Ricoh G190 Service Manual
G190
SERVICE MANUAL
003603MIU
G190
SERVICE MANUAL
G190
SERVICE MANUAL
003603MIU
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interest of Ricoh Americas Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
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PERMISSION OF RICOH AMERICAS CORPORATION.
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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 of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
© 2008 RICOH Americas Corporation. All rights reserved.
The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Americas 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 Americas Corporation
WARNING
LEGEND
COMPANY PRODUCT
CODE
GESTETNER LANIER RICOH SAVIN
G190 SP C420DN LP331cn SP C420DN CLP131DN
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
04/2008 Original Printing
G190 i SM
G190
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION PROCEDURE ...............................................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 REQUIREMENTS .........................................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
PRINTER INSTALLATION..........................................................................1-4
1.2.3 INSTALLATION PROCEDURE....................................................1-4
Unpacking .......................................................................................1-4
Installing the toner .........................................................................1-11
Loading Paper ...............................................................................1-13
Turning Power on ..........................................................................1-15
Selecting the Panel Display Language..........................................1-16
Printing the Test Page...................................................................1-16
Settings Relevant to the Service Contract.....................................1-16
1.2.4 METER CLICK CHARGE...........................................................1-17
1.2.5 MOVING THE MACHINE...........................................................1-19
1.2.6 TRANSPORTING THE MACHINE.............................................1-19
1.3 OPTIONS INSTALLATION .................................................................1-20
1.3.1 PAPER FEED UNIT...................................................................1-20
1.3.2 TRAY HEATER..........................................................................1-20
1.4 CONTROLLER OPTIONS ..................................................................1-22
1.4.1 OVERVIEW................................................................................1-22
I/F Card Slots ................................................................................1-22
SD Card Slots................................................................................1-22
SM ii G190
1.4.2 SD CARD APPLI MOVE ............................................................1-22
Overview .......................................................................................1-22
Move Exec.....................................................................................1-23
Undo Exec.....................................................................................1-24
Storing the SD Card ......................................................................1-25
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE ...............................................2-1
2.1 USER REPLACEABLE ITEMS .............................................................2-1
2.2 SERVICE MAINTENANCE ...................................................................2-2
2.2.1 RECOMMENDED CLEANING PROCEDURE .............................2-2
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ....................................3-1
3.1 BEFORE YOU START..........................................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS..................................................3-2
3.2.1 TOOLS.........................................................................................3-2
3.3 ELECTRICAL COMPONENTS .............................................................3-3
3.3.1 ELECTRICAL BOARD UNIT........................................................3-3
3.3.2 IOB (INPUT/OUTPUT BOARD) ...................................................3-6
3.3.3 CONTROLLER BOARD...............................................................3-6
3.3.4 INSTALLING THE NEW NVRAM.................................................3-8
3.3.5 PSU (POWER SUPPLY UNIT) BOARD.......................................3-8
3.3.6 HIGH VOLTAGE POWER SUPPLY BOARD 1............................3-9
3.3.7 EGB (ENGINE BOARD) AND HIGH VOLTAGE POWER SUPPLY
BOARD 2 ............................................................................................3-10
3.3.8 LCD PANEL ...............................................................................3-11
3.3.9 NVRAM REPLACEMENT PROCEDURE ..................................3-11
NVRAM on the EGB (Engine Board).............................................3-11
NVRAM on the Controller..............................................................3-12
NVRAMs on the EGB and Controller.............................................3-13
G190 iii SM
3.4 LASER OPTICS ..................................................................................3-14
3.4.1 CAUTION DECAL LOCATIONS ................................................3-14
3.4.2 LD UNIT .....................................................................................3-14
