Ricoh G133 User manual

G133
SERVICE MANUAL
002906MIU

G133
SERVICE MANUAL

G133
SERVICE MANUAL
002906MIU

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©2006 RICOH Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G133 C7640nD LP440c SP C811DN CLP240D
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 12/2006 Original Printing

SM i G133
G133
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 REQUIREMENTS ...............................................1-2
1.1.4 POWER REQUIREMENTS ...............................................................1-2
1.2 OPTIONAL UNIT COMBINATIONS ...........................................................1-3
1.2.1 MACHINE OPTIONS.........................................................................1-3
1.2.2 CONTROLLER OPTIONS.................................................................1-3
1.3 PRINTER INSTALLATION .........................................................................1-5
1.3.1 POWER SOCKET FOR PERIPHERAL .............................................1-5
1.3.2 INSTALLATION FLOW CHART ........................................................1-5
1.3.3 INSTALLATION PROCEDURE .........................................................1-7
Unpacking.............................................................................................1-7
Installing the Toner .............................................................................1-11
Loading Paper ....................................................................................1-11
Turning Power On...............................................................................1-13
Selecting the Panel Display Language ...............................................1-14
Printing the Test Page ........................................................................1-14
Settings Relevant to the Service Contract ..........................................1-15
1.3.4 METER CLICK CHARGE ................................................................1-15
1.3.5 MOVING THE MACHINE ................................................................1-18
1.3.6 TRANSPORTING THE MACHINE ..................................................1-18
1.4 BRIDGE UNIT (B227)...............................................................................1-19
1.4.1 COMPONENT CHECK....................................................................1-19
1.4.2 INSTALLATION PROCEDURE .......................................................1-19
1.5 1000-SHEET BOOKLET FINISHER (B793) .............................................1-23
1.5.1 ACCESSORY CHECK ....................................................................1-23
1.5.2 INSTALLATION PROCEDURE .......................................................1-24
1.6 PUNCH UNIT (B807)................................................................................1-28
1.6.1 COMPONENT CHECK....................................................................1-28
1.6.2 INSTALLATION PROCEDURE .......................................................1-29
1.7 3000-SHEET FINISHER (B805) ...............................................................1-34
1.7.1 ACCESSORY CHECK ....................................................................1-34
1.7.2 INSTALLATION PROCEDURE .......................................................1-35
Support Tray Installation .....................................................................1-38
1.8 PUNCH UNIT (B702)................................................................................1-39
1.8.1 COMPONENT CHECK....................................................................1-39
1.8.2 INSTALLATION PROCEDURE .......................................................1-39

G133 ii SM
1.9 TRAY HEATER (STANDARD TRAY).......................................................1-43
1.9.1 INSTALLATION PROCEDURE .......................................................1-43
1.10 TRAY HEATER (OPTIONAL TRAY)...................................................1-44
1.10.1 COMPONENT CHECK ..............................................................1-44
1.10.2 INSTALLATION PROCEDURE..................................................1-44
For installing the tray heater in the B800 (Two-tray paper feed unit) ..1-45
For installing the tray heater in the B801 (LCT) ..................................1-47
For installing the tray heater in the G832 (Paper tray unit) .................1-50
1.11 CONTROLLER OPTIONS ..................................................................1-54
1.11.1 OVERVIEW ...............................................................................1-54
I/F Card Slots......................................................................................1-54
SD Card Slots .....................................................................................1-54
1.11.2 SD CARD APPLI MOVE ............................................................1-55
Overview.............................................................................................1-55
Move Exec ..........................................................................................1-56
Undo Exec ..........................................................................................1-56
1.11.3 DATA OVERWRITE SECURITY UNIT TYPE G (G874) ............1-57
Before You Begin the Procedure ........................................................1-57
Seal Check and Removal ...................................................................1-57
Installation Procedure .........................................................................1-58
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE ....................................................2-1
2.1 USER MAINTENANCE ITEMS...................................................................2-1
2.1.1 MAINFRAME.....................................................................................2-1
Replacement Items...............................................................................2-1
2.2 SERVICE MAINTENANCE ITEMS.............................................................2-2
2.2.1 MAINFRAME.....................................................................................2-2
Cleaning Items......................................................................................2-2
2.2.2 OPTIONAL UNITS.............................................................................2-2
Paper Tray Unit/ Two-tray Paper Feed Unit/ LCT .................................2-2
1000/3000-Sheet (Booklet) Finisher .....................................................2-2
1000/3000-Sheet (Booklet) Finisher Punch Kit .....................................2-3
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT.........................................3-1
3.1 BEFOREHAND...........................................................................................3-1
3.2 SPECIAL TOOLS .......................................................................................3-2
3.3 IMAGE ADJUSTMENT...............................................................................3-3
3.3.1 REGISTRATION................................................................................3-3
Image Area ...........................................................................................3-3
Leading Edge........................................................................................3-3
Side to Side ..........................................................................................3-3

