DOLPHIN (Machine Code: B010) SERVICE MANUAL

DOLPHIN (Machine Code: B010) SERVICE MANUAL

TABLE OF CONTENTS 1 INSTALLATION PROCEDURE... 1-1 1.1 PREPARATION...1-1 1.1.1 ENVIRONMENT...1-1 1.1.2 MINIMUM SPACE REQUIREMENTS...1-2 1.1.3 MACHINE LEVEL...1-2 1.1.4 POWER SOURCE...1-3 1.2 COPIER INSTALLATION PROCEDURE...1-4 1.2.1 ACCESSORY CHECK...1-4 1.2.2 INSTALLATION PROCEDURE...1-5 1.3 ROLL TRAY INSTALLATION PROCEDURE...1-11 1.3.1 ACCESSORY CHECK...1-11 1.3.2 INSTALLATION PROCEDURE...1-12 1.4 HDD INSTALLATION PROCEDURE...1-17 1.4.1 ACCESSORY CHECK...1-17 1.4.2 INSTALLATION PROCEDURE...1-18 1.5 STAMP BOARD INSTALLATION PROCEDURE...1-20 1.5.1 ACCESSORY CHECK...1-20 1.5.2 INSTALLATION PROCEDURE...1-20 1.6 ORIGINAL TRAY INSTALLATION PROCEDURE...1-21 1.6.1 ACCESSORY CHECK...1-21 1.6.2 INSTALLATION PROCEDURE...1-22 1.7 I/F BOARD INSTALLATION PROCEDURE...1-24 1.7.1 ACCESSORY CHECK...1-24 1.7.2 INSTALLATION PROCEDURE...1-25 2 PREVENTIVE MAINTENANCE... 2-1 2.1 PM TABLE...2-1 2.2 LUBRICATION POINTS...2-3 2.2.1 FUSING SECTION...2-3 2.2.2 DEVELOPMENT SECTION...2-3 3 REPLACEMENT AND ADJUSTMENT... 3-1 3.1 OPENING AND CLOSING THE MACHINE...3-1 3.2 EXTERNAL COVERS...3-2 3.2.1 FRONT VIEW...3-2 3.2.2 REAR VIEW...3-2 3.3 SCANNER...3-3 3.3.1 OPERATION PANEL...3-3 3.3.2 ORIGINAL SIZE SENSORS, ORIGINAL SET SENSOR, ORIGINAL REGISTRATION SENSOR...3-5 3.3.3 WHITE PLATEN ROLLER...3-6 3.3.4 ORIGINAL UPPER TRANSPORT UNIT AND EXIT SENSOR...3-7 3.3.5 ORIGINAL TRANSPORT ROLLER...3-8 3.3.6 CIS (CONTACT IMAGE SENSOR)...3-8 i

3.4 AROUND THE DRUM...3-9 3.4.1 VDB (VIDEO DRIVE BOARD)...3-9 3.4.2 LPH (LED PRINT HEAD)...3-9 3.4.3 CHARGE CORONA WIRE, GRID WIRE, WIRE CLEANER...3-10 3.4.4. QUENCHING LAMPS...3-11 3.5 DRUM AND DEVELOPMENT UNIT...3-11 3.5.1 DEVELOPMENT UNIT...3-11 3.5.2 DEVELOPER...3-12 3.5.3 BY-PASS FEED SENSOR, REGISTRATION SENSOR...3-13 3.5.4 TONER SUPPLY CLUTCH...3-14 3.5.5 DRUM DRIVE MOTOR...3-14 3.5.6 DRUM UNIT, ID SENSOR, AND CLEANING BLADE...3-15 3.6 PAPER FEED...3-17 3.6.1 CUTTER UNIT...3-17 3.6.2 CUTTING SENSOR AND FEED EXIT ROLLER...3-18 3.6.3 ROLL TRAY...3-19 3.6.4 PAPER FEED DRIVE MOTOR...3-21 3.6.5 FIRST FEED ROLLER AND CLUTCH...3-21 3.6.6 SECOND FEED ROLLER AND CLUTCH...3-22 3.6.7 REGISTRATION MOTOR...3-22 3.6.8 REGISTRATION CLUTCH...3-23 3.6.9 REGISTRATION ROLLER...3-23 3.7 TRANSFER UNIT...3-24 3.7.1 TRANSFER AND SEPARATION CORONA WIRES...3-24 3.7.2 TRANSPORT UNIT...3-25 3.7.3 TRANSPORT BELTS...3-26 3.8 FUSING SECTION...3-27 3.8.1 FUSING UNIT...3-27 3.8.2 PAPER JUNCTION GATE SOLENOID/EXIT SENSOR...3-29 3.8.3 FPDB (FUSING PRESSURE DRIVE BOARD)...3-29 3.8.4 HOT ROLLER STRIPPERS/PRESSURE MOTORS...3-29 3.8.5 PRESSURE ROLLER THERMISTOR...3-30 3.8.6 THERMOFUSE/HOT ROLLER THERMISTOR...3-30 3.8.7 FUSING CLEANING ROLLER...3-30 3.8.8 FUSING LAMPS...3-31 3.8.9 HOT ROLLER AND PRESSURE ROLLER...3-32 3.8.10 FUSING DRIVE MOTOR...3-34 3.9 BOARDS...3-35 3.9.1 PSU (POWER SUPPLY UNIT)...3-35 3.9.2 IOB (INPUT OUTPUT BOARD), MCU (MAIN CONTROL UNIT)...3-35 3.9.3 IPU (IMAGE PROCESSING UNIT)...3-36 3.9.4 HDD REPLACEMENT...3-36 3.10 ADJUSTMENTS...3-37 3.10.1 CIS AND WHITE PLATEN ROLLER ADJUSTMENT...3-37 3.10.2 LPH ADJUSTMENT...3-38 3.10.3 IMAGE POSITION, MAGNIFICATION, MARGIN ADJUSTMENTS...3-41 ii

