Ricoh G031 User manual

®
SERVICE MANUAL
000832MIU
G031/G032/G049/G054
®
RICOH GROUP COMPANIES

SERVICE MANUAL
G031/G032/G049/G054
RICOH GROUP COMPANIES
®
®

G031/G032/G049/G054
SERVICE MANUAL
000832MIU

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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.
2000 RICOH Corporation. All rights reserved.

The Service Manual contains informatio
n
regarding service techniques, procedures,
processes and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of thi
s
manual should be either service trained o
r
certified by successfully completing a Rico
h
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual t
o
repair or modify Ricoh equipment risk persona
l
injury, damage to property. or loss of warrant
y
protection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
G031 P7020 AP2000 SLP20
G032 P7014 AP1400 SLP14
G049 P7021 AP2100 SLP21
G054 P7016 AP1600 SLP16
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*5/99 Original Printing
4/2000 G049/G054 Addition
Rev. 7/2000

SM i G031/G032/G049/G054
TABLE OF CONTENTS
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS.....................................................................................1-1
1.2 MACHINE CONFIGURATION ...................................................................1-5
1.3 PAPER PATH............................................................................................1-6
1.4 MECHANICAL COMPONENT LAYOUT....................................................1-7
1.5 ELECTRICAL COMPONENT LAYOUT .....................................................1-8
1.6 ELECTRICAL COMPONENT DESCRIPTIONS ......................................1-10
1.7 PRINTING PROCESS.............................................................................1-12
1.8 BOARD STRUCTURE.............................................................................1-14
1.8.1 OVERVIEW ....................................................................................1-14
1.8.2 MAJOR COMPONENTS ................................................................1-15
1.9 COMPARISON ........................................................................................1-16
DETAILED DESCRIPTIONS
2. DETAILED SECTION DESCRIPTIONS ...................................... 2-1
2.1 PRINTING .................................................................................................2-1
2.1.1 IMAGE DATA PATH .........................................................................2-1
2.1.2 PRINTER CONTROL BOARD..........................................................2-2
2.1.3 IMAGE DATA PROCESSIING..........................................................2-3
2.1.4 HOST INTERFACE ..........................................................................2-4
2.2 LASER EXPOSURE ..................................................................................2-5
2.2.1 OVERVIEW ......................................................................................2-5
2.2.2 OPTICAL PATH................................................................................2-6
2.2.3 AUTO POWER CONTROL (APC) ....................................................2-8
2.2.4 LD SAFETY SWITCH .......................................................................2-9
2.3 TONER CARTRIDGE..............................................................................2-10
2.3.1 OVERVIEW ....................................................................................2-10
2.3.2 DRIVE.............................................................................................2-11
2.3.3 DRUM CHARGE.............................................................................2-12
2.3.4 DEVELOPMENT.............................................................................2-13
2.3.5 DRUM CLEANING..........................................................................2-15
2.4 IMAGE TRANSFER AND PAPER SEPARATION ...................................2-16
2.4.1 OVERVIEW ....................................................................................2-16
2.4.2 TRANSFER ROLLER CLEANING..................................................2-17
2.5 PAPER FEED..........................................................................................2-18
2.5.1 OVERVIEW ....................................................................................2-18
2.5.2 PAPER TRAY.................................................................................2-20
2.5.3 BY-PASS TRAY..............................................................................2-25
2.5.4 PAPER REGISTRATION................................................................2-27
2.6 IMAGE FUSING ......................................................................................2-29
2.6.1 OVERVIEW ....................................................................................2-29

