerate toner bottles or used toner. Toner dust may ignite
suddenly when exposed to an open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
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 Unit section. Laser beams can seriously damage
your eyes.
CAUTION MARKING:
Conventions in this Manual
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)
INSTALLATION
Rev. 05/2004
AUTO REVERSE DOCUMENT FEEDER B541
FAX O PTIO N B65 3
PREVENTIVE MAINTENANCE
PAPER TRAY UNIT B542
PRINTER OPTION B654
REPLACEMENT AND ADJUSTMENT
LARGE CAPACITY TRAY B543
TROUBLESHOOTING
BOOKLET FINISHER B546
1000 SHEET FINISHER B408
2-TRAY FINISHER B545
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
SERVICE TABLES
DETAILED DESCRIPTIONS
SPECIFICATIONS
1-BIN TRAY B544
BRIDGE UNIT B538
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
DATAOVERWRITESECURITY Unit
B692/B694
POSITION 8
INSTALLATION
INSTALLATION REQUIREMENTS
1. INSTALLATION PROCEDURE
CAUTION
Never turn off the main power switch when the power LED is lit or flashing.
To avoid damaging the hard disk or memory, press the operation power
switch to switch the power off, wait for the power LED to go off, and then
switch the main power switch off.
NOTE: The main power LED lights or flashes while the platen cover or ARDF is
open, while the main machine is communicating with a facsimile or the
network server, or while the machine is accessing the hard disk or memory
for reading or writing data.
1.1 INSTALLATION REQUIREMENTS
CAUTION
ARDF
Installation
LCT
“Rating Voltage of Output
Connector, Max. DC24 V”
B135I016.WMF
“Rating Voltage of Output
Connector, Max. DC24 V”
Scanner Unit
“Rating Voltage of Output
Connector, Max. DC24 V”
Finisher
“Rating Voltage of Output
Connector, Max. DC24 V”
SM 1-1 B135/B138
INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
1. Temperature Range:
2. Humidity Range:
3. Ambient Illumination:
4. Ventilation:
5. Ambient Dust:
6. Avoid areas exposed to sudden temperature changes:
1) Areas directly exposed to cool air from an air conditioner.
2) Areas directly exposed to heat from a heater.
7. Do not place the machine where it will be exposed to corrosive gases.
8. Do not install the machine at any location over 2,000 m (6,500 ft.) above sea
level.
9. Place the main machine on a strong and level base. Inclination on any side
should be no more than 5 mm (0.2").
10. Do not place the machine where it may be subjected to strong vibrations.
10 °C to 32 °C (50 °F to 90 °F)
15% to 80% RH
Less than 1,500 lux (do not expose to direct
sunlight.)
Room air should turn over
at least 30 m3/hr/person
Less than 0.10 mg/m3 (2.7 x 10/6 oz/yd3)
1.1.2 MACHINE LEVEL
Front to back: Within 5 mm (0.2") of level
Right to left: Within 5 mm (0.2") of level
B135/B138 1-2 SM
INSTALLATION REQUIREMENTS
1.1.3 MINIMUM SPACE REQUIREMENTS
Place the main machine near the power source, providing clearance as shown:
Installation
C
B
D
A
B135I010.WMF
A: Front: >75 cm (29.6")
B: Left: > 10 cm (4")
C: Rear: > 10 cm (4")
D: Right > 10 cm (4")
NOTE: The 75 cm (29.5") recommended for the space at the front is for pulling out
the paper tray only. If the operator stands at the front of the main machine,
more space is required.
SM 1-3 B135/B138
INSTALLATION REQUIREMENTS
726 mm (28.6") 670 mm (23.4")
670 mm (26.4")
620 mm (24.4")
180 mm (7.1")
B135I012.WMF
B135I014.WMF
B135/B138 1-4 SM
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