Ricoh G147 User manual

G147
SERVICE MANUAL
002813MIU

G147
SERVICE MANUAL

G147
SERVICE MANUAL
002813MIU

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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
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WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G147 P7245 LP145n Aficio SP 8100DN MLP145
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 09/2006 Original Printing

SM i G147
G147
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION ....................................................................... 1-1
1.1 CAUTIONS ............................................................................................1-1
1.2 INSTALLATION REQUIREMENTS .......................................................1-2
1.2.1 ENVIRONMENT...........................................................................1-2
1.2.2 MACHINE LEVEL.........................................................................1-2
1.2.3 MINIMUM SPACE REQUIREMENTS ..........................................1-2
1.2.4 POWER REQUIREMENTS ..........................................................1-3
1.3 MAIN MACHINE INSTALLATION..........................................................1-4
1.3.1 INSTALLATION OVERVIEW........................................................1-4
1.3.2 INSTALLATION FLOWCHART ....................................................1-5
1.4 LCT (B543) ............................................................................................1-6
1.4.1 ACCESSORY CHECK: LCT.........................................................1-6
1.4.2 INSTALLATION PROCEDURE: LCT ...........................................1-6
1.5 BRIDGE UNIT (B538)............................................................................1-9
1.5.1 ACCESSORY CHECK: BRIDGE UNIT ........................................1-9
1.5.2 INSTALLATION PROCEDURE: BRIDGE UNIT ...........................1-9
1.6 TWO-TRAY FINISHER (G838)............................................................1-13
1.6.1 ACCESSORY CHECK: TWO TRAY FINISHER.........................1-13
1.6.2 INSTALLATION PROCEDURE: TWO-TRAY FINISHER ...........1-13
1.7 PUNCH UNIT (B377)...........................................................................1-17
1.7.1 ACCESSORY CHECK: PUNCH UNIT .......................................1-17
1.7.2 INSTALLATION PROCEDURE: PUNCH UNIT ..........................1-17
1.8 DATA OVERWRITE SECURITY UNIT (B735) ....................................1-21
1.8.1 BEFORE YOU BEGIN… ............................................................1-21
1.8.2 SEAL CHECK AND REMOVAL..................................................1-21
1.8.3 INSTALLATION PROCEDURE: DOS UNIT ...............................1-22
1.9 CONTROLLER OPTIONS...................................................................1-24
1.9.1 BOARDS AND SLOTS ...............................................................1-24
1.9.2 INSTALLING SD CARDS ...........................................................1-25
1.9.3 MERGING APPLICATIONS ON ONE SD CARD .......................1-26
1.9.4 INSTALLING CONTROLLER OPTIONS ....................................1-28
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE ............................................... 2-1
2.1 PM TABLES ..........................................................................................2-1
2.1.1 PM TABLES FOR THE PRINTER ................................................2-1
2.1.2 PM TABLES FOR OPTIONS........................................................2-4

