G024 SM

G024/G047/G048 SERVICE MANUAL
RICOH GROUP COMPANIES
000837MIU
G024/G047/G048
SERVICE MANUAL
G024 (ENGINE)/G047/G048 CONTROLLER AND NETWORK INTERFACE BOARD TYPE305 CONTROLLER AND NETWORK INTERFACE BOARD TYPE306 FIERY 500 CONTROLLER SERVICE MANUAL
000837MIU
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.
2000 RICOH Corporation. All rights reserved.
WARNING
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. Unt rained and uncer tified 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
Rev. 09/2000
LEGEND
COMPANY GESTETNER RICOH G024(WIN) C7005W AP305 G024(PS) C7005P AP505 G047/G048(WIN+)* C7006w/7006dw AP306/AP306D PRODUCT CODE SAVIN SLP517c SLP517cp SLP624s/SLP624d
*Note: The two product codes and two model names refer to the simplex (manual duplex) and auto-duplex versions respectively.
DOCUMENTATION HISTORY
REV. NO. * 1 2 DATE 6/99 7/99 9/2000 COMMENTS Original Printing G024 Fiery 500 Controller Service Manual Addition G047/G048 Service Manual Addition
TABLE OF CONTENTS
ENGINE OVERALL MACHINE INFORMATION
1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS .................................................................................... 1-1 1.2 MECHANICAL OVERVIEW ...................................................................... 1-3 1.2.1 IMAGE FORMATION PROCESS OVERVIEW ................................ 1-3 1.2.2 TRANSFER...................................................................................... 1-6 1.2.3 CHARGE CORONA UNIT VOLTAGES ........................................... 1-7 1.2.4 DEVELOPMENT UNIT BIAS VOLTAGES ....................................... 1-8 1.2.5 TRANSFER BIAS VOLTAGES ........................................................ 1-9 Primary transfer (from OPC belt to transfer belt).................................. 1-9 Secondary transfer (from transfer belt to paper) .................................. 1-9 1.3 MAIN UNIT LAYOUT .............................................................................. 1-10 1.4 PARTS LAYOUT..................................................................................... 1-12 1.4.1 MECHANICAL COMPONENT LAYOUT ........................................ 1-12 1.4.2 DRIVE LAYOUT............................................................................. 1-13 1.4.3 SENSORS ..................................................................................... 1-15 1.4.4 SWITCHES .................................................................................... 1-16 1.4.5 MOTORS, CLUTCHES, AND SOLENOIDS................................... 1-17 1.4.6 PCBS AND PSU ............................................................................ 1-18 1.4.7 THERMISTORS, HEATERS, AND FUSES.................................... 1-19 1.5 SYSTEM BLOCK .................................................................................... 1-20 1.5.1 BLOCK DIAGRAM ......................................................................... 1-20 1.6 ELECTRICAL COMPONENT LIST ......................................................... 1-21 1.6.1 SENSORS ..................................................................................... 1-21 1.6.2 SWITCHES .................................................................................... 1-21 1.6.3 MOTORS ....................................................................................... 1-22 1.6.4 SOLENOIDS .................................................................................. 1-22 1.6.5 CLUTCHES.................................................................................... 1-22 1.6.6 FANS ............................................................................................. 1-22 1.6.7 CIRCUIT BOARDS AND POWER SUPPLIES............................... 1-23 1.6.8 THERMISTORS............................................................................. 1-23 1.6.9 FUSES ........................................................................................... 1-23 1.6.10 LAMPS......................................................................................... 1-23
DETAILED DESCRIPTIONS
2. DETAILED SECTION DESCRIPTIONS....................................... 2-1
2.1 PROCESS CONTROL.............................................................................. 2-1 2.1.1 OVERVIEW...................................................................................... 2-1 2.1.2 ID SENSOR ..................................................................................... 2-2 2.1.3 PROCESS CONTROL STEPS ........................................................ 2-3
SM I G024
Step 1: ID sensor calibration ................................................................ 2-4 Step 2: K development bias initialization .............................................. 2-4 Step 3: Color development bias initialization........................................ 2-4 Step 4: Charge grid bias voltage adjustment........................................ 2-5 Step 5: Y, C, M, and K bias fine adjustment......................................... 2-5 Step 6: Resetting the process control interval counter ......................... 2-5 2.2 PCU (PHOTOCONDUCTOR UNIT).......................................................... 2-6 2.2.1 OVERVIEW...................................................................................... 2-6 2.2.2 COMPONENTS ............................................................................... 2-7 2.2.3 DRIVE MECHANISMS..................................................................... 2-8 Belt drive .............................................................................................. 2-8 Used toner collection drive ................................................................... 2-9 Transfer belt revolutions....................................................................... 2-9 Transfer belt speed ............................................................................ 2-10 2.2.4 TRANSFER VOLTAGE SUPPLY................................................... 2-11 2.2.5 CHARGE CORONA UNIT.............................................................. 2-12 2.2.6 OPC BELT ..................................................................................... 2-13 2.2.7 PRIMARY TRANSFER .................................................................. 2-14 Voltage application............................................................................. 2-14 Transfer belt cleaning......................................................................... 2-15 2.2.8 USED TONER TANK ..................................................................... 2-16 2.2.9 PCU DETECTION.......................................................................... 2-17 2.2.10 CHARGE CORONA UNIT DETECTION ...................................... 2-17 2.2.11 BELT MARK DETECTION ........................................................... 2-18 2.2.12 NEW PCU DETECTION .............................................................. 2-18 2.2.13 LUBRICANT APPLICATION MODE ............................................ 2-19 Lubricant application mode for a new PCU ........................................ 2-19 Regular lubricant application mode .................................................... 2-20 2.3 VIDEO DATA PROCESSING ................................................................. 2-21 2.3.1 FLOW CHART ............................................................................... 2-21 2.3.2 GAMMA COMPENSATION ........................................................... 2-21 2.3.3 GRADATION PROCESSING......................................................... 2-22 2.3.4 AMDG (ADAPTIVE MULTI-DOT GAMMA) .................................... 2-22 2.3.5 LASER DIODE CONTROL ............................................................ 2-22 Modulation.......................................................................................... 2-22 Smoothing .......................................................................................... 2-22 2.4 OPTICAL UNIT ....................................................................................... 2-23 2.4.1 OVERVIEW.................................................................................... 2-23 2.4.2 COMPONENTS ............................................................................. 2-24 2.4.3 LD UNIT ......................................................................................... 2-25 LD safety switch ................................................................................. 2-25 LD unit configuration .......................................................................... 2-25 Cylindrical lens ................................................................................... 2-26 Polygon mirror.................................................................................... 2-26 F-theta mirror ..................................................................................... 2-27 BTL (Barrel Torroidal Lens)................................................................ 2-27 Synchronization detection .................................................................. 2-28 Synchronization detection error.......................................................... 2-28 2.4.4 APC (AUTO POWER CONTROL) ................................................. 2-29
G024 II SM
Circuit ................................................................................................. 2-29 LD error .............................................................................................. 2-29 2.4.5 LASER EXPOSURE CONTROL.................................................... 2-29 2.4.6 LASER EXPOSURE TIMING......................................................... 2-30 2.5 DEVELOPMENT UNIT ........................................................................... 2-31 2.5.1 OVERVIEW.................................................................................... 2-31 2.5.2 COMPONENTS ............................................................................. 2-32 2.5.3 REVOLVER DRIVE ....................................................................... 2-33 2.5.4 DEVELOPMENT UNIT DRIVE....................................................... 2-34 2.5.5 TONER AGITATION ...................................................................... 2-35 2.5.6 TONER TRANSPORT ................................................................... 2-36 2.5.7 DEVELOPMENT BIAS................................................................... 2-37 2.5.8 DTM (DEVELOPMENT TONER MAGAZINE) DETECTION .......... 2-38 2.5.9 TONER NEAR-END DETECTION ................................................. 2-39 2.5.10 DEVELOPMENT TIMING ............................................................ 2-40 2.6 PAPER TRANSFER UNIT ...................................................................... 2-41 2.6.1 OVERVIEW.................................................................................... 2-41 2.6.2 COMPONENTS ............................................................................. 2-42 2.6.3 CONTACT AND SEPARATION ..................................................... 2-43 2.6.4 BIAS............................................................................................... 2-44 2.7 PAPER FEED/REGISTRATION UNIT .................................................... 2-45 2.7.1 OVERVIEW.................................................................................... 2-45 2.7.2 COMPONENTS ............................................................................. 2-46 2.7.3 STANDARD TRAY......................................................................... 2-47 Drive................................................................................................... 2-47 Paper feed/separation ........................................................................ 2-48 Tray lift ............................................................................................... 2-49 Paper end detection ........................................................................... 2-50 Paper size detection........................................................................... 2-51 2.7.4 BY-PASS FEED TABLE................................................................. 2-52 Drive................................................................................................... 2-52 Paper feed/separation ........................................................................ 2-53 Paper end detection ........................................................................... 2-53 Paper size detection........................................................................... 2-54 2.7.5 REGISTRATION ............................................................................ 2-55 2.8 TRANSPORT/FUSING/PAPER EXIT UNIT............................................ 2-56 2.8.1 OVERVIEW.................................................................................... 2-56 2.8.2 COMPONENTS ............................................................................. 2-57 2.8.3 FUSING UNIT DRIVE .................................................................... 2-58 2.8.4 PAPER TRANSPORT.................................................................... 2-59 2.8.5 TEMPERATURE CONTROL ......................................................... 2-60 Fusing unit SC codes ......................................................................... 2-61 2.8.6 PRESSURE ROLLER .................................................................... 2-62 2.8.7 OIL END DETECTION ................................................................... 2-63 2.8.8 OIL SUPPLY .................................................................................. 2-64 2.8.9 CLEANING..................................................................................... 2-65 2.8.10 PAPER EXIT COVER OPEN/CLOSED DETECTION.................. 2-65 2.9 OPEN COVER DETECTION .................................................................. 2-66 2.9.1 FRONT COVER OPEN/CLOSED DETECTION ............................ 2-66
SM III G024
Rev. 08/2000
2.8.2 DTM COVER OPEN/CLOSED DETECTION..................................2-66
INSTALLATION
3. INSTALLATION PROCEDURE.................................................... 3-1
3.1 3.2 3.3 3.4 3.5 3.6 ENVIRONMENT ........................................................................................3-1 MACHINE LEVEL ......................................................................................3-2 MINIMUM SPACE REQUIREMENTS........................................................3-2 POWER REQUIREMENTS .......................................................................3-3 UNPACKING .............................................................................................3-3 MOVING ....................................................................................................3-4
SERVICE TABLES AND PROCEDURES

4. SP MODE ..................................................................................... 4-1
4.1 OVERVIEW ...............................................................................................4-1 4.2 ENGINE SP MODE ...................................................................................4-1 4.2.1 OVERVIEW ......................................................................................4-1 Entering engine SP mode .....................................................................4-1 To exit engine SP mode........................................................................4-1 Outline of the engine SP mode functions..............................................4-2 4.2.2 MENU OPERATION/DISPLAY .........................................................4-2 Key operation........................................................................................4-2 4.2.3 MARGIN (REGISTRATION ADJUSTMENT) ....................................4-4 4.2.4 PARAMETER ...................................................................................4-6 4.2.5 CLEAR MEMORY.............................................................................4-6 4.2.6 SENSOR CHECK .............................................................................4-7 4.2.7 NIP WIDTH .......................................................................................4-9 4.2.8 RESET SC........................................................................................4-9 4.2.9 PROCESS CTRL............................................................................4-10 4.2.10 TEST PRINT.................................................................................4-11 4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)....................4-11 4.2.12 IMAGE ADJUST ...........................................................................4-12 4.2.13 OUTPUT CHECK .........................................................................4-12 4.2.14 HIGHLIGHT ADJUSTMENT .........................................................4-14 4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT).............................................................................4-14 4.2.16 BELT TRANSFER BIAS ADJUSTMENT ......................................4-15
PREVENTIVE MAINTENANCE
5. PREVENTIVE MAINTENANCE.................................................... 5-1
5.1 PM TASKS ................................................................................................5-1 5.1.1 REPLACEMENT...............................................................................5-1 5.1.2 CLEANING .......................................................................................5-1 5.1.3 INSPECTION....................................................................................5-1
G024 IV SM
5.2 PM TABLE ................................................................................................ 5-2 5.2.1 MAIN UNIT....................................................................................... 5-2 5.2.2 OPTIONAL PAPER FEED UNIT...................................................... 5-2
REPLACEMENT AND ADJUSTMENT

6. REPLACEMENT AND ADJUSTMENT........................................ 6-1
6.1 EXTERIOR ............................................................................................... 6-1 6.1.1 RIGHT COVER/OZONE FILTER COVER ....................................... 6-1 6.1.2 LEFT COVER .................................................................................. 6-2 6.1.3 BOTTOM FRONT COVER............................................................... 6-3 6.1.4 FRONT COVER AND OPERATION PANEL.................................... 6-3 6.1.5 TOP COVER AND TOP REAR COVER .......................................... 6-4 6.2 INSIDE THE MAIN UNIT .......................................................................... 6-5 6.2.1 GENERAL CAUTIONS .................................................................... 6-5 6.2.2 ID SENSOR ..................................................................................... 6-6 6.2.3 CALIBRATING THE ID SENSOR .................................................... 6-7 6.2.4 PCU SET SWITCH/CHARGE CORONA UNIT SET SWITCH/PCU RESET SENSOR/ USED TONER NSOR/ QUENCHING LAMP ......................................................................... 6-8 6.2.5 PULL-OUT SENSOR/PAPER END SENSOR ................................. 6-9 Pull-out sensor ..................................................................................... 6-9 Paper end sensor................................................................................. 6-9 6.2.6 OIL END SENSOR/EXIT COVER SWITCH................................... 6-10 6.2.7 FRONT COVER SAFETY SWITCH, PCU MOTOR, MAIN MOTOR................................................................................ 6-11 6.2.8 TRANSFER BELT CLEANING SOLENOID/DEVELOPMENT DRIVE SOLENOID ........................................................................ 6-12 6.2.9 ADJUSTING THE DEVELOPMENT COUPLING JOINT................ 6-13 6.2.10 PCU DRIVE UNIT ........................................................................ 6-14 6.2.11 REVOLVER MOTOR ................................................................... 6-15 6.2.12 DTM UNIT.................................................................................... 6-16 6.3 LASER OPTICS SECTION..................................................................... 6-17 6.3.1 LD UNIT ......................................................................................... 6-17 6.3.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR ............ 6-19 6.4 FUSING SECTION ................................................................................. 6-22 6.4.1 FUSING UNIT ................................................................................ 6-22 6.4.2 OIL SUPPLY UNIT, PRESSURE ROLLER LAMP, HOT ROLLER LAMP, PRESSURE ROLLER THERMOFUSE, PRESSURE ROLLER THERMISTOR........................................... 6-23 Reinstallation...................................................................................... 6-26 6.4.3 OIL SUPPLY ROLLER, OIL SUPPLY SUB-ROLLER, BLADE ...... 6-27 6.4.4 PAPER EXIT SENSOR, CLEANING ROLLER .............................. 6-29 Paper exit sensor ............................................................................... 6-30 Cleaning roller .................................................................................... 6-30 6.4.5 PRESSURE ROLLER, HOT ROLLER, HOT ROLLER THERMOFUSE, HOT ROLLER THERMISTOR ............................. 6-31 6.4.6 CHECKING AND ADJUSTING THE FUSING NIP WIDTH ............ 6-33
SM V G024
Rev. 08/2000
Troubleshooting ..................................................................................6-34 6.5 ELECTRICAL WIRING ............................................................................6-35 6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR ..6-35 6.5.2 POWER SUPPLY UNIT..................................................................6-36 6.5.3 HIGH VOLTAGE SUPPLY UNIT ....................................................6-38 6.5.4 MCU ...............................................................................................6-39 6.5.5 UPGRADING THE MCU FIRMWARE ............................................6-40 6.6 PAPER FEED SECTION .........................................................................6-41 6.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR......6-41 6.6.2 PAPER WIDTH DETECTION BOARD ...........................................6-42 6.6.3 BY-PASS PAPER FEED ROLLER .................................................6-43 6.6.4 PAPER FEED ROLLER..................................................................6-44 6.6.5 PCU HOLDER ................................................................................6-45 6.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS PAPER FEED CLUTCH, REGISTRATION CLUTCH, AND TRANSFER ROLLER CLUTCH ....................................................6-46 Transfer roller position sensor.............................................................6-47 By-pass paper feed clutch ..................................................................6-47 Registration clutch ..............................................................................6-47 Transfer roller clutch ...........................................................................6-47 6.6.7 TRANSFER ROLLER .....................................................................6-48 6.6.8 REGISTRATION ROLLER IDLER ..................................................6-48 6.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE ROLLER ..........................................................................................6-49 6.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH, AND PULL-OUT/RELAY ROLLER CLUTCH ................................6-50 Paper size switch ................................................................................6-50 Paper feed clutch ................................................................................6-50 Pull-out clutch .....................................................................................6-51 Relay roller clutch ...............................................................................6-51
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................. 7-1
7.1 SC TABLES...............................................................................................7-1 7.1.1 TYPES OF SERVICE CALL .............................................................7-1 7.1.2 SC ERROR LIST ..............................................................................7-2 7.1.3 PROCESS CONTROL ERROR LIST ...............................................7-6 7.2 USER ERROR LIST ..................................................................................7-8 7.3 FIRMWARE HISTORY ............................................................................7-13
500-SHEET PAPER TRAY UNIT (G908)

1. OVERALL MACHINE INFORMATION.......................................... 8-1
1.1 SPECIFICATIONS.....................................................................................8-1 1.2 PARTS LAYOUT .......................................................................................8-2
G024 VI SM
2. DETAILED SECTION DESCRIPTIONS........................................ 8-3

2.1 OVERVIEW .............................................................................................. 8-3 2.1.1 MECHANICAL LAYOUT .................................................................. 8-3 2.1.2 CONFIGURATION........................................................................... 8-4 2.2 MECHANISMS.......................................................................................... 8-5 2.2.1 DRIVE .............................................................................................. 8-5 2.2.2 PAPER FEED AND SEPARATION.................................................. 8-6 2.2.3 TRAY LIFT ....................................................................................... 8-7 2.2.4 PAPER END DETECTION............................................................... 8-7 2.2.5 SIZE DETECTION ........................................................................... 8-8 2.2.6 VERTICAL TRANSPORT ................................................................ 8-9 2.3 CIRCUITS............................................................................................... 8-10 2.3.1 BLOCK DIAGRAM ......................................................................... 8-10
3. REPLACEMENT AND ADJUSTMENT...................................... 8-12

3.1 PAPER FEED ROLLER.......................................................................... 8-12 3.2 FRICTION PAD AND PULL-OUT IDLE ROLLER ................................... 8-13 Friction pad ........................................................................................ 8-13 Pull-out idle roller ............................................................................... 8-13 3.3 PAPER END SENSOR AND PULL-OUT SENSOR................................ 8-14 Paper end sensor............................................................................... 8-14 Pull-out sensor ................................................................................... 8-14 3.4 TOP COVER........................................................................................... 8-15 3.5 PAPER FEED CLUTCH AND PAPER SIZE SWITCH ............................ 8-16 3.5.1 PAPER FEED CLUTCH................................................................. 8-16 Paper size switch ............................................................................... 8-16 3.6 PULL-OUT DRIVE ROLLER................................................................... 8-17 3.7 TRAY MAIN MOTOR AND TRAY CONTROL BOARD........................... 8-18 Tray main motor ................................................................................. 8-18 Tray control board .............................................................................. 8-18 8.3 BASIC OPERATIONS............................................................................... 8-3 8.3.1 OVERVIEW...................................................................................... 8-3 8.3.2 LED FUNCTIONS ............................................................................ 8-3 8.3.3 SWITCH FUNCTION ....................................................................... 8-4 NVRAM Reset Procedure .................................................................... 8-4 8.3.4 NETWORK SETTING INFORMATION ............................................ 8-5
SM
VII
G024
IMPORTANT SAFETY NOTICES

PHYSICAL INJURY PREVENTION 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. Note that some printer components are supplied with electrical voltage even if the main switch is turned off. 4. If an adjustment or operation check must be made requiring the removal or opening of the exterior covers while the main switch is on, keep hands away from any electrically or mechanically driven components. 5. The printer drives some of its components when it completes the warm-up period. Keep hands away from mechanical and electrical components when the printer starts operation. 6. The interior and metal parts for the fusing unit become extremely hot while the printer is operating. Do NOT touch these components with bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the printer without ozone filters installed. 2. Always replace the ozone filters with the specified replacement at the specified maintenance intervals. 3. Toner is non-toxic, but if it gets in your eyes by accident, it may cause temporary eye discomfort. Remove it with eye drops or flush eyes with water. If this is unsuccessful, get medical attention immediately. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do NOT incinerate toner cartridges, development toner magazine (DTM) or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner bottle and photoconductor unit (PCU) in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is only replaceable in the field by a qualified Customer Engineer. The laser chassis is not field repairable. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when the optical subsystem requires replacement.
WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
WARNING
WARNING: Turn OFF the main switch before attempting any of the procedures in the Optical Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:
Trademarks Microsoft, Windows 98/95/3.1x, and Windows NT 4.0 are registered trademarks of Microsoft Corporation. Macintosh and AppleTalk are registered trademarks of Apple Computer, Inc. NetWare is a registered trademark of Novell, Inc. Ethernet is a registered trademark of Xerox Corporation. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies. We disclaim any and all rights in those marks.
Rev. 7/99
CONTROLLER OVERALL MACHINE INFORMATION

