Ricoh G186 User manual

G186

SERVICE MANUAL

003108MIU

G186

SERVICE MANUAL

G186

SERVICE MANUAL

003108MIU

It is the reader's responsibility when discussing the information contained

within this document to maintain a level of confidentiality that is in the best

interest of Ricoh Corporation and its member companies.

NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY

FASHION AND DISTRIBUTED WITHOUT THE PRIOR

PERMISSION OF RICOH CORPORATION.

All product names, domain names or product illustrations, including

desktop images, used in this document are trademarks, registered

trademarks or the property of their respective companies.

They are used throughout this book in an informational or editorial fashion

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.

The Service Manual contains information

regarding service techniques, procedures,

processes and spare parts of office equipment

distributed by Ricoh Corporation. Users of this

manual should be either service trained or

certified by successfully completing a Ricoh

Technical Training Program.

Untrained and uncertified users utilizing

information contained in this service manual to

repair or modify Ricoh equipment risk personal

injury, damage to property or loss of warranty

protection.

Ricoh Corporation

WARNING

LEGEND

PRODUCT

CODE

COMPANY

GESTETNER LANIER RICOH SAVIN

G186

SP 5100N

(RLA only)

SP 5100N Aficio SP 5100N SP 5100N

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

*

04/2007 Original Printing

Rev. 04/2007

SM i G186

G186

TABLE OF CONTENTS

INSTALLATION

1. INSTALLATION ........................................................................... 1-1

1.1 INSTALLATION REQUIREMENTS ............................................................1-1

PREVENTIVE MAINTENANCE

2. PREVENTIVE MAINTENANCE.................................................... 2-1

2.1 PM INTERVALS .........................................................................................2-1

REPLACEMENT AND ADJUSTMENT

3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1

3.1 GENERAL PRECAUTIONS ON DISASSEMBLY .......................................3-1

3.1.1 CHECK POINTS FOR SERVICING ..................................................3-1

3.1.2 RELEASING PLASTIC LATCHES.....................................................3-1

3.2 EXTERIOR COVER ...................................................................................3-2

3.2.1 COVER RIGHT..................................................................................3-2

3.2.2 REAR COVER...................................................................................3-3

3.2.3 COVER LEFT....................................................................................3-4

3.2.4 TOP COVER .....................................................................................3-5

3.2.5 OPEN COVER...................................................................................3-7

3.2.6 INNER COVER..................................................................................3-8

3.2.7 BY-PASS TRAY ................................................................................3-9

3.3 PAPER FEED AND EXIT .........................................................................3-12

3.3.1 KNOCK UP PLATE UNIT ................................................................3-12

3.3.2 EXIT ROLLER .................................................................................3-12

3.3.3 REGISTRATION ROLLER UNIT .....................................................3-14

3.3.4 BY-PASS PICK UP UNIT ................................................................3-16

3.3.5 STOPPER ROLLER UNIT...............................................................3-19

3.3.6 IDLE ROLLER UNIT........................................................................3-19

3.3.7 PICK UP AND REGISTRATION ROLLER ......................................3-20

3.3.8 FEED ROLLER................................................................................3-23

3.3.9 RUBBER PAD .................................................................................3-24

3.4 LASER OPTICS .......................................................................................3-25

3.4.1 LSU .................................................................................................3-25

3.5 IMAGE TRANSFER..................................................................................3-26

3.5.1 TRANSFER ROLLER......................................................................3-26

CAUTIONS When Replacing a Transfer Roller ..................................3-27

3.6 FUSING ....................................................................................................3-28

3.6.1 FUSER UNIT...................................................................................3-28

G186 ii SM

3.7 DRIVE.......................................................................................................3-32

3.7.1 MAIN DRIVE UNIT ..........................................................................3-32

3.7.2 DEVELOPMENT DRIVE UNIT ........................................................3-33

3.8 OTHERS...................................................................................................3-36

3.8.1 MAIN PCB .......................................................................................3-36

3.8.2 CONNECTOR PCB .........................................................................3-37

3.8.3 SOLENOIDS ...................................................................................3-38

3.8.4 DUPLEX SOLENOID.......................................................................3-40