G147 ii SM
2.2 LUBRICATION ......................................................................................2-6
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT.................................... 3-1
3.1 PRECAUTIONS.....................................................................................3-1
3.1.1 GENERAL PRECAUTIONS .........................................................3-1
3.1.2 LASER UNIT PRECAUTIONS .....................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS ..................................................3-2
3.2.1 SPECIAL TOOLS .........................................................................3-2
3.2.2 LUBRICANTS...............................................................................3-2
3.3 COVERS AND COMMON PROCEDURES ...........................................3-3
3.3.1 FRONT DOOR .............................................................................3-3
3.3.2 DUPLEX UNIT..............................................................................3-3
3.3.3 RIGHT UPPER COVER ...............................................................3-4
3.3.4 BY-PASS TRAY UNIT ..................................................................3-5
3.3.5 REAR COVERS ...........................................................................3-5
3.3.6 LEFT COVERS.............................................................................3-6
3.4 OPERATION PANEL.............................................................................3-7
3.5 PAPER OUTPUT TRAY ........................................................................3-8
3.6 LASER UNIT .......................................................................................3-10
3.6.1 CAUTION DECAL LOCATIONS.................................................3-10
3.6.2 LASER UNIT REMOVAL............................................................3-10
3.6.3 POLYGON MIRROR MOTOR....................................................3-12
3.6.4 LASER SYNCHRONIZATION DETECTOR ...............................3-13
3.6.5 LD UNIT .....................................................................................3-13
3.7 PCDU ..................................................................................................3-16
3.7.1 PHOTOCONDUCTOR CLEANING/DEVELOPMENT UNIT.......3-16
3.7.2 DRUM.........................................................................................3-17
3.7.3 PICK-OFF PAWLS .....................................................................3-19
3.7.4 CHARGE ROLLER AND CLEANING ROLLER..........................3-20
3.7.5 DRUM CLEANING BLADE.........................................................3-21
3.7.6 ID SENSOR................................................................................3-22
3.8 DEVELOPMENT .................................................................................3-23
3.8.1 DEVELOPMENT UNIT ...............................................................3-23
3.8.2 DEVELOPMENT FILTER ...........................................................3-24
3.8.3 DEVELOPMENT ROLLER .........................................................3-24
3.8.4 DEVELOPER .............................................................................3-25
3.8.5 TD SENSOR ..............................................................................3-27
3.9 TRANSFER UNIT................................................................................3-28
3.9.1 TRANSFER BELT UNIT.............................................................3-28
3.9.2 TRANSFER BELT ......................................................................3-29
3.9.3 TRANSFER BELT CLEANING BLADE AND TONER OVERFLOW
SENSOR .............................................................................................3-30
3.10 PAPER FEED..................................................................................3-31
3.10.1 PICK-UP, SEPARATION, AND FEED ROLLERS ....................3-31

SM iii G147
3.10.2 LOWER RIGHT COVER ..........................................................3-31
3.10.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED
CLUTCHES .........................................................................................3-32
3.10.4 UPPER PAPER FEED UNIT FOR TRAY 1 ..............................3-33
3.10.5 LOWER PAPER FEED UNIT FOR TRAY 2 .............................3-34
3.10.6 PAPER END/PAPER HEIGHT/RELAY SENSORS..................3-35
3.10.7 REGISTRATION SENSOR ......................................................3-35
3.10.8 TRAY LIFT MOTOR .................................................................3-38
3.10.9 FEED/DEVELOPMENT MOTOR..............................................3-39
3.10.10 IDLE ROLLER DUST BLADE.................................................3-40
3.10.11 REGISTRATION ROLLER DUST BLADE ..............................3-40
3.11 FUSING UNIT..................................................................................3-42
3.11.1 FUSING UNIT REMOVAL ........................................................3-42
3.11.2 FUSING UNIT EXIT GUIDE .....................................................3-43
3.11.3 HOT ROLLER STRIPPERS .....................................................3-43
3.11.4 FUSING LAMPS.......................................................................3-44
3.11.5 THERMISTORS AND THERMOSTATS...................................3-45
3.11.6 HOT ROLLER/PRESSURE ROLLER.......................................3-46
3.12 BY-PASS TRAY ..............................................................................3-49
3.12.1 COVERS ..................................................................................3-49
3.12.2 BY-PASS PAPER FEED AND PICK-UP ROLLER REPLACEMENT
.................................................................................................3-49
3.12.3 BY-PASS SEPARATION ROLLER...........................................3-50
3.12.4 PAPER END SENSOR, PICK-UP SOLENOID.........................3-51
3.12.5 PAPER SIZE SENSOR BOARD ..............................................3-52
3.12.6 BY-PASS TABLE REMOVAL ...................................................3-53
3.12.7 PAPER FEED CLUTCH ...........................................................3-54
3.13 DUPLEX UNIT.................................................................................3-55
3.13.1 DUPLEX COVER REMOVAL...................................................3-55
3.13.2 DUPLEX ENTRANCE SENSOR ..............................................3-55
3.13.3 DUPLEX EXIT SENSOR ..........................................................3-56
3.14 DRIVE MECHANISMS ....................................................................3-57
3.14.1 REGISTRATION CLUTCH, TRANSFER BELT CONTACT
CLUTCH..............................................................................................3-57
3.14.2 MAIN MOTOR ..........................................................................3-59
3.14.3 FUSING/EXIT MOTOR.............................................................3-60
3.14.4 TONER SUPPLY MOTOR .......................................................3-61
3.15 BOARDS .........................................................................................3-63
3.15.1 NVRAM ....................................................................................3-63
3.15.2 HVPS........................................................................................3-67
3.15.3 IOB ...........................................................................................3-67
3.15.4 BICU BOARD ...........................................................................3-68
3.15.5 PSU ..........................................................................................3-69
3.15.6 HDD AND CONTROLLER BOARD ..........................................3-69
3.16 PARALLELOGRAM IMAGE ADJUSTMENT ...................................3-71