G024 Fiery 500 Version Service Manual
CONTROLLER DETAILED DESCRIPTIONS
CONTROLLER INSTALLATION
CONTROLLER SERVICE TABLES
CONTROLLER PERIODIC MAINTENANCE
CONTROLLER REPLACEMENT AND ADJUSTMENT
CONTROLLER TROUBLESHOOTING
CONTROLLER NETWORK INTERFACE BOARD TYPE
TAB POSITION 8
500 - SHEET PAPER TRAY UNIT G908
TAB POSITION 7
TROUBLESHOOTING
TAB POSITION 6
TAB POSITION 5
TAB POSITION 4
TAB POSITION 3
INSTALLATION
TAB POSITION 2
TAB POSITION 1
G024 OVERALL MACHINE INFORMATION
G047/G048
TAB POSITION 1 TAB POSITION 8 TAB POSITION 7 TAB POSITION 6 TAB POSITION 5 TAB POSITION 4 TAB POSITION 3 TAB POSITION 2
OVERALL INFORMATION CONTROLLER DETAILED DESCRIPTIONS
DETAILED DESCRIPTIONS CONTROLLER INSTALLATION
INSTALLATION CONTROLLER SERVICE TABLES
SERVICE TABLES CONTROLLER PERIODIC MAINTENANCE
CONTROLLER REPLACEMENT AND ADJUSTMENT
REPLACEMENT AND ADJUSTMENT CONTROLLER TROUBLESHOOTING
TROUBLESHOOTING
CONTROLLER NETWORK INTERFACE BOARD
CONTROLLER OVERALL INFORMATION
OVERALL INFORMATION
Rev. 7/99
SPECIFICATIONS
1.1 SPECIFICATIONS
Configuration Print Process Resolution Paper Size Desk top Dry electrostatic transfer system 600 dpi Standard tray Short edge feed: A3, 11" x 17", 81/2" x 14", Others* (B4, JIS, 8" x 13", 81/4" x 13", 81/2" x 13") Long edge feed: A4, 8 1/2" x 11", 71/4" x 101/2", Others* (B5 JIS, A5, 51/2" x 81/2") By-pass feed tray* Short edge feed: A3, A6, B4 JIS, B6 JIS, 11" x 17", 81/2" x 14", 8" x 13", 81/4" x 13", 81/2" x 13" Long edge feed: A4, A5, B5 JIS, 81/2" x 11", 51/2" x 81/2", 71/4" x 101/2" Custom size paper (Length: 148 to 432 mm, Width: 90 to 297 mm) * Specify the paper size with the system menu (selectable by the user from the operation panel). Paper Weight Standard and optional trays: 64 to 163 g/m2 (17 to 28 lbs.) By-pass feed tray: 64 to 163 g/m2 (17 to 90 lbs. index) Plain paper mode: 64 to 105 g/m2 Thick paper mode: 105 to 163 g/m2 (90lb. index), adhesive labels OHP transparency mode: OHP transparencies First Printout Time Print Speed Warm-up Time Paper Capacity Color: Less than 30 seconds (A4) Monochrome: Less than 14 seconds (A4) Color: 5 ppm (A4/81/2" x 11") Monochrome: 17 ppm (A4/81/2" x 11") Less than 450 seconds (at 23C/73F) Standard tray: 250 sheets (80 g/m2, 20 lbs.) By-pass feed tray: 50 sheets (80 g/m2, 20 lbs.) Optional trays: 500 sheets (80 g/m2, 20 lbs.) 250 sheets (A4/81/2" x 11" sized paper or less) 100 sheets (Greater than A4/81/2" x 11"sized paper) Face down 120 Vac, 60 Hz, 10 A 220 to 240 Vac, 50/60 Hz, 5.2 A
1-1 G024
Paper Output Capacity Output Method Power Supply
SM
Overall Machine Information
1. OVERALL MACHINE INFORMATION
SPECIFICATIONS
Rev. 7/99 Rev. 6/10/99
Power Consumption
Maximum: Less than 1200 W Average during printing: Less than 750 W Standby mode: Less than 150 W Energy saver mode: Less than 45 W Stand-by: Less than 43 dB Operating: Less than 64 dB (without paper tray unit) Less than 66 dB (with paper tray unit) 660 x 625 x 475 mm (26" x 24.6" x 18.7") (without paper tray unit) Approximately 62kg (136.7lb.) Black DTM (G756) EDP# - 400338 Yellow DTM (G757) EDP# - 400341 Magenta DTM (G758) EDP# - 400340 Cyan DTM (G759) EDP# - 400339 Paper Feed Unit Type 305 (Paper Tray Unit) up to two of these units can be installed Memory Unit Type 204 (16 & 32MB) Network Interface Board Type 305 Ricoh-Script2 Type 305 IEEE 1284 Parallel Type 305 LEGEND
Noise Emission (Sound Power Level) Dimensions Weight Toner (Type 305)
Options
Product Code G024 G908 G503 G678 G660 G688 AP305
RICOH
SAVIN SLP517C Paper Feed Unit Type 305 Ricoh-Script2 Type 305 Network Interface Board Type 305 IEEE 1284 Type 305 Memory Unit Type 204 (16 & 32MB)
GESTETNER C7005W Paper Feed Unit Type 305 Ricoh-Script2 Type 305 Network Interface Board Type 305 IEEE 1284 Type 305 Memory Unit Type 204 (16 & 32MB)
Paper Feed Unit Type 305 Ricoh-Script2 Type 305 Network Interface Board Type 305 IEEE 1284 Type 305 Memory Unit Type 204 (16 & 32MB)
G024
1-2
SM
MECHANICAL OVERVIEW
1.2.1 IMAGE FORMATION PROCESS OVERVIEW

7 6 8
10
G024V151.WMF
11 2 1 12
1. OPC belt 2. Charge 3. Exposure 4. Development 5. Transfer belt 6. Transfer belt cleaning
7. Paper separation 8. Paper transfer (secondary transfer) 9. Belt transfer (primary transfer) 10. ID sensor 11. OPC belt cleaning 12. Quenching
SM
1-3
G024
1.2 MECHANICAL OVERVIEW
MECHANICAL OVERVIEW
(1) OPC belt The OPC (organic photoconductor) belt is the central part of the machine. This is where the laser beam "writes" an image of the original. (2) Charge In the dark, a negative corona discharge charges the OPC belt. The grid ensures the even distribution of charge over the OPC belt. (3) Exposure The laser beam from the laser diode (LD) goes through the lens and the mirror and reaches the OPC belt. The beam discharges the areas of the OPC belt that it illuminates. Turning the laser beam on and off, and varying the intensity of the beam, creates a latent image on the OPC belt. (4) Development The development section consists of four independent development units, one for each color (Y, C, M, and K) and the structure necessary to support them. These modules are known as DTMs (Development Toner Magazines). This unit forms visual images by allowing toner to adhere to portions of the OPC belt where negative potentials are lower than the development bias. In this machine, monocomponent toner is used (there is no carrier). In black single-color mode (1C), the image is developed in K only. In full color mode (4C), the image is developed in Y, C, M, and K, in that order. (5) Transfer This printer uses a transfer belt. Four toner images, each a different color, are super-imposed onto each other on the transfer belt. The combined image is then transferred to the paper. (6) Transfer belt cleaning A cleaning brush applies lubricant to the transfer belt to improve cleaning. Then, a blade scrapes off the remaining toner on the transfer belt. (7) Paper separation Paper separates from the transfer belt when the belt curves away from it. The roller at the end of the transfer belt is 31 mm in diameter. (8) Paper transfer (secondary transfer) A charge applied to the transfer roller attracts the toner from the transfer belt onto the paper. (9) Belt transfer (primary transfer) A charge applied to the bias roller attracts toner from the OPC belt onto the transfer belt. (10) ID sensor The ID sensor detects the density of the ID sensor pattern on the transfer belt. The ID sensor outputs determine the process control conditions.
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MECHANICAL OVERVIEW
(11) OPC belt cleaning A cleaning brush applies lubricant to the OPC belt to improve cleaning. Then, a blade scrapes off the remaining toner on the OPC belt. (12) Quenching After cleaning, the entire surface of the OPC belt is exposed to light from a red LED. This quenches the residual potential on the OPC belt, in preparation for the next image.
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MECHANICAL OVERVIEW
1.2.2 TRANSFER
An image is formed on the OPC belt in four colors, one color at a time. The resulting four images transfer to the transfer belt in the order of Y, C, M, then K. These four images form a full-color image on the transfer belt, then the image is finally transferred to the paper.
Forming a visual image on the OPC belt Transferring the image onto the transfer belt Turning the transfer belt
Depositing Y toner on the belt
Depositing C toner after Y
Transferring the image on the transfer belt onto the paper (the paper transfer side is the opposite side from the OPC belt)
Depositing M toner after Y and C
Depositing K toner after Y, C, and M

G024V670.WMF
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MECHANICAL OVERVIEW
OPC belt
G = 600 V
Cleaning blade
Charge grid C = 700 A (About 5000 V) Quenching lamp

G024V662.WMF
Charge corona unit
The charge corona wire receives a constant current (C) of 700 A (about 5000 V). The charge grid voltage (G) varies depending on the process control results. Range: 320 V to 820 V Default: 600 V
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1.2.3 CHARGE CORONA UNIT VOLTAGES
MECHANICAL OVERVIEW
1.2.4 DEVELOPMENT UNIT BIAS VOLTAGES

Each development unit contains a supply roller and a development roller. These rollers are conductive. The voltage applied to the supply roller (SB) depends on the process control results. The other voltages in turn all depend on SB, as described below. SB (supply roller bias) Default: -348 V Range: -218 V to 468 V BL (development blade bias) This is always SB 132 V. If SB changes, so does BL. Default: -480 V 180 Vac is always super-imposed over this voltage. B (development roller voltage) This is always SB +68 V. If SB changes, so does B. The development roller voltage (B) is the VB determined during process control.
Development roller Supply roller OPC belt
SB = 348 V 68 V
BL = 480 V AC180 V
Toner Development blade
BL = 480 V 180 VAC equivalent (400 Vp-p) 2 kHz

G024V663.WMF
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MECHANICAL OVERVIEW
Paper transfer roller Paper TC = 16 A (About 1.1 kV) TC+ = +16 A (About +1.8 kV)
Transfer belt
TB = 800 V Toner
Bias roller
OPC belt
G024V664.WMF
Primary transfer (from OPC belt to transfer belt)

An 800-V bias voltage (TB) is applied to the bias roller. This attracts the toner from the OPC belt.
Secondary transfer (from transfer belt to paper)

A constant +16 A current (TC) is supplied to the paper transfer roller (at about 1.8 kV) to attract the toner from the transfer belt. The machine adjusts the transfer current automatically for variations in temperature, humidity, paper size, and paper thickness. After a paper jam has occurred, the paper transfer roller must be cleaned. Positive and negative currents are supplied alternately to repel any particles that may be on the roller as a result of a paper jam.
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1.2.5 TRANSFER BIAS VOLTAGES
MAIN UNIT LAYOUT
1.3 MAIN UNIT LAYOUT

6 5 4 7
G024V561.WMF
10
1. Optical housing unit 2. Main control unit (MCU) 3. High voltage supply unit 4. Controller board 5. Power supply unit
6. Fusing unit 7. Paper transfer unit 8. Photoconductor unit (PCU) 9. Paper tray/By-pass paper tray paper feed mechanism 10. Development unit
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MAIN UNIT LAYOUT
(1) Optical housing unit Optical system: 6-sided polygon mirror, F-theta mirror, BTL Resolution: 600 dpi Modulation method: PM+PWM (Phase modulation and pulse width modulation) (2) MCU CPU: XC68334 GFC16 Engine system control Process control Video interface (3) High voltage supply unit Constant current type: Paper transfer, charge corona wire Constant voltage type: Charge corona grid, belt transfer, supply roller, development blade (4) Controller board Host interface Video interface Image processing Operation panel control (5) Power supply unit Outputs: +5 VDC, +24 VDC, 120/230 VAC (6) Fusing unit Fusing method: Heat and pressure roller method Oil application: Application roller method Cleaning: Cleaning roller method Temperature detection: Thermistor Safety precaution: Thermofuse (7) Paper transfer unit Transfer: Transfer roller method (8) PCU A unit consisting of the OPC belt and the primary (belt) transfer section. OPC belt: 93mm diameter Charging: Single scorotron charge corona wire Primary transfer: Transfer belt Cleaning: Counter blade Lubricant: Zinc stearate (9) Tray/transport Standard tray: Universal tray, friction pad separation By-pass tray: FRR method (10) Development unit Development method: Monocomponent non-magnetic toner Development unit changeover: Revolver method Toner replenishment: DTM change
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PARTS LAYOUT
1.4 PARTS LAYOUT

1.4.1 MECHANICAL COMPONENT LAYOUT
10
11
12
13
14
15
16 17
9 8 7 6
18 19 20 21 22 23
5
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24
1. Tray paper feed roller 2. Paper tray 3. Charge corona unit 4. Polygon mirror 5. MCU (Main control unit) 6. High voltage supply unit 7. Development unit 8. Controller board 9. Power supply unit 10. Exit rollers 11. Hot roller 12. Pressure roller
13. Transfer belt cleaning unit 14. Transport fan 15. Paper transfer unit 16. Transfer belt 17. Registration rollers 18. Registration sensor 19. By-pass feed table 20. By-pass paper feed roller 21. OPC belt 22. Relay rollers 23. OPC belt cleaning unit 24. Used toner tank
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PARTS LAYOUT
4 5 6 7
9 10 11 12 14
G024V553.WMF
13
1. Main motor 2. Fusing drive input gear 3. Fusing drive gear 4. Transfer belt toner collection drive gear 5. Transfer roller clutch 6. Registration clutch 7. By-pass feed clutch
8. Relay roller clutch 9. Pull-out clutch 10. Paper feed clutch 11. Paper feed drive gear 12. OPC cleaning drive gear 13. Revolver drive gear 14. Revolver motor
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1.4.2 DRIVE LAYOUT
PARTS LAYOUT
G024V563.WMF
1. PCU pulley 2. PCU motor 3. OPC drive relay gear 4. OPC drive gear
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PARTS LAYOUT
14 13
12
11 10 5 9 8 7 6
G024V551A.WMF
1. Exit sensor 2. Oil end sensor 3. Transfer belt H.P. sensor 4. Transfer roller position sensor 5. Used toner sensor 6. PCU reset sensor 7. Paper end sensor
8. ID sensor 9. Pull-out sensor 10. By-pass paper end sensor 11. Registration sensor 12. Toner end sensor 13. Revolver H.P. sensor 14. Development toner magazine (DTM) set sensor
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1.4.3 SENSORS
PARTS LAYOUT
1.4.4 SWITCHES
1 7 2
5
G024V551.WMF
1. Main switch 2. Exit cover switch 3. Front cover safety switches 4. Paper size switch 5. PCU set switch 6. Charge corona unit set switch 7. Development toner magazine (DTM) cover switch
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PARTS LAYOUT
17 16 15
1 2 3 4
14 13 12 11 10 9
G024V552.WMF
5 6 8 7
1. Exhaust fan 2. PCU motor 3. Transfer belt cleaning solenoid 4. Main motor 5. Revolver motor 6. Polygon mirror motor 7. Development drive solenoid 8. Pull-out clutch 9. Paper feed clutch
10. Relay roller clutch 11. By-pass feed clutch 12. Registration clutch 13. Transfer roller clutch 14. By-pass feed solenoid 15. Charge inlet fan 16. Inlet fan 17. Transport fans
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1.4.5 MOTORS, CLUTCHES, AND SOLENOIDS
PARTS LAYOUT
1.4.6 PCBS AND PSU

1 10 9 2
6 7
G024V108.WMF
1. Power supply unit (PSU) 2. Controller board 3. High voltage supply board 4. Temperature/humidity sensor 5. Main control unit (MCU)
6. Laser synchronization detector board 7. Quenching lamp 8. By-pass paper width detection board 9. Laser diode (LD) unit 10. Operation panel
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PARTS LAYOUT
1 2
G024V111.WMF
1. Pressure roller thermistor 2. Pressure roller lamp 3. Hot roller thermofuse 4. Hot roller thermistor 5. Hot roller lamp 6. Pressure roller thermofuse
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1.4.7 THERMISTORS, HEATERS, AND FUSES
SYSTEM BLOCK
1.5 SYSTEM BLOCK

1.5.1 BLOCK DIAGRAM
ID Sensor
D/A
CPU ADC ROM NVRAM DRAM
Humidity Sensor
PWM
High Voltage Supply Board
ASIC
I/O AMDG Pattern Generation Motor Control
IC Card Sensors
FIFO PSU
Fusing Control
GAVD/PLLC
Video I/F
Selector
Thermistor
MCU
Solenoids Clutches LD Modulation Control Printer Controller Operation Panel Revolver Main Motor PCU Motor G024V554.WMF
Fusing Unit
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ELECTRICAL COMPONENT LIST
1.6.1 SENSORS
Symbol S19 S17 S14 S11 S2 S4 S5 S8 S6 S10 S15 S12 S13 S16 Name Exit sensor Oil end sensor Transfer belt H.P. sensor Transfer roller position sensor Used toner sensor PCU reset sensor Paper end sensor ID sensor Pull-out sensor By-pass paper end sensor Registration sensor Toner end sensor Revolver H.P. sensor DTM set sensor Function Detects exiting paper. Detects oil in the oil pan. Detects the marks on the transfer belt. Detects when the transfer roller contacts the transfer belt. Detects when the used toner tank is full. Detects when a new PCU has just been installed. Detects when paper in the first tray has run out. Detects the toner pattern density on the transfer belt. Detects paper fed from the paper tray. Detects paper in the by-pass tray. Detects paper at the registration roller. Detects whether there is toner in the DTM. Detects when the revolver is at home position. Detects whether a DTM has been installed. Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1.6.2 SWITCHES
Symbol SW1 SW2 SW3 S7 S1 S3 SW4 Name Main switch Exit cover switch Front cover safety switches Paper size switch PCU set switch Charge corona unit set switch DTM cover switch Function Makes and breaks the 120/230 VAC input power. Detects when the exit cover is opened/closed. Makes and breaks 24 VDC and LD5V. Detects the paper size in the standard tray set on the dial by the user. Detects whether the PCU and used toner tank are installed. Detects whether the charge corona unit is installed. Detects when the DTM cover is opened/closed. Index No. 1 2 3 4 5 6 7
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1.6 ELECTRICAL COMPONENT LIST
1.6.3 MOTORS
Symbol M4 M2 M1 M3 Name Main motor PCU motor Revolver motor Polygon mirror motor Function Drives the paper feed mechanisms, fusing unit, and development roller. Drives the OPC belt and transfer belt. Drives the revolver (development). Drives the polygon mirror. Diag. No. 4 2 5 6
1.6.4 SOLENOIDS
Symbol SOL1 SOL2 SOL3 Name By-pass feed solenoid Transfer belt cleaning solenoid Development drive solenoid Function Releases the by-pass tray pull-out roller. Moves the transfer belt cleaning unit into contact and away from the transfer belt. Connects the development unit drive mechanism to the main motor. Diag. No. 14 3 7
1.6.5 CLUTCHES
Symbol CL5 CL2 CL3 CL1 CL4 CL6 Name Pull-out clutch Paper feed clutch Function Controls the pull-out roller drive. Controls the first tray paper feed roller drive. Relay roller clutch Controls the relay roller drive. By-pass feed clutch Controls the by-pass tray paper feed roller drive. Registration clutch Controls the registration roller drive. Transfer roller Moves the transfer roller into contact clutch and away from the transfer belt. Diag. No. 8 9 10 11 12 13
1.6.6 FANS
Symbol FM2 FM5 FM4 FM1 FM3 Name Exhaust fan Charge inlet fan Inlet fan Transport fan Function Expels air from inside the printer; ozone is broken down by an ozone filter Prevents ozone from being trapped in the charge corona unit. Ventilates and cools the printer. Applies a downward draw to the back side of the paper after image transfer, guiding the paper to the fusing unit entrance. Diag. No. 1 15 16 17
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Symbol PCB1 PCB8 PCB3 S9 PCB2 PCB4
Name Power supply unit (PSU) Controller board High voltage supply board Temperature/ humidity sensor Main control unit (MCU) Laser synchronization detector board Quenching lamp By-pass paper width detection board Laser diode (LD) unit Operation panel
Function Supplies low-voltage power (5 VDC and 24 VDC) and ac power to the fusing unit. Houses the controller, host interface, engine interface, and image generator. Supplies high voltages for charge, development, and transfer. Detects temperature and humidity. Houses the controller interface and engine controller. Detects the laser main scan synchronization beam from the polygon mirror. Quenches the OPC by exposing it to light. Detects the paper width in the by-pass feeder. Controls laser beam output. Displays information and allows access to functions.
Diag. No. 1 2 3 4 5 6 7 8 9 10
L3 PCB6
PCB5 PCB7
1.6.8 THERMISTORS
Symbol TH1 TH2 Name Pressure roller thermistor Hot roller thermistor Function Detects the pressure roller temperature. Detects the hot roller temperature. Diag. No. 1 4
1.6.9 FUSES
Symbol TF2 TF1 Name Pressure roller thermofuse Hot roller thermofuse Function Provides protection against abnormal heating (250 VAC, 10 A, 167C). Provides protection against abnormal heating (250 VAC, 10 A, 167C). Diag. No. 6 3
1.6.10 LAMPS
Symbol L2 L1 Name Pressure roller lamp Hot roller lamp Function Heats the pressure roller (120/230 VAC, 400 W) Heats the hot roller (120/230 VAC, 600 W) Diag. No. 2 5
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1.6.7 CIRCUIT BOARDS AND POWER SUPPLIES
PROCESS CONTROL
2. DETAILED SECTION DESCRIPTIONS

2.1 PROCESS CONTROL
2.1.1 OVERVIEW
In this machine, to compensate for changes in the environment, aging of the units, and differences between individual units after they are replaced, process control adjusts the following two parameters. Development bias (VB): This is adjusted to maintain a constant image density in solid areas Charge corona grid voltage (VG): This is adjusted to maintain a constant image density in low image density (highlight) areas. To monitor the machine's condition, only the ID sensor is used. There are no toner density or potential sensors. The ID sensor monitors the density of standard sensor patches made on the transfer belt. This printer uses a single-component (or mono-component) toner. Unlike printers based on a two-component (or dual component) toner, this printer does not require any toner density control system.
Detailed Descriptions
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PROCESS CONTROL
2.1.2 ID SENSOR
ID sensor output [V]
Diffused light detection curve
Straight reflection detection curve
Amount of attached toner (M/A, mg/cm2 )

G024D520.WMF
The ID sensor consists of two separate sensors. For detecting the density of black toner patterns, there is a straight reflection sensor for K toner (this is the type of sensor normally used in black-and-white copiers), and for colored toner there is a diffused light sensor. Both sensors share the same LED, but have separate light receivers for K and color toners. However, the LED current (light intensity) used for detecting black toner is different from the one used to detect colored toner. As shown in the diagram, the output from the straight reflection sensor decreases as the amount of attached toner (M/A: mass/area or density) increases. This is because black toner is blocking the reflection of light back into the sensor from the transfer belt (the transfer belt itself is black, but it is reflective). However, the diffused light sensor output increases for higher M/A, because colored toner is reflective. The diffused light sensor is more accurate for detecting colored toner, no matter how much or how little toner is present. However, if the amount of toner on the transfer belt is small, the low level of reflected light means that without an initial calibration, the error in detection could be very great. The diffused light sensor cannot be used for black toner, because there is little difference between the diffuse light reflected from black toner and from the transfer belt surface.
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PROCESS CONTROL
2.1.3 PROCESS CONTROL STEPS

Process control is performed as the result of several specific events (see the 'Event' column in the table below). Process control consists of several steps. The steps that are done depend upon which one of the seven events has occurred. The steps that are done for each event are given in the 'Steps done' column of the table below.
? ID sensor calibration @ K development bias initialization A Color development bias initialization B Charge grid bias voltage adjustment C Y, C, M, and K bias fine adjustment D Process control interval counter reset
Event Forced process control Process control regular interval Condition When forced process control is done (engine SP mode 7. Process Ctrl - Initialize) When more than 100 sheets in 4C mode (or an equivalent number of sheets in another mode) have been printed upon completion of a job. (The interval can be changed with engine SP 7 Process Control Interval Set) When the fusing temperature is 80C or lower just after the power is turned on. When the change in the temperature/humidity sensor output since the previous process control exceeds a certain value This is done after clearing the K-DTM nearend state (i.e., when a new K-DTM is added). The machine idles and when the development roller stops for 10 seconds, indicating that idling is over, process control occurs. After the color toner end or near-end state is reset, the machine idles to transfer color toner to the development unit. After idling, process control occurs. After a new PCU is detected, it is lubricated (new PCU lubricant application mode). Then process control occurs. Steps done ? through D
?, B, C, D
Power on Environmental change K-DTM (Development Toner Magazine) replacement Color DTM replacement
?, Z, B through D ?, Z, B through D ?, Z, B
? through D ? through D
PCU replacement
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PROCESS CONTROL
Step 1: ID sensor calibration

To calibrate the ID sensor, the light reflected from the bare transfer belt is measured. The LED current is adjusted until the sensor output is 2.5 V. The detector for black is used for the calibration. The LED current will be adjusted for color toner detection, based on the adjustment that was made during the calibration for the black toner detection. Calibrating the ID sensor in this way compensates for any changes in the sensor's response caused by changes in transfer belt surface conditions or impurities in the ID sensor light source/receiver.
Step 2: K development bias initialization

The machine creates a patch of black toner on the transfer belt. The specifications for this pattern are as follows. Size: Main scan 20 mm x sub-scan 40 mm Laser power: 210 (out of a maximum of 255) The ID sensor detects the density of this pattern. Based on the result, the development bias for black is adjusted to obtain a M/A of 0.58 mg/cm2 on the transfer belt for areas of maximum image density. This development bias is called VB. This step is required when a new machine is installed, or when a black DTM is changed. This is because the amount of toner that adheres to the development roller varies for each unit. This means that the amount of toner transferred to the image for a certain development bias will not be the same.
Detect the density of the toner pattern by the ID sensor Generate the toner pattern on the transfer belt
Specify a development bias (V B ) that ensures a solid area toner amount of 0.58 m g / c m2
G024D530.WMF
Step 3: Color development bias initialization

The initialization for the Color DTM is the same as for black. VB is obtained for each of the color toners in the order of Y, C, then M. The target M/A for each color is as follows: Cyan, Yellow = 0.56 mg/cm2 Magenta = 0.62 mg/cm2
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PROCESS CONTROL
Step 4: Charge grid bias voltage adjustment