3.8.5 HOLDER PAD UNIT........................................................................3-41

3.8.6 TONER SENSOR PCB ...................................................................3-42

3.8.7 ENGINE PCB ..................................................................................3-44

3.8.8 DC FAN ...........................................................................................3-46

TROUBLESHOOTING

4. TROUBLESHOOTING ................................................................. 4-1

4.1 PROCEDURE OF CHECKING SYMPTOMS .............................................4-1

4.2 THE CAUSES AND SOLUTIONS OF BAD IMAGES .................................4-2

4.2.1 VERTICAL BLACK LINE AND BAND................................................4-2

4.2.2 VERTICAL WHITE LINE ...................................................................4-2

4.2.3 HORIZONTAL BLACK BAND............................................................4-3

4.2.4 BLACK/WHITE SPOT .......................................................................4-4

4.2.5 LIGHT IMAGE ...................................................................................4-5

4.2.6 DARK IMAGE OR BLACK PAGE......................................................4-6

4.2.7 UNEVEN DENSITY...........................................................................4-7

4.2.8 BACKGROUND.................................................................................4-7

4.2.9 GHOST (1) ........................................................................................4-8

4.2.10 GHOST (2)...................................................................................4-9

4.2.11 GHOST (3): FUSER...................................................................4-10

4.2.12 STAINS ON THE FACE OF PAGE............................................4-10

4.2.13 STAINS ON THE BACK OF PAGE............................................4-11

4.2.14 BLANK PAGE PRINT OUT (1)...................................................4-12

4.2.15 BLANK PAGE PRINT OUT (2)...................................................4-12

4.3 THE CAUSES AND SOLUTIONS OF BAD DISCHARGE ........................4-14

4.3.1 WRONG PRINT POSITION ............................................................4-14

4.3.2 JAM 0 ..............................................................................................4-14

4.3.3 JAM 1 ..............................................................................................4-15

4.3.4 JAM 2 ..............................................................................................4-16

4.3.5 DUPLEX JAM 1...............................................................................4-17

4.3.6 DUPLEX JAM 0...............................................................................4-18

4.3.7 MULTI-FEEDING.............................................................................4-18

4.3.8 PAPER ROLLED IN THE FUSER ...................................................4-19

4.3.9 PAPER ROLLED ON THE OPC DRUM ..........................................4-19

4.4 MALFUNCTION CAUSES AND SOLUTIONS..........................................4-21

4.4.1 FUSER ERROR ..............................................................................4-21

4.4.2 LSU (LASER SCANNING UNIT) ERROR .......................................4-21

4.4.3 MALFUNCTION OF THE GEAR OF THE FUSER DUE TO MELTING4-22

4.4.4 PAPER EMPTY...............................................................................4-22

SM iii G186

4.4.5 NO PAPER EMPTY MESSAGE......................................................4-22

4.4.6 COVER OPEN.................................................................................4-23

4.4.7 NO ERROR MESSAGE WHEN THE COVER IS OPEN .................4-23

4.4.8 DEFECTIVE MOTOR OPERATION ................................................4-24

4.4.9 NO POWER ....................................................................................4-24

4.4.10 CURVED VERTICAL LINE ........................................................4-25

4.5 CAUSES AND SOLUTIONS OF SOFTWARE ERRORS .........................4-26

4.5.1 THE PRINTER IS NOT WORKING (1)............................................4-26

4.5.2 THE PRINTER IS NOT WORKING (2)............................................4-27

4.5.3 ABNORMAL PRINTING ..................................................................4-28

4.5.4 SPOOL ERROR ..............................................................................4-29

4.6 PERIODIC DEFECTIVE IMAGE...............................................................4-30

SERVICE TABLES

5. SERVICE TABLES....................................................................... 5-1

5.1 OVERVIEW ................................................................................................5-1

5.1.1 KEY OPERATION .............................................................................5-1

5.2 EDC (ENGINE DIAGNOSTIC CONTROL) MODE .....................................5-2

5.2.1 EDC SETUP......................................................................................5-2

5.2.2 ENTERING EDC ...............................................................................5-2

Usage ...................................................................................................5-2

5.2.3 COVER OPEN/CLOSE STATUS ......................................................5-2

Usage ...................................................................................................5-2

Function ................................................................................................5-3