G031/G032/G049/G054 ii SM
2.6.2 FUSING ..........................................................................................2-30
2.6.3 FUSING UNIT DRIVE.....................................................................2-30
2.6.4 PRESSURE ROLLER/PAPER EXIT...............................................2-31
2.6.5 FUSING UNIT DRIVE RELEASE ...................................................2-31
2.6.6 NEW FUSING UNIT DETECTION (STINGER - P3 ONLY) ............2-32
2.6.7 FUSING TEMPERATURE CONTROL............................................2-33
2.6.8 OVERHEAT PROTECTION............................................................2-35
2.6.9 ENERGY SAVER MODE................................................................2-36
2.7 COVER OPEN DETECTION ...................................................................2-37
2.7.1 FRONT COVER LOCK...................................................................2-37
2.7.2 FRONT COVER SAFETY SWITCH................................................2-37
2.7.3 REMOVING THE FUSING UNIT ....................................................2-38
2.8 ENGINE CONTROL BOARD...................................................................2-39
2.8.1 PCB LAYOUT.................................................................................2-39
2.8.2 DEVICES........................................................................................2-40
2.8.3 STRUCTURE..................................................................................2-41
2.8.4 CONNECTION TO THE ECB .........................................................2-42
2.9 SIGNAL TABLE .......................................................................................2-44
2.10 PRINTER CONTROL BOARD...............................................................2-47
2.10.1 PCB LAYOUT ...............................................................................2-47
2.10.2 DEVICES......................................................................................2-48
INSTALLATION
3. INSTALLATION .......................................................................... 3-1
3.1 INSTALLATION REQUIREMENTS ...........................................................3-1
3.1.1 ENVIRONMENT ...............................................................................3-1
3.1.2 POWER REQUIREMENTS ..............................................................3-1
3.2 PRINTER INSTALLATION ........................................................................3-2
3.3 PAPER FEED UNIT INSTALLATION ........................................................3-2
3.4 ENVELOPE FEEDER INSTALLATION .....................................................3-2
3.5 HARD DISK INSTALLATION.....................................................................3-2
3.6 MEMORY UNIT INSTALLATION...............................................................3-2
3.7 NETWORK INTERFACE BOARD INSTALLATION...................................3-2
3.8 CHECKING THE CONNECTIONS ............................................................3-3
3.8.1 CONNECTION BETWEEN MAIN PRINTER CONTROL BOARD
(AND RELATED OPTIONS: HDD, RAM SIMM, NIC) AND
OPTIONAL HDD & PERIPHERALS .................................................3-3
3.8.2 CONNECTION BETWEEN PRINTER CONTROL BOARD AND
NETWORK INTERFACE BOARD ....................................................3-6
3.8.3 PRINTING THE NETWORK INTERFACE BOARD
CONFIGURATION SHEET...............................................................3-6
SERVICE TABLES AND PROCEDURES
4. SERVICE PROCEDURES AND TABLES ................................... 4-1
4.1 OVERVIEW ...............................................................................................4-1
4.2 SERVICE PROGRAM MODE....................................................................4-2