Adjusting the development bias VB controls the density of solid areas on the printout, and adjusting the charge grid bias VG controls the density of low image density (highlight) areas. These two biases maintain a consistent (gamma) for the engine.
To adjust VG, the machine makes another pattern on the transfer belt. The ID sensor detects the density of this pattern. Based on the result, the machine adjusts the grid bias voltage. The figure on the right shows the pattern formed on the transfer belt during this process. The pattern is 20 mm (main scan) x 40 mm (sub scan), and consists of a repeating pattern of two pixels made with an LD intensity of 240 surrounded by pixels with no LD intensity, as shown in the opposite diagram. This is very pale, and suitable for calibrating the low ID point of the engines gamma.
0 240 0 0 240 0 0 0 0
If the density of low image areas is not acceptable, adjust the target ID sensor output for this sensor pattern with engine SP mode 12 (High-light adj). Then do a forced process control (engine SP mode 7. Process Ctrl. Normal, or Initialize).
Step 5: Y, C, M, and K bias fine adjustment

Steps 2 and 3 for determining VB are not done every process control (refer back to the table at the beginning of this chapter, 2.1.3). Because of this, the solid area density, based on the VB obtained during initialization, may change as a result of changes inside the machine after a period of use, or because of environmental changes. To suppress these fluctuations, this step "fine-tunes" VB at regular intervals, or if the environmental conditions change. The method is described below. An ID sensor pattern is formed on the transfer belt based on the most recently measured VB for each toner color. The ID sensor then reads the pattern formed. VB changes in accordance with the difference between the ID sensor outputs during this process and during the initial calibration. The change in VB is restricted to a certain range, so that the density does not vary widely after process control. However, this restriction does not apply to the process control executed when fluctuations in the output from the temperature/humidity sensor are detected (i.e., upon an environmental change).
Step 6: Resetting the process control interval counter

An internal counter in the MCU NV-RAM controls the process control interval. The counter is reset at the end of process control. If power is shut down or if the cover is opened during a process control operation, terminating the process control operation, the process control restarts from the beginning upon recovery. The counter is not reset when process control is performed for K-DTM replacement.
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PCU (PHOTOCONDUCTOR UNIT)
2.2 PCU (PHOTOCONDUCTOR UNIT)

2.2.1 OVERVIEW
17 18 19 1 2 3 4 9 5 10 16 15 14 13 12 11
The PCU consists of an OPC* section, a primary (belt) transfer section, and a used toner tank that collects the used toner from the OPC and belt transfer sections.
1. OPC belt idle roller 2. OPC belt 3. OPC belt brush (grounded) 4. OPC belt drive roller 5. Charge corona unit 6. OPC belt cleaning blade 7. Quenching lamp 8. Used toner tank 9. Transfer belt idle roller 10. OPC belt toner collection auger
11. OPC belt lubricant bar 12. OPC belt cleaning brush 13. Transfer belt bias roller 14. Transfer belt 15. Transfer belt drive roller 16. Transfer belt lubricant bar 17. Transfer belt cleaning brush 18. Transfer belt cleaning blade 19. Transfer belt toner collection auger *OPC: Organic Photoconductor
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2.2.2 COMPONENTS
Section Component Cleaning unit Drive mechanism Belt drive OPC belt OPC Cleaning unit Lubricant bar Charge corona unit Charge corona unit Charge inlet fan Transfer belt Transfer bias Primary transfer section Cleaning unit ID sensor Overview The main motor (a brushless DC motor) drives the used toner collection unit and the cleaning unit. The PCU motor (an externally synchronized brushless DC motor) drives the OPC belt and the transfer belt. 292 mm in circumference. A counter blade scrapes the OPC belt to remove excessive toner. This applies lubricant to the OPC surface to improve toner removal. The scorotron corona wire inside the charge corona unit evenly charges the OPC surface. The charge inlet fan blows air into the charge corona unit to disperse ozone. The toner image on the OPC belt is transferred onto the transfer belt. Later it will be transferred to the paper from the belt. The transfer bias attracts the toner from the OPC to the transfer belt surface. A counter blade scrapes the transfer belt to remove toner. The ID sensor detects the density of the black and color patterns on the transfer belt surface. This applies lubricant to the transfer belt surface to improve toner separation from the belt. This collects the used toner from the OPC belt and transfer sections. The used toner sensor detects when the used toner tank is full. Light from a red LED removes residual charge from the OPC belt in preparation for receiving the next image.
Lubricant bar Used toner tank Used toner Used toner sensor Quenching Quenching lamp
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2.2.3 DRIVE MECHANISMS

Belt drive
[F] [C] [D] [A]
[E] [J] [K] [G] [B]

G024D602.WMF
[D] [H] [I]
G024D194.WMF
[K]
The PCU motor [A] drives the OPC belt drive roller [B] and transfer belt drive roller [C] via gears and two couplings [D]. The OPC [E] and transfer [F] belts rotate at the same speed. The two couplings (for the transfer belt [G] and the OPC [H]) engage when the front cover [I] is closed. When the front cover is closed, the two actuators [J] on the inner side of the cover push the coupling levers [K].
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Used toner collection drive

[B]
[E] [A] [F]
[C]
G024D604.WMF
The main motor drives the used toner collection process. There are two mechanisms, one for the transfer belt and one for the OPC. The pulley [A] drives the transfer belt toner collection auger [B] via gears. The paper feed drive gear [C] drives the OPC cleaning brush [D], OPC belt toner collection auger [E], and used toner collection auger [F] via a series of gears.
Transfer belt revolutions

The transfer belt has 15 separate positioning marks on it, each located at 39.2 mm intervals (one full rotation of the transfer belt is 588 mm). The number of transfer belt revolutions differs between single-color black (K) mode and 4C (YCMK) mode, as shown in the following table.
Print mode Single-color black (K) 4C mode (YCMK) Revolutions (Paper length + 4 marks)/588 4
Even when the printing data consists of only one, two, or three colors out of Y, C, and M, the printing operation is the same for 4C data.
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[D]
Transfer belt speed

One revolution of the transfer belt (39.2 x 15 = 588)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1
LT long edge feed two-image print A3 one-image print LT long edge feed one-image print
216
40
376.8 506.8 Single-color black print 4 marks
Double-speed revolution
Unit: mm
G024D517.WMF
4C mode (color printing) For color printing, the machine places two pages at a time on the transfer belt if the image size is LT long edge feed or smaller (width: 216 mm to 148 mm), except for the final page of a job containing an odd number of pages. When there is only one color image on the transfer belt, the transfer belt turns at double speed to move the non-image area past the image transfer point (from OPC to transfer belt). This shortens the total printing time. For printing on transparencies or on thick paper, the paper transfer and fusing unit speeds slow to 1/2 speed to improve paper transfer and fusing. Single-color black mode (K) When four transfer belt marks have been detected after the end of the first page, the image for the next page is placed on the transfer belt. For printing on transparencies or on thick paper, the paper transfer and fusing unit speeds slow to 1/2 speed to improve paper transfer and fusing.
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2.2.4 TRANSFER VOLTAGE SUPPLY
[D]
[C] [A] [E]
[B]
G024D157.WMF
The high voltage board [A] supplies the belt transfer voltage to the PCU through the connector [B], then the coil spring electrode [C] and finally the bias roller [D] to the transfer belt [E]. Opening the front cover separates the coil spring electrode from the PCU.
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2.2.5 CHARGE CORONA UNIT
[D]
[C] [A]
[B]
G024D605.WMF
Electrode for the grid
Electrode for the wire
G024D607.WMF
The charge corona unit [A] supplies a negative charge to the OPC using a single scorotron corona wire. The coil spring electrode [B] supplies the voltage as soon as the PCU motor starts. The charge inlet fan [C] removes ozone from the charge corona unit. The charge corona unit has a sliding cleaner [D] so that the user can clean the wire and grid. The high voltage board applies a constant current (-700 A) to the charge corona wire. The grid (a stripe-pattern type grid) receives a constant voltage, which depends on the results of process control (the default setting is -600 V).
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2.2.6 OPC BELT
[A]
[B]
[C] [D]
[I] [F] [E]

G024D156.WMF
[H] [G]
[J]
G024D616.WMF
The inner side of the OPC belt [A] is in continual contact with the grounding brush [B]. After primary transfer (from OPC to transfer belt), the cleaning brush [C] lubricates the OPC belt with zinc stearate, by using a spring to apply pressure to the lubricant bar [D]. A cleaning blade [E] scrapes the OPC belt to remove the remaining toner. The OPC belt toner collection augers [F] carry the toner removed by cleaning to the used toner collection opening [G] in directions [H] and [I]. The toner then falls into the used toner tank [J].
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2.2.7 PRIMARY TRANSFER

Voltage application
[A]
[B]
G024D155.WMF
[C]
The primary transfer bias is applied to the transfer belt bias roller [A]. The default is +800 V. It changes according to environmental conditions (temperature and humidity measured by the sensors). The bias pulls the toner from the OPC belt to the transfer belt. The transfer belt idle roller [B] is connected to a grounding electrode [C].
G024
2-14
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Transfer belt cleaning

[C] [A] [B]
[F]
[D]
[H] [G]
[E]
G024D154.WMF
G024D153.WMF
When the cleaning brush [A] is moved into contact with the transfer belt [B], friction caused by the pressure from this contact turns the cleaning brush. The lubricant bar [C], due to its weight, presses against the cleaning brush which applies lubricant to the transfer belt improving image quality and cleaning. The cleaning blade [D], positioned so that the edge is against the rotation of the transfer belt (counter blade system) removes the toner from the transfer belt. The transfer belt toner collection auger [E] carries the removed toner to the left end of the PCU. Finally, a guide directs the toner into the OPC toner collection area. In 4C mode, the cleaning unit separates from the transfer belt after the first image, Y, has been formed, and stays away from the belt while the C, M, and K images are forming. (In single-color black mode, the cleaning unit is in constant contact with the transfer belt.) Then, after secondary transfer (from transfer belt to paper), the cleaning unit is moved into contact with the transfer belt. To control the movement of the cleaning unit [F], the transfer belt cleaning solenoid [G] turns on and off moving the contact/separation lever [H].
Primary transfer Y C 4C mode M K Single-color black mode Solenoid ON/OFF OFF ON ON ON OFF Cleaning unit contact/separation Contact Separated Separated Separated Contact
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2.2.8 USED TONER TANK
[B]
[A]
[C]
G024D611.WMF
[D]
G024D612.WMF
The used toner tank [A] has a shutter mechanism [B]. When the used toner tank is placed in the PCU, a protrusion [C] on the PCU opens the shutter. When the tank is removed from the PCU, the spring (under tension) in the shutter cover pulls and closes the shutter. The toner collection auger (inside the tank) transports the toner falling into the used toner tank, preventing the toner from accumulating in a particular place in the tank. The used toner sensor [D] detects when the tank becomes full. After detecting a near full used toner tank, the printer can make an additional 20 prints before the machine stops printing (used toner tank full condition).
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2.2.9 PCU DETECTION

[A]
G024D613.WMF
The PCU set switch [A] is installed on the main unit (printer mainframe) under the bottom center of the PCU. The used toner tank (waste tank) case presses the PCU set switch and the presence of the PCU is detected. If the PCU is not detected, the display indicates, "Reset PCU Correctly." Additionally, when the used toner tank is absent, the PCU set switch detects that the used toner tank is missing and displays, "Reset Waste T Bottle Correctly."
2.2.10 CHARGE CORONA UNIT DETECTION
[B]
[A]
G024D158 WMF
The main unit (printer mainframe) has a switch [A] to detect the presence of the charge corona unit. If the charge corona unit [B] is installed in the PCU, the charge corona unit activates this switch. The switch actually detects the sliding cleaner for the grid and charge corona wire. So, if the user has not put the sliding cleaner fully back into its home position, the LCD will display an error message.
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2.2.11 BELT MARK DETECTION

[A]
[B] [A]
G024D614.WMF
There are 15 belt marks [A] on the right edge of the transfer belt. The transfer belt home position sensor [B] (a reflective photosensor) located on the front cover unit is used to detect these marks. This detection process is performed so as to properly align the laser exposure start position in the sub-scan direction for the next image. In 4C mode, when a printing phase is completed and the transfer belt returns to the write start position, the transfer belt moves forward one mark. Laser exposure in the sub-scan direction for the next image begins at this position. Because the PCU motor drives the transfer and OPC belts at the same time, multiple exposures from the laser beam in exactly the same position on the OPC belt is prevented.
2.2.12 NEW PCU DETECTION

[B]
[A]
G024D615.WMF
On a new PCU, the new PCU detection lever [A] at the bottom right is pointing straight down. When the PCU reset sensor, located in the main unit, detects the new PCU detection lever, the PCU counter resets. The main motor drives the new detection lever via a gear [B] so as to release the sensor from the "new PCU" detection state.
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2.2.13 LUBRICANT APPLICATION MODE

Lubricant application mode for a new PCU
Lubricant application mode for a new PCU
Output a full-color A3 page

using internal pattern #6. Turn off the primary transfer bias. Apply other bias voltages using the process control values. Turn off the transfer belt cleaning solenoid (cleaning brush contacts belt).
Free run without laser exposure (24 belt revolutions - to simulate 6 full-color A3 sheets) Turn off the transfer belt cleaning solenoid (cleaning brush contacts belt).
End
G024D521.WMF
A new PCU does not have used toner on it. Without used toner to act as a lubricant, rotation of a new PCU could result in scratches on the OPC belt, damage to the blade, and insufficient cleaning due to friction between the cleaning blade and the OPC belt or transfer belt. To prevent this friction, the above lubricant mode is executed. The first step of this process puts toner on the OPC belt to lubricate it. The transfer belt is also lubricated at this time. However, the transfer belt requires more lubrication than the OPC belt. Therefore, step 2 is done to lubricate the transfer belt without applying toner to the OPC. This process takes place when the machine detects that a new PCU has been installed.
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Regular lubricant application mode
Regular lubricant application mode
No
Lubricant application counter = A Yes Reset the counter. Drive the PCU motor and main motor.
Turn off everything after 30 seconds.
End
G024D522.WMF
Lubricant is applied to the OPC and transfer belts when the lubricant application counter reaches "A" (default: 100). If the regular lubricant application interval and the process control interval run out at the same time, process control is done first. Counting method Color: 4 counts/print Monochrome: 1 count/print The lubrication interval ("A" in the flow chart) can be adjusted with the following engine SP mode: 13: Lub_interval
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2-20
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VIDEO DATA PROCESSING
2.3 VIDEO DATA PROCESSING

2.3.1 FLOW CHART
Gamma compensation
Controller
Gradation processing
VIDEO I/F
Engine
AMDG
GAVD I/F
HEMA
G024D526.WMF
2.3.2 GAMMA COMPENSATION

The controller receives either 8-bit RGB or 8-bit CMYK data from the driver (in the case of 8-bit RGB data, the controller has to convert this to 8-bit CMYK data before image processing can start). Then, gamma compensation corrects the CMYK data (a combination of the controller gamma and service gamma is used; see Detailed Descriptions Gamma Correction in the controller service manual).
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VIDEO DATA PROCESSING
2.3.3 GRADATION PROCESSING

The gamma-compensated data is dithered. The result of dithering depends on whether 1-bit or 2-bit mode was selected with the driver. After dithering, the data is converted to 4-bit and sent to the engine through the video interface. 1-bit mode: The output for each pixel after dithering is either 0 or 1. This becomes either 0 or F after conversion to 4-bit data. 2-bit mode: The output for each pixel after dithering is 0, 1, 2, or 3. This becomes either 0, 5, A, or F after conversion to 4-bit data.
2.3.4 AMDG (ADAPTIVE MULTI-DOT GAMMA)

This process converts 4-bit data into 8-bit data (256 shades). Each pixel is compared with a range of pixels above and to the left, and is converted to an 8-bit value based on the results, using an internal look-up table. The data then passes to the GAVD (Gate Array Video) interface through the laser diode control chip (HEMA) on the LD unit.
2.3.5 LASER DIODE CONTROL

Modulation
PM and PWM modulation for LD control converts the 8-bit data (equivalent to 256 gradations) to laser power levels.
Smoothing
Smoothing only occurs if the following settings have been made with the printer driver. Resolution: 600 dpi Color level: 1-bit Smoothing: Auto The LD controller smoothes the data to reduce jagged edges. Normally, the laser writes the colored part of each pixel at the left side of the pixel. However, to smooth the image, the laser sometimes writes the colored part at the right side of the pixel. The machine determines automatically which pixels have to be treated in this way.
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OPTICAL UNIT
2.4 OPTICAL UNIT

2.4.1 OVERVIEW
5 6 2 4 3
10 7 8 9
G024D501.WMF
11
G024D502.WMF
1. Polygon Mirror 2. Polygon Mirror Motor 3. 1st Mirror 4. Cylindrical Lens 5. LD (Laser Diode) Unit 6. 2nd Mirror
7. F-theta Mirror 8. BTL (Barrel Torroidal Lens) 9. Laser Synchronization Mirror 10. Laser Synchronization Detector Board 11. Dust Shield Glass
The optical unit uses a six-sided polygon mirror that turns at 23,922 rpm. The optical unit can create 256 gradations for each color by implementing a combination of laser power modulation (PM) and pulse width modulation (PWM).
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OPTICAL UNIT
2.4.2 COMPONENTS
Section Overview LD Wavelength 780 nm, rated power 10 mW LD control board Drives the LD. Collimating lens Makes the laser beams parallel. Prevents the laser beams from expanding Aperture beyond the required beam diameter. Cylindrical lens Compensates for beam shape irregularities. Polygon mirror Revolving six-sided mirror Polygon mirror motor Turns the mirror at 23,922 rpm. Compensates for dot position irregularities F-theta mirror in the main scan direction. BTL Compensates for leaning faces. Mirror Reflects the laser beams. Shields the optical system from dust and Dust shield glass toner. Synchronization Reflects the laser beam to the detection mirror synchronization detection board. Detects the beam from the synchronization Synchronization detection mirror, synchronizes the laser detection board beams main scan. Component
LD unit
Laser optical system
Synchronization detection
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OPTICAL UNIT
2.4.3 LD UNIT
LD safety switch
GND +5V +24V Power supply unit MCU +5V INT
+5V
LD unit
Front cover safety switches To the paper exit cover switch
Front cover LD safety switch switch G024D518.WMF
A safety switch is provided to prevent accidental laser emission while the front cover is open for maintenance. The safety switch is on the +5V DC line from the power supply unit to the LD unit via the MCU. When the front cover is opened, the safety switch shuts off the +5V DC line to the LD unit.
LD unit configuration
[D] [A] [B] [C] E
G024D511.WMF
The LD unit consists of a laser diode (LD) [A], collimating lens [B], aperture [C], and LD control board [D]. The collimating lens focuses the laser beam into an accurately parallel beam. The aperture then prevents the beam from expanding beyond the required beam diameter [E] on the OPC belt.
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OPTICAL UNIT
Cylindrical lens
The cylindrical lens concentrates the laser beam from the LD unit and forwards it to the polygon mirror. The cylindrical lens determines the beam diameter in the subscan direction.
Polygon mirror
Thick
[A]
Thin
G024D503.WMF
The polygon mirror [A] is a combined unit consisting of a polygon mirror motor and a mirror. The polygon mirror is six-sided. The mirror surfaces are precisely ground to prevent dot misalignments and to improve reflective efficiency. The polygon mirror motor turns the mirror at 23,922 rpm. Six main scans are performed per polygon mirror motor revolution.
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OPTICAL UNIT
F-theta mirror
[B]
Evenly spaced pixels
[A]
G024D504.WMF
The distance to the reflective face of the polygon mirror [A] is different at the center and at the edges of the OPC belt. The gaps between pixels are longer at the edges (the beam is sweeping across the belt more quickly). The F-theta mirror [B] compensates for the differences in the distance to ensure an equal gap between pixels.
BTL (Barrel Torroidal Lens)
Main scan
Laser beam dot
Before compensation
After compensation
G024D505.WMF
Irregularities in the perpendicular inclination of the mirror faces causes the laser beam spacing in the sub-scan direction to fluctuate. The BTL compensates for this.
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OPTICAL UNIT
Synchronization detection
A mirror deflects the laser beam from the polygon mirror to the synchronization detection board. The detection board responses are sent to the MCU laser exposure controller as synchronization signals for determining the LD exposure start position across the main scan.
Synchronization detection error

If a synchronization detection signal is not detected within a certain period (about 500 s) after the LD turns on, the MCU assumes that there is a synchronization detection error. (SC 43 is displayed.)
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OPTICAL UNIT
2.4.4 APC (AUTO POWER CONTROL)

Circuit
+5V LDERR PD
LDOFF
LD U1 EMA
Control signal
G024D528.WMF
The LD has a built-in photodiode to monitor the laser beam. The output signals from the photodiode are input to the LD control board, which contains a feedback circuit to keep the laser beam at a constant intensity.
LD error
The LD control panel detects abnormal laser power output by monitoring the current flowing in the LD. When the current exceeds 133 mA DC, the LD control panel issues an error detection signal to the MCU. (SC 42 code is displayed.)
2.4.5 LASER EXPOSURE CONTROL

Laser exposure control enables an equivalent of 256 shades for each of Y, C, M, and K. This is achieved by a combination of two modulation methods: pulse width modulation (PWM) and power modulation (PM). At 600 dpi (if 1-bit mode was selected through the printer driver), the printer smoothes the output in the main scan direction by determining whether to place the "colored" part of the pixel on the left or on the right.
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OPTICAL UNIT
2.4.6 LASER EXPOSURE TIMING

Two-image output timing LGATE timing
FGATE timing
Laser exposure area
Laser exposure area
LGATE timing
LSYNC
LGATE A FGATE timing
START
MARK
PMSYNC
FGATE
G024D507.WMF
The FGATE (for the sub-scan direction) and LGATE (for the main scan direction) signals determine the laser exposure timing. When both are high, any data going to the laser diode is written on the belt. FGATE is generated from transfer belt mark detection signals and PMSYNC (polygon mirror motor synchronization signals once each turn of the mirror motor). When the machine is ready to print, the CPU waits for a certain number of clock cycles. Then, the first time that the MARK goes high after this, FGATE goes high after a certain number of PMSYNC signals. LGATE is generated from the LSYNC (laser main scan synchronization sensor signal). The main scan registration value determines when LGATE goes high after LSYNC is detected. Main scan registration adjustment changes the value of "A". An engine SP mode adjustment (1: Margin) can adjust main scan and sub-scan registration.
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DEVELOPMENT UNIT
2.5 DEVELOPMENT UNIT

2.5.1 OVERVIEW
4
G024D169.WMF
1. Revolver motor 2. Revolver gear 3. Hopper 4. Development roller
The development unit consists of independent Y, C, M, and K units (known as development toner magazines or DTMs) combined with a support unit. The development unit rotates clockwise (as seen from the left side of the printer) and develops images in the order of Y, C, M, and then K.
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DEVELOPMENT UNIT
2.5.2 COMPONENTS
Section Revolver Component Revolver drive Home position sensor DTM DTM set sensor Toner end sensor Toner supply Overview The revolver motor turns the revolver unit. The MCU controls the rotational angle. Detects when the revolver is at home position. Four colors (Y, C, M, and K) The DTM set sensor detects the presence of a DTM. The toner end sensor detects the presence of toner. The supply roller supplies toner to the development roller. The blade forms a thin layer of toner on the development roller. The main motor only drives the development unit for the color that is at the development position. Bias is only applied to the development unit for the color that is at the development position.
Toner supply
Development
Drive
Bias application
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DEVELOPMENT UNIT
2.5.3 REVOLVER DRIVE
[B]
G024D900.WMF
[C]
[D]
G024D529.WMF
[A]
45 degrees
90 degrees
90 degrees
90 degrees
45 degrees
Y Development
C Development
M Development
K Development
G024D513.WMF
A gear transfers drive from the revolver motor [A] to the revolver gear [B]. The support unit [C] has a protrusion for home position detection located on the left side. The home position sensor [D] located on the left side panel detects this protrusion. The revolver turns 45 degrees and stops for Y color development, then turns 90 degrees for C color development, then another 90 degrees for M color development. Then, the revolver turns 90 degrees once more for K color development. After completing development for all four colors, the revolver turns 45 degrees to the home position.
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DEVELOPMENT UNIT
2.5.4 DEVELOPMENT UNIT DRIVE
[B]
[D]
[C] [E] [A]