Replacement .................................................................................3-14
Color Registration Adjustment.......................................................3-15
3.4.3 LDB............................................................................................3-18
3.4.4 POLYGON MIRROR MOTOR ...................................................3-18
3.4.5 LASER SYNCHRONIZING DETECTOR BOARDS ...................3-19
3.4.6 LDU SHUTTER MOTOR UNIT AND SENSOR..........................3-20
3.5 PAPER FEED .....................................................................................3-21
3.5.1 PAPER FEED ROLLER .............................................................3-21
3.5.2 PAPER FRICTION PAD.............................................................3-22
3.5.3 BY-PASS PAPER SIZE SENSOR .............................................3-22
3.5.4 BY-PASS FEED ROLLER, FRICTION PAD ..............................3-23
Reassembling the by-pass friction pad..........................................3-24
3.5.5 REGISTRATION SENSOR ........................................................3-25
3.5.6 PAPER VOLUME SENSOR, END SENSOR AND PAPER WIDTH
SENSOR.............................................................................................3-25
3.5.7 PAPER SIZE SENSOR AND TEMPERATURE/ HUMIDITY
SENSOR.............................................................................................3-28
3.5.8 PAPER FEED MOTOR ..............................................................3-28
3.5.9 PAPER REGISTRATION CLUTCH, PAPER FEED CLUTCH AND
BY-PASS CLUTCH .............................................................................3-29
3.6 DEVELOPMENT .................................................................................3-31
3.6.1 COLOR DEVELOPMENT MOTOR, COLOR OPC MOTOR AND
BLACK OPC/DEVELOPMENT MOTOR .............................................3-31
3.6.2 DEVELOPMENT CLUTCH ........................................................3-32
3.6.3 TRANSFER BELT CONTACT MOTOR .....................................3-32
3.6.4 TONER SUPPLY MOTOR .........................................................3-33
3.6.5 TRANSFER ROLLER CONTACT MOTOR................................3-33
3.6.6 ID SENSORS.............................................................................3-35
3.7 DRIVE .................................................................................................3-36
3.7.1 DRIVE UNIT...............................................................................3-36
3.8 DUPLEX..............................................................................................3-38
3.8.1 DUPLEX JAM SENSOR ............................................................3-38
3.8.2 INVERTER SENSOR.................................................................3-39
SM iv G190
3.8.3 DUPLEX MOTOR AND INVERTER MOTOR ............................3-40
3.9 FUSING ..............................................................................................3-41
3.9.1 FUSING UNIT ............................................................................3-41
3.9.2 THERMISTOR AND THERMOSTAT .........................................3-41
3.9.3 FUSING LAMP...........................................................................3-44
3.9.4 FUSING EXIT SENSOR AND PAPER EXIT SENSOR..............3-44
3.9.5 FUSING REGISTRATION SENSOR .........................................3-45
3.9.6 FAN DIRECTION .......................................................................3-45
3.10 ADJUSTMENTS............................................................................3-46
3.10.1 GAMMA ADJUSTMENT.......................................................3-46
Summary.......................................................................................3-46
Adjustment Procedure...................................................................3-48
TROUBLESHOOTING
4. TROUBLESHOOTING .............................................................4-1
4.1 PROCESS CONTROL RESULTS.........................................................4-1
4.2 SERVICE CALL CONDITIONS.............................................................4-3
4.2.1 SUMMARY...................................................................................4-3
4.2.2 SC CODE DESCRIPTIONS.........................................................4-4
Engine SC .......................................................................................4-4
Controller Error..............................................................................4-25
4.3 TROUBLESHOOTING GUIDE............................................................4-43
4.3.1 BLANK PRINT ...........................................................................4-43
4.3.2 ALL-BLACK PRINT....................................................................4-44
4.3.3 MISSING CMY COLOR .............................................................4-45
4.3.4 LIGHT PRINT.............................................................................4-46
4.3.5 REPEATED SPOTS OR LINES ON PRINTS ............................4-47
4.3.6 DARK VERTICAL LINE ON PRINTS .........................................4-47
4.3.7 WHITE HORIZONTAL LINES OR BANDS ................................4-48
4.3.8 MISSING PARTS OF IMAGES ..................................................4-49
4.3.9 DIRTY BACKGROUND..............................................................4-49
4.3.10 PARTIAL CMY COLOR DOTS.............................................4-49
4.3.11 DARK IRREGULAR STREAKS ON PRINTS .......................4-50
4.3.12 CMY COLOR IRREGULAR STREAKS ................................4-50
