Ricoh G-P3, G190 Service Manual
Model G-P3
Machine Code: G190
SERVICE MANUAL
January, 2008
Subject to change
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.
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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:
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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.
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TABLE OF CONTENTS
Safety Notices.....................................................................................................................................................1
Important Safety Notices...............................................................................................................................1
LASER SAFETY................................................................................................................................................2
Symbols, Abbreviations, and Trademarks........................................................................................................3
Symbols and Abbreviations...........................................................................................................................3
Trademarks.....................................................................................................................................................3
1. Installation Procedure
Installation Requirements.................................................................................................................................11
Environment..................................................................................................................................................11
Machine Level..............................................................................................................................................12
Machine Space Requirements....................................................................................................................12
Power Requirements....................................................................................................................................12
Optional Unit Combinations............................................................................................................................14
Machine Options.........................................................................................................................................14
Controller Options.......................................................................................................................................14
Printer Installation.............................................................................................................................................15
Installation Procedure..................................................................................................................................15
Meter Click Charge.....................................................................................................................................28
Moving the Machine...................................................................................................................................30
Transporting the Machine...........................................................................................................................30
Options Installation..........................................................................................................................................31
Paper Feed Unit...........................................................................................................................................31
Tray Heater...................................................................................................................................................31
Controller Options............................................................................................................................................33
Overview......................................................................................................................................................33
SD Card Appli Move...................................................................................................................................34
2. Preventive Maintenance
User Replaceable Items...................................................................................................................................37
Service Maintenance.......................................................................................................................................38
Recommended Cleaning Procedure..........................................................................................................38
3. Replacement and Adjustment
Before You Start...............................................................................................................................................39
Special Tools and Lubricants...........................................................................................................................40
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Tools..............................................................................................................................................................40
Electrical Components.....................................................................................................................................41
Electrical board unit.....................................................................................................................................41
IOB (Input/Output Board)..........................................................................................................................44
Controller Board..........................................................................................................................................44
Installing the new NVRAM..........................................................................................................................46
PSU (Power Supply Unit) Board.................................................................................................................47
High Voltage Power Supply Board 1.........................................................................................................47
EGB (Engine Board) and High Voltage Power Supply Board 2.............................................................48
LCD Panel.....................................................................................................................................................49
NVRAM Replacement Procedure...............................................................................................................49
Laser Optics......................................................................................................................................................52
Caution Decal Locations.............................................................................................................................52
LD Unit...........................................................................................................................................................52
LDB................................................................................................................................................................56
Polygon Mirror Motor.................................................................................................................................56
Laser Synchronizing Detector Boards........................................................................................................57
LDU Shutter Motor Unit and Sensor...........................................................................................................58
Paper Feed........................................................................................................................................................60
Paper Feed Roller........................................................................................................................................60
Paper Friction Pad........................................................................................................................................61
By-Pass Paper Size Sensor..........................................................................................................................61
By-Pass Feed Roller, Friction Pad...............................................................................................................62
Registration Sensor......................................................................................................................................64
Paper Volume Sensor, End Sensor and Paper width Sensor...................................................................64
Paper Size Sensor and Temperature/ Humidity Sensor..........................................................................67
Paper Feed Motor........................................................................................................................................67
Paper Registration Clutch, Paper Feed Clutch and By-Pass Clutch.........................................................68
Development.....................................................................................................................................................69
Color Development Motor, Color OPC Motor and Black OPC/Development Motor.........................69
Development Clutch....................................................................................................................................70
Transfer Belt Contact Motor........................................................................................................................71
Toner Supply Motor ....................................................................................................................................72
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Transfer Roller Contact Motor....................................................................................................................72
ID Sensors.....................................................................................................................................................74
Drive..................................................................................................................................................................75
Drive unit.......................................................................................................................................................75
Duplex...............................................................................................................................................................77
Duplex Jam Sensor......................................................................................................................................77
Inverter Sensor.............................................................................................................................................78
Duplex Motor and Inverter Motor..............................................................................................................78
Fusing................................................................................................................................................................80
Fusing Unit....................................................................................................................................................80
Thermistor and Thermostat..........................................................................................................................80
Fusing Lamp..................................................................................................................................................83
Fusing Exit Sensor and Paper Exit Sensor..................................................................................................84
Fusing Registration Sensor..........................................................................................................................84
Fan Direction................................................................................................................................................85
Adjustments.......................................................................................................................................................86
Gamma Adjustment.....................................................................................................................................86
4. Troubleshooting
Process Control Results....................................................................................................................................91
Service Call Conditions...................................................................................................................................93
Summary.......................................................................................................................................................93
SC Code Descriptions.................................................................................................................................93
Troubleshooting Guide..................................................................................................................................124
Blank Print...................................................................................................................................................124
All-black Print.............................................................................................................................................124
Missing CMY Color...................................................................................................................................125
Light Print....................................................................................................................................................125
Repeated Spots or Lines on Prints............................................................................................................125
Dark Vertical Line on Prints.......................................................................................................................126
White Horizontal Lines or Bands..............................................................................................................127