G024D162.WMF
Gears and a coupling joint [A] transfers torque from the main motor [B] to drive the supply [C] and development [D] rollers. The coupling only engages while the development drive solenoid [E] is on.
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DEVELOPMENT UNIT
2.5.5 TONER AGITATION
A B
B A
G024D167.WMF
The rotation of the revolver agitates the toner inside the hopper. When the hopper is at the top, the toner is at the supply port (A) for the development roller. When the hopper turns towards the bottom, the toner falls from the toner supply port (B). As the revolution continues, the toner is scooped back into the toner supply port.
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DEVELOPMENT UNIT
2.5.6 TONER TRANSPORT

[A]
[C]
[B]
[E]
[D]
G024D161.WMF
The agitated toner passes from the hopper [A] to the supply and development rollers. The supply roller flicker [B] regulates the amount of toner applied to the supply roller. Then, the rotation of the supply roller [D] transports the toner to the development roller [C]. The development blade [E] forms an even layer of toner to a specified thickness on the development roller surface. Negative bias applied to the development blade charges the toner quickly. This negative charge is applied when the toner passes between the development blade and the development roller.
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DEVELOPMENT UNIT
2.5.7 DEVELOPMENT BIAS

[A] [A]
G024D166.WMF
G024D165.WMF
Development roller bias: A Supply roller bias: B Development blade bias: C
Revolver revolution
Y C M K
Development roller bias Supply roller bias Blade bias Blade AC bias
Bias change-over
G024D514.WMF
The electrode [A] on the main unit side supplies the voltages. The electrode is connected only while development is in progress. When development for one color finishes, the bias transfers to the next color.
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DEVELOPMENT UNIT
Rev. 7/99
2.5.8 DTM (DEVELOPMENT TONER MAGAZINE) DETECTION
[A]
[B]
G024D164.WMF
The DTM sensor [A] detects the presence of a DTM. The DTM sensor outputs an error detection signal when a toner bottle is not present or is incorrectly installed. Printing cannot start until this signal ceases (i.e., the error must be corrected). Installing a toner bottle and closing the DTM cover [B] automatically initiates the recovery procedure, ceasing the error condition.
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DEVELOPMENT UNIT
2.5.9 TONER NEAR-END DETECTION

[B] [D]
[A]
[C]
G024D163.WMF
Reflecting Board
Receive light
Emits light
G024D195.WMF
Each toner hopper has a toner monitoring window [A] with two mirrors [B] at a 45degree angle. The toner end sensor (a reflective photosensor) [C] detects the toner between the two mirrors. The cleaner [D] swings across to clean the mirror surfaces when the revolver turns. If there is sufficient toner, the light path is blocked. When light passes through the sensor for the first time, the machine detects a toner near-end condition. When the toner near-end condition occurs, the LCD indicates Add Toner. However, the user can continue printing until the copy quality becomes unacceptable (there is no toner end condition).
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DEVELOPMENT UNIT
2.5.10 DEVELOPMENT TIMING

LT, long edge feed, two-image print mode
Belt mark Laser exposure Y Revolver Development solenoid Development bias Belt transfer bias
G024D515.WMF
C and M
Change-over
Change-over
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PAPER TRANSFER UNIT
2.6 PAPER TRANSFER UNIT

2.6.1 OVERVIEW
3 4 2 1
G024D422.WMF
6
G024D426.WMF
1. Transfer roller casing 2. Transfer roller springs 3. Transfer roller 4. Antistatic brush 5. Transfer roller position sensor 6. Transfer roller clutch During the print process, the paper transfer unit makes and "breaks" contact with the transfer belt.
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PAPER TRANSFER UNIT
2.6.2 COMPONENTS
Section Overview Charges the back side of the Transfer roller paper to attract toner from the transfer belt. Presses the transfer roller Spring against the transfer belt. Moves the paper transfer unit Transfer roller clutch into contact and away from the transfer belt. Detects whether the paper Transfer roller transfer unit is in contact with position sensor or away from the transfer belt. Connects the transfer roller to Bias terminal the high-voltage supply board. Enables an electrical Conductive bearing connection to the transfer roller axle. Component
Transfer
Contact/separation
Bias
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PAPER TRANSFER UNIT
2.6.3 CONTACT AND SEPARATION
[C]
[B] [A]
[D]
G024D159.WMF
Registration clutch
Transfer roller clutch
Transfer bias 71.46 mm 31.5 mm

G024D516.WMF
The transfer roller contact/separation idler [A] and the transfer roller clutch [B] transfer drive from the main motor to the cam [C]. The transfer clutch (a 1/2-turn clutch) controls the contact between the transfer roller and the transfer belt. The transfer roller position sensor [D] detects the contact and separation positions. The transfer roller is driven by contact with the transfer belt. If the transfer roller contacts the transfer belt (i.e., the transfer roller position sensor is on) just after the main switch is turned on or just after the door safety switch is turned on (i.e., the front cover is closed), the machine assumes a paper jam has occurred. The main motor is driven to engage and disengage the transfer roller clutch, separating the transfer roller from the transfer belt (until the transfer roller position sensor is turned off).
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PAPER TRANSFER UNIT
2.6.4 BIAS
[B]
[A]
[C]
G024D427.WMF
[C]
G024D157.WMF
Normally, a constant current is applied to the transfer roller's [A] axle. A conductive bearing [B] allows an electrical connection between the bias terminal [C] and the transfer roller's axle. The current varies with paper type, size, and thickness as well as with humidity. After the user clears a paper jam or closes the front cover, the transfer roller turns and positive and negative currents are alternately applied. This removes any toner that may be attached to the transfer roller as the result of a jam. To be more specific, a negative bias is applied to the transfer roller for two revolutions. Then, a positive bias drives the transfer roller for 0.9 revolutions followed by a negative bias for another 0.9 revolutions. The positive/negative 0.9revolution cycle is done 30 times.
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PAPER FEED/REGISTRATION UNIT
2.7 PAPER FEED/REGISTRATION UNIT

2.7.1 OVERVIEW
14 13 12 11 10 9
8 7 6 5 4
G024D191.WMF
3 1 2
1. Friction pad 2. Paper size switch 3. Tray paper feed roller 4. Tray paper end sensor 5. Pull-out sensor 6. Pull-out rollers 7. Relay rollers
8. By-pass feed table 9. By-pass paper width detection board 10. By-pass pick-up roller 11. By-pass paper feed roller 12. By-pass paper end sensor 13. Registration sensor 14. Registration rollers
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2.7.2 COMPONENTS
Section Main function Paper feed/separation Paper tray bottom plate pressure Paper end detection Paper size detection By-pass feed table Registration Paper feed/separation Paper end detection Paper size detection Registration transport Registration detection Vertical transport Overview Friction pad separation method Paper tray bottom plate lifts by a spring Detection by a feeler and photo-interrupter User-specified by a dial; detected by switches FRR method Detection by a feeler and photo interrupter Width detection by a circuit board Drive transfer by electromagnetic clutch Detection by reflective photosensor Transport by roller
Paper tray
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2.7.3 STANDARD TRAY

Drive
[A]
[B]
[C]
G024D192.WMF
Drive from the main motor is transferred from a timing belt to the paper feed drive gear [A]. The paper feed drive gear drives the paper feed roller and pull-out roller via gears. These two rollers each have a clutch (paper pull-out: [B], feed: [C]) to transfer drive to the roller at the correct time.
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Paper feed/separation
[C] [A] [B]
G024D406.WMF
Mark detection Laser Exposure 175 Paper feed clutch Pull-out clutch 5 Pull-out sensor Relay roller clutch 297 Registration sensor 28 27.88 15
Registration clutch
524
G024D527.WMF
Timing for black, LT, long edge feed The paper tray uses a friction pad [A]. A compressed spring [B] pushes the friction pad up from the bottom, providing constant pressure to the sheet of paper against the paper feed roller [C]. The paper feed roller feeds the separated sheet to the relay rollers, which then feeds the sheet to the registration roller. When the registration sensor detects the sheet, the machine feeds the paper another 28 mm, then the relay roller clutch is disengaged to stop the paper.
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Tray lift
[D]
[A]
[B]
G024D402.WMF
Tension springs [A] connect the bottom plate [B] of the paper tray to the paper tray arm [C]. When the paper tray is placed in the main unit (printer), the guide block [D] for the main unit base lifts the paper tray arm. The springs keep the top of the paper stack at the correct level. Removing the paper tray extracts the paper tray arm from the guide block, lowering the bottom plate.
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[C]
Paper end detection

[B]
[A]
G024D403.WMF
The paper end sensor [A] is on the floor of the main unit (printer). When there is no paper in the paper tray, the sensor actuator [B] falls into the notch in the bottom plate, causing the sensor to trip.
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Paper size detection
[A]
[B]
G024D404.WMF
Paper size detection is based on the three paper size switches [A] on the main unit, which detect the setting of the paper size dial [B] on the paper tray. The paper size dial has grooves and ridges on the side facing the paper size switches. Each switch turns off when it falls into a groove, and turns on when a ridge presses it. Paper size detection for tray 1
Dial No. 1 2 3 4 5 6 7 8 Paper Size 11" x 17" SEF Others 71/4" x 101/2" LEF 81/2" x 14" SEF 81/2" x 11 LEF A4 LEF A3 SEF No Cassette Sensor Status XNOB2 XNOB1 XNOB0 0 0 0 0 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 1 0 1 1 1
SEF: Short edge feed LEF: Long edge feed Others: SEF - B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13", LEF - B5 JIS, A5, 51/2" x 81/2"
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2.7.4 BY-PASS FEED TABLE

Drive
[E] [D] [F] [C] [B]
G024D407.WMF
[A]
By-pass feed solenoid
By-pass paper feed clutch Registration sensor Registration clutch

G024D523.WMF
Timing for black, LT, long edge feed Drive is transferred from the paper feed drive gear [A] to the by-pass paper feed clutch [B] and the shaft [C]. The by-pass feed solenoid allows the pick-up roller to drop onto the top sheet of paper (refer to the next page). The by-pass paper feed clutch controls the drive change-over between the paper feed roller [D] and the pick-up roller [E]. (When the clutch is on, the pick-up roller turns; when the clutch is off, the feed roller turns.) The revolution of the separation roller [F] is synchronized with the main motor (in the opposite direction to the paper feed roller). Transparencies and thick paper are fed at half the speed of normal paper.
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Paper feed/separation
[B]
[D] [C]
[A]
G024D408.WMF
The paper feed/separation mechanism for the by-pass feed table is based on the FRR method. A spring [A] pulls the pick-up roller [B] towards the paper. When the solenoid [C] is turned on, the pick-up roller lowers and feeds the top sheet of paper in. A one-way clutch inside the paper feed roller [D] prevents the roller from turning in the opposite direction. The separation roller is driven in the opposite direction to the paper feed roller. The separation roller's axle utilizes a torque limiter made of a plastic coil spring. When the applied load exceeds a certain limit, the separation roller is forced to turn in the forward direction (due to the friction of the paper).
Paper end detection
[A] [B]
G024D193.WMF
When there is no paper on the by-pass feed table, the actuator [A] falls into the notch in the table. This actuates the paper end sensor (a photointerrupter) [B].
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Paper size detection

[A]
A4 DTL LT
A3
B5 EXE
B4
HLT LG
A5
B6
A6
[B]
G024D411. WMF
: Long edge feed : Short edge feed

A contact plate (or electrode plate) is connected to each of the two side fences [A]. The contact plates short the patterns on the paper size detection board [B]. Paper width is determined based upon which areas on the paper size detection board are connected (shorted together). Paper size detection for the by-pass feed tray
Paper Size A4 LEF A3 SEF 81/2" x 11" LEF 11" x 17" SEF 71/4" x 101/2" LEF B5 JIS LEF B4 JIS SEF 81/2" x 14" SEF 51/2" x 81/2" SEF A5 LEF 8" x 13" SEF 81/4" x 13" SEF 81/2" x 13" SEF B6 JIS SEF A6 SEF XBIT0 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 Sensor Status XBIT1 XBIT2 1 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 XBIT3 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1
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2.7.5 REGISTRATION
[A]
[B]
G024D414.WMF
[D]
[E]
G024D413.WMF
The registration sensor [A] detects the paper fed from the relay rollers. The paper then reaches the registration roller and the relay roller clutch disengages. This "pauses" the paper feed. The relay roller clutch [B] and registration clutch [C] engage simultaneously to restart paper feeding at the correct time in order to synchronize with the leading edge of the image on the transfer belt. The registration brake [D] at the center of the registration roller [E] helps to stop the roller quickly and prevents the axle from flexing.
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[C]
TRANSPORT/FUSING/PAPER EXIT UNIT
2.8 TRANSPORT/FUSING/PAPER EXIT UNIT

2.8.1 OVERVIEW
5 4 3 2 1
7 15 8 9 10 11 12 13 14
16
G024D182.WMF
1. Transport fan 2. Pressure roller thermistor 3. Pressure adjustment screw 4. Exit rollers 5. Oil bottle 6. Hot roller cleaning roller 7. Oil supply roller 8. Oil reservoir
9. Oil supply pad 10. Oil supply sub-roller 11. Oil blade 12. Hot roller 13. Fusing lamp (for the hot roller) 14. Hot roller thermistor 15. Pressure roller 16. Fusing lamp (for the pressure roller)
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2.8.2 COMPONENTS
Section Component Transport fan Drive unit Fusing unit Pressure unit Overview The transport fan creates an upward draw on the paper to hold the paper against the transport belt. This allows the paper to move smoothly towards the entrance of the fusing unit. Gears transfer drive from the main motor. Fuses the toner to the paper; has an oil supply mechanism. Applies constant pressure using a lever and screw mechanism. The oil supply pad absorbs oil. The oil supply roller applies a very small amount of oil to the hot roller via the oil supply sub-roller. The blade evenly spreads the oil on the hot roller. The pressure roller thermistor and hot roller thermistor detect temperature. The cleaning roller for the hot roller removes the toner attached to it. The scraper removes the toner attached to the cleaning roller. The actuator and photointerrupter detect when paper exits the machine. The microswitch detects an open cover.
Fusing
Oil supply
Heat detection Cleaning Paper exit detection Cover open detection
Paper exit
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Transport
2.8.3 FUSING UNIT DRIVE

[E [B] [C]
[D]
G024D303.WMF
[B]
[A]
G024D182.WMF
A gear train transfers drive from the main motor [A] to the fusing contact/separation gear [B]. Closing the front cover lowers the contact/separation lever [C] in direction [D]. This lifts the fusing contact/separation gear, which engages with the fusing drive gear [E]. Opening the front cover lowers the fusing contact/separation gear, disengaging the gear train. When the gears disengage, the knob for the fusing unit can be turned manually to remove paper jams. For thick paper or transparencies, the main motor revolution slows to half-speed.
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2.8.4 PAPER TRANSPORT
Registration sensor Registration clutch Transport fan

G024D525.WMF G024D304.WMF
1 second later
Transfer roller clutch 101.89 mm
[A]
The transport fan creates an upward draw holding the paper (fed by the transfer roller) against the transfer belt. The transfer belt then guides the paper to the fusing unit entrance guide plate. This prevents the side with toner from contacting the guide plate below the entrance to the fusing unit. The transport fan turns on when the paper has been fed 101.89 mm since the registration clutch turned on. The transport fan is turned off one second after the registration sensor detects the papers trailing edge. The paper exit sensor [A] is located at the exit of the fusing unit. The status of the paper exit sensor is checked by the CPU at specific time intervals. This is performed to detect jams.
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2.8.5 TEMPERATURE CONTROL

[D]
[C] [B] [A]

G024D305.WMF
The hot roller [A] and pressure roller [B] have independent thermistors [C] to monitor temperature. The hot roller fusing lamp is easier to heat or cool than the pressure roller fusing lamp, and may overheat quickly if left on. Therefore, the reheat start temperature for the hot roller fusing lamp is 10C higher than that for the pressure roller fusing lamp. The hot roller and pressure roller fusing lamps are heated alternately. When a fusing lamp reaches the reheat start temperature, the lamp is switched on and off alternately (the cycle is 1 second; for example, within this cycle, the printer may switch the lamp on for 0.6 s, and off for 0.4 s). In level-1 energy-saving mode, the fusing lamps are turned off. In level-2 energysaving mode, the fusing lamps are intermittently turned on to keep the pressure and hot roller temperature at 120C. The user can select which mode to use with the system menu in the user tools.
C 150 140 130 a b c
Time
a: Target temperature: 150C G024D524.WMF b: Hot roller temperature: Reheating starts at 150-10C. c: Pressure roller temperature: Reheating starts at 150-20C.
Fusing lamp Hot roller Pressure roller
Below 130C Full power Full power
Fusing lamp status 130C 140C Full power On/off On/off On/off
150C Off Off
The thermofuse [D] opens when it reaches 167C, removing power from the fusing lamp (this prevents the fusing unit from overheating).
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Fusing unit SC codes

SC No. 21 22 Name Pressure roller thermistor error High pressure roller temperature Low pressure roller temperature Condition The detected roller temperature has been at 0C for five seconds. The roller temperature has been at 190C for three seconds. Reheating has been done and the motor is not running, or 60 seconds have passed after the main motor halted. Then, the roller temperature has been below 130C for 60 seconds. The roller temperature has been at 0C for five seconds. The roller temperature has been at 190C for three seconds. Reheating has been done and the motor is not running, or 60 seconds have passed after the main motor halted. Then, the roller temperature has been below 130C for 60 seconds. When reheating, the roller temperature does not reach the reheat start temperature (target temperature -20C) within five minutes. When reheating, the roller temperature does not reach the reheat start temperature (target temperature -10C) within five minutes. During full-power operation for reheating, the main motor is not running and the difference between the temperatures now and 60 seconds ago is 3C or less. During full-power operation for reheating, the main motor is not running and the difference between the temperatures now and 60 seconds ago is 3C or less.
23
24 25
Hot roller thermistor error High hot roller temperature Low hot roller temperature
26
Pressure roller reheat timeout 49 Hot roller reheat timeout 50 Pressure roller full-power operation error (before reheating) Hot roller full-power operation error (before reheating)
51
52
The above SC codes are reset only by the Reset SC operation in engine SP mode. They cannot be reset by turning the main switch off and on.
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2.8.6 PRESSURE ROLLER

[C]
[B]
[A]
G024D531.WMF
The hot roller [A] is made of silicone. The pressure roller [B] is made of silicone covered with Teflon tubing. A compression spring and a screw [C] press the pressure roller against the hot roller. NOTE: Do not turn the pressure screw except for when performing the nip width adjustment. Nip width adjustment is necessary when the roller is replaced or uneven fusing across the page occurs.
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2.8.7 OIL END DETECTION
[A]
G024D307.WMF
A photointerrupter [A] detects the presence of oil. When there is no oil, the beam from the LED passes through to the phototransistor. However, if oil is present, the beam from the LED is refracted away and does not reach the phototransistor. When oil is not detected continuously for 10 seconds, the machine detects a fusing oil near-end condition. After near-end is detected, 200 sheets can be printed. Then, the machine detects a fusing oil end condition and no printing can be done.
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2.8.8 OIL SUPPLY
[A] [C] [B] [F] [C] [F] [D] [E]

G024D306.WMF
Oil drips from the oil bottle [A] to the oil reservoir [B]. The oil is absorbed in the oil supply pad [C], fed to the oil supply roller [D] by the oil supply sub-roller [E], and supplied to the hot roller [F]. NOTE: When an oil bottle is replaced with oil still in it, oil may drip from the oil bottle cap. To remove an oil bottle, use a cloth to prevent oil from dripping.
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2.8.9 CLEANING
[C] [A]
[B]
G024D313.WMF
[D]
The cleaning roller [A] cleans the hot roller [B]. The cleaning roller picks up any toner or paper dust from the hot roller. The scraper [C] removes the toner or paper dust from the cleaning roller. The collected toner or dust drops into the recess [D] behind the scraper.
2.8.10 PAPER EXIT COVER OPEN/CLOSED DETECTION
[A]
G024D309.WMF
[B]
The paper exit cover switch [A] detects when the paper exit cover [B] is opened or closed. This switch turns the 24 VDC power line on and off.
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OPEN COVER DETECTION
2.9 OPEN COVER DETECTION

2.9.1 FRONT COVER OPEN/CLOSED DETECTION
[B]
[A]
G024D101.WMF
This feature ensures safety during maintenance and inspection while the front cover [A] is opened. Opening or closing the front cover vertically moves the lever in contact with the actuators of the door safety switches [B]. The safety switches disable the 5 VDC and 24 VDC power lines.
2.9.2 DTM COVER OPEN/CLOSED DETECTION

A contact switch is used to detect whether the DTM cover [A] is open or closed. This feature prevents the machine from working if the DTM cover was accidentally left open after DTM replacement. This switch interrupts the 24 VDC supply.
[A]
G024D172.WMF
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INSTALLATION
ENVIRONMENT
3. INSTALLATION PROCEDURE
3.1 ENVIRONMENT
Recommended temperature and humidity
%RH 80 70 Recommended operation range

Installation
54 Possible range
40 30 20
10C (50F)
15C (59F)
25C 27C 32C (77F)(80.6F)(89.6F)

G024I502.WMF
1. Temperature Range: 2. Humidity Range: 3. Ambient Illumination:
10C to 32C (50F to 89F) 20% to 80% RH Less than 2,000 lux (do not expose to direct sunlight.)
4. If the place of installation is air-conditioned or heated, do not place the machine a) where it will be subjected to sudden temperature changes. b) where it will be directly exposed to cool air from an air conditioner. c) where it will be directly exposed to heat from a heater. 5. Do not place the machine where it will be exposed to corrosive gasses. 6. Do not install the machine at any location over 2,500 m (6,500 feet) above sea level. 7. Place the printer on a strong and level base. 8. Do not place the machine where it may be subjected to strong vibrations.
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MACHINE LEVEL
3.2 MACHINE LEVEL

1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level
3.3 MINIMUM SPACE REQUIREMENTS

Place the printer near the power source, providing clearance as shown:
G024I503.WMF
A: More than 5 cm (2.0") B: More than 10 cm (4.0") C: More than 70 cm (27.6") D: More than 65 cm (25.6")
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Installation
POWER REQUIREMENTS
3.4 POWER REQUIREMENTS

1. Input voltage level: 85 138V, 60 3 Hz: More than 12 A 187 276 V, 50/60 3 Hz: More than 6 A 2. Permissible voltage fluctuation: 10% 3. Do not set anything on the power cord. NOTE: 1) Make sure the plug is firmly inserted in the outlet. 2) Avoid multi-wiring.
For unpacking and installation procedures, refer to the Operating Instructions and the Quick Installation Guide.
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Installation
3.5 UNPACKING
TRANSPORTING
3.6 TRANSPORTING
To move a previously installed laser printer, follow the instructions below. 1. The printer weighs about 62 kg. Always be sure two or more people move the printer. 2. Keep the printer horizontal during transportation. (Do not concentrate the load on any one part of the base.) 3. Before moving the printer, pack the printer using the factory-supplied cushioning materials whenever possible. 4. Remove the oil from the fusing unit. 1) Remove the oil bottle from the printer before moving. 2) Drain the oil from the fusing unit. Refer to the Fusing section, Chapter 6 (Replacement and Adjustment Procedures), to remove the oil supply unit of the fusing unit. Gradually tilt the oil sump to drain the oil from the oil sump [A] to the oil bottle [B]. 3) After draining the oil to the oil bottle, wipe the oil sump and oil bottle with a clean cloth.
[A] [B]
G024I500.WMF
CAUTION
Make sure that no fusing oil remains in the printer. Remove the oil and clean the oil sump and oil bottle as explained above. Otherwise, the oil may spread inside the printer while moving it.
5. Insert cushioning material [E] between the DTM [C] and the left side panel [D] to secure the DTM in place. 6. Replace the fusing unit and cover. 7. Clean the printer before re-packing. 8. Remove paper from the paper tray. 9. Remove the optional paper tray. 10. Secure with tape the left, right, front, rear, top covers and the paper tray. [C] [E]
[D]
G024I501.WMF
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Installation
OVERVIEW
4. SP MODE
4.1 OVERVIEW
This printer has two SP modes: 1) Engine SP mode 2) Controller SP mode The various controller SP modes are detailed in the service manual for the controller. These two modes perform different functions.
4.2 ENGINE SP MODE