SM iii G133
Adjustment Standard ............................................................................3-3
Paper Registration Standard.................................................................3-3
Adjustment Procedure ..........................................................................3-3
3.3.2 ERASE MARGIN ADJUSTMENT ......................................................3-4
3.3.3 COLOR REGISTRATION..................................................................3-5
Line Position Adjustment ......................................................................3-5
3.3.4 GAMMA ADJUSTMENT....................................................................3-6
Summary ..............................................................................................3-6
Adjustment Procedure ..........................................................................3-7
3.4 EXTERIOR COVERS ...............................................................................3-10
3.4.1 FRONT DOOR ................................................................................3-10
3.4.2 LEFT COVER..................................................................................3-11
3.4.3 REAR COVER.................................................................................3-11
3.4.4 TOP RIGHT AND REAR COVER....................................................3-12
3.4.5 RIGHT REAR COVER.....................................................................3-12
3.4.6 OPERATION PANEL.......................................................................3-13
3.4.7 PAPER EXIT COVER......................................................................3-13
3.4.8 OUTPUT TRAY ...............................................................................3-13
3.4.9 OZONE FILTER ..............................................................................3-14
Ozone filter for charge unit..................................................................3-14
Ozone filter for IH inverter...................................................................3-15
3.5 LASER OPTICS .......................................................................................3-16
3.5.1 CAUTION DECAL LOCATION ........................................................3-16
3.5.2 LASER OPTICS HOUSING UNIT ...................................................3-16
Preparing the new laser optics housing unit .......................................3-17
Before removing the old laser optics housing unit ..............................3-17
Recovery procedure for no replacement preparation of laser optics
housing unit ........................................................................................3-18
Removing the old laser optics housing unit.........................................3-19
Installing a new Laser Optics Housing Unit.........................................3-20
After installing the new laser optics housing unit ................................3-20
3.5.3 POLYGON MIRROR MOTOR AND DRIVE BOARD.......................3-22
3.5.4 SHUTTER MOTOR .........................................................................3-23
3.6 IMAGE CREATION ..................................................................................3-26
3.6.1 PCU.................................................................................................3-26
3.6.2 SECOND DUCT FAN ......................................................................3-27
When reinstalling the second duct fan ................................................3-28
3.6.3 THIRD DUCT FAN ..........................................................................3-28
When reinstalling the third duct fan.....................................................3-29
3.6.4 TONER PUMP UNIT .......................................................................3-29
When you install the new toner pump unit ..........................................3-32
3.6.5 TONER END SENSOR ...................................................................3-35
3.7 IMAGE TRANSFER..................................................................................3-36
3.7.1 IMAGE TRANSFER BELT UNIT .....................................................3-36
3.7.2 IMAGE TRANSFER BELT...............................................................3-36
When reinstalling the image transfer belt............................................3-40

