Ricoh G188 User manual

G188/G189
SERVICE MANUAL
004261MIU

G188/G189
SERVICE MANUAL

G188/G189
SERVICE MANUAL
004261MIU

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within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Americas Corporation and its member companies.
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only and for the benefit of such companies. No such use, or the use of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
©2009 RICOH Americas Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Americas 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 Americas Corporation
WARNING

LEGEND
COMPANYPRODUCT
CODE GESTETNER LANIER RICOH SAVIN
G188 C8140ND LP540C SP C820DN CLP340D
G189 C8150ND LP550C SP C821DN CLP350D
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 02/2009 Original Printing

SM i G188/G189
G188/G189
TABLE OF CONTENTS
PRODUCT INFORMATION
1. PRODUCT INFORMATION.......................................................... 1-1
1.1 SPECIFICATIONS......................................................................................1-1
1.2 MACHINE CONFIGURATION....................................................................1-2
1.3 OVERVIEW................................................................................................1-5
1.3.1 COMPONENT LAYOUT....................................................................1-5
1.3.2 PAPER PATH....................................................................................1-6
1.3.3 DRIVE LAYOUT................................................................................1-7
1.4 GUIDANCE FOR THOSE WHO ARE FAMILIAR WITH PREDECESSOR
PRODUCTS .....................................................................................................1-9
INSTALLATION
2. INSTALLATION ........................................................................... 2-1
2.1 INSTALLATION REQUIREMENTS............................................................2-1
2.1.1 ENVIRONMENT................................................................................2-1
2.1.2 MACHINE LEVEL..............................................................................2-1
2.1.3 MACHINE SPACE REQUIREMENTS...............................................2-2
2.1.4 POWER REQUIREMENTS...............................................................2-2
2.2 OPTIONAL UNIT COMBINATIONS ...........................................................2-3
2.2.1 MACHINE OPTIONS.........................................................................2-3
2.2.2 CONTROLLER OPTIONS.................................................................2-3
2.3 PRINTER INSTALLATION .........................................................................2-5
2.3.1 POWER SOCKET FOR PERIPHERAL.............................................2-5
2.3.2 INSTALLATION FLOW CHART ........................................................2-5
2.3.3 INSTALLATION PROCEDURE.........................................................2-7
Unpacking.............................................................................................2-7
Installing the Toner .............................................................................2-11
Loading Paper ....................................................................................2-11
Turning Power On...............................................................................2-13
Selecting the Panel Display Language ...............................................2-14
Printing the Test Page ........................................................................2-14
Settings Relevant to the Service Contract ..........................................2-15
Settings for @Remote Service............................................................2-15
2.3.4 METER CLICK CHARGE................................................................2-19
2.3.5 MOVING THE MACHINE................................................................2-21
2.3.6 TRANSPORTING THE MACHINE ..................................................2-21
2.4 BRIDGE UNIT (D386) ..............................................................................2-22
2.4.1 COMPONENT CHECK....................................................................2-22
2.4.2 INSTALLATION PROCEDURE.......................................................2-22