4.3.13 GHOSTING ..........................................................................4-50
G190 v SM
4.3.14 UNFUSED OR PARTIALLY FUSED PRINTS ......................4-51
4.3.15 IMAGE SKEW ......................................................................4-51
4.3.16 BACKGROUND STAIN ........................................................4-52
4.3.17 NO PRINTING ON PAPER EDGE .......................................4-52
4.3.18 IMAGE NOT CENTERED WHEN IT SHOULD BE...............4-53
4.4 ELECTRICAL COMPONENT DEFECTS ............................................4-54
4.4.1 SENSORS .................................................................................4-54
4.5 BLOWN FUSE CONDITIONS .............................................................4-59
4.5.1 POWER SUPPLY UNIT .............................................................4-59
4.5.2 IOB.............................................................................................4-59
4.6 LEDS...................................................................................................4-60
SERVICE TABLES
5. SERVICE TABLES...................................................................5-1
5.1 SERVICE PROGRAM MODE ...............................................................5-1
5.1.1 SERVICE MODE OPERATION ...................................................5-1
Entering the Service Mode ..............................................................5-1
Accessing the Required Program....................................................5-2
Inputting a Value or Setting for a Service Program .........................5-2
Exiting Service Mode.......................................................................5-2
5.1.2 REMARKS ...................................................................................5-3
Display on the Control Panel Screen...............................................5-3
5.1.3 BIT SWITCH PROGRAMMING ...................................................5-6
5.2 SERVICE MODE TABLE ......................................................................5-7
5.2.1 CONTROLLER SERVICE MODE ................................................5-7
5.2.2 ENGINE SERVICE MODE.........................................................5-14
SP1-XXX (Feed)............................................................................5-14
SP2-XXX (Drum) ...........................................................................5-38
SP3-XXX (Process).....................................................................5-111
SP5-XXX (Mode).........................................................................5-136
SP7-XXX (Data Log) ...................................................................5-179
SP8-XXX (Data Log 2) ................................................................5-207
SP9-XXX .....................................................................................5-224
5.2.3 INPUT CHECK TABLE ............................................................5-231
5.2.4 OUTPUT CHECK TABLE ........................................................5-237
SM vi G190
5.3 FIRMWARE UPDATE .......................................................................5-240
5.3.1 TYPE OF FIRMWARE .............................................................5-240
5.3.2 BEFORE YOU BEGIN .............................................................5-241
5.3.3 UPDATING FIRMWARE ..........................................................5-241
File Arrangement.........................................................................5-241
Update Procedure .......................................................................5-242
Error Handling .............................................................................5-243
Power Failure ..............................................................................5-243
5.3.4 NVRAM DATA UPLOAD/DOWNLOAD....................................5-245
Uploading NVRAM Data..............................................................5-245
Downloading NVRAM Data .........................................................5-246
5.3.5 ADDRESS BOOK UPLOAD/DOWNLOAD...............................5-247
Download ....................................................................................5-247
Upload.........................................................................................5-247
5.3.6 HANDLING FIRMWARE UPDATE ERRORS ..........................5-249
Error Message Table...................................................................5-249
5.4 CONTROLLER SELF-DIAGNOSTICS..............................................5-251
5.4.1 OVERVIEW..............................................................................5-251
5.5 USING THE DEBUG LOG ................................................................5-252
5.5.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG ......5-252
5.5.2 RETRIEVING THE DEBUG LOG FROM THE HDD ................5-256
5.5.3 DEBUG LOG CODES..............................................................5-257
SP5857-015 Copy SD Card-to-SD Card: Any Desired Key.........5-257
SP5857-016 Create a File on HDD to Store a Log......................5-257
SP5857-017 Create a File on SD Card to Store a Log................5-257
5.6 DIP SWITCHES ................................................................................5-258
5.6.1 CONTROLLER BOARD...........................................................5-258
DETAILED DESCRIPTIONS
6. DETAILED DESCRIPTIONS....................................................6-1
6.1 OVERVIEW...........................................................................................6-1
