Ricoh G104 User manual

G104/G160/G161
SERVICE MANUAL
002111MIU
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

G104/G160/G161
SERVICE MANUAL
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

G104/G160/G161
SERVICE MANUAL
002111MIU
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

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©2006 RICOH Corporation. All rights reserved.
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The Service Manual contains information
regarding service techniques, procedures,
p
rocesses and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
r
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual to
repair or modify Ricoh equipment risk persona
l
injury, damage to property or loss of warrant
y
p
rotection.
Ricoh Corporation
WARNING
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LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G104 P7425dn LP126cn Aficio CL4000DN CLP26DN
G160 C7526dn LP226cn Aficio SP C410DN CLP27DN
G161 C7531dn LP231cn Aficio SP C411DN CLP31DN
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 11/2004 Original Printing
1 05/2006 G160/G161 Addition
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SM i G104/G160/G161
G104/G160/G161
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION............................................................................ 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 REQUIREMENT.................................................1-2
1.1.4 POWER REQUIREMENTS ..............................................................1-2
1.2 MACHINE INSTALLATION........................................................................1-3
1.2.1 UNPACKING ....................................................................................1-3
1.2.2 INSTALLING THE TONER BOTTLE ................................................1-5
1.2.3 LOADING PAPER ............................................................................1-7
1.2.4 CONNECTING THE POWER CORD ...............................................1-9
1.2.5 SELECTING THE PANEL DISPLAY LANGUAGE..........................1-10
1.2.6 PRINTING THE TEST PAGE .........................................................1-10
1.3 OPTIONAL UNIT INSTALLATION...........................................................1-11
1.4 METER CHARGE....................................................................................1-12
1.5 TRAY HEATER .......................................................................................1-13
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 SPECIAL TOOLS AND LUBRICANTS ................................................3-1
3.1.1 TOOLS .............................................................................................3-1
3.2 ELECTRICAL COMPONENTS..................................................................3-2
3.2.1 ELECTRICAL BOARD UNIT ............................................................3-2
3.2.2 IOB (INPUT/OUTPUT BOARD)........................................................3-4
3.2.3 CONTROLLER BOARD ...................................................................3-4
3.2.4 PSU (POWER SUPPLY UNIT) BOARD ...........................................3-5
3.2.5 HIGH VOLTAGE POWER SUPPLY BOARD 1 ................................3-5
3.2.6 EGB (ENGINE BOARD) AND HIGH VOLTAGE POWER
SUPPLY BOARD 2...........................................................................3-6
3.2.7 LCD PANEL......................................................................................3-6
3.3 LASER OPTICS ........................................................................................3-7
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G104/G160/G161 ii SM
3.3.1 CAUTION DECAL LOCATIONS.......................................................3-7
3.3.2 LD UNIT............................................................................................3-8
Color registration adjustment ................................................................3-8
3.3.3 LDB.................................................................................................3-10
3.3.4 POLYGON MIRROR MOTOR ........................................................3-10
3.3.5 LASER SYNCHRONIZING DETECTOR BOARDS ........................3-11
3.3.6 LDU SHUTTER MOTOR UNIT AND SENSOR ..............................3-11
3.4 PAPER FEED..........................................................................................3-12
3.4.1 PAPER FEED ROLLER..................................................................3-12
3.4.2 PAPER FRICTION PAD .................................................................3-13
3.4.3 BY-PASS PAPER SIZE SENSOR..................................................3-13
3.4.4 BY-PASS FEED ROLLER, FRICTION PAD ...................................3-14
3.4.5 REGISTRATION SENSOR.............................................................3-15
3.4.6 0PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................3-15
3.4.6 PAPER VOLUME SENSOR, END SENSOR AND PAPER
WIDTH SENSOR............................................................................3-16
3.4.7 PAPER SIZE SENSOR AND TEMPERATURE/ HUMIDITY
SENSOR ........................................................................................3-17
3.4.8 PAPER FEED MOTOR...................................................................3-18
3.4.9 PAPER REGISTRATION CLUTCH, PAPER FEED CLUTCH
AND BY-PASS CLUTCH................................................................3-19
3.5 DEVELOPMENT .....................................................................................3-20
3.5.1 COLOR DEVELOPMENT MOTOR, COLOR OPC MOTOR
AND BLACK OPC/DEVELOPMENT MOTOR ................................3-20
3.5.2 DEVELOPMENT CLUTCH .............................................................3-20
3.5.3 TRANSFER BELT CONTACT MOTOR..........................................3-21
3.5.4 TONER SUPPLY MOTOR..............................................................3-21
3.5.5 TRANSFER ROLLER CONTACT MOTOR ....................................3-22