G188/G189 ii SM
2.5 1000-SHEET BOOKLET FINISHER (B793).............................................2-25
2.5.1 ACCESSORY CHECK ....................................................................2-25
2.5.2 INSTALLATION PROCEDURE.......................................................2-26
2.6 PUNCH UNIT (B807)................................................................................2-30
2.6.1 COMPONENT CHECK....................................................................2-30
2.6.2 INSTALLATION PROCEDURE.......................................................2-31
2.7 3000-SHEET FINISHER (B805)...............................................................2-36
2.7.1 ACCESSORY CHECK ....................................................................2-36
2.7.2 INSTALLATION PROCEDURE.......................................................2-37
Support Tray Installation.....................................................................2-40
2.8 PUNCH UNIT (B702)................................................................................2-41
2.8.1 COMPONENT CHECK....................................................................2-41
2.8.2 INSTALLATION PROCEDURE.......................................................2-41
2.9 OUTPUT JOGGER UNIT (B703)..............................................................2-45
2.9.1 ACCESSORIES...............................................................................2-45
2.9.2 INSTALLATION...............................................................................2-45
2.10 MAIL BIN (G835) ................................................................................2-47
2.10.1 COMPONENT CHECK..............................................................2-47
2.10.2 INSTALLATION PROCEDURE..................................................2-48
2.11 TRAY HEATER (STANDARD TRAY).................................................2-54
2.11.1 INSTALLATION PROCEDURE..................................................2-54
2.12 TRAY HEATER (OPTIONAL TRAY)...................................................2-55
2.12.1 COMPONENT CHECK..............................................................2-55
2.12.2 INSTALLATION PROCEDURE..................................................2-55
For installing the tray heater in the D351 (Two-tray paper feed unit)..2-56
For installing the tray heater in the D352 (LCT)..................................2-58
For installing the tray heater in the D387 (Paper tray unit)..................2-61
2.13 CONTROLLER OPTIONS..................................................................2-65
2.13.1 OVERVIEW ...............................................................................2-65
I/F Card Slots......................................................................................2-65
SD Card Slots.....................................................................................2-65
2.13.2 SD CARD APPLI MOVE............................................................2-66
Overview.............................................................................................2-66
Outline of SD Card Appli Move...........................................................2-66
Move Exec..........................................................................................2-67
Undo Exec..........................................................................................2-67
PREVENTIVE MAINTENANCE
3. PREVENTIVE MAINTENANCE.................................................... 3-1
3.1 MAINTENANCE ITEMS..............................................................................3-1
REPLACEMENT AND ADJUSTMENT
4. REPLACEMENT AND ADJUSTMENT ........................................ 4-1
4.1 BEFOREHAND...........................................................................................4-1

SM iii G188/G189
4.2 SPECIAL TOOLS .......................................................................................4-2
4.3 IMAGE ADJUSTMENT...............................................................................4-3
4.3.1 REGISTRATION................................................................................4-3
Image Area...........................................................................................4-3
Leading Edge........................................................................................4-3
Side to Side ..........................................................................................4-3
Adjustment Standard ............................................................................4-3
Paper Registration Standard.................................................................4-3
Adjustment Procedure ..........................................................................4-3
4.3.2 ERASE MARGIN ADJUSTMENT......................................................4-4
4.3.3 COLOR REGISTRATION..................................................................4-5
Line Position Adjustment ......................................................................4-5
4.3.4 GAMMA ADJUSTMENT....................................................................4-6
Summary ..............................................................................................4-6
Adjustment Procedure ..........................................................................4-7
4.4 EXTERIOR COVERS...............................................................................4-10
4.4.1 FRONT DOOR ................................................................................4-10
4.4.2 LEFT COVER..................................................................................4-11
4.4.3 REAR COVER.................................................................................4-11
4.4.4 TOP RIGHT AND REAR COVER....................................................4-12
4.4.5 RIGHT REAR COVER.....................................................................4-12
4.4.6 OPERATION PANEL.......................................................................4-13
4.4.7 PAPER EXIT COVER......................................................................4-13
4.4.8 OUTPUT TRAY...............................................................................4-13
4.4.9 OZONE FILTER ..............................................................................4-14
Ozone filter for charge unit..................................................................4-14
Ozone filter for IH inverter...................................................................4-15
4.5 LASER OPTICS .......................................................................................4-16
4.5.1 CAUTION DECAL LOCATION........................................................4-16
4.5.2 LASER OPTICS HOUSING UNIT ...................................................4-16
Preparing the new laser optics housing unit .......................................4-17
Before removing the old laser optics housing unit ..............................4-17
Recovery procedure for no replacement preparation of laser optics
housing unit ........................................................................................4-17
Removing the old laser optics housing unit.........................................4-18
Installing a new Laser Optics Housing Unit.........................................4-19
After installing the new laser optics housing unit ................................4-20
4.5.3 POLYGON MIRROR MOTOR AND DRIVE BOARD.......................4-21
4.6 IMAGE CREATION ..................................................................................4-23
4.6.1 PCU.................................................................................................4-23
4.6.2 SECOND DUCT FAN......................................................................4-24
When reinstalling the second duct fan................................................4-25
4.6.3 THIRD DUCT FAN ..........................................................................4-25
When reinstalling the third duct fan.....................................................4-26
4.6.4 TONER PUMP UNIT.......................................................................4-26
When you install the new toner pump unit..........................................4-29
4.6.5 TONER END SENSOR...................................................................4-31
4.7 IMAGE TRANSFER..................................................................................4-33
4.7.1 IMAGE TRANSFER BELT UNIT .....................................................4-33