6.1.1 COMPONENT LAYOUT ..............................................................6-1
6.1.2 PAPER PATH ..............................................................................6-2
6.1.3 DRIVE LAYOUT...........................................................................6-3
6.1.4 BOARD STRUCTURE .................................................................6-4
G190 vii SM
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
Process Control Self-Check Procedure.........................................6-10
6.2.3 TONER SUPPLY CONTROL.....................................................6-12
Toner Supply Control Modes.........................................................6-12
Low Image Coverage ....................................................................6-12
6.2.4 TONER NEAR END/TONER END DETECTION .......................6-13
Introduction....................................................................................6-13
Toner Near End Detection.............................................................6-14
Toner End Detection .....................................................................6-14
Toner End Recovery .....................................................................6-14
6.2.5 DEVELOPER INITIALIZATION..................................................6-15
6.3 PAPER FEED .....................................................................................6-16
6.3.1 OVERVIEW................................................................................6-16
6.3.2 PAPER FEED DRIVE ................................................................6-17
6.3.3 PAPER TRAY ............................................................................6-18
Paper Lift.......................................................................................6-18
Paper Size Detection.....................................................................6-19
Paper Near End/End Detection .....................................................6-20
6.3.4 BY-PASS TRAY FEED AND SIZE DETECTION .......................6-21
Paper Feed Mechanism ................................................................6-21
Paper Size Detection Mechanism .................................................6-21
6.3.5 DUPLEX.....................................................................................6-22
Drive..............................................................................................6-23
Interleaving....................................................................................6-24
6.4 LASER EXPOSURE ...........................................................................6-26
6.4.1 OVERVIEW................................................................................6-26
6.4.2 OPTICAL PATH .........................................................................6-27
6.4.3 LASER SYNCHRONIZING DETECTOR....................................6-28
Overview .......................................................................................6-28
Main Scan Start Detection.............................................................6-28
6.4.4 LD SAFETY SWITCH ................................................................6-29
SM viii G190
6.4.5 AUTOMATIC LINE POSITION ADJUSTMENT..........................6-30
Overview .......................................................................................6-30
Summary of Each Adjustment.......................................................6-30
Adjustment Conditions ..................................................................6-31
Main Scan Skew Adjustment.........................................................6-34
LDU Shutter...................................................................................6-34
6.5 PHOTOCONDUCTOR UNIT...............................................................6-35
6.5.1 OVERVIEW................................................................................6-35
6.5.2 DRIVE AND DRIVE GEAR POSITION SENSOR ......................6-36
Mechanism ....................................................................................6-36
Initialization Process and SC Codes .............................................6-36
6.5.3 DRUM CHARGE AND QUENCHING ........................................6-38
6.5.4 DRUM CLEANING.....................................................................6-39
6.5.5 WASTE TONER COLLECTION.................................................6-40
6.5.6 WASTE TONER BOTTLE FULL DETECTION AND SET
DETECTION .......................................................................................6-41
6.5.7 PCU DETECTION (DEVELOPMENT UNIT DETECTION) ........6-42
Unit Set Detection Pins .................................................................6-42
New Unit Detection........................................................................6-42
Error Message...............................................................................6-42
6.6 DEVELOPMENT .................................................................................6-43
6.6.1 OVERVIEW................................................................................6-43
6.6.2 DRIVE ........................................................................................6-44
6.6.3 DEVELOPER MIXING ...............................................................6-44
6.6.4 DEVELOPMENT BIAS...............................................................6-45
6.6.5 TONER SUPPLY MECHANISM ................................................6-46
Overview .......................................................................................6-46
6.7 IMAGE TRANSFER ............................................................................6-47
