Ricoh AP-P2 G188 Quick start guide

Model AP-P2
Machine Code: G188/G189
Field Service Manual
January, 2009
Subject to change

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
1. 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.
2. The printer, which use high voltage power source, can generate ozone gas. High ozone density is
harmful to human health. Therefore, the machine must be installed in a well-ventilated room.
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.
•Keep the machine away from flammable liquids, gases, and aerosols. A fire or an explosion might
occur.
• The Controller board on this machine contains a lithium battery. The danger of explosion exists if a
battery of this type is incorrectly replaced. Replace only with the same or an equivalent type
recommended by the manufacturer. Discard batteries in accordance with the manufacturer's
instructions and local regulations.
• The optional fax and memory expansion units contain lithium batteries, which can explode if replaced
incorrectly. Replace only with the same or an equivalent type recommended by the manufacturer. Do
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not recharge or burn the batteries. Used batteries must be handled in accordance with local
regulations.
Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an
open flame.
2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor
in accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100
batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical
reactions and heat build-up.
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Symbols, Abbreviations and Trademarks
This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are
as follows:
*See or Refer to
Clip ring
Screw
Connector
Clamp
E-ring
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
Important Safety Notices...................................................................................................................................1
Prevention of Physical Injury..........................................................................................................................1
Health Safety Conditions...............................................................................................................................1
Observance of Electrical Safety Standards.................................................................................................1
Safety and Ecological Notes for Disposal...................................................................................................2
Symbols, Abbreviations and Trademarks.........................................................................................................3
Trademarks.....................................................................................................................................................3
1. Product Information
Specifications....................................................................................................................................................11
Machine Configuration....................................................................................................................................12
Overview..........................................................................................................................................................15
Component Layout.......................................................................................................................................15
Paper Path....................................................................................................................................................16
Drive Layout..................................................................................................................................................17
Guidance for Those Who are Familiar with Predecessor Products..............................................................19
2. Installation
Installation Requirements.................................................................................................................................21
Environment..................................................................................................................................................21
Machine Level..............................................................................................................................................22
Machine Space Requirements....................................................................................................................22
Power Requirements....................................................................................................................................23
Optional Unit Combinations............................................................................................................................24
Machine Options.........................................................................................................................................24
Controller Options.......................................................................................................................................24
Printer Installation.............................................................................................................................................26
Power Socket for Peripheral........................................................................................................................26
Installation Flow Chart.................................................................................................................................26
Installation Procedure..................................................................................................................................28
Meter Click Charge.....................................................................................................................................40
Moving the Machine...................................................................................................................................43
Transporting the Machine...........................................................................................................................43
Bridge Unit (D386)..........................................................................................................................................44
Component Check.......................................................................................................................................44
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Installation Procedure..................................................................................................................................44
1000-Sheet Booklet Finisher (B793).............................................................................................................48
Accessory Check..........................................................................................................................................48
Installation Procedure..................................................................................................................................49
Punch Unit (B807)............................................................................................................................................53
Component Check.......................................................................................................................................53
Installation Procedure..................................................................................................................................54
3000-Sheet Finisher (B805)...........................................................................................................................60
Accessory Check..........................................................................................................................................60
Installation Procedure..................................................................................................................................61
Punch Unit (B702)............................................................................................................................................66
Component Check.......................................................................................................................................66
Installation Procedure..................................................................................................................................67
Output Jogger Unit (B703).............................................................................................................................71
Accessories...................................................................................................................................................71
Installation....................................................................................................................................................71
Mail Bin (G835)..............................................................................................................................................74
Component Check.......................................................................................................................................74
Installation Procedure..................................................................................................................................75
Tray Heater (Standard Tray)...........................................................................................................................81
Installation Procedure..................................................................................................................................81
Tray Heater (Optional Tray)............................................................................................................................82
Component Check.......................................................................................................................................82
Installation Procedure..................................................................................................................................83
Controller Options............................................................................................................................................93
Overview......................................................................................................................................................93
SD Card Appli Move...................................................................................................................................94
3. Preventive Maintenance
Maintenance Items...........................................................................................................................................97
4. Replacement and Adjustment
Beforehand.......................................................................................................................................................99