Missing Parts of Images............................................................................................................................127
Dirty Background.......................................................................................................................................127
Partial CMY Color Dots............................................................................................................................128
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Dark Irregular Streaks on Prints................................................................................................................128
CMY Color Irregular Streaks....................................................................................................................128
Ghosting.....................................................................................................................................................128
Unfused or Partially Fused Prints..............................................................................................................128
Image Skew...............................................................................................................................................129
Background Stain......................................................................................................................................129
No Printing on Paper Edge.......................................................................................................................130
Image not centered when it should be....................................................................................................130
Electrical Component Defects.......................................................................................................................131
Sensors.......................................................................................................................................................131
Blown Fuse Conditions..................................................................................................................................135
Power Supply Unit.....................................................................................................................................135
IOB.............................................................................................................................................................135
LEDs.................................................................................................................................................................136
5. Service Tables
Service Program Mode.................................................................................................................................137
Service Mode Operation.........................................................................................................................137
Remarks......................................................................................................................................................139
Bit Switch Programming............................................................................................................................141
Service Mode Table......................................................................................................................................142
Controller Service Mode..........................................................................................................................142
Engine Service Mode................................................................................................................................147
Input Check Table.....................................................................................................................................319
Output Check Table..................................................................................................................................323
Firmware Update...........................................................................................................................................326
Type of Firmware.......................................................................................................................................326
Before You Begin.......................................................................................................................................326
Updating Firmware...................................................................................................................................327
NVRAM Data Upload/Download..........................................................................................................330
Address Book Upload/Download..........................................................................................................332
Handling Firmware Update Errors...........................................................................................................333
Controller Self-Diagnostics...........................................................................................................................335
Overview....................................................................................................................................................335
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Using the Debug Log.....................................................................................................................................337
Switching On and Setting Up Save Debug Log......................................................................................337
Retrieving the Debug Log from the HDD.................................................................................................340
Debug Log Codes.....................................................................................................................................340
DIP Switches...................................................................................................................................................342
Controller Board........................................................................................................................................342
6. Detailed Function Descriptions
Overview........................................................................................................................................................343
Component Layout....................................................................................................................................343
Paper Path..................................................................................................................................................344
Drive Layout...............................................................................................................................................345
Board Structure..........................................................................................................................................346
Printing Process..........................................................................................................................................348
Process Control..............................................................................................................................................350
Overview....................................................................................................................................................350
Potential Control........................................................................................................................................350
Toner Supply Control................................................................................................................................353
Toner Near End/Toner End Detection....................................................................................................355
Developer Initialization.............................................................................................................................356
Paper Feed.....................................................................................................................................................357
Overview....................................................................................................................................................357
Paper Feed Drive.......................................................................................................................................358
Paper Tray..................................................................................................................................................359
By-pass Tray Feed and Size Detection....................................................................................................362
Duplex........................................................................................................................................................363
Laser Exposure...............................................................................................................................................367
Overview....................................................................................................................................................367
Optical Path...............................................................................................................................................368
Laser Synchronizing Detector...................................................................................................................369
LD Safety Switch........................................................................................................................................370
Automatic Line Position Adjustment..........................................................................................................371
Photoconductor Unit......................................................................................................................................376
Overview....................................................................................................................................................376
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Drive and Drive Gear Position Sensor.....................................................................................................377
Drum Charge and Quenching.................................................................................................................379
Drum Cleaning...........................................................................................................................................380
Waste Toner Collection............................................................................................................................381
Waste Toner Bottle Full Detection and Set Detection.............................................................................382
PCU Detection (Development Unit Detection).........................................................................................383
Development..................................................................................................................................................385
Overview....................................................................................................................................................385
Drive...........................................................................................................................................................386
Developer Mixing.....................................................................................................................................387
Development Bias......................................................................................................................................387
Toner Supply Mechanism.........................................................................................................................388
Image Transfer...............................................................................................................................................389
Overview....................................................................................................................................................389
Transfer Unit Detection and New Unit Detection....................................................................................390
Drive and Transfer Belt Roller Voltage.....................................................................................................391
Transfer Roller Unit....................................................................................................................................393
Fusing..............................................................................................................................................................396
Overview....................................................................................................................................................396
Fusing Temperature Control.....................................................................................................................397
Drive...........................................................................................................................................................400
Controller........................................................................................................................................................401
7. Specifications
Specifications.................................................................................................................................................403
General Specifications..............................................................................................................................403
Supported Paper Sizes.............................................................................................................................406
Software Accessories................................................................................................................................407
Machine Configuration.............................................................................................................................408
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1. Installation Procedure
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Installation Requirements
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.