4.2.1 OVERVIEW
Entering engine SP mode
Service Tables
To enter engine SP mode, hold down the [Online] [A] and [Menu] [B] keys on the operation panel and turn on the power. [A]
[B]
G024O015.WMF
G024O016.WMF
To exit engine SP mode

Turn off the unit. NOTE: Be sure to exit from SP mode when you are finished.
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ENGINE SP MODE
Rev. 08/2000
Outline of the engine SP mode functions

The engine SP mode has the following menu items:
Menu Item 1: Margin 2: Parameter 3: Clear Memory 4: Sensor Check 5: Nip Width 6: Reset SC 7: Process Ctrl Function and application Independent vertical/horizontal registration adjustment for each tray, and for OHP mode Independent adjustment of transfer bias and fusing temperature for normal paper, thick paper, and OHPs Resets the counters and other values stored in NVRAM Sensor output check Nip width measurement for fusing pressure adjustment Resets fusing unit SC codes Implementation of forced, normal, and color bias setting process control and setting of execution intervals for periodic process control Prints internally generated patterns (4C overlay grids, 4x4 color belts, and solid-area color belts) for the print engine ID sensor output calibration Adjustment of image reproduction ratio in the main scan and subscan directions Tests for motors, clutches, and solenoids Fine adjustment of density for highlight (low-ID) areas. Adjustment of lubricant application interval Default 0. Do not change. Adjustment of the Primary (Belt) Transfer Bias.
8: Test Print 9: ID Sensor PWM 10: Image Adjust 11: Output Check 12: Hi-light 13: Lub_Interval 14: Soft Version 15: Belt-Tr Bias
4.2.2 MENU OPERATION/DISPLAY

In the engine SP mode menu, you can move between menu levels, specify parameters, and view LCD indications in the same way as with the user menu. The different menu items are described on the following pages. All menus are in English only.
Key operation
[!] and ["] keys: Scroll through the menus. When either of these keys is pressed in a number setting menu, the displayed value changes by the minimum value. [# Enter] key: When the selected item has a lower level menu, pressing this key moves you to the next lower level. At the lowest level, this key is used to determine the specified setting or execute the selected item. Pressing this key moves you to a higher level in the current menu. Before the specified value is confirmed by the [# Enter] key, pressing this key keeps the existing setting.
4-2 SM
[Escape] key:
G024
ENGINE SP MODE
LCD indications:
Title Selected item Maintenance 1. Margin
8 9
Arrow marks
Title: Selected item:
The menu title is displayed to show the current menu level. The currently selected item on the menu is displayed. Pressing the [v] or [w] key scrolls through the items at that level. The scrolling is sequential and loops back to the beginning (i.e. the first item is again displayed after the last item). In the lowest level of the menu, the currently selected item/setting is prefixed with an asterisk (*). To select an item/setting, press the [Enter] key while the target item is displayed. The item is then prefixed with an asterisk (*) for 0.5 seconds, and the next highest level menu is displayed. The arrow marks indicate that the items can be scrolled. These arrow marks are not shown if there is only one item in the menu.
Service Tables
Arrow marks:
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ENGINE SP MODE
4.2.3 MARGIN (REGISTRATION ADJUSTMENT)

The SP mode menu levels for registration adjustment are described below.
Layer 1 Layer 2 Layer 3 Layer 4 Print: Std Tray 1 It is also possible to print from the optional trays (tray 2 & tray 3) and the by-pass tray as performed for tray 1. Print: Thick By-pass Tray Print: Trans By-pass Tray Tray1:Left X.X Tray1:Top:1st X.X It is also possible to perform the adjustment for tray 2, tray 3, and the by-pass tray in the same way as for tray1. Trans:Top:1st X.X
Margin: Print Std. Paper Margin Pattern Print Margin: Print Thick Paper Margin: Print Transparency Margin: Adjust Tray1:Left Margin: Adjust Tray1:Top:1st Margin Adjust
Maintenance 1:Margin
Margin: Adjust Trans:Top:1st (For OHPs)
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ENGINE SP MODE
Follow the steps below to adjust registration in the 1. Margin item of the engine SP mode menu: 1. From the Pattern Print menu, select the media type and paper tray. Then, print the registration adjustment pattern (4C overlay grid pattern). 2. Measure the distance from the paper edge to the first vertical and horizontal lines of the grid patterns (X and Y in the diagram). 3. Move to the Adjust menu to adjust the vertical and horizontal registration. The adjustment range for the horizontal (Left) registration is between 2.0 and + 2.0 mm in units of 0.4 mm. The adjustment range for the vertical (Top) registration is between 2.5 and +2.5 mm in increments of 0.5 mm.
Adjustment standard values: X (horizontal) = 12.7 1.5 mm Y (vertical) = 10.8 1.0 mm NOTE: The LCD panel displays the horizontal registration as "Left" and the vertical registration as "Top".
Service Tables
G024P500.WMF
Paper transport direction
Y X
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ENGINE SP MODE
4.2.4 PARAMETER
Use this menu to specify the paper transfer bias and fusing temperature for normal paper, thick paper, and OHPs. The paper transfer bias can be specified in 1% increments between 50% and 200%. (Default: 100%) The fusing temperature can be specified in three steps: Low, Normal, and High (Default: Normal = 150C). The Low temperature is the Normal temperature minus 15C. The High temperature is the Normal temperature plus 15C. See the table below for Parameter menu details.
Layer 1 Layer 2 Layer 3 Std. Paper Transfer Bias Layer 4 Bias XXX% Temp. Low Temp. Std. Paper Normal Fusing Temp. Temp. High Same as Std. Paper Same as Std. Paper Same as Std. Paper Same as Std. Paper
Parameter Std. Paper Maintenance 2:Parameter Parameter Thick Paper Parameter Transparency
4.2.5 CLEAR MEMORY

Use this menu to reset all the settings stored in NV-RAM in the MCU or to reset the jam and SC counters individually. NOTE: Do not execute All in the field, because it clears all counters used to manage the replacement cycles for supplies. See the table below for Clear Memory menu details.
Layer 1 Layer 2 Clear Memory SC Clear Memory Jam Clear Memory All NOTE: Factory use only. Layer 3 Clear: SC Press # to clear Clear: Jam Press # to clear Clear: ALL Press # to clear Layer 4 Clearing SC Clearing Jam Clearing ALL
Maintenance 3:Clear Memory
SC: Resets the SC counter and SC history log Jam: Resets the paper feed jam counter, transfer jam counter, eject jam counter, and jam history log
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ENGINE SP MODE
4.2.6 SENSOR CHECK

Use this menu to check for sensor failures and status. Select the target sensor in the second level menu using the [v] and [w] arrow keys. Then, manually change the sensor status and check the corresponding output. After changing the sensor status, be sure to press the [Enter] key to update the display. See the table below for details of the Sensor Check menu.
Layer 1 Maintenance 4:Sensor Check Layer 2 Sensor Check XXX 0 or 1 Layer 3 Layer 4
The table below describes the relationship between the display values and the detected output of the sensors.
Sensor Name Name Display Paper End Sensor P End-1st (Tray 1) Paper End Sensor P End-By-pass (By-pass Tray) Paper End Sensor P End-2nd (Tray 2) Paper End Sensor P End-3rd (Tray 3) Registration Sensor Registration Exit Sensor Exit Paper Size Switch P Size-1st (Tray 1) Paper Size Switch P Size-2nd (Tray 2) Paper Size Switch P Size-3rd (Tray 3) By-pass Paper Width P Size-By-pass Detection Board PCU Set Switch PCU Set DTM Set Sensor CTC Set Toner End Sensor CTC Toner End Door Safety Switch Cvr Opn-F Exit Cover Switch Cvr Opn-EX Oil End Sensor Oil End (Fusing Unit) Fusing Set Used Toner Sensor Used Toner (Tray 2) Tray Set-2nd (Tray 3) Tray Set-3rd PCU Reset Sensor PCU Reset Revolver H.P. Sensor Revolver H.P. Sensor Status Service Tables 0 Paper detected Paper detected Paper detected Paper detected Paper not detected Paper detected *1 *1 *1 *2 Detected Detected Not end Closed Closed End Detected Not full Not detected Not detected Old Home position 1 Paper not detected Paper not detected Paper not detected Paper not detected Paper detected Paper not detected *1 *1 *1 *2 Not detected Not detected End Open Open Not end Not detected Full Detected Detected New Not home position
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ENGINE SP MODE
Sensor Name Name Display Transfer Roller Tfr Position Position Sensor Pull-out Sensor P Feed-2nd (Tray 2) Pull-out Sensor P Feed-3rd (Tray 3) ID Sensor ID Temperature/Humidity Humidity Sensor Temp DTM Cover Switch Cvr Opn-S Pull-out Sensor (Main Picup Body) Charger Corona Set Main Charger Switch Sensor Status 0 Release Paper not detected Paper not detected *3 *4 *5 Open Paper detected Detected Touch Paper detected Paper detected *3 *4 *5 Closed Paper not detected Not detected 1
*1: Paper size detection in Section 2 explains the status of the paper size switches for paper size detection. (0: Pressed, 1: Not pressed) *2: The table below shows the correspondence between the paper guide positions and displayed values.
Guide position Display Guide position Display A3W 20 12 20 A3/A4 04 11 04 B4/B5 22 10 22 A5 12 8 12 B6 0b 8 12 A6 0b 8 12
*3: The displayed value indicates the K sensor output when the LED in the ID sensor is turned on. The specified output value (reference for normal operation) is 2.7 0.8 V. *4: The detection results are shown in the XXX YYY format. XXX indicates absolute humidity, and YYY indicates relative humidity. (Reference for normal operation: YYY should be between 5 and 95.) *5: The displayed value indicates the detected temperature. (Reference for normal operation: Between 8 and 42)
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ENGINE SP MODE
4.2.7 NIP WIDTH

Use this to re-adjust the fusing pressure, which is required when the pressure adjustment screw for the fusing unit is loosened. This function feeds a transparency from the by-pass feed tray, then stops and resumes feed through the fusing unit three times, and finally ejects the transparency. This operation produces white cloudy patches on the transparency due to heating. For details of the operation, see Replacement and Adjustment - Checking and Adjusting the Fusing Nip Width. The table below shows the details of the Nip Width menu.
Layer 1 Maintenance 5:Nip Width Layer 2 Nip Width Press # to start Layer 3 Executing Layer 4
4.2.8 RESET SC
Service Tables
For safety purposes, fusing system SCs cannot be reset by turning the power off and on. Use this menu to reset a fusing system SC. The table below shows the details of the Reset SC menu.
Layer 1 Maintenance 6:Rest SC Layer 2 Rest SC Press # to reset Layer 3 Reseting* Fusing SC Layer 4
*As displayed in LCD
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ENGINE SP MODE
4.2.9 PROCESS CTRL

Use this menu either: To execute process control after performing maintenance work that affects process conditions (ID sensor cleaning/replacement, bias electrode cleaning, MCU NV-RAM replacement) To change the intervals for periodic process control and belt lubrication. There are four types of forced process control (these are listed below), and the parameters that are adjusted are different for each. (For a list of the steps in a process control operation, see Detailed Section Descriptions Process Control. Initialize: Forced process control to initialize the machine. This does all six steps of the process control procedure. Normal: This forced process control adjusts the process control parameters in the same way as the periodic process control self check Color Bias: Process control for setting color development bias. Only the color development bias initialization step is done. PCU Getting OK: Complete process control followed by belt lubrication routine for a new PCU After the end of each process control, Finish is displayed with the final status following it (OK for a successful process control, or NG in the event of an error). Use Interval set to change the interval at which the periodic process control is done. The interval for process control can be specified in units of 50 sheets between 0 and 250 sheets (default: 100 sheets). NOTE: Specifying 0 for the interval disables all process controls.
Layer 1 Layer 2 Process Ctrl. Initialize Process Ctrl. Normal Process Ctrl. Color Bias Process Ctrl. PCU Getting OK Process Ctrl. Interval Set Layer 3 Initialize Press # to start Normal Press # to start Color Bias Press # to start PCU Getting OK Press # to start Interval Set Press # to start Layer 4 Executing Executing Executing Executing
Maintenance 7:Process Ctrl
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ENGINE SP MODE
4.2.10 TEST PRINT

Use this menu to check print quality. This function prints a pattern that is internally generated by the print engine and is not processed by the controller. To stop printing, press the [Escape] key. The following three patterns can be printed using this function: Pattern 1: 4C overlay grids (color shifting, registration, and skew check) Pattern 2: 4x4 dots in each of 4C (jitter check) Pattern 3: 4C solid belt (use this for the ID sensor adjustment procedure) The table below shows the Test Print menu details.
Layer 1 Layer 2 Test Print Pattern 1 Test Print Pattern 2 Test Print Pattern 3 Layer 3 Pattern 1 Tray X Same as Pattern 1 Same as Pattern 1 Layer 4 Printing Tray X Same as Pattern 1 Same as Pattern 1
Service Tables
Maintenance 8:Test Print
4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)

Use this menu to calibrate the ID sensor output after replacing the ID sensor. For the full details of the calibration method, see Replacement and Adjustment Calibrating the ID Sensor. The table below shows the details for the ID Sensor PWM menu. The PWM value can be specified in one step increments between 140 and 160. (Default: 150)
Layer 1 Maintenance 9:ID Sensor PWM Layer 2 ID Sensor PWM XXX Layer 3 Layer 4
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ENGINE SP MODE
4.2.12 IMAGE ADJUST

Use this menu to adjust the reproduction ratio of images. With the top left corner as the reference point, adjustment can be done in steps of 0.1% within 1%.
Layer 1 Maintenance 10:Image adjust Layer 2 Image Adjust Main Scanning Image Adjust Sub-scanning Layer 3 Main Scanning XXX Sub-scanning XXX Layer 4
4.2.13 OUTPUT CHECK

Use this menu to check the operation of the clutches, motors, and solenoids individually. NOTE: Before testing the PCU, main, or revolver motors, remove the load beforehand (to do this, remove the motor from the machine, but keep it connected). The table below shows the Output Check menu details.
Layer 1 Maintenance 11:Output Check Layer 2 Out Put Check XXXXXXXX Layer 3 XXXXXXXX ON (OFF) Layer 4
Name By-pass feed clutch Pull-out clutch Paper feed clutch Relay roller clutch Registration clutch Transfer roller clutch Development drive solenoid By-pass feed solenoid Transfer belt cleaning solenoid
Display Bypass Feed Cl. Pick-up Cl. Feed Cl. Transport Cl. Regist. Cl. Tr. Roller Cl. Development Sol. Bypass Sol. Cleaning Sol.
Operation Operating for a certain time Operating until inputting OFF Operating for a certain time Operating until inputting OFF Operating until inputting OFF Operating for a certain time Operating until inputting OFF Operating for a certain time Operating until inputting OFF
G024
4-12
SM
ENGINE SP MODE Name Quenching lamp PCU motor Display Quenching LED PCU Motor-slow PCU Motor-normal PCU Motor-fast PCU Motor-reverse Main motor Main Mtr-normal Main Mtr-slow Polygon mirror motor Revolver motor Tray main motor (for tray 2) Paper feed clutch (for tray 2) Tray main motor (for tray 3) Paper feed clutch (for tray 3) Scanner Motor Revolver Motor OT1 Motor OT1 Feed Clutch OT2 Motor OT2 Feed Clutch Operation Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating until inputting OFF Operating for a certain time Operating until inputting OFF Operating for a certain time
SM
4-13
G024
Service Tables
ENGINE SP MODE
4.2.14 HIGHLIGHT ADJUSTMENT

Use this menu to adjust the density in high-light (low ID) areas for each of Y, C, M, and K. This adjusts the grid bias. After adjusting this setting, do a forced process control (engine SP mode 7, Process Contrl Normal, or Initialize) to make the new setting come into effect.
Layer 1 Layer 2 Hi-light adj cyan Hi-light adj magenta Hi-light adj yellow Hi-light adj black Layer 3 cyan 1 to 7 Same as cyan Same as cyan Same as cyan Layer 4
Maintenance 12:Hi-light adj
4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)

The belt lubrication interval is adjustable. The counter for this interval increases by one for each transfer belt revolution. (e.g. It increases by 4 with A3/DLT full color printing and by 1 in monochrome mode.) The default value is 100 transfer belt revolutions. This mode is helpful when insufficient toner is transferred to the printout, especially on text and/or line images. This can occur when a machine is used heavily. (The expected job size for this model is 5 sheets per job on average).In this case, making the interval shorter solves this problem. NOTE: This value should not be set to 0 because no lubrication is done with this value. The recommended value is between 50 to 100 for optimum machine performance.
Layer 1 Maintenance 13:Lub_Interval Layer 2 M Interval XXX Layer 3 Layer 4
G024
4-14
SM
Rev. 08/2000
ENGINE SP MODE
4.2.16 PRIMARY (BELT) TRANSFER BIAS ADJUSTMENT
This mode is used to adjust The Primary (Belt) Transfer Bias.

This value can be specified in 100V increments, between 800V and 1500V. The default setting is 800V. Increasing this parameter can print vertical lines more sharply but white dots may appear on solid image areas. Therefore, this mode should only be used when blurry vertical lines appear.
Layer 1 Layer 2 BLT-BIAS adj Cyan BLT-BIAS adj Magenta BLT-BIAS adj Yellow BLT-BIAS adj Back Layer 3 Cyan XXXX Magenta XXXX Yellow XXXX Back XXXX /# /# /# /# Layer 4
Maintenance 15: BLT-TR BIAS
NOTE: This mode is available starting from ROM version 2.23 (applied to November 1999 production.)
SM
4-15
G024
Service Tables
PM TASKS
5. PREVENTIVE MAINTENANCE
5.1 PM TASKS
5.1.1 REPLACEMENT
Replace the PM parts every 100 K printouts as shown in the PM table on the next page. The fusing unit replacement interval is not determined in the same way. For details, see the note after the PM table. For the replacement procedures, refer to Chapter 6 Replacement and Adjustment in this manual and Chapter 3, Replacement and Adjustment in the manual for the optional 500-sheet paper tray.
CAUTION
When replacing components, be aware that the fusing unit may be hot. Handle it with care.
5.1.2 CLEANING
Clean the printer components when visiting the customer site. See the PM table for the correct way to wipe the components. NOTE: Ensure that the charge corona unit cleaner is in the home position.
Preventive Maintenance
5.1.3 INSPECTION
Inspect the printer components when visiting the customers site. Visually inspect the components, and replace the components if there is any damage.
CAUTION
A high voltage is applied to bias electrodes. To inspect a bias electrode, ensure that the power switch is turned off.
SM
5-1
G024
PM TABLE
5.2 PM TABLE
5.2.1 MAIN UNIT
C: Clean R: Replace I: Inspect
item Paper feed roller Registration roller Friction pad Bottom plate pad By-pass feed roller Pull-out roller By-pass separation roller Charge corona unit Quenching lamp ID sensor Dust shield glass Fusing unit EM C C C C C C C C*1 I C C*1 60k 100k R R Note Alcohol or water Alcohol or water Water Water Alcohol or water Alcohol or water Alcohol or water Cleaner in the PCU Blower brush (if dirty) Dry cloth Cleaner brush (P/N: G0241533)
R*2
*1: This is a common item with user maintenance. *2: The amount per page that the counter counts up depends on the paper size: A3 or larger: 2 counts Smaller than A3: 1 count When the fusing unit counter reaches 60k a message is displayed on the LCD. However, printing can still continue.
5.2.2 OPTIONAL PAPER FEED UNIT

item Paper feed roller Friction pad Bottom plate pad EM C C C 60k 100k Note R Alcohol or water R Water Water
G024
5-2
SM
EXTERIOR
6. REPLACEMENT AND ADJUSTMENT

6.1 EXTERIOR
6.1.1 RIGHT COVER/OZONE FILTER COVER
[B] [A]
[C]
G024R151.WMF
1. Open the front cover. 2. Remove the right cover [C] (three screws). 3. Located inside the right cover, remove the ozone filter cover [A].
Replacement and Adjustment 6-1 G024
4. Remove the ozone filter [B].
SM
EXTERIOR
6.1.2 LEFT COVER
[A]
[B]
G024R152.WMF
1. Open the Front cover 2. Open the oil bottle cover [A]. 3. Remove the left cover [B] (three screws).
G024
6-2
SM
EXTERIOR
6.1.3 BOTTOM FRONT COVER
[B] [C]
[B] [A] 1. Open the front cover half way, and remove the two snap rings. [A] 2. Carefully slide the hinge levers [B] out from the bottom front cover [C]. Note that the levers are spring loaded. 3. Remove the bottom front cover.
6.1.4 FRONT COVER AND OPERATION PANEL

[D] [C]
[B] [B] [A]

Replacement and Adjustment 6-3 G024
1. Open the By-pass Tray [A]. 2. Remove the two front cover screws [B] and carefully move the front cover away from the printer. NOTE: The display's harness does not allow for much movement. 3. Carefully reach behind the front cover and unplug the display's connector. 4. It is now possible to remove the front cover. Next, release the two front hooks retaining the operation panel [D] and carefully "tilt" the operation panel to remove. NOTE: The surface of the operation panel circuit board is not insulated. If turning on the printer while the operation panel is removed from the front cover is required, be careful not to short-circuit this board.
SM
EXTERIOR
6.1.5 TOP COVER AND TOP REAR COVER
[B]
[A]
G024R167.WMF
[C]
G024R251.WMF
1. Open the oil bottle cover [A]. Remove the two screws holding the top cover [B], then slide and remove the top cover [B]. 2. Remove the top rear cover [C] (two "brass colored" screws).
G024
6-4
SM
INSIDE THE MAIN UNIT
6.2 INSIDE THE MAIN UNIT

6.2.1 GENERAL CAUTIONS
[B] [A]
[C]
[A]
G024R500.WMF
CAUTION: When replacing the components inside the main unit, follow the instructions below. 1. When placing the PCU outside of the printer, cover the photosensitive face with a sheet of paper, or similar material, to avoid direct exposure to light. 2. When rotating the PCU holder with the PCU removed, be careful not to touch the detection face of the ID sensor. 3. Do not turn the PCU coupling joints [A] manually. (Otherwise, the transfer belt [B] will scratch the OPC belt [C].) To turn the OPC or transfer belt manually, set the PCU in the main unit and check that the coupling joints are engaged. Then, turn one of the two flywheels at the rear. (First, pull the transfer cleaning contact/separation lever to release the cleaner if the cleaning unit is contacting the belt.)
Replacement and Adjustment
SM
6-5
G024
6.2.2 ID SENSOR
[A]
[B]
G024R106.WMF
1. Remove the PCU. Be sure to properly protect the PCU from light exposure. 2. Remove the ID sensor [A] (1 screw, 1 connector [B]). NOTE: Calibrate the new ID sensor after installing it. Follow the steps described in Calibrating the ID sensor on the next page.
G024
6-6
SM
6.2.3 CALIBRATING THE ID SENSOR