5.2.4 SENSOR STATUS ............................................................................5-3

Usage ...................................................................................................5-3

Function ................................................................................................5-3

5.2.5 MOTOR TEST...................................................................................5-6

Usage ...................................................................................................5-6

5.2.6 FAN TEST .........................................................................................5-7

Usage ...................................................................................................5-7

Function ................................................................................................5-7

5.2.7 CLUTCH/ SOLENOID .......................................................................5-8

Usage ...................................................................................................5-8

Function ................................................................................................5-8

5.2.8 FUSER CONTROL............................................................................5-8

Usage ...................................................................................................5-9

5.2.9 LSU ...................................................................................................5-9

Usage ...................................................................................................5-9

5.2.10 DEVELOPER CONTROL ..........................................................5-10

Usage .................................................................................................5-10

Function ..............................................................................................5-10

5.2.11 CRU COUNTER ........................................................................5-11

Usage .................................................................................................5-11

Function ..............................................................................................5-12

5.2.12 PRINT TEST AND OPTION VERSION......................................5-12

Usage .................................................................................................5-12

G186 iv SM

Function ..............................................................................................5-12

5.3 FIRMWARE DOWNLOAD ........................................................................5-14

5.3.1 DOWNLOAD PROCEDURE ...........................................................5-14

DOS Command Mode.........................................................................5-14

WIM (Web Image Monitor) mode........................................................5-14

5.3.2 FIRMWARE RECOVERY PROCEDURE ........................................5-16

5.4 SAMPLE PATTERN .................................................................................5-17

5.4.1 INFORMATION PAGES ..................................................................5-17

To print information pages: .................................................................5-17

5.4.2 DEMO PAGES ................................................................................5-17

DETAILED SECTION DESCRIPTIONS

6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1

6.1 PRINTER COMPONENTS .........................................................................6-1

6.1.1 FRONT VIEW....................................................................................6-1

6.1.2 REAR VIEW ......................................................................................6-2

6.2 SYSTEM LAYOUT .....................................................................................6-3

6.2.1 FEEDING ..........................................................................................6-3

Separation method................................................................................6-3

Basic cassette.......................................................................................6-4

Pick-up roller.........................................................................................6-4

Stopper roller ........................................................................................6-4

Registration roller..................................................................................6-4

By-pass tray..........................................................................................6-4

Duplex unit............................................................................................6-4

SCF (Second Cassette Feeder)............................................................6-4

6.2.2 TRANSFER .......................................................................................6-4

6.2.3 DRIVE ...............................................................................................6-5

6.2.4 FUSER ..............................................................................................6-5

Thermostat............................................................................................6-5

Heat roller .............................................................................................6-5

Pressure roller ......................................................................................6-5

Items for safety .....................................................................................6-5

6.2.5 LSU (LASER SCANNER UNIT) ........................................................6-5

6.2.6 PRINT CARTRIDGE..........................................................................6-6

6.3 ENGINE HARDWARE SPECIFICATIONS .................................................6-7

6.3.1 MAIN BOARD....................................................................................6-7

Asic (ORION 2).....................................................................................6-7

Memory.................................................................................................6-8

Others ...................................................................................................6-9

6.3.2 INTERNAL BLOCK DIAGRAM..........................................................6-9

6.3.3 SENSOR INPUT CIRCUIT ................................................................6-9

Paper Empty Sensing ...........................................................................6-9

Paper Sensing on the By-pass Tray ...................................................6-10

Paper Feeding/ Width Toner Cartridge Sensing .................................6-10

Paper Exit Sensing .............................................................................6-10

Cover Open Sensing...........................................................................6-10

SM v G186

DC Fan/ Solenoid Driving ...................................................................6-10

Motor Driving ......................................................................................6-10

6.3.4 SMPS & HVPS BOARD ..................................................................6-11

HVPS (High Voltage Power Supply) ...................................................6-11

SMPS (Switching Mode Power Supply) ..............................................6-13

Fuser AC Power Control .....................................................................6-14

6.3.5 ENGINE FIRMWARE ......................................................................6-15

Control Algorithm ................................................................................6-15

Driver ..................................................................................................6-16

Transfer ..............................................................................................6-16

Fusing .................................................................................................6-16