4 TROUBLESHOOTING... 4-1 4.1 SERVICE CALL CONDITIONS...4-1 4.1.1 SUMMARY...4-1 4.2 SC CODE DESCRIPTIONS...4-2 4.3 JAM CODE TABLE...4-18 4.4 COVER OPEN...4-19 4.5 IMAGE DATA PROCESSING FLOW CHART...4-20 4.5.1 DATA FLOW IN 1-TO-1 COPY MODE...4-20 4.5.2 DATA FLOW IN REPEAT COPY MODE...4-20 4.5.3 DATA FLOW IN SCANNING MODE...4-21 4.5.4 DATA FLOW IN PRINTING MODE (A0 OR SMALLER)...4-21 4.5.5 DATA FLOW IN PRINTING MODE (LARGER THAN A0)...4-22 4.5.6 DATA FLOW IN TEST PATTERN PRINTING...4-22 4.6 IMAGE PROBLEM TROUBLESHOOTING...4-23 4.6.1 FLOW CHART...4-23 4.6.2 SCANNING...4-24 4.6.3 PRINTING...4-26 5 SERVICE TABLES... 5-1 5.1 SOFTWARE UPGRADING...5-1 5.1.1 OVERVIEW...5-1 5.1.2 UPGRADING THE SCU FIRMWARE...5-2 5.1.3 UPGRADING THE BICU FIRMWARE...5-4 5.1.4 UPGRADING THE SCU AND BICU TOGETHER...5-5 5.1.5 UPGRADING THE AMDP FIRMWARE...5-6 5.2 UP (USER PROGRAM) MODE...5-7 5.2.1 INITIAL SYSTEM SETTINGS...5-7 5.2.2 INITIAL COPIER SETTINGS...5-8 5.3 SERVICE PROGRAM (SP) MODES...5-10 5.3.1 ENTERING SP MODE...5-10 5.3.2 HOW TO USE THE SP MODE...5-12 5.4 TOUCH PANEL CALIBRATION...5-14 5.5 SOFTWARE RESET...5-14 5.6 PRINTING TEST PATTERNS...5-15 5.6.1 IMAGE PROCESSING TEST PATTERNS...5-15 5.6.2 IMAGE DATA PATH TEST PATTERNS...5-16 5.7 INPUT CHECK...5-17 5.8 OUTPUT CHECK...5-20 5.9 SP (SERVICE PROGRAM) MODE TABLES...5-21 6 DETAILED DESCRIPTIONS... 6-1 6.1 OVERVIEW...6-1 6.1.1 MACHINE LAYOUT...6-1 6.1.2 MECHANICAL COMPONENT LAYOUT...6-2 6.1.3 DRIVE LAYOUT...6-4 6.1.4 ORIGINAL/COPY PAPER PATHS...6-5 iii