Special Tools..................................................................................................................................................100
Image Adjustment..........................................................................................................................................101
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Registration................................................................................................................................................101
Erase Margin Adjustment..........................................................................................................................102
Color Registration......................................................................................................................................103
Gamma Adjustment...................................................................................................................................104
Exterior Covers...............................................................................................................................................108
Front Door..................................................................................................................................................108
Left Cover...................................................................................................................................................109
Rear Cover.................................................................................................................................................109
Top Right and Rear Cover........................................................................................................................110
Right Rear Cover.......................................................................................................................................110
Operation Panel........................................................................................................................................111
Paper Exit Cover........................................................................................................................................111
Output Tray................................................................................................................................................112
Ozone Filter...............................................................................................................................................112
Laser Optics....................................................................................................................................................115
Caution Decal Location............................................................................................................................115
Laser Optics Housing Unit........................................................................................................................115
Polygon Mirror Motor and Drive Board..................................................................................................121
Image Creation..............................................................................................................................................123
PCU.............................................................................................................................................................123
Second Duct Fan.......................................................................................................................................124
Third Duct Fan............................................................................................................................................125
Toner Pump Unit........................................................................................................................................127
Toner End Sensor......................................................................................................................................133
Image Transfer...............................................................................................................................................134
Image Transfer Belt Unit............................................................................................................................134
Image Transfer Belt Cleaning Unit...........................................................................................................135
Image Transfer Belt....................................................................................................................................135
Paper Transfer................................................................................................................................................142
Paper Transfer Roller Unit.........................................................................................................................142
Paper Transfer Unit....................................................................................................................................142
High Voltage Supply Board – Discharge Plate......................................................................................144
ID Sensor Board........................................................................................................................................145
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Temperature and Humidity Sensor..........................................................................................................148
Drive Unit........................................................................................................................................................149
Gear Unit...................................................................................................................................................150
Registration Motor.....................................................................................................................................155
Paper Feed Motor.....................................................................................................................................156
Drum/Development Motors for M, C, and Y.........................................................................................156
Drum/Development Motor-K...................................................................................................................157
ITB Drive Motor.........................................................................................................................................158
Fusing/Paper Exit Motor..........................................................................................................................158
Image Transfer Belt Contact Motor..........................................................................................................159
Duplex Inverter Motor...............................................................................................................................159
Pressure Roller Contact Motor..................................................................................................................161
Duplex/By-pass Motor.............................................................................................................................161
Paper Transfer Contact Motor..................................................................................................................163
Toner Transport Motor..............................................................................................................................165
Toner Collection Unit.................................................................................................................................165
Paper Feed Clutches.................................................................................................................................166
Development Clutch-Y..............................................................................................................................169
Development Clutches for M and C........................................................................................................170
Development Clutch-K..............................................................................................................................171
Fusing..............................................................................................................................................................173
Fusing Unit..................................................................................................................................................173
Heating Roller and Heating Roller Bearing.............................................................................................174
Fusing Cleaning Felt..................................................................................................................................179
Fusing Lamp...............................................................................................................................................180
Fusing Drive Gear.....................................................................................................................................181
Pressure Roller and Pressure Roller Bearing............................................................................................181
Heating Roller Thermistor..........................................................................................................................185
Pressure Roller Thermostat........................................................................................................................185
Pressure Roller Thermistor.........................................................................................................................186
Bearing Gear and Idle Gear....................................................................................................................187
Fusing Fan..................................................................................................................................................187
Paper Exit Fan............................................................................................................................................188
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IH (Induction Heating) Inverter Fan.........................................................................................................189
Thermopile.................................................................................................................................................190
Pressure Roller HP Sensor.........................................................................................................................193
IH Coil Fan.................................................................................................................................................195