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1. Installation Procedure
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Machine Level
Front to back: Within 5 mm (0.2")
Right to left: Within 5 mm (0.2")
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.
Power Requirements
• Insert the plug firmly in the outlet.
• Do not use an outlet extension plug or cord.
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• Ground the machine.
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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.
Installation Requirements
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1. Installation Procedure
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Optional Unit Combinations
Machine Options
U: User installation, C: CE installation
No. Options Remarks
1 Paper Feed Unit Type 4000 (G392) U Up to x 3
Controller Options
U: User installation, C: CE installation
No. Options Remarks
1 Printer Hard Disk Drive Type 420 (M344) U
2 Memory Unit Type G /128MB (M345) U
3 Memory Unit Type G /256MB (D362) U
4 IEEE1284 Interface Board Type A (B679) U
IEEE802.11a/g Interface Unit Type L (M344)
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-or-
IEEE802.11a/g Interface Unit Type M (M344)
6 IEEE802.11g Interface Unit Type P (M344) U
7 Gigabit Ethernet Board Type A (874) U
8 Bluetooth Interface Unit (B826) U
9 Camera Direct Print Card Type E (M344) U
11 Data Storage Card Type A (G874) U
12 HDD Encryption Unit Type C (M344) U
13 VM Card Type H (G344) C
U
I/F slot
SD slot 110 Data Overwrite Security Unit (M344) U
SD slot 2
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Printer Installation
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Printer Installation
Installation Procedure
• Remove the tape from the development units before you turn the main switch on. The development
units can be severely damaged if you do not remove the tape.
• Keep the shipping retainers after you install the machine. You may need them in the future if you
transport the machine to another location.
Unpacking
• When lifting the machine, use the inside grips on both sides of the machine.
• If not, the machine could be dropped. This may cause an injury and may damage the machine.
• Place no objects to the left or on the cover.
1. Remove the plastic bag.
2. Lift the machine with two people by using the inset grips on both sides of the machine.
• Do not remove the tapes before placing the machine.
• Lower the machine slowly and carefully, so as not to pinch your hands.
3. Remove the tape from the printer.
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1. Installation Procedure
1
4. Open the left cover [A] of the printer.
5. Turn the two green levers counterclockwise ¬, and then slowly open the inner cover Á
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6. Remove the end of the tape from the printer.
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Printer Installation
7. Remove the four pieces of tape from the PCU in a horizontal direction.
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1. Installation Procedure
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8. Remove the securing pin, as shown, from the transfer unit.
9. Turn the green lever of the transfer unit counterclockwise to unlock the unit.
10. Remove the protective sheet.
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11. Turn the green lever clockwise to lock the unit.
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Printer Installation
12. Close the inner cover.
13. Push the two green levers ¬ to lock the inner cover, and then turn them clockwise Á.
14. Close the left cover.
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1. Installation Procedure
1
15. Open the top cover [A] by grasping the handles on the left and right sides.
• Be sure to remove the caution sheet, which is attached to the toner compartment.
16. Remove the tapes and cover.
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17. Remove the clips protecting the mouths of all four toner compartments.
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18. Close the top cover.
Printer Installation
19. Put labels “1” on the front of the paper tray.
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1. Installation Procedure
1
• Be sure to read the label which is attached to the front surface of the printer. This warns you that
ink-jet paper cannot be used with this printer.