ID sensor calibration flowchart
SP "9: ID Sensor PWM" Set 150 as PWM.
SP "7: Process Ctrl" Execute "Color Bias."
SP "8: Test Print" Print "Pattern 3."
Is the density good? Yes SP "7: Process Ctrl" Execute "Initialize."
No
SP "9: ID Sensor PWM" Dark: PWM +1 Pale: PWM -1
Restart the printer in normal mode.
G024R510.WMF
NOTE: After replacing the ID sensor, calibrate it as described below. Without calibration, proper color densities may not be achieved. 1. Hold down the Online and Menu keys, and turn on the printer. (This initiates the engine SP mode.) 2. Select 9: ID Sensor PWM in the engine SP menu. Specify 150 as the PWM value. Press # Enter, an asterisk (*) is displayed next to the value. Next, Press the [Escape] or [Menu key].
3. Select 7: Process Ctrl in the engine SP menu. Execute Color Bias. (This starts (executes) the process control for the color development bias settings.) Wait until "Finish OK" is displayed and the printer finishes cycling. Then, press the [Escape] or [Menu] key. 4. Select 8: Test Print in the engine SP menu. Execute Pattern 3 to print pattern 3. (Select a tray with paper in it.) NOTE: Test printing is executed continuously. To stop test printing, press the [Escape] or [Menu] key. 5. Check the test print. If the YCM solid areas of the printed image are too dark, return to step 2 and increase the PWM value by one. If the YCM solid areas are too pale, return to step 2 and decrease the PWM value by one. Then, repeat steps 3 to 5. 6. If the YCM solid area density is good, select 7: Process Ctrl in the engine SP menu and execute Initialize. (This executes a complete forced process control self-check.) 7. After the forced process control self-check is completed, restart the printer in normal mode.
SM 6-7 G024
6.2.4 PCU SET SWITCH/CHARGE CORONA UNIT SET SWITCH/PCU RESET SENSOR/ USED TONER SENSOR/QUENCHING LAMP
[A]
[D]
[B]
[C] [E] [F]

G024R107A.WMF
1. Remove the PCU. Be sure to properly protect the PCU light exposure. 2. Remove the PCU set switch [A] (two hooks). Make sure to unplug the connector. 3. Remove the right cover. (See Right Cover Removal.) 4. Remove the PCU reset sensor [B] (four hooks, one connector). 5. Remove the quenching lamp and its bracket [C] (three screws, one connector). 6. Remove the charge corona unit set switch [D] (two hooks, one connector [E]). 7. Remove the used toner sensor [F] (two screws, one connector).
G024
6-8
SM
6.2.5 PULL-OUT SENSOR/PAPER END SENSOR

Pull-out sensor
[A]
[B]
G024R275.WMF
1. Remove the PCU. Be sure to properly protect the PCU from light exposure. 2. Remove the pull-out sensor [A] (four hooks, one connector [B]).
Paper end sensor

[E] [C]
[D]
G024R900.WMF
1. Remove the paper end sensor bracket [C] (one screw). 2. Remove the paper end sensor [D] (four hooks, one connector [E]).
SM
6-9
G024
6.2.6 OIL END SENSOR/EXIT COVER SWITCH

[C] [D] [A]
[B]
G024R108B.WMF
1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the oil end sensor [A] (two hooks, one connector [B]). 3. Remove the exit cover switch bracket [C] (one screw, two connectors). 4. Remove the exit cover switch [D] (two screws). NOTE: The top terminal for the exit cover switch is not connected to the cable.
G024
6-10
SM
6.2.7 FRONT COVER SAFETY SWITCH, PCU MOTOR, MAIN MOTOR

[A] [D]
[C]
G024R115.WMF
[E]
G024R161.WMF
[B]
G024R162.WMF
1. Remove the right cover. (See Right Cover Removal.) 2. Remove the front cover (door) safety switch [A] (two screws, six connectors). 3. Remove the top flywheel [B] (three screws). 4. Loosen the tightener [C], and remove the PCU timing belt from the motor shaft. 5. Remove the PCU motor [D] (four screws, one connector). 6. Remove the main motor [E] (four screws, one connector).
SM
6-11
G024
6.2.8 TRANSFER BELT CLEANING SOLENOID/DEVELOPMENT DRIVE SOLENOID

[G]
[E]
[D]
[C]
[E] [B] [A] [F]

G024R163A.WMF
1. Remove the right cover. (See Right Cover Removal.) 2. Remove the PCU motor. (See PCU Motor Removal.) 3. Remove the bottom flywheel [A] (three screws). 4. Remove the bracket assembly [B] (six screws, one E ring [C], one bearing [D], two connectors [E]). 5. Remove the development drive solenoid [F] and/or transfer belt cleaning solenoid [G]. 6. After replacing the development drive solenoid, adjust the development joint position (see the procedure on the next page). NOTE: When putting back the bearing, hold the shaft in order to place the bearing between the revolver gear and side plate.
G024
6-12
SM
6.2.9 ADJUSTING THE DEVELOPMENT COUPLING JOINT

[A] [E] [D]
[C] [B]
[F]
G024R518.WMF
G024R516.WMF
Performing this procedure is required after replacing the development drive solenoid. 1. Remove the left cover. (See Left Cover Removal.) 2. Remove the right cover. (See Right Cover Removal.) 3. Remove the PCU and properly protect it from light exposure. 5. Remove the YCMK DTMs. (See DTM Unit Removal.) 6. Remove the support. (See LD Unit Removal.) 7. Loosen the two screws [B] retaining the development drive solenoid [A]. 8. Enter SP mode. Select Development Sol in the output test menu to turn on the development drive solenoid. (See Section 4, Output Check.) 9. Set the adjustment tool (P/N: G0249310) [F] between the development coupling joint [E] and right side plate [D]. (For this step, the part of the tool containing the hole should be between the coupling joint and the side plate.) 10. Push the solenoid from the back towards the solenoid bracket [C] (see the arrow in the diagram), and tighten the two screws [B]. 11. Extract the adjustment tool. Place the other part of the adjustment tool (without the hole) between the coupling joint and the side plate. If there is no friction between the adjustment tool and the development joint, the adjustment is completed. If there is any friction, repeat from step (7).
SM 6-13 G024 Replacement and Adjustment
4. Remove the main motor. (See Main Motor Removal.)
6.2.10 PCU DRIVE UNIT
[D] [C]
[A]
[A]
[C] [D] [B]

G024R111.WMF
1. Remove the right cover. (See Right Cover Removal.) 2. Loosen the tightener retaining screws [A] to release tension. 3. Remove the PCU joint drive unit [B] (four screws). NOTE: When installing the PCU drive unit, make sure that the arm is set in the constrictions of the two coupling joints. Also set the coupling joint pressure springs [C] between the pressure arm protrusion and the bracket embossment. After the PCU drive unit is retained, check that the belt is given sufficient tension from the tension springs [D] before tightening the tightener screws.
G024
6-14
SM
6.2.11 REVOLVER MOTOR
[B]
[A]
G024R901.WMF
1. Remove the right cover. (See Right Cover Removal.) 2. Remove the revolver motor unit [A] (three screws, one connector [B]).
SM
6-15
G024
6.2.12 DTM UNIT
[B]
[A]
G024D164A.WMF
1. Turn off the printer. 2. Open the DTM cover [A] and remove the DTM unit [B]. Refer to the Quick Installation Guide and Operating Instructions. NOTE: 1) Be careful not to drop toner onto the floor. (Before placing the DTM unit on the floor, lay several clean sheets of paper first.) 2) After installing a new DTM unit, remove the seal. Then, close the DTM cover and turn on the printer to enter setup mode. Set up the subsequent DTM units according to the instructions displayed on the panel. For details of installing cartridges in setup mode, refer to the Operating Instructions.
G024
6-16
SM
LASER OPTICS SECTION
6.3 LASER OPTICS SECTION

6.3.1 LD UNIT
[A]
[B]
G024R266.WMF
[C] [D]
[E]
G024R267.WMF
1. Remove the right cover. (See Right Cover Removal.) 3. Lift the handle [A] to release the lock. Remove the Y, M, C, and K DTM units [B]. NOTE: Do not hold and turn the DTM units by hand as this puts too much load on the revolver motor. Hold and turn the revolver motor to move the DTM units to the removal position. 4. Loosen the support stopper screw [C]. Lift the support stopper [D] and temporarily tighten the screw. Then, remove the support [E]. NOTE: After putting back the support, remember to lower the support stopper and tighten the screw.
2. Remove the left cover. (See Left Cover Removal.)
SM
6-17
G024
[A]
[B]
G024R258.WMF
[E] [D]
[C] [E]
G024R259A.WMF
5. Remove the development top cover [A] (three screws). 6. Remove the development bottom cover [B] (two screws and 3 hooks). 7. Remove the LD unit [C] (two screws, one connector [D]). CAUTION: Do not loosen the painted screws [E].
G024
6-18
SM
6.3.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR
WARNING
Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes.
[C] [D]
[A]
[A]
[D]
[B]
G024R269.WMF
[B]
G024R270.WMF
2. Remove the fusing unit. (See Fusing Unit Removal.) 3. Remove the PCU reset sensor from the bracket. (See PCU Reset Sensor Removal.) 4. Remove the LD unit. (See LD Unit Removal.) 5. Open the front cover. Insert a long phillips screwdriver through the opening [A] in the bottom front cover towards the PCU holder notch. 6. Remove the two screws [B] holding the front side of the stay. 7. Remove the two screws [C] retaining the charge bias electrode. 8. Remove the two screws [D] retaining the top side of the stay. Tilt the stay forward.
SM
6-19
G024
1. Remove the PCU (Be sure to protect the PCU from excessive light exposure.) and the Y, C, M, and K DTM units (see DTM Unit Removal), left cover (see Left Cover Removal), rear top cover (see Top Cover Removal), bottom front cover (see Bottom Front Cover Removal), and tray cover (see Controller Board Removal).
[E]
G024R522.WMF
[H]
[G]
G024R504A.WMF
CAUTN-V.WMF
LASER-3.WMF
9. Remove the duct [E] for the exhaust fan (one screw). 10. Remove the optical housing unit [G] (four screws, two connectors [H]), lifting it in the direction of the arrow in the diagram. NOTE: When putting back the optical housing unit, check that the positioning boss on the housing bottom plate is in the hole in the main unit base.
G024
6-20
SM
[I]
[J]
G024R263.WMF
G024R506A.WMF
12. Remove the polygon mirror motor [J] (four screws).
SM
6-21
G024
11. Remove the optical housing unit cover [I] (four screws and two hooks). NOTE: When removing or putting back the bracket, be careful not to touch the polygon mirror faces.
FUSING SECTION
6.4 FUSING SECTION

6.4.1 FUSING UNIT
CAUTION
1. The fusing unit is hot. Handle with care. 2. Be careful not to spill silicone oil. 3. In the event of a fusing-related SC, replace the applicable components and execute 6: Reset SC in the engine SP menu to release the SC. 4. When the fusing unit has been replaced, execute S3 Maintenance Clear in the controller SP menu to reset the fusing counter.
[B]
[A]
[C]
G024R168.WMF
1. Remove the top cover. (See Top Cover Removal.) 2. Open the oil bottle cover [A] and remove the fusing unit [B] (three green flat "knob" screws [C] and a grounding wire). NOTE: The flat "knob" type screws retaining the fusing unit remain attached to the bottom of the fusing unit stay even when they are fully loosened.
G024
6-22
SM
FUSING SECTION
6.4.2 OIL SUPPLY UNIT, PRESSURE ROLLER LAMP, HOT ROLLER LAMP, PRESSURE ROLLER THERMOFUSE, PRESSURE ROLLER THERMISTOR
[A] [C] [B] [D]
G024R169A.WMF
[D]
G024R170.WMF
NOTE: If the pressure spring retaining screw has been turned while replacing the pressure or hot roller, adjust the nip width. See Checking and Adjusting the Fusing Nip Width for details. 1. Remove the fusing top cover [A] (four screws). 2. Remove the pressure roller thermistor [B] (one screw, one connector). 3. Remove the pressure thermofuse [C] (one screw, two connectors [D]).
Replacement and Adjustment SM 6-23 G024
FUSING SECTION
[A] [B]
G024R172.WMF
G024R173.WMF
4. Remove the exit guide. (See Exit Sensor Removal.) 5. Remove the oil supply unit [A] (two screws). 6. Remove the holder [B] for the right fusing lamp terminals (three screws, three connectors). Make note of all connector locations prior to unplugging.
G024
6-24
SM
FUSING SECTION
[A]
G024R174.WMF
[B]
[C]
G024R175.WMF
7. Remove the holder [A] for the left fusing lamp terminals (two screws, five connectors). Make note of all connector locations prior to unplugging. 8. Carefully extract the pressure roller lamp [B]. 9. Carefully extract the hot roller lamp [C].
FUSING SECTION
Reinstallation
Make sure that the cables are connected to their correct places. Refer to your observations made during removal and the illustrations below. [b] [d]
[a] [c]
G024R174.WMF
[B] [D]
[C] [A]
G024R173.WMF
Pressure roller lamp connector [a], [A] Hot roller lamp connector [b], [B] Pressure roller thermofuse connector [c], [C] Hot roller thermofuse connector [d], [D]
G024
6-26
SM
FUSING SECTION
6.4.3 OIL SUPPLY ROLLER, OIL SUPPLY SUB-ROLLER, BLADE

[C]
[A]
[B] [D] [C] [E]

G024R176.WMF
1. Remove the oil bottle [A]. NOTE: Oil tends to remain in the cap. Keep the oil bottle [A] lifted a little for a while, wait for the oil drips to stop, then move the oil bottle outside the printer. 2. Remove the oil supply felt cover [B] (four washers and four screws). 3. Remove the upper oil supply felt [C] (three screws). NOTE: When installing the upper oil supply felt on the oil pan, place it on the lower oil supply felt [D] and tighten the screws as shown in the diagram. Then, attach the oil supply felt cover. (Make sure that the upper oil supply felt is resting on top of the lower oil supply felt.) Also, check that the felt contacts the bottom surface of the oil pan [E].
SM
6-27
G024
FUSING SECTION
[A]
[C] [B]
G024R177.WMF
[D]
G024R178.WMF
4. Remove the oil supply stay [A] (two screws). NOTE: When installing the oil supply stay, ensure that the notch fits over its counterpart. 5. Remove the oil supply sub-roller [B] (two E rings and two bearings). 6. Remove the oil supply roller [C] (two E rings and two bearings). 7. Remove the blade [D] (one screw).
G024
6-28
SM
FUSING SECTION
6.4.4 PAPER EXIT SENSOR, CLEANING ROLLER
[B]
[D] [C]
G024R309.WMF
[A]
[F] [E] [G] [H]

G024R521.WMF G024R171A.WMF
1. Open the exit top guide [A], and remove the exit bottom guide [B] (two screws). NOTE: When installing the exit bottom guide, put the paper exit feeler [C] under the guide notch [D] as shown in the diagram. 2. Remove the exit guide [E] (one snap ring [F], one screw [G], and one bracket [H]). NOTE: Be careful not to break the hooks on the guide.
SM
6-29
G024
FUSING SECTION
[A]
[B]
G024R179.WMF
Paper exit sensor

3. Remove the paper exit sensor [A] (one screw and four hooks).
Cleaning roller
4. Remove the cleaning roller [B] (two E rings, one gear, two springs, and two bearings).
G024
6-30
SM
FUSING SECTION
6.4.5 PRESSURE ROLLER, HOT ROLLER, HOT ROLLER THERMOFUSE, HOT ROLLER THERMISTOR
[A] [B] [E]
[F]
[C]
G024R180.WMF
[E]
[D]
G024R181.WMF
1. Remove the inlet guide plate [A] (two screws). NOTE: Put the two screws into the central screw holes [F] in the inlet guide plate when reinstalling it. The right and left screw holes are intended for adjusting the inlet path in the event of wrinkling or other similar feed problems. 2. Remove the fusing stay [B] (two screws). NOTE: Be careful not to scratch the pressure roller. 3. Remove the left pressure lever [C] (one screw and one spring). 4. Remove the right pressure lever [D] (one screw and one spring). 5. Remove the pressure roller [E] (one C ring, two bearings, and one gear).
SM
6-31
G024
FUSING SECTION
[A]
G024R182.WMF
[D] [B] [C]

G024R183.WMF
6. Remove the hot roller [A] (two "C" rings, two bearings, and one gear). 7. Remove the inlet guide plate [B] (two screws). 8. Remove the hot roller thermistor [C] (one screw). 9. Remove the hot roller thermofuse [D] (one screw).
G024
6-32
SM
FUSING SECTION
6.4.6 CHECKING AND ADJUSTING THE FUSING NIP WIDTH

10 mm 10 mm
L1 Alteration belt
R1
L2
R2
L3
R3
G024R520.WMF
NOTE: 1) Wait five minutes or longer after completion of warm-up before starting the steps below. 2) Put one transparency (long edge feed) in the by-pass feed table. 1. Enter engine SP mode. Select Nip Width mode. 2. Wait until the transparency is ejected. For each of the three "alteration" bands, measure the width at 10 mm from both the right and left ends and at the center. If the widths of the "alteration" bands fluctuate at small intervals, measure the narrowest width near the three points above.
3. Obtain an average of the right and left widths of the three bands. Check that the average meets the following standard. L (left): 6.5 0.2 mm R (right): (L+0.25) 0.15 mm
SM
6-33
G024
FUSING SECTION
[A]
G024R314.WMF
4. If the average fails to meet the standard, turn the pressure screw [A]. (Black arrow direction: more nip width. White arrow direction: less nip width)
Troubleshooting
1. Wrinkles Adjust the nip width to the upper limit of the standard (L: 6.7 mm, R: 7.1 mm). After adjustment, check that worm-like images (Mimizu) do not appear. 2. Worm-like images Adjust the nip width to the lower limit of the standard (L: 6.3 mm, R: 6.4 mm). After adjustment, check that no wrinkles are generated.
G024
6-34
SM
ELECTRICAL WIRING
6.5 ELECTRICAL WIRING

6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR
NOTE: Before replacing the controller, print the list of settings whenever possible. In the event of NVRAM damage, it is necessary to configure all settings according to this printed list. 1. Remove the tray cover [A]. (two screws). 2. Remove the temperature/humidity sensor cover [B] (one screw). 3. Remove the temperature/humidity sensor [C] (one screw, one connector [D]). NOTE: If the customer has added the optional expansion memory or a NIC, remove it before controller replacement. Remember to install the memory or NIC on the new controller board. 4. Remove the controller cover [E] (16 screws, including 2 screws at the parallel port connector). 5. Remove the controller board [F] with the bracket [G] attached to it (six screws, one connector [H]). 6. Remove two screws and one bracket [G] from the controller board. [G]
G024R184.WMF
[B]
[C]
[D] [A]
G024R164.WMF
[E]
NOTE: To replace controller boards, remove the NVRAM chip (IC23) on the old board, install it on the new board, then install the new board. The NVRAM chip stores user settings and service records. These settings will be lost if the NVRAM chip is not transferred. [F] [H]
G024R166.WMF
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ELECTRICAL WIRING
6.5.2 POWER SUPPLY UNIT
WARNING
To avoid the risk of electric shock, unplug the power cable before starting power supply unit replacement.
1. Remove the fusing unit (see Fusing Unit Removal) and the controller board (see Controller Board Removal).
[A]
2. Remove the bracket [A] (two screws).
G024R253.WMF
3. Remove the eight screws retaining the electrical wiring box [B], unplug two connectors, and release the two hooks. Lift the left side of the electrical wiring box [B] upwards ? to swing it out @.
[B]
G024R252.WMF
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ELECTRICAL WIRING
4. Remove the power supply unit [C] (six screws, six connectors).
[C]
G024R254.WMF
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G024
ELECTRICAL WIRING
6.5.3 HIGH VOLTAGE SUPPLY UNIT

[A]
[B]
G024R255.WMF
1. Remove the right cover (see Right Cover Removal), left cover (see Left Cover Removal), controller board (see Controller Board Removal), and power supply unit (see Power Supply Unit Removal). 2. Open the rear side panel [A] (eight screws and two hooks). NOTE: Before opening the rear side panel, unplug connectors from the power supply unit and the high-voltage supply unit as necessary. 3. Remove the high-voltage supply unit [B] (four screws, two hooks, eight connectors).
CAUTION
Carefully connect the high-voltage wires as shown in the diagram below.
Blue connector: Supply roller
CN190
White connector: Transfer roller
White connector: White connector: Belt transfer bias Development roller roller Yellow connector: Development blade
Yellow connector: Charge corona unit wire
G024R512.WMF
Blue connector: Charge corona unit grid
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ELECTRICAL WIRING
6.5.4 MCU
[A]
G024R256.WMF
1. Open the rear side panel (See High Voltage Supply Unit Removal). 2. Remove the MCU [A] (four screws, 18 connectors). NOTE: When replacing an MCU, remove the NVRAM chip (IC106) from the old board, install it on the new board, then install the new board. In the event of NVRAM damage, install a new NVRAM chip, and contact your supervisor for additional steps. A forced process control will also have to be done (engine SP mode 7: Process Control Initialize).
ELECTRICAL WIRING
Rev. 02/00
6.5.5 UPGRADING THE MCU FIRMWARE

NOTE: Turn off the printer before inserting or removing the IC card. (Otherwise the IC card may be damaged.) 1. Remove the left cover. (See Left Cover Removal.) 2. Remove the bracket to the bottom left of the revolver unit (one screw). 3. Insert the IC card that contains the MCU software into the IC card slot of the MCU. The side with A on it must be facing upwards. 4. Turn on the printer. (Check that the following is displayed on the operation panel.)
R Vxxx C Vxxx Enter On Line KEY

G024R514.WMF
Current Firmware version
Version of Firmware in the IC card
5. Check that the firmware versions are correct. (Make sure that the firmware in the IC card is later than the current one.) Press the On Line key. 6. Check that the messages on the operation panel change in the following sequence:
FLASH DWLOADING ERASE!!
FLASH DWLOADING WRITING
FLASH DWLOADING OK!! OK!!