3.5.6 ID SENSORS .................................................................................3-23
3.6 DRIVE .....................................................................................................3-23
3.6.1 DRIVE UNIT ...................................................................................3-23
3.7 DUPLEX ..................................................................................................3-24
3.7.1 DUPLEX JAM SENSOR .................................................................3-24
3.7.2 INVERTER SENSOR .....................................................................3-24
3.7.3 DUPLEX MOTOR AND INVERTER MOTOR .................................3-25
3.8 FUSING...................................................................................................3-26
3.8.1 FUSING UNIT.................................................................................3-26
3.8.2 THERMISTOR AND THERMOSTAT..............................................3-26
3.8.3 FUSING LAMP ...............................................................................3-27
3.8.4 FUSING EXIT SENSOR AND PAPER EXIT SENSOR ..................3-28
3.8.5 FUSING REGISTRATION SENSOR ..............................................3-28
Fan Direction ......................................................................................3-29
3.9 ADJUSTMENTS ......................................................................................3-30
3.9.1 GAMMA ADJUSTMENT .................................................................3-30
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SM iii G104/G160/G161
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 PROCESS CONTROL RESULT ...............................................................4-1
4.2 SERVICE CALL CONDITIONS .................................................................4-2
4.2.1 SUMMARY .......................................................................................4-2
4.2.2 SC CODE DESCRIPTIONS .............................................................4-3
Engine SC.............................................................................................4-3
Controller Error ...................................................................................4-14
4.3 TROUBLESHOOTING GUIDE ................................................................4-21
4.3.1 BLANK PRINT ................................................................................4-21
4.3.2 ALL-BLACK PRINT.........................................................................4-21
4.3.3 MISSING CMY COLOR..................................................................4-22
4.3.4 LIGHT PRINT .................................................................................4-22
4.3.5 REPEATED SPOTS OR LINES ON PRINTS .................................4-23
4.3.6 DARK VERTICAL LINE IN PRINT..................................................4-23
4.3.7 WHITE HORIZONTAL LINES OR BANDS .....................................4-24
4.3.8 MISSING PARTS OF IMAGES.......................................................4-24
4.3.9 DIRTY BACKGROUND ..................................................................4-24
4.3.10 PARTIAL CMY COLOR DOTS .....................................................4-24
4.3.11 DARK IRREGULAR STREAKS ON PRINTS................................4-24
4.3.12 CMY COLOR IRREGULAR STREAKS ........................................4-25
4.3.13 GHOSTING ..................................................................................4-25
4.3.14 UNFUSED OR PARTIALLY FUSED PRINTS ..............................4-25
4.3.15 IMAGE SKEW ..............................................................................4-25
4.3.16 BACKGROUND STAIN ................................................................4-26
4.3.17 NO PRINTING ON PAPER EDGE................................................4-26
4.3.18 IMAGE NOT CENTERED WHEN IT SHOULD BE .......................4-26
4.4 ELECTRICAL COMPONENT DEFECTS ................................................4-27
4.4.1 SENSORS ......................................................................................4-27
4.5 BLOWN FUSE CONDITIONS .................................................................4-29
Power supply unit ...............................................................................4-29
IOB......................................................................................................4-29
4.6 LEDS ........................................................................................................4-29
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
Others ...................................................................................................5-4
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G104/G160/G161 iv SM
5.2 SERVICE MODE TABLE...........................................................................5-5
5.2.1 CONTROLLER SERVICE MODE.....................................................5-5
5.2.2 BIT SWITCH PROGRAMMING ........................................................5-9
5.2.3 ENGINE SERVICE MODE .............................................................5-10
SP1-XXX (Feed) .................................................................................5-10
SP2-XXX (Drum).................................................................................5-21
SP3-XXX (Process) ............................................................................5-47
SP5-XXX (Mode) ................................................................................5-57
SP7-XXX (Data Log)...........................................................................5-71
SP8-XXX (Data Log 2)........................................................................5-82
SP9-XXX.............................................................................................5-92
5.2.4 INPUT CHECK TABLE ...................................................................5-96
5.2.5 OUTPUT CHECK TABLE ...............................................................5-98
5.3 FIRMWARE UPDATE ...........................................................................5-100