6.7.1 OVERVIEW................................................................................6-47
6.7.2 TRANSFER UNIT DETECTION AND NEW UNIT DETECTION 6-48
6.7.3 DRIVE AND TRANSFER BELT ROLLER VOLTAGE ................6-49
Transfer belt contact......................................................................6-50
Transfer Belt Cleaning...................................................................6-51
6.7.4 TRANSFER ROLLER UNIT .......................................................6-52
Discharge ......................................................................................6-53
Transfer Roller Contact .................................................................6-54
G190 ix SM
6.8 FUSING ..............................................................................................6-55
6.8.1 OVERVIEW................................................................................6-55
6.8.2 FUSING TEMPERATURE CONTROL.......................................6-56
Overall Procedure .........................................................................6-56
Fusing Roller Idling........................................................................6-56
Idling Ready Temperature before First Print Job: [A] ....................6-57
Machine Ready Temperature: [B]..................................................6-57
Print ready temperature: [C] ..........................................................6-57
Target Printing Temperature: [D]...................................................6-57
First Print Temperature: [G]...........................................................6-57
Corrections for Small Paper Sizes (less than A5)..........................6-58
Overheat Protection ......................................................................6-58
6.8.3 DRIVE ........................................................................................6-59
6.9 CONTROLLER....................................................................................6-60
SPECIFICATIONS
7. SPECIFICATIONS....................................................................7-1
7.1 SPECIFICATIONS ................................................................................7-1
7.1.1 GENERAL SPECIFICATIONS .....................................................7-1
7.1.2 SUPPORTED PAPER SIZES ......................................................7-5
7.1.3 SOFTWARE ACCESSORIES......................................................7-7
Printer Drivers .................................................................................7-7
Utility Software ................................................................................7-8
7.1.4 MACHINE CONFIGURATION .....................................................7-9
INSTALLATION
PREVENTIVE MAINTENANCE
REPLACEMENT AND ADJUSTMENT
TROUBLESHOOTING
SERVICE TABLES
DETAILED DESCRIPTIONS
SPECIFICATIONS
APPENDIX
TAB
POSITION 2
TAB
POSITION 1
TAB
POSITION 3
TAB
POSITION 4
TAB
POSITION 6
TAB
POSITION 5
TAB
POSITION 8
TAB
POSITION 7
Read This First
Safety Notices
Important Safety Notices
Prevention of Physical Injury
1. Before disassembling or assembling parts of the printer and peripherals, make sure
that the printer power cord is unplugged.
2. The wall outlet should be near the printer 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 printer 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
printer starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while the printer
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 printer and its peripherals must be serviced by a customer service representative who
has completed the training course on those models.
Lithium Batteries
Incorrect replacement of lithium battery(s) on the EGB and controller board may pose risk
of explosion. Replace only with the same type or with an equivalent type recommended by
the manufacturer. Discard used batteries in accordance with the manufacturer’s
instructions.
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.
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.
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:
Symbols, Abbreviations, and Trademarks
Symbols and Abbreviations
This manual uses the symbols and abbreviations shown below.
Symbol Meaning
Refer to section number
Clip ring
Screw
Connector
=
Clamp
E-ling
SEF Short Edge Feed
LEF Long Edge Feed
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.
INSTALLATION
Installation Requirements
G190 1-1 SM
Installation
1. INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT
1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)
2. Humidity Range: 15% to 80% RH
3. Ambient Illumination: Less than 1500 lux (do not expose to direct sunlight)
4. Ventilation: 3 times/hr/person or more
5. Do not let the machine get exposed 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")
Installation Requirements
SM 1-2 G190
1.1.3 MACHINE SPACE REQUIREMENTS
This machine, which uses high voltage power sources, can generate ozone gas.
High ozone density is harmful to human health. Therefore, the machine must be
installed in a well-ventilated room.
Left side: Over 50cm (19.7”)
Rear: Over 10cm (4”)
Right side: Over 10cm (4”)
Front: Over 70cm (27.6”)
Put the machine near the power source with the clearance.
1.1.4 POWER REQUIREMENTS
Insert the plug firmly in the outlet.
Do not use an outlet extension plug or cord.
Ground the machine.
1. Input voltage level:
2. 120 V, 60 Hz: More than 11 A
3. 220 V to 240 V, 50 Hz/60 Hz: More than 6 A
4. Permissible voltage fluctuation: ±10 %
5. Do not put things on the power cord.
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