G133 iv SM
3.8 PAPER TRANSFER .................................................................................3-42
3.8.1 PAPER TRANSFER ROLLER UNIT ...............................................3-42
3.8.2 PAPER TRANSFER UNIT...............................................................3-42
3.8.3 HIGH VOLTAGE SUPPLY BOARD - DISCHARGE PLATE ............3-44
3.8.4 ID SENSOR BOARD .......................................................................3-44
Cleaning for ID sensors ......................................................................3-45
After installing a new ID sensor unit/board..........................................3-46
3.8.5 TEMPERATURE AND HUMIDITY SENSOR ..................................3-46
3.9 DRIVE UNIT .............................................................................................3-47
3.9.1 GEAR UNIT.....................................................................................3-48
When installing the drive unit ..............................................................3-54
Adjustment after replacing the gear unit .............................................3-54
3.9.2 REGISTRATION MOTOR ...............................................................3-54
3.9.3 PAPER FEED MOTOR ...................................................................3-55
3.9.4 DRUM/DEVELOPMENT MOTORS FOR M, C, AND Y ...................3-56
3.9.5 DRUM/DEVELOPMENT MOTOR-K................................................3-56
3.9.6 ITB DRIVE MOTOR.........................................................................3-57
3.9.7 FUSING/PAPER EXIT MOTOR.......................................................3-57
3.9.8 IMAGE TRANSFER BELT CONTACT MOTOR ..............................3-58
3.9.9 PAPER TRANSFER CONTACT MOTOR .......................................3-58
3.9.10 DUPLEX INVERTER MOTOR ...................................................3-59
3.9.11 DUPLEX/BY-PASS MOTOR......................................................3-60
3.9.12 TONER TRANSPORT MOTOR.................................................3-61
3.9.13 TONER COLLECTION UNIT .....................................................3-62
3.9.14 PAPER FEED CLUTCHES........................................................3-63
3.9.15 DEVELOPMENT CLUTCH-Y.....................................................3-65
3.9.16 DEVELOPMENT CLUTCHES FOR M AND C...........................3-66
3.9.17 DEVELOPMENT CLUTCH-K.....................................................3-67
3.10 FUSING ..............................................................................................3-68
3.10.1 FUSING UNIT............................................................................3-68
3.10.2 FUSING LAMP...........................................................................3-68
3.10.3 PRESSURE ROLLER AND PRESSURE ROLLER BEARING ..3-70
When re-installing the pressure roller .................................................3-73
3.10.4 FERRITE ROLLER GEAR .........................................................3-75
3.10.5 FUSING ROLLER BUSHING AND TENSION ROLLER
BUSHING .................................................................................................3-75
When re-installing the fusing roller bushing and tension roller bushing3-76
3.10.6 TENSION ROLLER....................................................................3-76
When re-installing the tension roller....................................................3-77
3.10.7 FUSING BELT, HEATING ROLLER, HEATING ROLLER
BUSHING AND FUSING ROLLER...........................................................3-77
When re-installing the fusing belt, heating roller, fusing roller and
heating roller bushing..........................................................................3-79
3.10.8 LUBRICANT ROLLER BUSHING..............................................3-80
3.10.9 LUBRICANT ROLLER AND CLEANING ROLLER ....................3-80
3.10.10 HEATING ROLLER THERMISTOR .......................................3-81

SM v G133
3.10.11 PRESSURE ROLLER THERMOSTAT...................................3-81
3.10.12 PRESSURE ROLLER THERMISTOR....................................3-82
3.10.13 FUSING ROLLER ONE-WAY CLUTCH AND IDLE GEAR ....3-82
When re-installing the idle gear ..........................................................3-83
3.10.14 FUSING FAN..........................................................................3-83
When installing the fusing fan .............................................................3-84
3.10.15 PAPER EXIT FAN ..................................................................3-84
When installing the paper exit fan.......................................................3-85
3.10.16 IH (INDUCTION HEATING) INVERTER FAN ........................3-85
When installing the IH inverter fan ......................................................3-85
3.10.17 THERMOPILE ........................................................................3-85
3.10.18 FUSING BELT SENSOR AND FERRITE ROLLER HP
SENSOR 3-86
3.10.19 IH COIL FAN ..........................................................................3-87
3.10.20 IH COIL UNIT.........................................................................3-88
3.11 PAPER FEED .....................................................................................3-90
3.11.1 PAPER FEED UNIT...................................................................3-90
3.11.2 PICK-UP, FEED AND SEPARATION ROLLERS.......................3-90
Tray 1 and Tray 2 ...............................................................................3-90
3.11.3 TRAY LIFT MOTOR...................................................................3-91
3.11.4 VERTICAL TRANSPORT, PAPER OVERFLOW, PAPER END
AND PAPER FEED SENSOR ..................................................................3-91
3.11.5 REGISTRATION SENSOR........................................................3-92
3.11.6 BY-PASS PAPER SIZE SENSOR SWITCH ..............................3-92
When reinstalling this switch...............................................................3-93
3.11.7 BY-PASS BOTTOM TRAY ........................................................3-93
3.11.8 BY-PASS PAPER END SENSOR..............................................3-95
3.11.9 BY-PASS PICK-UP, FEED AND SEPARATION ROLLER,
TORQUE LIMITER ...................................................................................3-96
3.11.10 BY-PASS FEED CLUTCH......................................................3-97
3.11.11 PAPER EXIT UNIT.................................................................3-97
3.11.12 FUSING EXIT, PAPER OVERFLOW, JUNCTION PAPER JAM
AND PAPER EXIT SENSOR....................................................................3-98
3.11.13 JUNCTION GATE 1 MOTOR .................................................3-99
3.12 DUPLEX UNIT ..................................................................................3-100
3.12.1 DUPLEX UNIT .........................................................................3-100
3.12.2 DUPLEX DOOR SENSOR.......................................................3-101
3.12.3 DUPLEX ENTRANCE SENSOR..............................................3-101
3.12.4 DUPLEX EXIT SENSOR .........................................................3-102
3.13 ELECTRICAL COMPONENTS .........................................................3-103
3.13.1 CONTROLLER UNIT ...............................................................3-103
3.13.2 CONTROLLER BOX RIGHT COVER ......................................3-103
3.13.3 CONTROLLER BOX................................................................3-104
When opening the controller box ......................................................3-104
When removing the controller box ....................................................3-104
3.13.4 IOB (IN/OUT BOARD) .............................................................3-106