G024R513.WMF
7. Upon the OK!! OK!! message, the MCU flash ROM has been updated. (If the NG message is displayed, try performing the upgrade procedure again from the beginning.) 8. Turn off the printer. 9. Remove the IC card. 10. Put back the bracket and the left cover. 11. Start the printer in engine SP mode. Check the engine firmware version, which is displayed immediately after power-on. (If the firmware version differs from the IC card firmware version displayed in step 3, repeat from step 1.)
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PAPER FEED SECTION
6.6 PAPER FEED SECTION

6.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR
[A] [B]
[C]
[D]
G024R154.WMF
1. Remove the front cover. (See Front Cover Removal.) 2. Remove the paper end sensor bracket [A] (one screw). 3. Remove the by-pass paper end sensor [B] (one connector and four hooks). 4. Remove the registration sensor [C] (one screw, one connector [D]).
PAPER FEED SECTION
6.6.2 PAPER WIDTH DETECTION BOARD
[A]
[B]
G024R155.WMF
[E] [C] [D] [D] [F] [B]
G024R105.WMF G024R156.WMF
1. Remove the front cover. (See Front Cover Removal.) 2. Remove the by-pass feed table unit [A] (two snap rings, two hooks, one connector [B]). 3. Remove the auxiliary tray [C] (two hooks), from the cover [D] for the by-pass feed table. 4. Remove the table [E] (two hooks). 5. Remove the paper width detection board [F] (one screw).
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PAPER FEED SECTION
6.6.3 BY-PASS PAPER FEED ROLLER
[A]
G024R157A.WMF
[B]
[E]
[C]
Replacement and Adjustment G024
[D] 1. Remove the front cover. (See Front Cover Removal.)
G024R158.WMF
2. Remove the paper end sensor bracket. (See By-pass Paper End Sensor Removal.) 3. Remove the pad bracket [A] (three screws). 4. Remove the transport guide plate [B] (two screws). 5. Remove the pick-up roller [C] (one snap ring). 6. Remove the separation roller [D] (one snap ring). 7. Remove the paper feed roller [E] (one snap ring).
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PAPER FEED SECTION
6.6.4 PAPER FEED ROLLER
[A]
[B]
G024R408.WMF
1. Remove the paper feed tray. 2. If necessary, carefully pull the front bottom cover forward slightly. Slide the lever [A] in the direction of the arrow in the diagram, and remove the paper feed roller [B].
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PAPER FEED SECTION
6.6.5 PCU HOLDER
CAUTION
Before removing the torsion springs [C] in the following procedure, make sure that the front cover is closed (to release the pressure). If the springs are removed while pressure is applied to them, they may jump out and cause injury. [B] 1. Remove the sensor bracket [A] (two screws, two connectors). 2. Remove the bracket [B] (two screws). Remove the right and left torsion springs [C]. Remove the right and left caps [D] (one screw each). [D]
[C]
[A] [E] 3. Open the paper feed frame and unplug the ID sensor connector. Pull out the right and left rotation shafts [F] until the [G] PCU holder [E] can be removed.
G024R409.WMF
NOTE: Do not entirely pull out the rotation shafts, or the paper feed frame will drop. Hold the PCU holder with one hand, [H] and gradually pull out the rotation shafts with the other [F] hand. To remove the PCU holder, lift it with the front side G024R410.WMF panel kept vertical. When installing the PCU holder, keep the front side panel vertical and lower it straight down between the printer side panels. (There is a toothed section [G] below the left side panel of the holder, which engages the damper gear [H].)
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PAPER FEED SECTION
6.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS PAPER FEED CLUTCH, REGISTRATION CLUTCH, AND TRANSFER ROLLER CLUTCH
[A]
G024R159.WMF
1. Remove the right inner cover [A] (three screws). 2. Remove the front cover. (See Front Cover Removal.)
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PAPER FEED SECTION
[A] [B]
G024R519.WMF
[E] [F] [C] [H] [I] [G]

G024R160.WMF
[D]
Transfer roller position sensor

3. Remove the transfer roller position sensor [A] (four hooks, one connector [B]).
By-pass paper feed clutch

4. Remove the by-pass paper feed clutch [C] (one hook, one connector [D]).
Replacement and Adjustment G024
Registration clutch
5. Remove the registration clutch [E] (one hook, one connector [F]).
Transfer roller clutch

6. Remove the bracket [G] (two screws). 7. Remove the transfer roller clutch [H] (one cam, one bearing, one connector [I]). NOTE: When putting back the by-pass paper feed clutch, registration clutch, or transfer roller clutch, put the stopper on the bent part of the bracket.
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PAPER FEED SECTION
6.6.7 TRANSFER ROLLER
[A]
G024R265.WMF
1. Remove the front cover. (See Front Cover Removal.) 2. Remove the right inner cover (three screws). See Transfer Roller Position Sensor Removal. 3. Remove the transfer roller [A] (three E rings, one gear, and two bearings).
6.6.8 REGISTRATION ROLLER IDLER

[A]
[B] [C]
G024R406.WMF
1. Remove the front cover. (See Front Cover Removal.) 2. Remove the right inner cover (three screws). See Transfer Roller Position Sensor Removal. 3. Remove the grounding plate [A] (one screw). 4. Remove the registration roller idler [B] and guide plate [C] (two E rings, two bearings, and two springs).
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PAPER FEED SECTION
6.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE ROLLER

[E]
[B]
[D]
[A]
[C]
G024R407A.WMF
1. Remove the front cover (see Front Cover Removal) and registration roller idler (see Registration Roller Idler Removal). 2. Remove the registration clutch [A] (one hook, one connector [B]). NOTE: When putting back the registration clutch, put the stopper on the bent part of the bracket. 3. Remove the guide plate [C] (three hooks, one connector [D]). 4. Remove the registration drive roller [E] (two E rings and two bearings).
PAPER FEED SECTION
6.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH, AND PULL-OUT/RELAY ROLLER CLUTCH
[A]
[B] [C]
G024R273.WMF
[H] [G] [D]

G024R274.WMF
[E]
[F]
1. Remove the front bottom cover (see Front Bottom Cover Removal) and the paper feed roller (see Paper Feed Roller Removal). 2. With a flat-blade screwdriver, lift the hook [A] of the paper feed roller lever. Push the paper feed roller shaft [B] towards the left until it disconnects from the tray paper feed clutch [C]. NOTE: Rotate the shaft into the correct orientation when putting it back into the clutch. (The shaft and the hole for the shaft in the clutch are D-shaped.)
Paper size switch

1. Remove the paper size switch bracket [D] (one screw). 2. Remove the paper size switch [E] (two hooks, one connector [F]).
Paper feed clutch

3. Remove the tray paper feed clutch [G] (one hook, one connector [H]). NOTE: When installing the paper feed clutch, put the stoppers in the two holes in the bracket before inserting the shaft.
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PAPER FEED SECTION
Pull-out clutch
[B]
[A] [C]
G024R271.WMF
4. Remove the pull-out clutch bracket [A] (two screws). 5. Remove the pull-out clutch [B] (one bearing, one connector [C]).
Relay roller clutch
[E]
G024R272.WMF
[D] 6. Remove the relay roller clutch [D] (one hook, one connector [E]).
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TROUBLESHOOTING
SC TABLES
7. TROUBLESHOOTING
7.1 SC TABLES
7.1.1 TYPES OF SERVICE CALL
For this printer engine, service calls and process control errors are classified into three types:
TYPE 1: Safety warning and immediate shutdown (Fusing unit errors) TYPE 2: Immediate shutdown TYPE 3: Log only (Process control errors) The printer stops immediately and the LCD displays an SC error message. The error is logged. The printer stops immediately and the LCD displays an SC error message. The error is logged. The printer does not stop. No SC error message is displayed. The error is only logged.
Fusing unit SC errors Fusing unit SC errors (type 1 errors) can be released by executing the Reset SC item in the engine SP mode menu. They cannot be released by turning the main switch off and on.
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Troubleshooting
SC TABLES
Rev. 09/2000
7.1.2 SC ERROR LIST

SC No. 20 Type 1 21 Type Type 2 Name Optional tray unit error Pressure roller thermistor error Occurrence conditions The detection signal for the 500 sheet paper tray unit is abnormal. The roller temperature has been at 0C for five seconds. Detection conditions Always monitored. Cause The optional tray unit connector has a bad connection. Pressure roller thermistor, MCU.
Type 1 22 Type 1
23
High pressure roller temperature Low pressure roller temperature
The roller temperature has been at 190C or higher for three seconds. Reheating has been done and the motor is not running, or 60 seconds have passed after the main motor halted. The roller temperature has been below 130C for 60 seconds. The roller temperature has been 0C for five seconds.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit. No detection in the event of SC or no fusing unit installed. No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit .
Pressure roller thermistor, MCU.
Pressure roller thermistor, MCU, pressure roller lamp connector.
Type 1 24
Hot roller thermistor error
Type 1 25 Type 1
High hot roller temperature Low hot roller temperature
26
27
Type 1
AC Power zero-cross detection error
The roller temperature has been 190C or higher for three seconds. Reheat has been done and the motor is not running, or 60 seconds has passed after main motor halt. The roller temperature has been below 130C for 60 secs. No zero-cross signal can be detected when the fusing heaters turn on. NOTE: From main engine firmware ver. 2.21 or later, this SC can be released by turning the unit OFF then ON.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit . No detection in the event of SC or fusing unit absence. No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence. No detection in the event of SC or fusing unit absence.
Hot roller thermistor, MCU.
Hot roller thermistor, MCU. Hot roller thermistor, MCU, hot roller lamp connector.
60HZ AC The number of zerocross cycles is detected less than 109 times or more than 131 times for 5 continuous seconds.
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7-2
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Rev. 09/2000
SC TABLES
Name Paper transfer positive bias release error Occurrence conditions The PWM duty has been 50% or higher for 240 ms. Or, the paper transfer roller clutch does not operate. Detection conditions Detection starts 60 ms after control starts for this component. Cause There is a disconnection in the paper transfer bias supply circuit. (Deformation of terminals or springs, dirty bearings) When the contact / separation lever is normal: Bad transfer roller position sensor harness, or MCU. When the contact/separation lever is faulty: Bad transfer roller clutch or MCU. There is a disconnection in the primary transfer bias supply circuit. (Dirty or deformed electrodes.) There is a short circuit in the supply bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter.) There is a short circuit in the blade bias supply circuit.
SC No.
Type Type 2
28
Type 2 29
Primary transfer bias open
The PWM duty has been 50% or higher for 240 ms.
Detection starts 60 ms after control starts for this component.
Type 2
Supply bias error
31
Type 2
Blade bias error
32
Type 2 33
Charge corona unit bias open
The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher. The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher. The PWM duty has been 50% or higher for 240 ms.
Type 2
34
35 36
Type 2 Type 2
Main motor error PCU motor error
PCU motor, MCU.
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Troubleshooting
Charge corona unit grid bias error
The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher. Continuous unlock for two seconds. Continuous unlock for two seconds.
There is disconnection in the charge corona unit bias supply circuit. (Dirty or deformed electrodes.) There is a short circuit in the charge corona unit grid bias supply circuit (due to deformed terminals or electrodes or conductive foreign matters). Main motor, MCU.
SC TABLES
Rev. 09/2000
Name Revolver motor error Occurrence conditions Movement to the home position took four or more seconds. For black, movement to the home position took one second or longer. Continuous unlock for two seconds. The ID sensor output voltage is not between 0.1 V and 1.1 V while the ID sensor LED is off. No mark has been detected for 500 ms during PCU motor operation. LD error (abnormal laser power output) Synchronization detection error of the optical unit A/D converted voltage has been 4.8 V or more for 240 ms. ID sensor calibration. Detection conditions Cause Incorrect installation of color development unit, revolver motor, MCU defective. Polygon mirror motor, MCU. ID sensor.
SC No.
Type Type 2
38
Type 2 39 Type 2 40 Type 2 41 Type 2 Type 2 43 Type 2
Polygon mirror motor error ID sensor error
Transfer belt H.P. sensor error Laser diode error Synchronizat ion detection error Charge bias short
Transfer belt H.P. sensor, MCU.
42
During polygon mirror motor revolution Detection starts 60 ms after control starts for this component.
45
Type 2
46
Paper transfer positive current error
A/D converted voltage has been 0.2 V or less for 240 ms.
Type 2 47
Paper transfer negative bias open
The PWM duty has been 50% or greater for 240 ms.
Type 2
48
Paper transfer negative current error
A/D converted voltage has been 4.8 V or more for 240 ms.
Type 1 49
Pressure roller reheat timeout
When reheating, the roller temperature does not reach the reheat start temperature (target temperature -20C) within five minutes.
During reheating
LD, LD control board Synchronization detection board, LD control board There is a short circuit in the charge bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) There is disconnection in the paper transfer bias supply circuit. (Dirty or deformed electrodes) There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) Pressure roller thermistor, pressure roller lamp connector, MCU
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Rev. 09/2000
SC TABLES
Name Hot roller reheat timeout Occurrence conditions When reheating, the roller temperature does not reach the reheat start temperature (target temperature -10C) within five minutes. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When an abnormal combination of print commands is received. 5 V (4.75 V) or more has continuously been detected for five seconds. 5 V (4.75 V) or more has continuously been detected for five seconds. Detection conditions During reheating Cause Hot roller thermistor, hot roller lamp connector, MCU
SC No.
Type Type 1
50
Type 1
51
Pressure roller lamp full-power operation error
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence.
Pressure roller thermistor, pressure roller lamp connector, MCU
Type 1
52
Hot roller lamp fullpower operation error
Hot roller thermistor, hot roller lamp connector, MCU
Type 2 57 Type 2 59 Type 2 60
Print command error Temperature sensor error
Humidity sensor error
When the power is on, or the AC development bias is off. When the power is on, or the AC development bias is off.
Temperature sensor
Humidity sensor
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Troubleshooting
SC TABLES
7.1.3 PROCESS CONTROL ERROR LIST

PE No. Type Type 3 103 Name K ID sensor error Occurrence conditions While the LED is off, the ID sensor output does not meet the standard voltage (between 0.05 V and 1.5 V). The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal0.4 V). The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal0.1 V). The slope M of the line representing the relationship between the C development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the M development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the Y development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the K development bias and attached toner amount is not between 0.01 and 0.001. The difference in ID sensor outputs when the ID sensor pattern is read and when the background surface of the transfer belt is read is 0.8 V or less. Detection conditions ID sensor (K) calibration Cause When the output meets the standard voltage: MCU, harness When the output does not meet the standard: K ID sensor K ID sensor, MCU, transfer belt error, transfer belt surface unevenness, incorrect ID sensor installation K ID sensor, MCU, transfer belt error, transfer belt surface unevenness
Type 3 104
ID sensor output error (rough adjustment)
ID sensor (K) calibration
Type 3 105
ID sensor output error (fine adjustment)
Type 3
ID sensor pattern error (Cyan)
Color DTM initialization
110
Type 3
ID sensor pattern error (Magenta)
111
Type 3
ID sensor pattern error (Yellow)
112
Type 3
ID sensor pattern error (k)
116
Type 3
ID sensor pattern read error (K)
K-DTM bias initialization
118
Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect K DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization
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SC TABLES
PE No. Type Type 3 Name ID sensor pattern error (K) Occurrence conditions The slope M of the line representing the relationship between the DTM bias and attached toner amount is not between 0.01 and 0.001. Detection conditions K-DTM bias control Cause Incorrect DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization
123
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Troubleshooting
USER ERROR LIST
7.2 USER ERROR LIST

Error Add Toner: xx Operation after error Printing can be done. Detection conditions Toner near-end detection is enabled two seconds after the development drive solenoid turns on until it turns off. The toner near-end message is displayed when toner end is detected five times. Release method Replace the DTM. Remarks When near-end is detected, closing the front cover initiates recovery. If the toner near-end status is cleared, it is not detected during recovery. In singlecolor (black-andwhite) continuous output, toner nearend is detected during process control. Double-image mode: Two images on the transfer belt at the same time.
Load xx (By-pass feed table)
Load xx (Tray 1)
Load xx (Tray 2)
Load xx (Tray 3)
Printing is disabled when the by-pass paper feed table is specified. If paper end is detected for the second image in double-image mode, the printer stops after the first sheet is printed. Printing is disabled when the paper tray is specified. If paper end is detected for the second image of the double-image mode, the printer stops after the first sheet is printed. Printing is disabled when the second paper tray is specified. If paper end is detected for the second image of the doubleimage mode, the printer stops after the first sheet is printed. Printing is disabled when the third paper tray is specified. If paper end is detected for the second image in double-image mode, the printer stops after printing the first sheet.
Paper end is detected by the bypass feed paper end sensor.
Supply paper.
Paper end is detected by the paper end sensor of the first paper tray.
Supply paper.
Paper end is detected by the paper end sensor of the second paper tray.
Supply paper.
Paper end is detected by the paper end sensor of the third paper tray.
Supply paper.
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USER ERROR LIST

Error Paper Size Error Operation after error Printing is disabled. Detection conditions The specified paper size for the by-pass feed table differs from that detected. Or the paper size in the tray differs from the paper size dial setting by 40 mm. The CPU counter reaches 60,000. Release method Open the door. Remarks
Change PCU
Printing can be done.
Replace the PCU to reset the counter.
Change Fusing Unit
The fusing unit counter reaches 60,000.
Manually release the error using Maintenance Clear in controller SP mode.
Counting (upon exit) A3/DLT or smaller K single-color: Plus 1 Full color: Plus 4 For sizes larger than A3/DLT, counting doubles. A3 or larger: Number of sheets that have passed x2 Smaller than A3: Number of sheets that have passed The near-full status is reset if the full used toner bottle status is not detected continuously for 10 seconds. The near-full status is reset if the full used toner bottle status is not detected continuously for 10 seconds. The oil near-end status is reset when oil end is not detected continuously for 10 seconds. The oil near-end status is reset when oil end is not detected continuously for 10 seconds.
Waste Toner Nearly Full
20 sheets can be printed.
The used toner bottle is detected as full for 10 seconds.
Replace the used toner bottle.
Waste Toner is Full
Printing is disabled.
20 sheets have been printed in the used toner near-full status.
Replace the used toner bottle.
Add Fuser Oil
200 sheets can be printed after the fusing oil near-end message is displayed. Printing is disabled.
Oil end is continuously detected for 10 seconds.
Supply fusing oil.
Fuser Oil is Low
200 sheets have been printed in the fusing oil near-end status.
Supply fusing oil.
Reset PCU Correctly
The PCU set sensor detects no PCU when the main switch is turned on or the cover is closed.
Set the PCU.
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Troubleshooting
USER ERROR LIST

Error Reset Charger Correctly Operation after error Printing is disabled. Detection conditions The charge corona unit set switch does not detect the wire cleaner for the charge corona unit when the main switch is turned on or the cover closed. Disconnection is detected for both the hot and pressure roller thermistors when the main switch turns on. None of the paper size switches for that tray detect anything. Release method Install the charge corona unit correctly. Return the wire cleaner to the home position. Remarks
Reset Fusing Unit Correctly
Install the fusing unit correctly.
Reset Tray Correctly
Reset Toner Correctly
Printing is disabled when the no tray message is displayed for the specified tray Printing is disabled.
Install the tray correctly.
The DTM sensor does not detect a DTM when the main switch is turned on or the front cover closed.
Install the DTM correctly.
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USER ERROR LIST
Detection conditions Operation after error Paper feed clutch to pull-out sensor Paper feed clutch to registration st sensor (1 ) Paper feed clutch to registration nd sensor (2 in doubleimage mode
Release method
Remarks
Error
Paper tray
Tray 1
0.9 s
3.24 s
3.82 s
Paper feed jam
Tray 2 (Option)
0.9 s
3.9 s
4.08 s
Tray 3 (Option)
0.9 s
5.14 s
5.31 s
Remove the jammed paper and close the front cover. Remove the jammed paper and close the front cover. Remove the jammed paper and close the front cover.
The paper feed jam counter increases by 1. Doubleimage mode: Two images on the transfer belt at the same time.
A jam is detected if more time than that indicated above passes. The time lapses, or time periods, are doubled for thick paper and transparencies.
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Troubleshooting
USER ERROR LIST
Error Transport jam
Operation after error Printing is disabled.
Detection conditions The exit sensor does not detect paper 3.14 seconds after the registration clutch activates. (6.28 seconds for transparencies and thick paper) The exit sensor detects paper 2.18 seconds after the registration sensor deactivates. The following conditions are regarded as roll-in jams, however, an exit jam message is displayed: The exit sensor is deactivates less than two seconds after the registration clutch turns off. (Four seconds or longer for transparencies and thick paper) When the exit sensor is turned off before the registration sensor turns off. Always monitored Always monitored
Release method Remove the jammed paper and close the front cover.
Remarks The transport jam counter increases by 1.
Exit jam
Remove the jammed paper and close the front and exit covers.
The exit jam counter increases by 1.
Front cover open Exit/DTM cover open
Printing is disabled. Printing is disabled.
Close the cover. Close the cover.
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7-12
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Rev. 08/2000
FIRMWARE HISTORY
7.3 FIRMWARE HISTORY
7.3.1
G024 FIRMWARE MODIFICATION HISTORY

DESCRIPTION OF MODIFICATION FIRMWARE LEVEL G0245500 H SERIAL NUMBER June 99 Production FIRMWARE VERSION 2.16
Corrects the following: No communication between controller while SC

error is issued due to defective Transfer Roller.
Improve Fusing Control Unit. Change the Toner Near End detection method for
black toner.
The process control counter value change on

printing over LT. Size images.
Transfer Bias applied to the paper between OHP

tranparency on OHP slip mode.
Corrects the following: Change the Transfer Current value on OHP

mode.
G0245500 J
July 99 Production September 99 Production
2.17
Corrects the following: Change the Transfer Current value on OHP mode
to optomize with FOLEX.
G0245500 K
2.18
Set Setup status flag when detecting DTM cover

sheet.
Corrects the following: SC98 may occur while continuous B/W printing
depending upon the timing.
G0245500 L
October 99 Production
2.20
SC28 may occur while continuous color printing

SC41 may occur if paper end is detected and

paper is added on the tray during half print speed. (Thick paper or OPC Transparency media printing)
Corrects the following: Condition for SC105 detection. Additional SP mode menu for Primary Transfer
Bias 15-BLT-TR BIAS.
G0245500 N
November 99 Production
2.23
Secondary Bias Control error may occur during

initialization.
Corrects the following: Auto pattern printing after PCU replacement. Corrects the following: Change timing for turning on the Revolver Motor
when detecting paper end as the countermeasure for SC38 detection error. Skip the K-DTM process control procedure on color DTM replacement to thin vertical lines. The development roller is rotated twice on DTM replacement to prevent thin vertical lines. Change the timing for turning off the charge bias when printing images wider than letter size in B/W mode.
G0245500 Q G0245500 S
February 00 Production April 00 Production
2.26 2.30 Troubleshooting G024
SM
7-13
500-SHEET PAPER TRAY UNIT (SECOND AND THIRD TRAYS) G908
SPECIFICATIONS

1.1 SPECIFICATIONS
Paper Feed Method Configuration Paper Capacity Paper Size Friction pad Front loading 500 sheets (80 g/m2, 20 lbs.) Short edge feed: (SEF) A3, 11" x 17", 81/2" x 14", Others* (B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13") Long edge feed: (LEF) A4, 81/2" x 11", 71/4" x 101/2", Others* (B5 JIS, A5, 51/2" x 81/2") * The paper size should be specified with the system menu (at the operation panel by the user). Paper Weight Power Dimensions Tray Weight 64 to 105 g/m2 (17 to 28 lbs.) DC 24V, DC 5V (supplied by the main unit) 580 x 465 x 138 mm (22.8 x 18.3 x 5.4) 6.0 kg.
SM
8-1
G024
500 Sheet Paper Tray Unit G908
PARTS LAYOUT
1.2 PARTS LAYOUT
1 2
G908D801.WMF
6 3 4 5
1. Pull-out sensor 2. Paper end sensor 3. Paper feed clutch 4. Paper size switch 5. Tray main motor 6. Tray control board
G024
8-2
SM
OVERVIEW

2.1 OVERVIEW
2.1.1 MECHANICAL LAYOUT
10
3
G908D802.WMF
1. Tray bottom plate 2. Friction pad 3. Paper lift arm 4. Paper size switch 5. Pull-out roller (idler roller) 6. Pull-out roller (drive roller) 7. Pull-out sensor 8. Paper feed roller 9. Paper end sensor 10. Grounding point
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8-3
G024
OVERVIEW
2.1.2 CONFIGURATION
Function Main function Paper feed/separation Tray bottom plate pressure Paper end detection Paper size detection Motor drive Overview Friction pad separation method Paper tray bottom plate pressurized by a spring under tension Detection by actuator and photo interrupter User-specified by a dial; detected by switches. Stepper motor
Paper feed
Drive
G024
8-4
SM
MECHANISMS
2.2 MECHANISMS
2.2.1 DRIVE
[C]
[D]
[B]
[A]
G908D803.WMF
Gears and the paper feed clutch [A] transfer drive from the tray main motor [B] to the paper feed roller [C]. The gear for the paper feed clutch transfers drive to the pull-out roller [D]. The MCU controls the drive motor and paper feed clutch.
SM
8-5
G024
MECHANISMS
2.2.2 PAPER FEED AND SEPARATION
[A]
[B]
G908D805.WMF
The paper feed unit uses a friction pad. The paper feed clutch drives the paper feed roller [A]. The paper feed roller feeds one sheet to the pull-out roller [B].
G024
8-6
SM
MECHANISMS
2.2.3 TRAY LIFT

[D] [C] [A]
[B]
G908D806.WMF
A spring [A] under tension connects the bottom plate [B] of each tray to the paper tray arm [C]. When the paper tray is placed in the main unit, the guide block [D] on the main unit base lifts the paper tray arm. The spring connected to the bottom plate keeps the top of the paper at the correct level for paper feed.
2.2.4 PAPER END DETECTION

[C] [A] [B]
G908D807.WMF
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8-7
G024
The paper end sensor [A] is installed in the main body of the 500-sheet paper tray unit. When the sensor feeler [B] falls into the notch in the bottom plate [C], paper end is detected.
MECHANISMS
2.2.5 SIZE DETECTION
[A] [B]
G908D808.WMF
Paper size detection is based on the three paper size switches [A] on the main body of the 500-sheet paper tray unit, which detect the setting of the paper size dial [B] on the tray. The paper size dial has grooves and ridges on the side facing the paper size switches. Each switch is turned off when it falls into a groove, and is turned on when a ridge presses it. Paper size detection for tray 2 and 3
Dial No. 1 2 3 4 5 6 7 8 Paper Size 11" x 17" SEF A3 SEF A4 LEF 81/2" x 11 LEF 81/2" x 14" SEF 71/4" x 101/2" LEF Others No Cassette Sensor Status J9 J10 J11 (SPS2) (SPS1) (SPS0) 0 0 0 1 1 0 0 1 0 1 0 1 1 0 0 0 0 1 0 1 0 1 1 1
SEF: Short edge feed LEF: Long edge feed Others: SEF - B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13" LEF - B5 JIS, A5, 51/2" x 81/2"
G024
8-8
SM
MECHANISMS
2.2.6 VERTICAL TRANSPORT