Installing the toner
1. Open the top cover [A].
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2. Shake the toner bottles up and down seven or eight times before installing.
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Printer Installation
3. Remove the tape from the toner bottle.
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1. Installation Procedure
1
4. Install the yellow toner bottle first. Holding the toner bottle horizontally ¬ with the locking lever on
the upper side, install the toner bottom first, and then move the locking lever to the triangle mark Á.
5. Turn the locking lever to the circle mark. Pull the locking lever toward front side of the printer, until it
locks and clicks into place.
• Do not repeatedly insert and remove toner bottles. This causes toner leakage.
6. Do the same procedure to install the other three bottles: cyan (C), magenta (M), and black (B).
7. Close the top cover.
Loading Paper
1. Pull out tray 1 [A] of the printer until it stops.
2. Lift it slightly, and then pull it out.
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3. Adjust the green clips of the side guide and the end guide to the paper size you want.
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Printer Installation
4. Move the green switch on the front of the tray to match the type of paper to be loaded. Move the
switch to the left when you load thick paper of 75 g/m2 or more.
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1. Installation Procedure
1
5. Arrange and load a stack of new paper into the tray with the print side up. Make sure that there is no
gap between the paper and the paper guides. Adjust the paper guides to close gaps if necessary.
6. Lift the front of paper tray 1, and slowly slide the paper tray back until it stops. Make sure that the
paper tray is fully inserted, to prevent paper jams.
Turning Power on
• Turn off the power switch whenever you plug in and unplug the power cord.
1. Make sure that the power switch is set to "" (Off).
2. Plug in the machine.
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3. Turn on the power switch.
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Printer Installation
• Do not turn off the power switch until initialization is completed (‘Ready’ appears on the display
when initialization is completed). Otherwise, the machine may malfunction.
Selecting the Panel Display Language
• You can select one of these languages (the default is English): English, German, French, Italian, Dutch,
Swedish, Norwegian, Danish, Spanish, Finnish, Portuguese, Czech, Polish or Hungarian.
• You do not have to do this procedure if you use English. Do this procedure if you want to use a different
language.
1. Turn on the power switch of the printer.
• “Ready” shows on the panel display after the machine warms up.
2. Press the "Menu" key.
• “Menu” shows on the panel display.
3. Press the "" or "" key to select “Language.”
4. Press the "OK" key.
5. Press the "" or "" key to select the language you want.
6. Press the "OK" key.
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1. Installation Procedure
1
7. Press the “Menu” key to return to the initial screen.
Printing the Test Page
1. You can check if the printer works correctly by printing a test page such as the configuration page.
However, you cannot check the connection between the printer and the computer by printing the test
page.
2. Turn on the power switch of the printer.
• “Ready” shows on the panel display after the machine warms up.
3. Press the "Menu" key.
4. Press the "" or "" key to select “List/Test Print.”
5. Press the "OK" key.
6. Press the "" or "" key to select “Config. Page”.
7. Press the "OK" key.
8. The test printing starts shortly after.
9. Press the “Menu” key to return to the initial screen.
10. Turn off the power switch of the printer.
Settings Relevant to the Service Contract
Change the necessary settings depending on the each customer's service contract. For details, refer to
"Meter Click Charge" following this section.
Meter Click Charge
Basically, there are two ways to set up this function.
Meter click change enabled (SP 5-930-001 set to ‘enabled’): The counter can be displayed and printed
by the customer. The technician can then call the customer and ask them to read the counter.
Meter click charge disabled (SP 5-930-001 set to ‘disabled’; this is the default setting): The counter cannot
be displayed or printed by the customer. To check the counter, the technician must print the SMC report
(SP 5-990).
• You must select one of the counter methods (developments/prints) in accordance with the contract
(* SP5-045-001).
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Printer Installation
1
Item SP No. Function Default
Enables or disables Meter Click Charge.
When enabled:
• The counter menu shows
immediately after you push the
Meter Click
Charge
Meter Click
Charge: PCU
SP5-930-001
SP5-930-010
"Menu" key. The "Counter
Method" (SP5-045) sets the type of
the counter.
• You can print the counter from the
counter menu.
When disabled:
• The counter menu does not show.
Enables or disables the PM alert for the
PCUs.
"0": OFF
"1": No alert
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