G133 vi SM
3.13.5 EGB .........................................................................................3-106
When installing the new EGB ...........................................................3-107
3.13.6 PSU .........................................................................................3-107
PSU bracket......................................................................................3-107
PSU board ........................................................................................3-108
3.13.7 ITB POWER SUPPLY BOARD................................................3-108
3.13.8 HIGH VOLTAGE SUPPLY BOARD .........................................3-109
3.13.9 HIGH VOLTAGE SUPPLY BOARD BRACKET .......................3-109
3.13.10 IH INVERTER.......................................................................3-110
3.13.11 CONTROLLER BOARD .......................................................3-110
When installing the new controller board ..........................................3-111
3.13.12 HDD FAN .............................................................................3-112
When installing the HDD fan.............................................................3-112
3.13.13 HDD .....................................................................................3-112
Disposal of HDD Units ......................................................................3-113
3.13.14 NVRAM REPLACEMENT PROCEDURE.............................3-114
NVRAM on the EGB .........................................................................3-114
NVRAM on the Controller .................................................................3-114
When installing a new NVRAM .........................................................3-115
TROUBLESHOOTING
4. TROUBLESHOOTING..................................................................4-1
4.1 PROCESS CONTROL ERROR CONDITIONS ..........................................4-1
4.1.1 DEVELOPER INITIALIZATION RESULT ..........................................4-1
4.1.2 PROCESS CONTROL SELF-CHECK RESULT................................4-2
Vsg Adjustment Result..........................................................................4-5
4.1.3 LINE POSITION ADJUSTMENT RESULT ........................................4-6
4.2 SERVICE CALL CONDITIONS ..................................................................4-8
4.2.1 SUMMARY ........................................................................................4-8
SC Code Classification .........................................................................4-9
4.3 SC TABLE ................................................................................................4-12
4.4 TROUBLESHOOTING GUIDE .................................................................4-77
4.4.1 IMAGE QUALITY.............................................................................4-77
4.4.2 LINE POSITION ADJUSTMENT .....................................................4-78
Test.....................................................................................................4-79
Countermeasure list for color registration errors.................................4-79
4.5 JAM DETECTION.....................................................................................4-86
4.5.1 PAPER JAM DISPLAY ....................................................................4-86
4.5.2 JAM CODES AND DISPLAY CODES .............................................4-86
Paper Size Code.................................................................................4-95
Sensor Locations ................................................................................4-96
4.6 ELECTRICAL COMPONENT DEFECTS..................................................4-97
4.6.1 SENSORS.......................................................................................4-97
4.6.2 BLOWN FUSE CONDITIONS .......................................................4-102
Power Supply Unit ............................................................................4-102