G147 iv SM
TROUBLESHOOTING
4. TROUBLESHOOTING............................................................. 4-1
4.1 SERVICE CALL CONDITIONS .............................................................4-1
SC CODE DESCRIPTIONS ..................................................................4-1
4.2 ELECTRICAL COMPONENT DEFECTS.............................................4-35
4.2.1 SENSORS..................................................................................4-35
4.2.2 SWITCHES ................................................................................4-36
4.2.3 BLOWN FUSE CONDITIONS (PSU)..........................................4-37
4.2.4 BICU LEDS ................................................................................4-37
4.2.5 CONTROLLER BOARD TEST POINTS.....................................4-37
SERVICE TABLES
5. SERVICE TABLES .................................................................. 5-1
5.1 SERVICE PROGRAM MODE OPERATION..........................................5-1
5.1.1 GENERAL NOTES.......................................................................5-1
5.1.2 ENTERING AND LEAVING THE SERVICE PROGRAM MODE..5-1
5.1.3 PRINTER CONTROLLER SERVICE MODE................................5-2
5.1.4 PRINTER ENGINE SERVICE MODE...........................................5-4
5.1.5 LEAVING THE SP MODE ............................................................5-5
5.2 SERVICE PROGRAM MODE TABLES.................................................5-6
5.2.1 SERVICE TABLE KEY .................................................................5-6
5.2.2 SERVICE TABLES.......................................................................5-6
5.3 TEST PATTERN PRINTING................................................................5-91
5.3.1 SELECTING THE TEST PATTERN ...........................................5-91
5.3.2 PRINTING THE TEST PATTERN ..............................................5-92
5.3.3 SP2902-03 PRINTING TEST PATTERNS .................................5-93
5.4 INPUT CHECK ....................................................................................5-95
5.5 OUTPUT CHECK ..............................................................................5-102
5.6 MEMORY CLEAR: SP5801...............................................................5-106
5.7 SMC REPORT...................................................................................5-108
5.8 UPDATING THE FIRMWARE ...........................................................5-110
5.8.1 SETTING THE MACHINE IN FIRMWARE UPDATE MODE ....5-110
5.8.2 REVIEWING THE MODULE STATUSES.................................5-110
5.8.3 HOW TO UPDATE A MODULE................................................5-111
5.8.4 PRINTING THE SELF-DIAGNOSIS REPORT .........................5-113
5.9 UPLOADING/DOWNLOADING NVRAM DATA.................................5-115
5.9.1 UPLOADING NVRAM DATA....................................................5-115
5.9.2 DOWNLOADING NVRAM DATA..............................................5-116
5.10 SELF-DIAGNOSTIC MODE ..........................................................5-118
5.10.1 SELF-DIAGNOSTIC MODE AT POWER ON.........................5-118
5.10.2 SELF-DIAGNOSTIC TEST FLOW..........................................5-119
5.10.3 DETAILED SELF-DIAGNOSTIC MODE.................................5-119
5.11 DIP SWITCHES.............................................................................5-121
5.11.1 CONTROLLER: DIP SW2 ......................................................5-121

