Ricoh G-P2 User manual

G160 Service Manual 23-Feb-06
Model G-P2
Machine Code: G160
SERVICE MANUAL
Copyright Ricoh Company, LTD©
Feb. 24th, 2006
Subject to change

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Read This First
Safety Notices
Important Safety Notices
Prevention of Physical Injury
1. Before disassembling or assembling parts of the printer and peripherals, make
sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. If any adjustment or operation check has to be made with exterior covers off or
open while the main switch is turned on, keep hands away from electrified or
mechanically driven components.
4. The printer drives some of its components when it completes the warm-up period.
Be careful to keep hands away from the mechanical and electrical components as
the printer starts operation.
5. The inside and the metal parts of the fusing unit become extremely hot while the
printer is operating. Be careful to avoid touching those components with your bare
hands.
Health Safety Conditions
Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it
may cause temporary eye discomfort. Immediately wash eyes with plenty of water. If
unsuccessful, get medical attention.
Observance of Electrical Safety Standards
The printer and its peripherals must be serviced by a customer service representative who
has completed the training course on those models.
Lithium Batteries
Incorrect replacement of lithium battery(s) on the EGB and controller board may pose risk of
explosion. Replace only with the same type or with an equivalent type recommended by the
manufacturer. Discard used batteries in accordance with the manufacturer’s instructions.

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Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when
exposed to an open flame.
2. Dispose of used toner, the maintenance unit which includes developer or the
organic photoconductor in accordance with local regulations. (These are non-toxic
supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not put
more than 100 batteries per sealed box. Storing larger numbers or not sealing
them apart may lead to chemical reactions and heat build-up.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based
optical units in the field. The optical housing unit can only be repaired in a factory or at a
location with the requisite equipment. The laser subsystem is replaceable in the field by a
qualified Customer Engineer. The laser chassis is not repairable in the field. Customer
engineers are therefore directed to return all chassis and laser subsystems to the factory or
service depot when replacement of the optical subsystem is required.
Use of controls, or adjustment, or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
Turn off the main switch before attempting any of the procedures in the Laser Optics Housing
Unit section. Laser beams can seriously damage your eyes.
CAUTION MARKING:

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Symbols, Abbreviations, and Trademarks
Symbols and Abbreviations
This manual uses the symbols and abbreviations shown below.
Symbol Meaning
Refer to section number
Clip ring
Screw
Connector
Clamp
SEF Short Edge Feed
LEF Long Edge Feed
Trademarks
Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation
in the United States and /or other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
PCL® is a registered trademark of Hewlett-Packard Company.
Ethernet® is a registered trademark of Xerox Corporation.
PowerPC® is a registered trademark of International Business Machines Corporation.
Other product names used herein are for identification purposes only and may be trademarks
of their respective companies. We disclaim any and all rights involved with those marks.

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Table of Contents
Read This First ..................................................................................................................... ii
Safety Notices ................................................................................................................... ii
Important Safety Notices ............................................................................................... ii
LASER SAFETY............................................................................................................iii
Symbols, Abbreviations, and Trademarks ........................................................................ iv
Symbols and Abbreviations .......................................................................................... iv
Trademarks................................................................................................................... iv
Table of Contents.................................................................................................................. v
Installation Procedure ........................................................................................................... 1
Installation Requirements..................................................................................................1
Optional Unit Installation ...................................................................................................2
Preventive Maintenance .......................................................................................................3
User Replaceable Items....................................................................................................3
Service Maintenance.........................................................................................................4
Recommended Cleaning Procedure..............................................................................4
Replacement And Adjustment............................................................................................... 5
Before You Start ................................................................................................................5
Laser Optics ...................................................................................................................... 6
Caution Decal Locations................................................................................................6
LD Unit........................................................................................................................... 7
Fusing ............................................................................................................................. 10
Thermistor and Thermostat .........................................................................................10
Electrical Components ....................................................................................................13
Controller Board ..........................................................................................................13
Installing the new NVRAM ...........................................................................................14
Troubleshooting .................................................................................................................. 15
Process Control Results.................................................................................................. 15
Service Call Conditions ...................................................................................................17
Summary .....................................................................................................................17
SC Code Descriptions .................................................................................................17
Troubleshooting Guide .................................................................................................... 46
Blank Print ...................................................................................................................46
All-black Print............................................................................................................... 46
Missing CMY Color ...................................................................................................... 46