6.2 SCANNER...6-6 6.2.1 OVERVIEW...6-6 6.2.2 ORIGINAL SIZE DETECTION...6-7 6.2.3 ORIGINAL FEED MECHANISM...6-7 6.2.4 ORIGINAL FEED SPEED...6-7 6.2.5 ORIGINAL TEMPORARY DELAY...6-8 6.2.6 SCANNING MECHANISM...6-8 6.2.7 AUTO IMAGE DENSITY CORRECTION...6-9 6.2.8 ORIGINAL EXIT SWITCHING MECHANISM...6-9 6.3 IMAGE PROCESSING...6-10 6.3.1 GENERAL IMAGE PROCESSING FLOW CHART...6-10 6.3.2 ORIGINAL MODES...6-11 Overview...6-11 Text Mode...6-12 Photo Mode...6-13 Text/Photo Mode...6-14 Pale Mode...6-15 Generation...6-16 Patched Original Mode...6-17 Blue Line Mode...6-18 Photo (Hard Tone) Mode...6-19 6.3.3 INDEPENDENT DOT ERASURE...6-20 6.3.4 FOUR-VALUE ERROR DIFFUSION...6-21 6.3.5 MTF SETTINGS...6-21 6.4 AROUND THE DRUM...6-22 6.4.1 OVERVIEW...6-22 6.4.2 DRUM DRIVE...6-23 6.4.3 CHARGE CORONA UNIT...6-23 6.4.4 CORONA WIRE CLEANING...6-23 6.4.5 CLEANING THE DRUM...6-24 6.4.6 COLLECTING USED TONER...6-25 6.4.7 QUENCHING...6-26 6.4.8 ANTI-CONDENSATION HEATERS...6-26 6.5 IMAGE WRITING...6-27 6.5.1 LED HEADS...6-27 6.6 DEVELOPMENT...6-28 6.6.1 OVERVIEW...6-28 6.6.2 DEVELOPER CROSS-MIXING...6-29 6.6.3 DEVELOPMENT BIAS...6-30 Copying...6-30 Making ID Sensor Patterns...6-30 6.6.4 DEVELOPMENT DRIVE MECHANISM...6-31 6.6.5 TONER SUPPLY MECHANISM...6-31 6.6.6 ID SENSOR...6-31 6.6.7 TONER END/NEAR-END CONTROL...6-32 6.6.8 TONER END RECOVERY...6-33 6.6.9 TONER DENSITY CONTROL...6-34 6.6.10 DEVELOPMENT TIMING CHART...6-35 iv

6.7 PAPER FEED AND REGISTRATION...6-36 6.7.1 OVERVIEW...6-36 6.7.2 PAPER HOLDER...6-37 6.7.3 PAPER WIDTH AND MEDIA TYPE SETTINGS...6-38 6.7.4 ROLL TRAY FEED MECHANISM...6-38 6.7.5 BY-PASS FEED MECHANISM...6-39 6.7.6 REGISTRATION...6-39 6.7.7 CUTTING MECHANISM...6-40 6.7.8 ROLL END DETECTION...6-41 6.7.9 CONDENSATION PREVENTION...6-41 6.7.10 PAPER FEED TIMING CHART...6-42 6.8 IMAGE TRANSFER AND PAPER SEPARATION...6-43 6.8.1 OVERVIEW...6-43 6.8.2 TRANSFER AND SEPARATION TIMING CONTROL...6-43 6.8.3 PICK-OFF PAWL OPERATION...6-44 6.9 PAPER TRANSPORT...6-45 6.9.1 OVERVIEW...6-45 6.10 FUSING UNIT...6-46 6.10.1 OVERVIEW...6-46 6.10.2 FUSING PRESSURE CONTROL MECHANISM...6-48 6.10.3 TEMPERATURE AND PRESSURE CONTROL...6-49 6.10.4 FUSING CONTROL SETTING TABEL...6-52 6.10.5 HOT ROLLER CLEANING...6-53 6.10.6 HOT ROLLER THERMOFUSE...6-53 6.10.7 FUSING UNIT DRIVE MECHANISM...6-53 6.10.8 WRINKLE PREVENTION...6-54 6.11 PAPER EXIT...6-55 6.11.1 OVERVIEW...6-55 6.11.2 PAPER EXIT DRIVE...6-55 6.11.3 PAPER EXIT ACCESS...6-55 6.11.4 SWITCHING EXITS...6-56 6.11.5 EXIT JAM DETECTION...6-56 6.12 ELECTRICAL COMPONENTS...6-57 6.12.1 MCU...6-57 6.12.2 IPU...6-59 6.12.3 IOB...6-60 6.12.4 VDB...6-60 6.12.5 RFDB...6-60 6.12.6 FPDB...6-60 6.12.7 PSU...6-61 SPECIFICATIONS 1 COPIER ENGINE... SPEC-1 2 2ND ROLL TRAY (OPTION)... SPEC-4 3 MACHINE CONFIGURATION... SPEC-5 v