SM v G147
5.11.2 I/O BOARD: DIP SW101 ........................................................5-121
5.12 USING DEBUG LOG.....................................................................5-122
5.12.1 SETTING UP "SAVE DEBUG LOG".......................................5-122
5.12.2 RETRIEVING THE DEBUG LOG FROM THE HDD...............5-128
5.12.3 MORE ABOUT DEBUG LOG .................................................5-128
DETAILED DESCRIPTIONS
6. DETAILED DESCRIPTIONS ................................................... 6-1
6.1 MACHINE OVERVIEW..........................................................................6-1
6.1.1 COMPONENT LAYOUT...............................................................6-1
6.1.2 PAPER PATH...............................................................................6-3
6.1.3 DRIVE LAYOUT ...........................................................................6-4
6.2 BOARD LAYOUT ..................................................................................6-5
6.2.1 BOARD BLOCK DIAGRAM..........................................................6-5
6.2.2 CONTROLLER BLOCK DIAGRAM ..............................................6-7
6.3 PRINTING PROCESS OVERVIEW.....................................................6-10
6.4 LASER EXPOSURE............................................................................6-12
6.4.1 LASER EXPOSURE OVERVIEW...............................................6-12
6.4.2 AUTO POWER CONTROL (APC)..............................................6-13
6.4.3 DUAL-BEAM WRITING ..............................................................6-13
6.4.4 LASER BEAM PITCH CHANGE MECHANISM..........................6-14
6.4.5 LD SAFETY SWITCHES ............................................................6-15
6.5 PHOTOCONDUCTOR UNIT (PCDU)..................................................6-16
6.5.1 OVERVIEW OF THE PCDU.......................................................6-16
6.5.2 DRUM DRIVE MECHANISM......................................................6-17
6.5.3 DRUM PAWLS ...........................................................................6-17
6.5.4 DRUM TONER SEALS...............................................................6-18
6.5.5 NEW PCDU UNIT DETECTION.................................................6-18
6.6 DRUM CHARGE .................................................................................6-21
6.6.1 OVERVIEW OF DRUM CHARGE ..............................................6-21
6.6.2 CHARGE ROLLER VOLTAGE CORRECTION..........................6-22
6.6.3 ID SENSOR PATTERN PRODUCTION TIMING........................6-23
6.6.4 DRUM CHARGE ROLLER CLEANING......................................6-25
6.7 DEVELOPMENT .................................................................................6-26
6.7.1 OVERVIEW OF DEVELOPMENT ..............................................6-26
6.7.2 DRIVE MECHANISM..................................................................6-27
6.7.3 DEVELOPER MIXING................................................................6-27
6.7.4 DEVELOPMENT BIAS ...............................................................6-28
6.7.5 TONER SUPPLY........................................................................6-29
6.7.6 TONER NEAR END/END DETECTION .....................................6-32
6.7.7 TONER END RECOVERY .........................................................6-32
6.7.8 TONER SUPPLY WITH ABNORMAL SENSORS ......................6-33
6.8 DRUM CLEANING AND TONER RECYCLING...................................6-34
6.8.1 DRUM CLEANING .....................................................................6-34
6.8.2 TONER RECYCLING .................................................................6-35