IH Coil Unit................................................................................................................................................196
Paper Feed.....................................................................................................................................................199
Paper Feed Unit.........................................................................................................................................199
Pick-Up, Feed and Separation Rollers.....................................................................................................200
Tray Lift Motor............................................................................................................................................201
Vertical Transport, Paper Overflow, Paper End and Paper Feed Sensors...........................................201
Registration Sensor....................................................................................................................................202
By-pass Paper Size Sensor and By-pass Paper Length Sensor.............................................................203
By-pass Bottom Tray..................................................................................................................................205
By-pass Paper End Sensor........................................................................................................................207
By-pass Pick-up, Feed and Separation Roller, Torque Limiter...............................................................208
By-pass Feed Clutch..................................................................................................................................209
Paper Exit Unit...........................................................................................................................................210
Fusing Exit, Paper Overflow, Junction Paper Jam and Paper Exit Sensors...........................................211
Duplex Unit.....................................................................................................................................................213
Duplex Unit................................................................................................................................................213
Duplex Door Sensor .................................................................................................................................214
Duplex Entrance Sensor............................................................................................................................215
Duplex Exit Sensor....................................................................................................................................216
Electrical Components...................................................................................................................................217
Controller Unit...........................................................................................................................................217
Controller Box Right Cover.......................................................................................................................217
Controller Box............................................................................................................................................218
IOB (In/Out Board)..................................................................................................................................220
BCU............................................................................................................................................................220
PSU.............................................................................................................................................................222
ITB Power Supply Board...........................................................................................................................223
High Voltage Supply Board.....................................................................................................................223
High Voltage Supply Board Bracket.......................................................................................................224
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IH Inverter..................................................................................................................................................224
Controller Board........................................................................................................................................225
HDD Fan....................................................................................................................................................227
HDD............................................................................................................................................................227
NVRAM Replacement Procedure............................................................................................................229
Using Dip Switches........................................................................................................................................230
Controller Board........................................................................................................................................230
BCU Board.................................................................................................................................................230
5. System Maintenance Reference
Service Program Mode.................................................................................................................................231
SP Tables....................................................................................................................................................231
Service Mode Operation.........................................................................................................................231
Remarks......................................................................................................................................................232
Bit Switch Programming............................................................................................................................234
Firmware Update...........................................................................................................................................235
Before You Begin.......................................................................................................................................235
Updating Firmware ..................................................................................................................................235
Handling Firmware Update Errors...........................................................................................................238
Controller Self-Diagnostics...........................................................................................................................240
Overview....................................................................................................................................................240
NVRAM Data Upload/Download..............................................................................................................242
Uploading NVRAM Data.........................................................................................................................242
Downloading NVRAM Data....................................................................................................................243
Using the Debug Log.....................................................................................................................................244
Switching ON and Setting UP Save Debug Log.....................................................................................244
Retrieving the Debug Log from the HDD.................................................................................................246
Debug Log Codes.....................................................................................................................................247
6. Troubleshooting
Service Call Conditions.................................................................................................................................249
Process Control Error Conditions..................................................................................................................250
Troubleshooting Guide..................................................................................................................................251
Image Problems.........................................................................................................................................251
Jam Detection.................................................................................................................................................252
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Electrical Component Defects.......................................................................................................................253
INDEX...........................................................................................................................................................255
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1. Product Information
Specifications
See "Appendices" for the following information:
• Mainframe Specifications
• Printer Specifications
• Supported Paper Sizes
• Software Accessories
• Optional Equipment
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Machine Configuration
Item Machine Code Call out Remarks
Mainframe G188/G189 [A] -
Mail Bin G835 [B] One from [C] and [D]
LCT D352-57/-67 [C]
One from the three and [D] + [E]Two-tray paper feed unit D351-57 [D]
Paper tray unit (one tray) D387-17 [E]
3000-sheet finisher B805 [F] One from [F] and [G];
Requires [H] and one from [C] and [D]
- Punch unit: 3/2 holes B702-17 - Requires [F]
- Punch unit: 4/2 holes B702-27 - Requires [F]
- Punch unit: 4 holes B702-28 - Requires [F]
- Output Jogger Unit B703 - Requires [F]
1. Product Information
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Item Machine Code Call out Remarks
1000-sheet booklet finisher B793 [G] One from [F] and [G];
Requires [H] and one from [C] and [D]
- Punch unit: 3/2 holes B807-17 - Requires [G]
- Punch unit: 4/2 holes B807-27 - Requires [G]
- Punch unit: 4 holes B807-30 - Requires [G]
Bridge unit D386 [H] -
Item Machine code Call out Remark
USB 2.0: - - Standard
USB Host - - Standard
Ethernet: - - Standard
Machine Configuration
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IEEE 1284 B679-17 [C]
One from the four devices
Wireless LAN
(IEEE 802.11a/g) D377-01/ 02
[D]
Wireless LAN
(IEEE 802.11 g) D377-19
Bluetooth B826 [E]
Gigabit Ethernet D377-21 [F]
Hard Disk Drive M354-05 [H] Standard for G189
Option for G188
Data Overwrite Security Unit M354-21
[A] One from the five in SD slot 1 at a
time.