SM iii G031/G032/G049/G054
4.2.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...........4-2
4.2.2 SERVICE PROGRAM MODE MENU TREE.....................................4-3
4.2.3 SERVICE MODE MENU TABLE ......................................................4-5
4.2.4 PRINT LOG ......................................................................................4-9
4.2.5 PRINTER ID ...................................................................................4-13
4.3 IC CARD BOOT SERVICE MODE ..........................................................4-15
4.3.1 OVERVIEW ....................................................................................4-15
4.3.2 ENABLING AND DISABLING IC CARD BOOT SERVICE
MODE.............................................................................................4-15
4.3.3 IC CARD BOOT SERVICE MODE TREE.......................................4-16
4.3.4 SERVICE MENU TABLE ................................................................4-17
4.4 EEPROM AND NVRAM RESET PROCEDURES ...................................4-18
4.5 DOWNLOADING NEW CONTROLLER SOFTWARE .............................4-19
4.5.1 OVERVIEW ....................................................................................4-19
4.5.2 DOWNLOADING NEW FIRMWARE FROM AN IC CARD .............4-20
4.6 USER MENU ...........................................................................................4-23
4.7 ECB TEST PATTERN .............................................................................4-24
4.8 DIAGNOSTIC TEST MODES ..................................................................4-25
4.8.1 OVERVIEW ....................................................................................4-25
4.8.2 POWER-UP DIAGNOSTIC MODE .................................................4-25
4.8.3 DETAILED DIAGNOSTIC MODE ...................................................4-26
4.8.4 DIAGNOSTIC TEST DETAILS .......................................................4-27
4.9 FIRMWARE HISTORY ............................................................................4-29
4.9.1 CONTROLLER FIRMWARE HISTORY (G031)..............................4-29
4.9.2 CONTROLLER FIRMWARE HISTORY (G032)..............................4-30
PREVENTIVE MAINTENANCE
5. PREVENTIVE MAINTENANCE.................................................... 5-1
5.1 PREVENTIVE MAINTENANCE SCHEDULE ............................................5-1
REPLACEMENT AND ADJUSTMENT
6. REPLACEMENT AND ADJUSTMENT ........................................ 6-1
6.1 COVERS ...................................................................................................6-1
6.1.1 EXTERIOR COVER REMOVAL .......................................................6-1
6.1.2 FRONT COVER REMOVAL .............................................................6-2
6.1.3 CONTROL BOARD COVER REMOVAL ..........................................6-3
6.2 FUSING UNIT............................................................................................6-4
6.2.1 FUSING UNIT REPLACEMENT .......................................................6-4
6.2.2 HOT ROLLER AND FUSING LAMP REPLACEMENT .....................6-5
6.2.3 PRESSURE ROLLER REPLACEMENT...........................................6-7
6.2.4 FUSING THERMOFUSE REPLACEMENT ......................................6-8
6.2.5 FUSING DRAWER CONNECTOR REPLACEMENT .......................6-9
6.3 TRANSFER ROLLER ..............................................................................6-10
6.3.1 TRANSFER ROLLER REPLACEMENT .........................................6-10
6.4 PAPER FEED..........................................................................................6-11
6.4.1 BY-PASS TRAY REMOVAL ...........................................................6-11
Rev. 01/2003

G031/G032/G049/G054 iv SM
6.4.2 BY-PASS FEED ROLLER REPLACEMENT ..................................6-12
6.4.3 PAPER FEED ROLLER REPLACEMENT......................................6-15
6.4.4 RELAY ROLLER REPLACEMENT (STINGER - P4 ONLY) ...........6-17
6.4.5 FRICTION PAD REPLACEMENT...................................................6-18
6.4.6 TRAY PAPER FEED CLUTCH REPLACEMENT ...........................6-19
6.5 LASER UNIT ...........................................................................................6-20
6.5.1 CAUTION DECAL LOCATIONS.....................................................6-20
6.5.2 LASER UNIT/SHIELD GLASS REPLACEMENT ............................6-21
6.5.3 LD UNIT/LASER SYNCHRONIZATION DETECTOR
REPLACEMENT.............................................................................6-22
6.5.4 POLYGONAL MIRROR MOTOR REPLACEMENT ........................6-23
6.5.5 LD UNIT/POLYGONAL MIRROR MOTOR REPLACEMENT .........6-24
6.6 OTHERS..................................................................................................6-25
6.6.1 TONER NEAR-END SENSOR REPLACEMENT............................6-25
6.6.2 MAIN MOTOR/GEAR BOX REMOVAL ..........................................6-26
6.6.3 ENGINE CONTROL BOARD REPLACEMENT ..............................6-27
6.6.4 PRINTER CONTROL BOARD REPLACEMENT ............................6-28
6.6.5 HIGH VOLTAGE SUPPLY BOARD................................................6-29
6.6.6 POWER SUPPLY UNIT REPLACEMENT......................................6-30
6.7 PRINT REGISTRATION ADJUSTMENT.................................................6-31
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................ 7-1
7.1 OPERATOR ERRORS ..............................................................................7-1
7.2 PRINTER ENGINE SC CODES ................................................................7-6
7.3 DIAGNOSTIC ERROR CODES.................................................................7-9
7.3.1 DIAGNOSTIC ERROR CODE TABLE..............................................7-9
7.4 ELECTRICAL COMPONENT DEFECTS.................................................7-17
7.4.1 SENSORS ......................................................................................7-17
7.4.2 SWITCHES.....................................................................................7-17
7.4.3 FUSES............................................................................................7-17
ENVELOPE FEEDER G913
1. OVERALL INFORMATION.......................................................... 8-1
1.1 SPECIFICATIONS.....................................................................................8-1
1.2 MECHANICAL COMPONENT LAYOUT....................................................8-1
2. DETAILED SECTION DESCRIPTIONS ...................................... 8-2
2.1 PAPER LIFT ..............................................................................................8-2
3. INSTALLATION .......................................................................... 8-3
4. REPLACEMENT AND ADJUSTMENT........................................ 8-4
4.1 FRICTION PAD REPLACEMENT .............................................................8-4
Rev. 03/2000