SM vii G133
IH Inverter .........................................................................................4-103
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.........................................................................................5-2
Display on the Control Panel Screen ....................................................5-2
Others ...................................................................................................5-3
5.1.3 BIT SWITCH PROGRAMMING .........................................................5-4
5.2 SERVICE MODE TABLE............................................................................5-5
5.2.1 CONTROLLER SERVICE MODE......................................................5-5
5.2.2 ENGINE SERVICE MODE ..............................................................5-11
SP1-XXX (Feed) .................................................................................5-11
SP2-XXX (Drum).................................................................................5-33
SP3-XXX (Process) ..........................................................................5-154
SP5-XXX (Mode) ..............................................................................5-199
SP6-XXX (Peripherals) .....................................................................5-235
SP7-XXX (Data Log).........................................................................5-241
SP8-xxx: Data Log2 ..........................................................................5-271
SP9-XXX: Others..............................................................................5-296
5.2.3 INPUT CHECK TABLE..................................................................5-301
Copier ...............................................................................................5-301
Table 1: Paper Height Sensor...........................................................5-306
Table 2: Paper Size Switch (Tray 2) .................................................5-306
Table 3: Paper Size (By-pass Table) ................................................5-307
1000-Sheet Booklet Finisher (B793).................................................5-308
3000-Sheet Finisher (B805)..............................................................5-311
5.2.4 OUTPUT CHECK TABLE..............................................................5-314
Copier ...............................................................................................5-314
1000-Sheet Booklet Finisher (B793).................................................5-324
3000-Sheet Finisher..........................................................................5-326
5.2.5 TEST PATTERN PRINTING .........................................................5-328
5.3 FIRMWARE UPDATE.............................................................................5-330
5.3.1 TYPE OF FIRMWARE...................................................................5-330
5.3.2 BEFORE YOU BEGIN...................................................................5-331
5.3.3 UPDATING FIRMWARE ...............................................................5-331
File Arrangement ..............................................................................5-331
Update Procedure.............................................................................5-332
Error Handling...................................................................................5-333
Power Failure....................................................................................5-334

G133 viii SM
5.3.4 NVRAM DATA UPLOAD/DOWNLOAD .........................................5-334
Uploading NVRAM Data ...................................................................5-334
Downloading NVRAM Data...............................................................5-335
5.3.5 ADDRESS BOOK UPLOAD/DOWNLOAD ....................................5-336
Download..........................................................................................5-336
Upload ..............................................................................................5-336
5.3.6 HANDLING FIRMWARE UPDATE ERRORS................................5-337
Error Message Table ........................................................................5-337
5.4 SD CARD APPLI MOVE.........................................................................5-339
5.4.1 OVERVIEW ...................................................................................5-339
5.4.2 MOVE EXEC .................................................................................5-340
5.4.3 UNDO EXEC .................................................................................5-340
5.5 CONTROLLER SELF-DIAGNOSTICS ...................................................5-342
5.5.1 OVERVIEW ...................................................................................5-342
5.6 USING THE DEBUG LOG......................................................................5-343
5.6.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG............5-343
5.6.2 RETRIEVING THE DEBUG LOG FROM THE HDD......................5-346
5.6.3 DEBUG LOG CODES ...................................................................5-346
SP5857-015 Copy SD Card-to-SD Card: Any Desired Key ..............5-346
SP5857-016 Create a File on HDD to Store a Log ...........................5-346
SP5857-017 Create a File on SD Card to Store a Log .....................5-347
5.7 DIP SWITCHES......................................................................................5-348
5.7.1 CONTROLLER BOARD ................................................................5-348
Switch 1 ............................................................................................5-348
Switch 2 ............................................................................................5-348
Switch 3 ............................................................................................5-348
Switch 4 ............................................................................................5-348
5.7.2 EGB BOARD .................................................................................5-348
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.......................................................................6-5
Overview...............................................................................................6-5
6.1.5 PRINTING PROCESS.......................................................................6-6
6.2 PROCESS CONTROL................................................................................6-8
6.2.1 OVERVIEW .......................................................................................6-8
6.2.2 POTENTIAL CONTROL ....................................................................6-8
Overview...............................................................................................6-8
Process Control Self Check ..................................................................6-8
6.2.3 PROCESS CONTROL SELF CHECK PROCEDURE .....................6-10
6.2.4 TONER DENSITY ADJUSTMENT MODE.......................................6-12