NetWare printing M354-19
Data Storage Card G874
PictBridge M354-13
VM Card Type K M354-15/ 22/
23
[B]
In SD slot 2
HDD Encryption Unit M354-17 In SD card slot 2
Remove it from slot 2 after installing.
256 MB DIMM M354-01
[G] One from the two
512 MB DIMM M354-03
1. Product Information
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Overview
Component Layout
1. Decurler rollers
2. Duplex unit
3. Fusing unit
4. Paper transfer roller
5. Registration roller
6. By-pass feed table
7. Tray 2
8. Tray 1
9. Toner collection bottle
10. Laser optics housing unit
11. PCU (4 colors)
12. Image transfer belt cleaning unit
13. Image transfer belt unit
14. Toner bottle (4 colors)
15. ID sensor
16. IH coil unit
Overview
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Paper Path
1. Inner Tray
2. Mail Bin
3. Duplex inverter
4. Duplex feed
5. By-pass tray feed
6. Tray 1 feed
7. Tray 2 feed
8. Tray 3: Optional paper feed unit/LCT 9. Tray 4:
Optional paper feed unit
10. Finisher booklet stapler
(B793 Optional)
11. Finisher stapler (Optional)
12. Finisher upper tray (Optional)
13. Finisher proof tray (Optional)
The 3000-sheet finisher and 1000-sheet booklet finisher require the bridge unit (D386) and one from the
two-tray paper feed unit (D351) or the LCT (D352).
1. Product Information
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Drive Layout
1. Toner supply clutch-K and -
CMY: Turns on/off the drive power to the toner supply unit (K and -CMY).
2.ITB (Image Transfer Belt) contact
motor: Moves the ITB into contact and away from the color PCUs.
3. Toner transport motor:
Drives the toner attraction pumps and the toner collection coils from
the PCUs, from the transfer belt unit, and inside the toner collection
bottle. Also rotates the toner bottles.
4. Development clutch (K, Y, M,
C): Turns on/off the drive power to the development unit (K, Y, M, C).
5. Drum/Development drive
motor (K, Y, M, C) Drives the color drum unit and development unit (K, Y, M, C).
6. Paper feed clutch Switches the drive power between the tray 1 and tray 2.
7. Paper feed motor: Drives the paper feed mechanisms (tray 1/tray 2/by-pass tray).
Overview
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8. By-pass feed clutch: Turns on/off the drive power to the by-pass pick-up, feed and
separation rollers.
9. Registration motor: Drives the registration roller.
10. By-pass/duplex feed motor: Drives the by-pass pick-up, feed and separation roller, and duplex
transport rollers.
11. Paper transfer contact motor: Moves the paper transfer roller in contact with the image transfer
belt.
12. ITB drive motor: Drives the image transfer belt unit.
13. Duplex inverter motor Drives the duplex inverter rollers and duplex transport rollers.
14. Fusing/paper exit motor: Drives the fusing unit and paper exit section.
1. Product Information
18
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