G188/G189 iv SM
4.7.2 IMAGE TRANSFER BELT CLEANING UNIT..................................4-33
4.7.3 IMAGE TRANSFER BELT...............................................................4-34
When reinstalling the image transfer belt............................................4-37
4.8 PAPER TRANSFER.................................................................................4-40
4.8.1 PAPER TRANSFER ROLLER UNIT ...............................................4-40
4.8.2 PAPER TRANSFER UNIT...............................................................4-40
4.8.3 HIGH VOLTAGE SUPPLY BOARD – DISCHARGE PLATE...........4-41
4.8.4 ID SENSOR BOARD.......................................................................4-42
Cleaning for ID sensors ......................................................................4-43
After installing a new ID sensor unit/board..........................................4-44
4.8.5 TEMPERATURE AND HUMIDITY SENSOR ..................................4-44
4.9 DRIVE UNIT.............................................................................................4-45
4.9.1 GEAR UNIT.....................................................................................4-45
When installing the drive unit..............................................................4-50
Adjustment after replacing the gear unit .............................................4-50
4.9.2 REGISTRATION MOTOR...............................................................4-50
4.9.3 PAPER FEED MOTOR ...................................................................4-51
4.9.4 DRUM/DEVELOPMENT MOTORS FOR M, C, AND Y...................4-52
4.9.5 DRUM/DEVELOPMENT MOTOR-K................................................4-52
4.9.6 ITB DRIVE MOTOR.........................................................................4-53
4.9.7 FUSING/PAPER EXIT MOTOR ......................................................4-53
4.9.8 IMAGE TRANSFER BELT CONTACT MOTOR..............................4-54
4.9.9 DUPLEX INVERTER MOTOR.........................................................4-54
4.9.10 PRESSURE ROLLER CONTACT MOTOR ...............................4-56
4.9.11 DUPLEX/BY-PASS MOTOR......................................................4-56
4.9.12 PAPER TRANSFER CONTACT MOTOR..................................4-58
4.9.13 TONER TRANSPORT MOTOR.................................................4-59
4.9.14 TONER COLLECTION UNIT.....................................................4-59
4.9.15 PAPER FEED CLUTCHES........................................................4-60
4.9.16 DEVELOPMENT CLUTCH-Y.....................................................4-63
4.9.17 DEVELOPMENT CLUTCHES FOR M AND C...........................4-64
4.9.18 DEVELOPMENT CLUTCH-K.....................................................4-65
4.10 FUSING..............................................................................................4-66
4.10.1 FUSING UNIT............................................................................4-66
4.10.2 HEATING ROLLER AND HEATING ROLLER BEARING..........4-67
When re-installing the heating roller....................................................4-71
4.10.3 FUSING CLEANING FELT........................................................4-71
When attaching a new fusing cleaning felt..........................................4-72
4.10.4 FUSING LAMP...........................................................................4-72
4.10.5 FUSING DRIVE GEAR..............................................................4-74
4.10.6 PRESSURE ROLLER AND PRESSURE ROLLER BEARING ..4-74
When re-installing the pressure roller .................................................4-76
4.10.7 HEATING ROLLER THERMISTOR...........................................4-77
4.10.8 PRESSURE ROLLER THERMOSTAT......................................4-78
4.10.9 PRESSURE ROLLER THERMISTOR.......................................4-78
4.10.10 BEARING GEAR AND IDLE GEAR .......................................4-79
4.10.11 FUSING FAN..........................................................................4-79
When installing the fusing fan.............................................................4-80
4.10.12 PAPER EXIT FAN..................................................................4-80