B010 PARTS CATALOG RICOH GROUP COMPANIES 001194MIU

B010 PARTS CATALOG TABLE OF CONTENTS B010 PARTS LOCATION AND LIST LOCATION OF UNIT... 2 1.EXTERIOR 1 (B010)... 8 2.EXTERIOR 2 (B010)... 10 3.OPERATION PANEL (B010)... 12 4.OPTICAL SECTION 1 (B010)... 14 5.OPTICAL SECTION 2 (B010)... 16 6.OPTICAL SECTION 3 (B010)... 18 7.OPTICAL SECTION 4 (B010)... 20 8.OPTICAL SECTION 5 (B010)... 22 9.PLOTTER SECTION (B010)... 24 10.CHARGE CORONA SECTION (B010)... 26 11.PAPER TRAY UNIT 1 (B010)... 28 12.PAPER TRAY UNIT 2 (B010)... 30 13.PAPER TRAY UNIT 3 (B010)... 32 14.PAPER TRAY UNIT 4 (B010)... 34 15.PAPER TRAY UNIT 5 (B010)... 36 16.PAPER TRAY UNIT 6 (B010)... 38 17.PAPER REGISTRATION (B010)... 40 18.T/S CORONA SECTION (B010)... 42 19.PAPER TRANSFER SECTION (B010)... 44 20.DEVELOPMENT UNIT 1 (B010)... 46 21.DEVELOPMENT UNIT 2 (B010)... 48 22.DRUM SECTION (B010)... 50 23.FUSING UNIT 1 (B010)... 52 24.FUSING UNIT 2 (B010)... 54 25.FUSING UNIT 3 (B010)... 56 26.PAPER EXIT SECTION 1 (B010)... 58 27.PAPER EXIT SECTION 2 (B010)... 60 28.DRIVE SECTION (B010)... 62 29.ELECTRICAL SECTION (B010/B321)... 64 30.FRAME SECTION 1 (B010)... 66 31.FRAME SECTION 2 (B010/B342)... 68 32.IPU BOARD (B010)... 70 33.IOB BOARD (B010)... 78 34.MCU BOARD (B010)... 84 35.DECALS AND DOCUMENTS (B010)... 88 36.SPECIAL TOOLS (B010)... 92 B010 PARTS INDEX PARTS INDEX... 2 2ND ROLL TRAY TYPE A B340 PARTS LOCATION AND LIST 1.2ND TRAY UNIT 1 (B340)... 2 2.2ND TRAY UNIT 2 (B340)... 4 3.2ND TRAY UNIT 3 (B340)... 6 4.2ND TRAY UNIT 4 (B340)... 8

5.2ND TRAY UNIT 5 (B340)... 10 6.2ND TRAY UNIT 6 (B340)... 12 7.2ND TRAY UNIT 7 (B340)... 14 8.DECALS AND DOCUMENTS (B340)... 16 2ND TRAY UNIT B340 PARTS INDEX PARTS INDEX... 2 ORIGINAL TRAY TYPE G B341 PARTS LOCATION AND LIST 1.ORIGINAL TRAY (B341)... 2 ORIGINAL TRAY TYPE G B341 PARTS INDEX PARTS INDEX... 2 INTERFACE BOARD TYPE 470 G068 PARTS LOCATION AND LIST 1.CONTROLLER INTERCAFE UNIT (G068)... 2 INTERFACE BOARD TYPE 470 G068 PARTS INDEX PARTS INDEX... 2

LOCATIONS OF UNITS 1. EXTERIOR 1 (B010) 2. EXTERIOR 2 (B010) 3. OPERATION PANEL (B010) See Page 9 4. OPTICAL SECTION 1 (B010) See Page 11 5. OPTICAL SECTION 2 (B010) See Page 13 6. OPTICAL SECTION 3 (B010) See Page 15 See Page 17 See Page 19 B010 2 Parts Location and List