G147 vi SM
6.9 PAPER FEED......................................................................................6-36
6.9.1 OVERVIEW OF PAPER FEED ..................................................6-36
6.9.2 PAPER FEED DRIVE.................................................................6-37
6.9.3 PICK-UP AND SEPARATION ROLLER RELEASE MECHANISM....
...................................................................................................6-37
6.9.4 PAPER LIFT...............................................................................6-38
6.9.5 PAPER END DETECTION .........................................................6-39
6.9.6 PAPER REGISTRATION ...........................................................6-40
6.9.7 PAPER SIZE DETECTION.........................................................6-40
6.9.8 PAPER HEIGHT DETECTION ...................................................6-42
6.10 BY-PASS TRAY ..............................................................................6-43
6.10.1 OVERVIEW OF BY-PASS TRAY .............................................6-43
6.10.2 BY-PASS TRAY OPERATION .................................................6-44
6.10.3 BY-PASS PAPER SIZE DETECTION ......................................6-45
6.11 DUPLEX UNIT.................................................................................6-46
6.11.1 OVERVIEW OF DUPLEX UNIT ...............................................6-46
6.11.2 DUPLEX DRIVE LAYOUT........................................................6-47
DUPLEX BASIC OPERATION ............................................................6-47
6.11.3 DUPLEX UNIT FEED IN AND EXIT MECHANISM ..................6-48
6.12 IMAGE TRANSFER AND PAPER SEPARATION ...........................6-50
6.12.1 OVERVIEW OF TRANSFER AND SEPARATION ...................6-50
6.12.2 TRANSFER BELT DRIVE MECHANISM .................................6-51
6.12.3 TRANSFER BELT UNIT CONTACT MECHANISM..................6-52
6.12.4 IMAGE TRANSFER AND PAPER SEPARATION MECHANISM ....
.................................................................................................6-53
6.12.5 TRANSFER BELT CHARGE....................................................6-54
6.12.6 TRANSFER BELT CLEANING MECHANISM ..........................6-56
6.13 IMAGE FUSING AND PAPER EXIT................................................6-57
6.13.1 OVERVIEW IMAGE FUSING AND PAPER EXIT.....................6-57
6.13.2 FUSING DRIVE........................................................................6-58
6.13.3 FUSING DRIVE RELEASE MECHANISM................................6-58
6.13.4 FUSING ENTRANCE GUIDE SHIFT MECHANISM.................6-59
6.13.5 EXIT GUIDE PLATE AND DE-CURLER ROLLERS.................6-60
6.13.6 PRESSURE ROLLER ..............................................................6-60
6.13.7 CLEANING MECHANISM ........................................................6-61
6.13.8 FUSING TEMPERATURE........................................................6-61
6.14 ENERGY SAVE MODE ...................................................................6-64
SPECIFICATIONS
7. SPECIFICATIONS ................................................................... 7-1
7.1 PRINTER...............................................................................................7-1
7.1.1 PRINTER HARDWARE SPECIFICATIONS .................................7-1
7.1.2 SUPPORTED PAPER SIZES.......................................................7-4
7.1.3 SOFTWARE ACCESSORIES ......................................................7-6
7.1.4 SYSTEM CONFIGURATION........................................................7-7

SM vii G147
7.1.5 INSTALLABLE OPTION TABLE...................................................7-8
7.2 OPTION SPECIFICATIONS ..................................................................7-9
7.2.1 BRIDGE UNIT TYPE 2045 (B538) ...............................................7-9
7.2.2 FINISHER 3000 SR3040 (G838)..................................................7-9
7.2.3 LCIT RT45 (B543) ......................................................................7-10
7.2.4 PAPER FEED UNIT PB3020 (G839)..........................................7-11
PUNCH UNIT B377
SEE SECTION B377 FOR DETAILED TABLE OF CONTENTS
BRIDGE UNIT B538
SEE SECTION B538 FOR DETAILED TABLE OF CONTENTS
LARGE CAPACITY TRAY B543
SEE SECTION B543 FOR DETAILED TABLE OF CONTENTS
FINISHER G838
SEE SECTION G838 FOR DETAILED TABLE OF CONTENTS
PAPER TRAY UNIT G839
SEE SECTION G839 FOR DETAILED TABLE OF CONTENTS