5.3.1 TYPE OF FIRMWARE..................................................................5-100
5.3.2 PRECAUTIONS............................................................................5-100
Handling SD Cards ...........................................................................5-100
Upload or Download .........................................................................5-100
Network Connection..........................................................................5-100
5.3.3 FILE ARRANGEMENT .................................................................5-101
How the Program Works...................................................................5-101
Example............................................................................................5-101
5.3.4 UPDATING ...................................................................................5-102
Procedure .........................................................................................5-102
Error Handling...................................................................................5-103
Power Failure....................................................................................5-103
5.3.5 NVRAM DATA UPLOAD/DOWNLOAD ........................................5-104
Uploading NVRAM Data ...................................................................5-104
Downloading NVRAM Data...............................................................5-105
5.3.6 ERROR CODE TABLE .................................................................5-106
5.4 SD CARD APPLI MOVE........................................................................5-107
5.4.1 OVERVIEW ..................................................................................5-107
5.4.2 MOVE EXEC ................................................................................5-108
5.4.3 UNDO EXEC ................................................................................5-109
Keeping the SD card.........................................................................5-109
DETAILED SECTION DESCRIPTIONS
6. DETAILED SECTION 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
Descriptions ..........................................................................................6-5
6.1.5 PRINTING PROCESS ......................................................................6-6
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SM v G104/G160/G161
6.2 PROCESS CONTROL ..............................................................................6-8
6.2.1 OVERVIEW ......................................................................................6-8
6.2.2 POTENTIAL CONTROL ...................................................................6-9
Overview...............................................................................................6-9
Process Control Self-check...................................................................6-9
6.2.3 PROCESS CONTROL SELF-CHECK PROCEDURE ....................6-11
Step 1: VSG Adjustment .....................................................................6-11
Step 2: ID Sensor Solid Pattern Generation .......................................6-11
Step 3: Sensor Pattern Detection .......................................................6-11
Step 4: Toner Amount Calculation ......................................................6-11
Step 5: VD, VB, VL Selection and VREF Adjustment .........................6-12
6.2.4 TONER SUPPLY CONTROL .........................................................6-12
Toner Supply Control Modes ..............................................................6-12
Low Image Coverage..........................................................................6-13
6.2.5 TONER NEAR END/TONER END DETECTION............................6-14
Introduction .........................................................................................6-14
Toner Near End Detection ..................................................................6-15
Toner End Detection ...........................................................................6-15
Toner End Recovery ...........................................................................6-15
6.2.6 DEVELOPER INITIALIZATION ......................................................6-16
6.3 PAPER FEED..........................................................................................6-17
6.3.1 OVERVIEW ....................................................................................6-17
6.3.2 PAPER FEED DRIVE .....................................................................6-18
6.3.3 PAPER TRAY.................................................................................6-19
Paper Lift ............................................................................................6-19
Paper Size Detection ..........................................................................6-20
Paper Size Detection ..........................................................................6-20
Paper Near End/End Detection...........................................................6-21
Near-end detection .............................................................................6-21
End detection......................................................................................6-21
Paper width sensor .............................................................................6-21
By-pass Tray Feed and Size Detection...............................................6-22
6.3.4 DUPLEX .........................................................................................6-23
Drive ...................................................................................................6-24
Interleaving .........................................................................................6-25
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
6.4.5 AUTOMATIC LINE POSITION ADJUSTMENT ..............................6-30
Overview.............................................................................................6-30