LSU.....................................................................................................6-17

SPECIFICATIONS

7. SPECIFICATIONS........................................................................ 7-1

7.1 GENERAL SPECIFICATIONS....................................................................7-1

7.1.1 PRINTER...........................................................................................7-1

7.1.2 OPTION.............................................................................................7-2

7.2 CONTROLLER ...........................................................................................7-3

7.3 HANDLING PAPER....................................................................................7-4

APPENDIX

8. APPENDIX ................................................................................... 8-1

8.1 BLOCK DIAGRAM......................................................................................8-1

8.1.1 SYSTEM BLOCK DIAGRAM.............................................................8-1

8.2 CONNECTION DIAGRAM..........................................................................8-3

8.2.1 SIGNAL DESCRIPTION TABLE........................................................8-4

CN18 [POWER] Main ↔ SMPS/HVPS.................................................8-4

CN19 [DUPLEX] MAIN ↔ DUPLEX B'D...............................................8-5

CN20 [EXIT SENSOR] MAIN ↔ EXIT SENSOR ..................................8-5

CN24 [DC_MOT] MAIN ↔ MAIN MOTOR............................................8-6

CN25 [JOINT] MAIN ↔ JOINT B'D.......................................................8-6

CN22 [DEV_MOT] MAIN ↔ DEVE MOTOR.........................................8-7

CN23 [PTL] MAIN ↔ PTL.....................................................................8-7

CN18 [PANEL] MAIN ↔ PANEL...........................................................8-8

CN15 [COVER OPEN] MAIN ↔ COVER OPEN ..................................8-8

CN13 [DPX_SOL] MAIN ↔ DUPLEX SOLENOID................................8-9

CN9 [LSU] MAIN ↔ LSU ......................................................................8-9

CN4 [CART] MAIN ↔ TONER SENSOR............................................8-10

CN17 [SCF] MAIN ↔ SCF B'D ...........................................................8-11

CN8 [THERM] MAIN ↔ FUSER .........................................................8-11

Read This First

Precautions

In order to prevent accidents and to prevent damage to the equipment, please read the

precautions listed below carefully before servicing the printer and follow them closely.

Safety Warning

1. Only to be serviced by appropriately qualified service engineers.

 High voltages and lasers inside this product are dangerous. This printer should

only be serviced by a suitably trained and qualified service engineer.

2. Use only genuine replacement parts

 There are no user serviceable parts inside the printer. Do not make any

unauthorized changes or additions to the printer, these could cause the printer to

malfunction and create electric shock or fire hazards.

3. Laser Safety Statement

 The Printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR,

chapter 1 Subchapter J for Class 1(1) laser products, and elsewhere, it is certified

as a Class I laser product conforming to the requirements of IEC 825. Class I laser

products are not considered to be hazardous. The laser system and printer are

designed so there is never any human access to laser radiation above a Class I

level during normal operation, user maintenance, or prescribed service condition.

 Never operate or service the printer with the protective cover removed from

Laser/Scanner assembly. The reflected beam, although invisible, can damage

your eyes. When using this product, these basic safety pre-cautions should always

be followed to reduce risk of fire, electric shock, and injury to persons.

Caution for safety

Toxic material

This product contains toxic materials that could cause illness if ingested.

1. If the LCD control panel is damaged, it is possible for the liquid inside to leak. This

liquid is toxic. Contact with the skin should be avoided, wash any splashes from eyes

or skin immediately and contact your doctor. If the liquid gets into the mouth or is

swallowed, see a doctor immediately.

2. Please keep toner cartridges away from children. The toner powder contained in the

toner cartridge may be harmful and if swallowed, you should contact a doctor.

Electric Shock and Fire Safety Precautions

Failure to follow the following instructions could cause electric shock or potentially cause a

fire.

1. Use only the correct voltage, failure to do so could damage the printer and potentially

cause a fire or electric shock.

2. Use only the power cable supplied with the printer. Use of an incorrectly specified

cable could cause the cable to overheat and potentially cause a fire.

3. Do not overload the power socket, this could lead to overheating of the cables inside

the wall and could lead to a fire.

4. Do not allow water or other liquids to spill into the printer, this can cause electric shock.

Do not allow paper clips, pins or other foreign objects to fall into the printer these could

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