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Light Print ....................................................................................................................47
Repeated Spots or Lines on Prints ..............................................................................47
Dark Vertical Line on Prints .........................................................................................48
White Horizontal Lines or Bands ................................................................................. 48
Missing Parts of Images ..............................................................................................49
Dirty Background .........................................................................................................49
Partial CMY Color Dots................................................................................................ 49
Dark Irregular Streaks on Prints................................................................................... 49
CMY Color Irregular Streaks........................................................................................ 50
Ghosting ......................................................................................................................50
Unfused or Partially Fused Prints ................................................................................50
Image Skew.................................................................................................................51
Background Stain ........................................................................................................ 51
No Printing on Paper Edge..........................................................................................51
Image not centered when it should be......................................................................... 52
Electrical Component Defects .........................................................................................53
Sensors .......................................................................................................................53
Blown Fuse Conditions ...................................................................................................57
Power Supply Unit .......................................................................................................57
IOB .............................................................................................................................. 57
LEDs ............................................................................................................................... 58
Controller ..................................................................................................................... 58
Service Tables .................................................................................................................... 59
Service Program Mode ................................................................................................... 59
Service Mode Operation..............................................................................................59
Remarks ......................................................................................................................60
Bit Switch Programming ..............................................................................................62
Service Mode Table.........................................................................................................64
Controller Service Mode ..............................................................................................64
Engine Service Mode .................................................................................................. 68
Input Check Table......................................................................................................216
Output Check Table ...................................................................................................220
Firmware Update...........................................................................................................223
Types of Firmware ..................................................................................................... 223
Precautions................................................................................................................ 223
SD Card Application Move ............................................................................................224

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Overview....................................................................................................................224
Move Exec.................................................................................................................224
Undo Exec ................................................................................................................. 225
Keeping the SD Card................................................................................................. 226
Detailed Section Descriptions ...........................................................................................227
Beforehand.................................................................................................................... 227
Overview .......................................................................................................................228
Component Layout ....................................................................................................228
Board Structure.......................................................................................................... 229
Process Control............................................................................................................. 232
Overview....................................................................................................................232
Potential Control ........................................................................................................232
Toner Supply Control ................................................................................................. 235
Toner Near End/Toner End Detection ........................................................................ 237
Developer Initialization............................................................................................... 238
Paper Feed ...................................................................................................................239
By-pass Tray Feed and Size Detection......................................................................239
Laser Exposure ............................................................................................................. 240
LD Safety Switch .......................................................................................................240
Automatic Line Position Adjustment .......................................................................... 241
Fusing ........................................................................................................................... 245
Overview....................................................................................................................245
Fusing Temperature Control ...................................................................................... 246
Drive ..........................................................................................................................249
Controller....................................................................................................................... 250
Overview....................................................................................................................250
Board Layout .............................................................................................................252
Specifications.................................................................................................................... 253
Specifications ................................................................................................................253
General Specifications............................................................................................... 253
Supported Paper Sizes.............................................................................................. 256
Software Accessories ................................................................................................ 257
Machine Configuration...............................................................................................259

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Installation Procedure
Installation Requirements
The installation procedure for G-P2 (G160/G161) is the same as G-P1 (G104/G105). For
details, refer to the Quick Installation Guide for G-P2 (G160/G161).

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Optional Unit Installation
The following options are available for this machine. Refer to the Hardware Guide for how to
install these options:
Paper Tray Unit (G392)
HDD (G395)
IEEE802.11b Interface Unit (Wireless LAN: G813)
IEEE 1284 Interface Board (B679)
Bluetooth Interface Unit (B826)
Gigabit Ethernet Board (G874-01)
VM Card (G874-08)
USB Host Interface Unit (B825)
Data Overwrite Security Unit (G874-21)
PictBridge Interface (G874-19)
128 MB DIMM (B584)
256 MB DIMM (G818)
NVRAM (User account enhancement: G395)

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Preventive Maintenance
User Replaceable Items
The user replaces the following items if the service contract requires that the user does some
of the PM.
Item Remarks
PCU 50 KP (YMC, BK)
Transfer Belt Unit 100 KP
Waste Toner Bottle 50 KP
Maintenance Kit
Fusing Unit
Transfer Roller
Paper Feed Roller x 3
Friction Pad x 3
Dust Filter x 2
100 KP
Chart: A4 (LT), 5%
Mode: Continuously Printing
Environment: Recommended temperature and humidity
Yield changes depend on circumstances and print conditions
An error message shows when a maintenance counter gets to the value in the PM table when
the machine’s default settings are used.
It is not necessary to reset counters for each part if the technician does the PM. The machine
detects new components automatically and resets the necessary counters.

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Service Maintenance
Recommended Cleaning Procedure
1. Turn off the main switch.
2. Remove the waste toner bottle.
3. Remove the PCUs.
4. Remove the transfer belt unit. Do not touch the transfer belt surface.
5. Remove the fusing unit.
6. Remove the standard paper tray.
7. Clean the paper path.
8. Clean all printer rollers with dry cloth only.
Do not clean the transfer roller.
9. Use a blower brush to clean the laser unit windows.
10. Vacuum the interior of the printer.
11. Carefully clean the area around the transfer roller.