SM v G031/G032/G049/G054
PAPER FEED UNIT G914/G915
1. OVERALL MACHINE INFORMATION ........................................ 9-1
1.1 SPECIFICATIONS.....................................................................................9-1
1.1.1 STINGER - P3 ..................................................................................9-1
1.1.2 STINGER - P4 ..................................................................................9-1
1.2 MECHANICAL COMPONENT LAYOUT....................................................9-2
1.3 ELECTRICAL COMPONENT LAYOUT .....................................................9-3
1.4 ELECTRICAL COMPONENT DESCRIPTION...........................................9-4
2. DETAILED SECTION DESCRIPTIONS ...................................... 9-5
2.1 PAPER SIZE DETECTION........................................................................9-5
2.2 PAPER LIFT ..............................................................................................9-5
2.3 PAPER END DETECTION ........................................................................9-5
2.4 PAPER NEAR END DETECTION .............................................................9-5
2.5 PAPER FEED............................................................................................9-6
3. INSTALLATION .......................................................................... 9-8
4. REPLACEMENT AND ADJUSTMENT........................................ 9-9
4.1 PAPER FEED UNIT (OPTION FOR STINGER - P3) ................................9-9
4.1.1 PAPER FEED ASSEMBLY REMOVAL ............................................9-9
4.1.2 DRIVE ROLLER REPLACEMENT..................................................9-10
4.1.3 PAPER FEED MOTOR REPLACEMENT.......................................9-11
4.1.4 PAPER FEED CLUTCH REMOVAL ...............................................9-12
4.1.5 PAPER FEED UNIT BOARD/PAPER SIZE SWITCH
REPLACEMENT.............................................................................9-13
4.2 PAPER FEED UNIT (OPTION FOR STINGER - P4) ..............................9-14
4.2.1 PAPER FEED ROLLER/PAPER FEED CLUTCH
REPLACEMENT.............................................................................9-14
4.2.2 PAPER DRIVE ROLLER REPLACEMENT ....................................9-15
4.2.3 DRIVE ROLLER IDLER/FRICTION PAD REPLACEMENT ............9-16
4.2.4 PAPER FEED MOTOR/PAPER FEED UNIT BOARD
REPLACEMENT.............................................................................9-17
NETWORK INTERFACE BOARD G919 (TYPE2000)
1. OVERALL MACHINE INFORMATION ...................................... 10-1
1.1 SPECIFICATIONS...................................................................................10-1
2. INSTALLATION PROCEDURE................................................. 10-2
2.1 HARDWARE INSTALLATION .................................................................10-2
2.1.1 SERIAL NUMBER AND MAC ADDRESS.......................................10-2
2.1.2 STATUS SHEET.............................................................................10-2
2.2 PROGRAMMING NETWORK/PROTOCOL PARAMETERS...................10-3
2.2.1 IPX NETWORK...............................................................................10-3
2.2.2 TCP/IP NETWORK.........................................................................10-4
2.2.3 ETHERTALK (APPLETALK) NETWORK .......................................10-5