SM v G188/G189
When installing the paper exit fan.......................................................4-81
4.10.13 IH (INDUCTION HEATING) INVERTER FAN ........................4-81
When installing the IH inverter fan......................................................4-81
4.10.14 THERMOPILE........................................................................4-81
When cleaning the lens of the thermopile...........................................4-83
4.10.15 PRESSURE ROLLER HP SENSOR......................................4-84
4.10.16 IH COIL FAN..........................................................................4-85
4.10.17 IH COIL UNIT.........................................................................4-86
4.11 PAPER FEED.....................................................................................4-89
4.11.1 PAPER FEED UNIT...................................................................4-89
4.11.2 PICK-UP, FEED AND SEPARATION ROLLERS.......................4-90
Tray 1 and Tray 2 ...............................................................................4-90
4.11.3 TRAY LIFT MOTOR...................................................................4-90
4.11.4 VERTICAL TRANSPORT, PAPER OVERFLOW, PAPER END
AND PAPER FEED SENSORS................................................................4-91
4.11.5 REGISTRATION SENSOR........................................................4-92
4.11.6 BY-PASS PAPER SIZE SENSOR AND BY-PASS PAPER
LENGTH SENSOR...................................................................................4-92
When reinstalling this switch...............................................................4-93
4.11.7 BY-PASS BOTTOM TRAY ........................................................4-94
4.11.8 BY-PASS PAPER END SENSOR..............................................4-96
4.11.9 BY-PASS PICK-UP, FEED AND SEPARATION ROLLER,
TORQUE LIMITER...................................................................................4-97
4.11.10 BY-PASS FEED CLUTCH......................................................4-98
4.11.11 PAPER EXIT UNIT.................................................................4-98
4.11.12 FUSING EXIT, PAPER OVERFLOW, JUNCTION PAPER JAM
AND PAPER EXIT SENSORS .................................................................4-99
4.12 DUPLEX UNIT..................................................................................4-100
4.12.1 DUPLEX UNIT.........................................................................4-100
4.12.2 DUPLEX DOOR SENSOR.......................................................4-101
4.12.3 DUPLEX ENTRANCE SENSOR..............................................4-102
4.12.4 DUPLEX EXIT SENSOR .........................................................4-102
4.13 ELECTRICAL COMPONENTS.........................................................4-104
4.13.1 CONTROLLER UNIT...............................................................4-104
4.13.2 CONTROLLER BOX RIGHT COVER......................................4-104
4.13.3 CONTROLLER BOX................................................................4-104
When opening the controller box ......................................................4-104
When removing the controller box ....................................................4-105
4.13.4 IOB (IN/OUT BOARD) .............................................................4-106
4.13.5 BCU.........................................................................................4-107
When installing the new BCU ...........................................................4-107
4.13.6 PSU .........................................................................................4-108
PSU bracket......................................................................................4-108
PSU board........................................................................................4-108
4.13.7 ITB POWER SUPPLY BOARD................................................4-109
4.13.8 HIGH VOLTAGE SUPPLY BOARD.........................................4-109
4.13.9 HIGH VOLTAGE SUPPLY BOARD BRACKET .......................4-110
4.13.10 IH INVERTER.......................................................................4-110
4.13.11 CONTROLLER BOARD.......................................................4-111