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Replacement And Adjustment
Before You Start
This section shows the differences between G-P1 (G104/G105) and G-P2 (G160/G161). For
other items procedures, refer to the service manual for G-P1 (G104/G105).
Turn off the main power switch and unplug the machine before you do the
procedures in this section.
Remove these before you do a removal procedure:
4 toner bottles (cyan, magenta, yellow, and black)
Waste toner bottle
Standard paper tray

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Laser Optics
Turn off the main power switch and unplug the printer before you do the procedures
in this section. Laser beams can cause serious eye injury.
Caution Decal Locations
The caution decal is attached as shown below
Make sure to turn off the main power switch and disconnect the power plug from the
power outlet before you do any disassembly or adjustment of the laser unit. This
printer uses a class 3B laser beam with a wavelength of 655 nm and an output of 7
mW. The laser can cause serious eye injury.

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LD Unit
Replacement
Print the SMC report with SP 5990 2 before you replace the LDU.
1. Electrical board unit (see the Service Manual for G-P1 (G104/G105): ‘Electrical
Components – Electrical Board Unit’)
2. LDU [A]
Color Registration Adjustment
You must manually do the color registration adjustment after you install the new
LDU.
When the polygon mirror motor or LDB unit is defective, only replace the defective
parts. At this time, if only the motor is changed it is not necessary to do this
adjustment procedure.
1. Print the SMC report with SP 5990 2 before you replace the LDU. Find the values
for SP 2181 1, SP 2181 11, 2181 21, and 2181 31.
2. Do SP 2111 2 (Pro. Position Adj > Execute) to roughly adjust the line position after
you install the new LDU. “Result = OK” shows on the LCD if this is done correctly.
If not, do it again until you get “OK”.
3. Do SP2111 3 (Skew Adjust. > Execute) to measure the skew values for each color.
“Result = OK” shows on the LCD if this is done correctly. If not, do it again until
you get “OK”.
4. Check the skew values with SP 2181: Then write down the values. (You can also
check these if you print the SMC report again with SP 5990 2. The values will

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probably be different from the values on the report that you printed in step 1.)
SP 2181 1 for black skew
SP 2181 11 for magenta
SP 2181 21 for cyan
SP 2181 31 for yellow
5. Open the left cover
6. Adjust the skew adjustment cam [A] for each color with a screwdriver. You must
adjust the skew values for each color until they are all the same as the value for
magenta that you found in step 1, before you replaced the LDU.
For example: If the new value for K (after step 4) is –300 and the old value for
magenta (in step 1) is –250, you must adjust the skew for K until it is –250.
Turn the cam as shown in the “Cam Rotation Direction” column below to increase
the skew value.
Turn it in the opposite direction from this to decrease the skew value.
“Adjustment value” shows the change when you turn the cam one click.
Color Cam Rotation
Direction
Adjustment
Value
Yellow CW 14 μm
Cyan CW 10 μm
Magenta CCW 10 μm
Black CCW 10 μm
The adjustment values in the table are not exact values. These are
approximate values.

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CW: Clockwise, CCW: Counter-clockwise
The diagram shows the effect on line skew [B] when you turn the cam in a
counter clockwise direction.
7. Close the left cover. Then measure the skew values again with SP 2111 3. (To do
this, repeat step 3.)
If these are close to the value for magenta that you found in step 1 (within one click in
the above table), go to the next step. If not, do SP 2111 3 again until you get a good
result.
8. Do SP 2111 1 to finely adjust the line position for each color.
Try SP 2111 2 if “Result = OK” does not show.
9. When you get “Result = OK”, this adjustment is completed.

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Fusing
Make sure that the fusing unit is cool before you touch it. The fusing unit can
be very hot.
Make sure to restore the insulators, shields, etc after you service the fusing
unit.
Thermistor and Thermostat
1. Front door
2. Fusing unit (see the Service Manual for G-P1 (G105/G16): ‘Fusing Unit’)
3. Fusing unit guide plate [A] ( x 4)
4. Release the connector [B] from the fusing lower cover [C] (hook x 1).
5. Fusing lower cover [C] ( x 2)

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6. Thermistor with bracket [D] ( x 2, x 1)
Do not remove the thermistor from the bracket when removing it. The pressure
of the thermistor plate to the fusing belt is adjusted properly in the factory. If you
remove it, some image problem may occur.
7. Fusing upper cover [E] ( x 4)

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8. Thermostat [F] x 2 ( x 3)
Do not recycle a thermostat that is already opened. Safety is not guaranteed if you
do this.

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Electrical Components
Before you replace the EGB (Engine Board), the controller, or the NVRAM, print
out the SMC reports (“SP Mode Data” and “Logging Data”).
After you replace the EGB (Engine Board) or the controller, remove the NVRAM
from the old board and install it on the new board. If the NVRAM on the old
board is defective, replace the NVRAM (see ‘NVRAM Replacement
Procedure’).
Controller Board
1. Controller unit [A] ( x 3)
2. Controller unit cover [B] ( x 4)