G031/G032/G049/G054 vi SM
2.3 SETUP FOR VARIOUS NETWORK TYPES ...........................................10-6
2.3.1 PEER-TO-PEER NETWORK..........................................................10-6
2.3.2 NOVELL NETWARE NETWORK ...................................................10-7
2.3.3 TCP/IP NETWORK.........................................................................10-7
3. SERVICE TABLES AND PROCEDURES.................................. 10-8
3.1 FACTORY RESET (NVRAM CLEAR) .....................................................10-8
3.2 FLASH ROM UPDATE ............................................................................10-9
3.2.1 INTRODUCTION ............................................................................10-9
3.2.2 FLASHUP UTILITY (FOR NOVELL IPX NETWORKS) ................10-10
3.2.3 FTPDL UTILITY (FOR TCP/IP NETWORKS) ...............................10-13
4. TROUBLESHOOTING ............................................................. 10-16
4.1 LED INDICATIONS ................................................................................10-16
4.2 NIB FIRMWARE MODIFICATION HISTORY..………………...…………10-17
G049/G054 SERVICE MANUAL
OVERALL INFORMATION
1. OVERALL MACHINE INFORMATION....................................... 11-1
1.1 SPECIFICATIONS...................................................................................11-1
1.2 MACHINE CONFIGURATION .................................................................11-2
DETAILED DESCRIPTIONS
2. DETAILED SECTION DESCRIPTIONS ..................................... 11-3
2.5 PAPER FEED………………………………………………………………….11-3
2.5.1 OVERVIEW GO54..........................................................................11-3
2.10 PRINTER CONTROL BOARD........................................……………….11-3
2.10.2 DEVICES………………………………………………………………11-5
3. G049/G054 FIRMWARE HISTORY............................................ 11-6
3.1 G049 ENGINE FIRMWARE MODIFICATION HISTORY ..........................11-6
3.2 G054 ENGINE FIRMWARE MODIFICATION HISTORY ..........................11-6
3.3 G049 CONTROLLER FIRMWARE MODIFICATION HISTORY ...............11-7
3.4 G054 CONTROLLER FIRMWARE MODIFICATION HISTORY ...............11-8
Rev. 01/2003

SM vii G031/G032/G049/G054
APPENDIX
1. DOWNLOADING CONTROLLER FIRMWARE ........... APPENDIX-1
1.1 OVERVIEW ...............................................................................APPENDIX-1
1.1.1 IC CARD (FLASH CARD) .................................................APPENDIX-1
1.1.2 PC, VIA PARALLEL PORT...............................................APPENDIX-2
1.1.3 DIMM ................................................................................APPENDIX-2
1.1.4 RELEASING NEW CONTROLLER FIRMWARE ..............APPENDIX-3
1.2 SERVICE TOOLS......................................................................APPENDIX-4
1.2.1 OPERATION PANEL........................................................APPENDIX-4
1.2.2 SERVICE TOOL MENUS .................................................APPENDIX-5
1.2.3 STINGER SERVICE UTILITY (SSU) ................................APPENDIX-7
1.3 USING AN IC CARD .................................................................APPENDIX-8
1.3.1 PREPARING THE IC CARD.............................................APPENDIX-8
1.3.2 DOWNLOADING FROM THE IC CARD TO
THE PRINTER................................................................APPENDIX-13
1.4 USING A DIMM .......................................................................APPENDIX-14
1.4.1 PREPARING THE DIMM................................................APPENDIX-14
1.4.2 DOWNLOADING FROM THE DIMM TO
THE PRINTER................................................................APPENDIX-19
1.5 COPYING FROM A PC DIRECTLY ........................................APPENDIX-20
1.5.1 PREPARATION..............................................................APPENDIX-20
1.5.2 DOWNLOADING TO THE FLASH MEMORY.................APPENDIX-22
1.6 SSU TROUBLESHOOTING ....................................................APPENDIX-26