G188/G189 vi SM
When installing the new controller board..........................................4-112
4.13.12 HDD FAN .............................................................................4-113
When installing the HDD fan.............................................................4-113
4.13.13 HDD .....................................................................................4-113
Disposal of HDD Units......................................................................4-114
Reinstallation....................................................................................4-114
4.13.14 NVRAM REPLACEMENT PROCEDURE.............................4-114
NVRAM on the BCU .........................................................................4-114
NVRAM on the Controller .................................................................4-115
4.14 USING DIP SWITCHES....................................................................4-116
4.14.1 CONTROLLER BOARD...........................................................4-116
4.14.2 BCU BOARD ...........................................................................4-116
SYSTEM MAINTENANCE REFERENCE
5. SYSTEM MAINTENANCE REFERENCE .................................... 5-1
5.1 SERVICE PROGRAM MODE.....................................................................5-1
5.1.1 SP TABLES.......................................................................................5-1
5.1.2 SERVICE MODE OPERATION.........................................................5-1
Accessing the Required Program .........................................................5-1
Inputting a Value or Setting for a Service Program...............................5-2
Exiting Service Mode............................................................................5-2
5.1.3 REMARKS.........................................................................................5-2
Display on the Control Panel Screen....................................................5-2
Others...................................................................................................5-3
5.1.4 BIT SWITCH PROGRAMMING.........................................................5-3
5.2 FIRMWARE UPDATE.................................................................................5-5
5.2.1 BEFORE YOU BEGIN.......................................................................5-5
5.2.2 UPDATING FIRMWARE ...................................................................5-5
File Arrangement ..................................................................................5-5
Update Procedure.................................................................................5-6
Error Handling.......................................................................................5-8
Power Failure........................................................................................5-8
5.2.3 HANDLING FIRMWARE UPDATE ERRORS....................................5-8
Error Message Table ............................................................................5-8
5.3 CONTROLLER SELF-DIAGNOSTICS .....................................................5-10
5.3.1 OVERVIEW.....................................................................................5-10
5.4 NVRAM DATA UPLOAD/DOWNLOAD ....................................................5-11
5.4.1 UPLOADING NVRAM DATA...........................................................5-11
5.4.2 DOWNLOADING NVRAM DATA.....................................................5-12
5.5 USING THE DEBUG LOG........................................................................5-13
5.5.1 SWITCHING ON AND SETTING UP SAVE DEBUG LOG..............5-13
5.5.2 RETRIEVING THE DEBUG LOG FROM THE HDD........................5-16
5.5.3 DEBUG LOG CODES .....................................................................5-16
SP5857-015 Copy SD Card-to-SD Card: Any Desired Key................5-16
SP5857-016 Create a File on HDD to Store a Log .............................5-16
SP5857-017 Create a File on SD Card to Store a Log .......................5-17

SM vii G188/G189
TROUBLESHOOTING
6. TROUBLESHOOTING ................................................................. 6-1
6.1 SERVICE CALL CONDITIONS ..................................................................6-1
6.2 PROCESS CONTROL ERROR CONDITIONS..........................................6-2
6.3 TROUBLESHOOTING GUIDE...................................................................6-3
6.3.1 IMAGE PROBLEMS..........................................................................6-3
Stain on the outputs..............................................................................6-3
6.4 JAM DETECTION.......................................................................................6-4
6.5 ELECTRICAL COMPONENT DEFECTS....................................................6-5
G188/G189 APPENDICES
SEE APPENDIX SECTION FOR DETAILED TABLE OF CONTENTS
B793 BOOKLET FINISHER SR3000
SEE SECTION B793 FOR DETAILED TABLE OF CONTENTS
B804/B805 BOOKLET FINISHER SR3020/SR3030
SEE SECTION B804/B805 FOR DETAILED TABLE OF CONTENTS
D351 PAPER FEED UNIT PB3040
SEE SECTION D351 FOR DETAILED TABLE OF CONTENTS
D352 LCIT PB3050
SEE SECTION D352 FOR DETAILED TABLE OF CONTENTS
D386 BRIDGE UNIT BU3030
SEE SECTION D386 FOR DETAILED TABLE OF CONTENTS
D387 PAPER FEED UNIT PB3080
SEE SECTION D387 FOR DETAILED TABLE OF CONTENTS
G835 MAIL BIN TYPE C820
SEE SECTION G835 FOR DETAILED TABLE OF CONTENTS