Summary of Each Adjustment ............................................................6-31
Main Scan Skew Adjustment ..............................................................6-34
LDU Shutter ........................................................................................6-35
6.5 PHOTOCONDUCTOR UNIT ...................................................................6-36
6.5.1 OVERVIEW ....................................................................................6-36
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G104/G160/G161 vi SM
6.5.2 DRIVE AND DRIVE GEAR POSITION SENSOR...........................6-37
Mechanism .........................................................................................6-37
Initialization Process and SC Codes ...................................................6-38
6.5.3 DRUM CHARGE AND QUENCHING .............................................6-39
6.5.4 DRUM CLEANING..........................................................................6-40
6.5.5 WASTE TONER COLLECTION .....................................................6-41
6.5.6 WASTE TONER BOTTLE FULL DETECTION AND SET
DETECTION...................................................................................6-42
6.5.7 PCU DETECTION (DEVELOPMENT UNIT DETECTION) .............6-43
Unit Set Detection Pins .......................................................................6-43
New Unit Detection .............................................................................6-43
Error Message ....................................................................................6-44
6.6 DEVELOPMENT .....................................................................................6-45
6.6.1 OVERVIEW ....................................................................................6-45
6.6.2 DRIVE.............................................................................................6-46
6.6.3 DEVELOPER MIXING ....................................................................6-47
6.6.4 DEVELOPMENT BIAS ...................................................................6-48
6.6.5 TONER SUPPLY MECHANISM .....................................................6-49
Overview.............................................................................................6-49
Toner Near End Detection ..................................................................6-49
6.6.6 TONER BOTTLE DETECTION ......................................................6-49
6.7 IMAGE TRANSFER.................................................................................6-50
6.7.1 OVERVIEW ....................................................................................6-50
Transfer Unit Detection and New Unit Detection ................................6-51
Transfer belt unit detection .................................................................6-51
New transfer belt unit detection ..........................................................6-51
6.7.2 TRANSFER BELT DRIVE AND TRANSFER BELT ROLLER
VOLTAGE.................................................................................................6-52
Transfer belt contact ...........................................................................6-53
Transfer belt cleaning .........................................................................6-54
6.7.3 TRANSFER ROLLER UNIT............................................................6-55
Transfer from the belt..........................................................................6-55
Image transfer.....................................................................................6-55
Discharge............................................................................................6-56
Transfer roller contact .........................................................................6-57
6.8 FUSING...................................................................................................6-58
6.8.1 OVERVIEW ....................................................................................6-58
6.8.2 FUSING TEMPERATURE CONTROL............................................6-59
Machine ready temperature: [B]..........................................................6-60
Print ready temperature: [C]................................................................6-60
Target printing temperature: [D]..........................................................6-60
First print temperature: [G]..................................................................6-60
Corrections for Small Paper Sizes (less than A5) ...............................6-61
Overheat Protection............................................................................6-61
6.8.3 DRIVE.............................................................................................6-62
6.9 CONTROLLER ........................................................................................6-63
6.9.1 OVERVIEW ....................................................................................6-63
6.9.2 BOARD LAYOUT ............................................................................6-65
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SM vii G104/G160/G161
SPECIFICATIONS
1. GENERAL SPECIFICATIONS.....................................................................7-1
2. SUPPORTED PAPER SIZES......................................................................7-3
3. SOFTWARE ACCESSORIES .....................................................................7-4
3.1 PRINTER DRIVERS ............................................................................7-4
3.2 UTILITY SOFTWARE ..........................................................................7-4
4. MACHINE CONFIGURATION .....................................................................7-5
5. OPTIONAL EQUIPMENT ...........................................................................7-6
G160/G161 SECTION
SEE SECTION G160/G161 FOR DETAILED TABLE OF CONTENTS
PAPER FEED UNIT TYPE 4000 (G392)
SEE SECTION G392 FOR DETAILED TABLE OF CONTENTS
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