A sheet fed from the paper feed roller [A] for the third tray actuates the pullout sensor [B]. The pull-out roller [C] then sends the sheet upwards in the direction of the second tray. When the pull-out sensor for the third tray is actuated, the pull-out roller [D] for the second tray starts rotating. The pull-out roller for the second tray feeds the sheet arriving from the third tray to the pull-out roller [E] for the main unit. The pull-out roller rotates in synchronization with the drive motor. [E]
[D]
[C] [A] [B]

G908D809A.WMF
Main motor (3rd tray) Paper feed clutch (3rd tray) Pull-out switch (3rd tray) Main motor (2nd tray) Pull-out switch (2nd tray) Pull-out clutch Registration clutch Registration sensor
G908D810.WMF
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G024
Timing chart for optional trays
CIRCUITS
2.3 CIRCUITS
2.3.1 BLOCK DIAGRAM
Main
Upper CN860
CN501 CN 505
Main motor Paper feed clutch
CN 503
Paper switch Paper sensor Pull-out sensor
Tray control board

CN 504 6 7 CN502
CN 506
CN 507
Lower CN863 Upper CN860

CN501 CN 505
2nd 500-sheet paper tray
3rd 500-sheet paper tray

Paper switch Paper sensor Pull-out sensor
Main motor
CN 503
Tray control board Paper feed clutch

CN 504 6 7 CN502
CN 506
CN 507
Lower CN863
G908D811.WMF
G024
8-10
SM
CIRCUITS
CN863
CN860
G908D804.WMF
Combinations of signals from the J6 (XSPST0) and J5 (XSPST1) pins on the CN860 connector indicate the presence of a 500-sheet paper tray unit (second or third tray).
CN860 (Tray 2) Status J6 J5 H H L H L L H L
No tray detected Tray 2 detected Tray 2 and 3 detected Error
The J4 (SPSEL) pin of connector CN860 determines which of the two trays the CPU is controlling or detecting signals from.
J4 (SPSEL) of CN860 L H Selection Tray 2 Tray 3
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G024
PAPER FEED ROLLER

3.1 PAPER FEED ROLLER
[A]
[B]
G908R604.WMF
1. Remove the tray. 2. Push the paper feed roller lever [A] toward the right side, and remove the paper feed roller [B].
G024
8-12
SM
FRICTION PAD AND PULL-OUT IDLE ROLLER
3.2 FRICTION PAD AND PULL-OUT IDLE ROLLER

[A] [C] [E]
[D]
[B]
G908R601.WMF
Friction pad
1. Remove the tray. 2. From the back of the tray, remove the friction pad [A] (two hooks).
Pull-out idle roller

1. Remove the four screws retaining the front cover. Pull the bottom side of the front cover [B] forward, then lift it to remove it from the protrusion [C] on each side. 2. Remove the two springs [D] from the bearings. 3. Remove the pull-out idle roller [E] (two bearings).
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8-13
G024
PAPER END SENSOR AND PULL-OUT SENSOR
3.3 PAPER END SENSOR AND PULL-OUT SENSOR
[B]
[A]
G908R605.WMF
Paper end sensor

1. Detach the printer from the optional paper tray unit. 2. Remove the tray. 3. Remove the paper end sensor [A] (three hooks and one connector).
Pull-out sensor
1. Remove the pull-out sensor [B] (four hooks and one connector).
G024
8-14
SM
TOP COVER
3.4 TOP COVER
[A]
G908R602.WMF
1. Detach the printer from the optional paper tray unit. 2. Remove the tray. 3. Turn the main unit upside down. Remove the top cover [A] (four screws).
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8-15
G024
PAPER FEED CLUTCH AND PAPER SIZE SWITCH
3.5 PAPER FEED CLUTCH AND PAPER SIZE SWITCH

3.5.1 PAPER FEED CLUTCH
[A] [C] [B]
[D]
G908R606.WMF
1. Remove the top cover. (See Top Cover Removal.) 2. Place the top cover unit on a level surface, with the bottom facing down. 3. Remove the paper feed roller. (See Paper Feed Roller Removal.) 4. Lift the hook [A] of the paper feed roller lever, and push the paper feed roller shaft [B] towards the left until it is removed from the paper feed clutch [C]. NOTE: Rotate the shaft into the correct orientation when inserting it into the clutch. (The shaft and its hole in the clutch are D-shaped.) 5. Remove the paper feed clutch (one connector, one gear, one bearing, and one clamp). NOTE: When installing the paper feed clutch, put the stoppers in the two holes in the top cover before inserting the shaft.
Paper size switch

1. Remove the paper size switch [D] (two hooks, one connector).
G024
8-16
SM
PULL-OUT DRIVE ROLLER
3.6 PULL-OUT DRIVE ROLLER

[C] [D] [C] [A]
[B]
G908R607.WMF
1. Remove the top cover. (See Top Cover Removal.) 2. Place the top cover unit on a level surface, with the bottom facing down. 3. Remove the grounding plate [A] (one screw). 4. Remove the pull-out drive roller [D] (one gear [B], two snap rings, and two bearings [C]). NOTE: Be careful not to deform the grounding plate.
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G024
TRAY MAIN MOTOR AND TRAY CONTROL BOARD
3.7 TRAY MAIN MOTOR AND TRAY CONTROL BOARD

[C]
[A]
[B]
G908R603.WMF
Tray main motor

1. Remove the top cover. (See Top Cover.) 2. Remove the bracket [A] (two screws). 3. From the bracket [A], remove the motor [B] (two screws, one connector).
Tray control board

1. Remove the bracket [A] (two screws). 2. Remove the board [C] (two stud locks, two screws, seven connectors, and a grounding wire).
G024
8-18
SM
G024 CONTROLLER AND NETWORK INTERFACE BOARD TYPE 305 SERVICE MANUAL
NOTE: The first section of this part of the Service Manual refers to the Controller. The second section details the Network Interface Board Type 305. To differentiate this version from the G024 Fiery 500 Controller Version (G024 PS), when equipped with this controller the G024 is generally referred to as the G024 Win.
TABLE OF CONTENTS
CONTROLLER
1. OVERALL MACHINE INFORMATION ......................................... 1-1
1.1 SPECIFICATIONS.....................................................................................1-1 1.2 LAYOUT ....................................................................................................1-2
2. DETAILED DESCRIPTIONS ........................................................ 2-1

2.1 FUNCTIONAL OVERVIEW .......................................................................2-1 2.1.1 BLOCK DIAGRAM............................................................................2-1 2.1.2 PRINT DATA PROCESSING ...........................................................2-2 CMS (Color Management System) .......................................................2-3 Color Adjustment by the Driver .............................................................2-3 Color Conversion, and Gamma Correction by the Controller................2-3 2.1.3 GAMMA CORRECTION ...................................................................2-3 Controller gamma () (not adjustable)...................................................2-3 Service gamma () ................................................................................2-3 2.2 FUNCTIONAL DESCRIPTION ..................................................................2-4 1.2.1 CONTROLLER LAYOUT..................................................................2-4 1.1.2 FUNCTIONS OF COMPONENTS ....................................................2-5 2.3 POWER-UP SELF-DIAGNOSTICS ...........................................................2-7 1.3.1 OPERATION PANEL DISPLAY DURING POWER-UP SELF- DIAGNOSTICS.....................................................................2-7 Immediately after turning the power on.................................................2-7 During power-up self-diagnostics..........................................................2-7 If the test terminates normally...............................................................2-7 If an error is detected............................................................................2-7 Non-fatal error detected ........................................................................2-8 Fatal error detected ..............................................................................2-8 2.4 POWER-UP SELF-DIAGNOSTICS FLOW CHART ..................................2-9
3. INSTALLATION ............................................................................ 3-1 4. SERVICE TABLES ....................................................................... 4-1

4.1 SP MODES ...............................................................................................4-1 4.1.1 OVERVIEW ......................................................................................4-1 4.1.2 ENGINE SP MODE ..........................................................................4-1 4.1.3 CONTROLLER SP MODE................................................................4-1 Entering and Exiting Controller SP Mode..............................................4-1 SP Mode Menu Hierarchy.....................................................................4-2 Controller SP Mode Functions ..............................................................4-4 4.1.4 MENUS AND DISPLAY ....................................................................4-5 Key manipulation ..................................................................................4-5 LCD display ..........................................................................................4-6
SM
G024
4.1.5 SP MODE DETAILS .........................................................................4-7 S1. Maintenance Sheet ........................................................................4-7 S2. Color Chart .....................................................................................4-8 S3. Maintenance Clear .........................................................................4-8 S4. Clear All Memory ............................................................................4-8 S5. Gamma ( Calibration.....................................................................4-8 S6. Printer ID ........................................................................................4-9 S7. Brand (Default Setting: RICOH.EXP) .............................................4-9 4.2 DETAILED SELF-DIAGNOSTICS MODE ...............................................4-10 Overview.............................................................................................4-10 Operating Procedure ..........................................................................4-10 Operation Panel Behavior During Detailed Self-diagnostics ...............4-11 Detailed Self-diagnostics Flow Chart ..................................................4-12 Test Results Printout when No Fatal Errors Occur .............................4-13
5. PERIODIC MAINTENANCE ......................................................... 5-1 6. REPLACEMENT AND ADJUSTMENT......................................... 6-1

6.1 CONTROLLER BOARD REPLACEMENT ................................................6-1 6.2 IMAGE ADJUSTMENT..............................................................................6-1 6.2.1 OVERVIEW ......................................................................................6-1 6.2.2 SERVICE GAMMA ( ADJUSTMENT...............................................6-2 Adjustment Menu (Controller SP, S5. Gamma ( Calibration) ..............6-2 Adjustment Overview ............................................................................6-3 Adjustment Procedure ..........................................................................6-4 6.2.3 SOFTWARE UPGRADE PROCEDURE...........................................6-5
7. TROUBLESHOOTING.................................................................. 7-1
7.1 TYPES OF PROBLEMS............................................................................7-1 7.2 TROUBLESHOOTING PROCEDURE.......................................................7-2 7.2.1 HARDWARE TESTS ........................................................................7-2 7.2.2 OPERATION-RELATED TESTS ......................................................7-2 7.2.3 SOFTWARE-RELATED TESTS .......................................................7-3 7.3 ERROR MESSAGES ................................................................................7-4 7.3.1 OVERVIEW ......................................................................................7-4 7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS .............................7-5 7.3.3 CONTROLLER USER ERRORS......................................................7-6 7.3.4 INTERNAL ERRORS........................................................................7-7 7.3.5 ENGINE USER ERRORS (CAUTIONARY)......................................7-8 7.3.6 ENGINE SERVICE CODES .............................................................7-8
8. NETWORK INTERFACE BOARD TYPE 305............................... 8-1

8.1 OVERVIEW ...............................................................................................8-1 8.1.1 SPECIFICATIONS............................................................................8-1 8.1.2 BLOCK DIAGRAM............................................................................8-1 8.2 COMPONENT LAYOUT............................................................................8-2 8.2.1 NETWORK INTERFACE BOARD DIAGRAM...................................8-2 8.2.2 DEVICES..........................................................................................8-2
G024
II
SM
Rev. 05/2000
8.3 BASIC OPERATIONS ...............................................................................8-3 8.3.1 OVERVIEW ......................................................................................8-3 8.3.2 LED FUNCTIONS.............................................................................8-3 8.3.3 SWITCH FUNCTIONS......................................................................8-4 8.3.4 NETWORK SETTING FUNCTION ...................................................8-5 8.4 FIRMWARE HISTORY ..............................................................................8-6
SM
III
G024
OVERALL INFORMATION
OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
Page Description Language Printer Driver IPDL-C Ricoh-Script 2 (Option) IPDL-C: Windows 98/95/3.1x/NT4.0 Ricoh-Script 2: Windows 98/95/NT4.0, Macintosh (PPD for LaserWriter 8) Controller: 600/300 dpi Color (4 color mode only)/Monochrome (black only) Set by the printer driver 2 or 1 bit/pixel Auto/Off (by a printer driver setting) On/Off (by a printer driver setting) On/Off (by a printer driver setting) Default setting: Enabled Standard: Bi-directional Parallel (IEEE1284: compatible and nibble mode supported) Option: Parallel (IEEE1284: only compatible mode supported), Ethernet (100Base-TX/10Base-T) Network Protocol Fonts Memory SIMM Slot DIMM Slot Option Interface IPX/SPX, TCP/IP, AppleTalk (with Ricoh-Script 2) IPDL-C: Japanese fonts only - not used Ricoh-Script 2: 39 fonts Standard: 32 MB Optional upgrades: 16 MB SIMM, 32 MB SIMM 2 (for optional memory) 1 (for optional Ricoh-Script 2) 2 (for optional network I/F board and optional parallel I/F) 16 MB Memory 32 MB Memory Network Interface Board IEEE1284 Parallel Interface Ricoh-Script 2 Emulation Module
Resolution Color Mode Gradation Mode Smoothing Toner Saving Color Correction Interface
Options
SM
1-1
G024 Win
31 March, 1999
1.2 LAYOUT
G024O011.WMF
1. Controller
G024 Win
1-2
SM
2. DETAILED DESCRIPTIONS
2.1 FUNCTIONAL OVERVIEW
2.1.1 BLOCK DIAGRAM
Controller Control Block H ost Interface Block Print Image Generator Block
Printer Engine Printer Hardware

Synch. Detector LD Unit
Engine Interface Block
MCU Printer Engine Controller
Printer
Operation Panel G033C001.WMF
The functions and characteristics of the various blocks in the controller are described below. Control Block 1. Controls the controller and operation panel. 2. Stores the settings (system initial set-up items, printer settings, etc.) in NVRAM. Host Interface Block 1. Receives the print and control data (commands) from the host. 2. The interface settings depend on the controller settings. 3. Can accommodate optional interface boards (one parallel and one network interface). Print Image Generator Block 1. Converts the data received from the host into a print image and writes this image into the memory (the image conversion method depends on the controller's settings).
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2-1
G024 Win
Engine Interface Block 1. After converting the image data into 4-bit data, sends the image data in parallel on a 4-bit/pixel basis in synchronization with the synchronization signal and clock from the engine. 2. Receives status data from the engine and passes it to the controller. 3. Sets up the operating mode for the engine.
2.1.2 PRINT DATA PROCESSING

The diagram below illustrates the print data processing path. The boxes in the diagram represent function blocks and the text next to the arrows indicates the data type. The diagram is followed by a brief description of color processing by the printer driver.
IPDL-C Application RGB 8bit GDI RGB 8bit CMYK 8bit CMS * CMYK 8bit
Ricoh-Script Application
RGB 8bit
CMYK 8bit
Printer Driver RGB 8bit CMYK 8bit Controller

Ricoh-Script (including CMS*)
Printer Driver RGB 8bit CMYK 8bit Controller Conversion to 4-bit data
CMYK 2 or 1 bit
CMYK 2 or 1 bit
Conversion to 4-bit data
Printer Engine
Printer Engine
* CMS: Color Management System

G024O002.WMF
G024 Win
2-2
SM
CMS (Color Management System)

The CMS adjusts the RGB values of the colors in the application data in preparation for RGB to CMYK conversion, which is done in the controller. A file known as a profile is automatically installed in the \windows\system\folder with the file name extension .rcm (unique to this printer) during the printer driver installation. This file contains instructions for the CMS on how to compensate the colors in the print data produced by the application. CMS is used whenever the color correction setting in the printer driver is set to any value other than Off.
Color Adjustment by the Driver

The driver adjusts the following parameters in accordance with the driver settings made by the user: Brightness, Contrast, Saturation, and Color Balance. The driver does not perform RGB to CMYK color conversion.
Color Conversion, and Gamma Correction by the Controller

The controller performs RGB-to-CMYK conversion, and gamma () correction.
2.1.3 GAMMA CORRECTION

Gamma correction in this model has two components: controller gamma () (nonadjustable) and service gamma () (adjustable).
Controller gamma () (not adjustable)

This gamma is programmed into the flash ROM in the controller. If there has been no service gamma () adjustment in the machine since installation, the controller gamma () is the only gamma that is used (i.e., service gamma () = 0).
Service gamma ()
This gamma is stored in the NVRAM in the controller. It can be adjusted using the controller SP mode (S5. Gamma Calibration). See Section 6.2.2 Service Gamma Adjustment, for the adjustment procedure. The controller combines the service gamma () (the default setting is zero) with the controller gamma () when doing gamma correction.
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2-3
G024 Win
G024 Win
OPTION I/F 2 DRAM DRAM CPU FLASH ROM NV RAM ASIC ROCY F FONT ROM FLASH ROM DRAM DRAM DRAM DRAM DRAM DRAM FCI 2.5C FONT ROM DIMM SLOT Flash ROM Card Slot
OPTION I/F 1
DRAM
DRAM
2.2.1 CONTROLLER LAYOUT
DRAM
S I M M
S I M M
DRAM
2.2 FUNCTIONAL DESCRIPTION
2-4
DIP SW
VIDEO I/F
DRAM
S L O T 1
S L O T 2
DRAM
DRAM
DRAM
G024O003.WMF
CENTRONICS I/F
SM
2.2.2 FUNCTIONS OF COMPONENTS

Device CPU Description/Function
VR4310-177 MHz DRAM control Parallel interface

1 2
OFF
Timeout monitoring Timer control I/O port control Engine interface serial communications control Image data decompression Interrupt control
FLASH ROM
ASIC ROCKY F
For storing programs (2 MB) Programmable via a Flash ROM card. Stores initial set-up settings and printer parameters. Uses a 2 KB EEPROM. Smoothing Toner saving Uses two 32-Mbit mask ROMs (8 MB total). Stores internal printer fonts (Japanese fonts only - not used). Sixteen 16-Mbit DRAMs are installed as standard (32 MB total).
3 4
NVRAM
ASIC FCI2.5C
FONT ROM
DRAM
G024O004.WMF
SW No. DIP SW 1
Setting OFF
ON
2 to 4
Purpose The controller boots from the flash ROM located on the board (normal setting). The controller boots from the Flash ROM card (when upgrading the controller, NIB, or Ricoh-Script 2 software). Always set to OFF. For designers use only.
VIDEO I/F
Interfaces the controller with the printer engine.
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2-5
G024 Win
DETAILED DESCRIPTIONS Device PARALLEL I/F Description/Function
Provides an interface that connects to a local host (IEEE1284 compliant). Two slots; each can hold either an optional network interface or a parallel interface board. You cannot install two boards of the same type. The optional board type can be identified from the unique ID built into it.
OPTION I/F 1,2
DIMM SLOT
A 72-pin slot for accommodating the optional Ricoh-Script 2 emulation module. The emulation module is a programmable flash ROM. Two slots for optional expansion memory boards.
SIMM SLOT
SIMM specifications: 16 MB or 32 MB SIMM, 60 ns access speed For accommodating a Flash ROM card for upgrading the software.
FLASH ROM CARD SLOT
G024 Win
2-6
SM
2.3 POWER-UP SELF-DIAGNOSTICS

2.3.1 OPERATION PANEL DISPLAY DURING POWER-UP SELFDIAGNOSTICS
The controller starts power-up self-diagnostic tests when the printer power is turned on.
Immediately after turning the power on

The controller turns on all LEDs and the LCD.
During power-up self-diagnostics

When the controller starts self-diagnostics, it turns off all LEDs except the Power LED, which it causes to blink. It displays the message Warming UP on the lower line of the LCD.
If the test terminates normally

If an error is not detected during the self-diagnostic test, the controller turns the blinking Power LED on and turns off all the other LEDs. The controller starts the system immediately afterwards.
If an error is detected
Errors are divided broadly into fatal and non-fatal errors. The controller takes different actions and gives different status information for different types of errors. See Section 7.3.2 Controller Self-Diagnostics Errors for tables of the different types of errors.
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2-7
G024 Win
Non-fatal error detected

The controller causes the blinking Power LED to stay on, turns off all of the other LEDs and the LCD, and restores the standby display state. Since non-fatal errors do not adversely affect any print operation, the controller starts the system immediately after it takes these actions. The system turns on the Error LED and prints out a list of settings with error descriptions, in monochrome mode (see Section 7.3.2 Controller User Errors). After printing the above list of settings, the system returns to the normal state and enables all devices except the failed one.
Fatal error detected

Since there is no guarantee that the system can generate a list of settings when the error detected is fatal, the system turns off the Power LED and turns on the Error LED. At the same time, it displays and keeps an error message on the LCD until the power is turned off. The first line of the LCD contains a 4-digit code that identifies the error. (see Section 7.3.2 Controller Self-diagnostics Errors description of the error codes).
G024 Win
2-8
SM
2.4 POWER-UP SELF-DIAGNOSTICS FLOW CHART

Turn on power Fatal Error Detected
Code ROM sum check
Test Code ROM
Tests the timer functions of the ROCKY F ASIC Operation check
Test Timer
Fatal Error Detected Fatal Error Detected Fatal Error Detected Fatal Error Detected
Test CPU
Tests the engine interface functions of the ROCKY F ASIC Font ROM sum check
Test ASIC
Test Font ROM
NO Flash ROM card installed? YES
Display Error on Panel
Flash ROM card sum check, if Flash ROM card is installed
Test Flash ROM card
DIMM Installed?
NO
DIMM (emulation module) sum check, if DIMM is installed
YES Test DIMM
Non-fatal Error (user error)? YES Start System
NO
Generate List of Settings
Start System
G024O008.WMF
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2-9
G024 Win
INSTALLATION
INSTALLATION
3. INSTALLATION
Refer to the following materials. For the printer: Quick Installation Guide For options: Operating Instructions
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3-1
G024 Win
Installation
SERVICE TABLES
SERVICE TABLES
4. SERVICE TABLES
4.1 SP MODES
4.1.1 OVERVIEW
The printer has two types of SP modes: 1. Engine SP modes 2. Controller SP modes This manual deals with controller SP modes.
4.1.2 ENGINE SP MODE

Refer to the engine's service manual for how to enter and use the engine SP modes.
4.1.3 CONTROLLER SP MODE

Entering and Exiting Controller SP Mode
[A] [B]
Service Tables
G024O010.WMF
[A]
[B]
G024O016.WMF
To enter controller SP mode: Turn on the printer while holding down the [On Line] [A] and [Reset] [B] keys on the operator panel. Hold the keys down until all of the LEDs and the LCD turn off. After the printer completes its cycling, press the [Menu] key. To exit controller SP mode: Turn off the unit. NOTE: Be sure to exit from the controller SP mode when you are finished.
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SP Mode Menu Hierarchy

The table below shows the controller menu hierarchy. The menus in the table can be accessed in the controller SP mode. When in SP mode, S1 to S7 are added to the Maintenance menu.
Layer 1 IPDL-C Menu Layer 2 1.Job Timeout 2.I/O Timeout 1.Paper Tray Layer 3 Off 0 999 seconds 0 999 seconds Tray 1 Bypass Tray 2 Tray 3 8.5 x 13 A5 B4 JIS B5 JIS 5.5 x 8.5 8 x 13 8.25 x 15 16 kB 32 kB 64 kB 128 kB 256 kB 512 kB Off 5 minutes 15 minutes 30 minutes 45 minutes 60 minutes Level 1 Level 2 Hi-speed Normal Off On ACK inside ACK outside STB down ACK inside ACK outside STB down Original Mode Standard ON OFF IPDL-C Option Layer 4
System Menu
Tray 2 and 3 are selectable if an optional paper feed unit is installed.
2. Tray Size [*]
3.I/O Buffer
4.Energy Saver
5. Energy Level 6.Transfer 7.Image Memory 8.Parallel 1
9.Parallel 2
10.Bi-direction 11. OHP Slip 12. Printer Language
Emulation name is displayed if an emulation module is installed.
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SERVICE TABLES
Layer 1 System Menu Layer 2 13.Language Layer 3 English French German Italian Dutch Japanese Layer 4
32.IP ADDRESS to 39.Active PTL.
Displayed if an optional network interface board is installed. Cyan Magenta Yellow Black
Maintenance
1.Toner Select
2. Toner level 3.Menu Reset 4. Registration (Only when optional tray is installed.) 5. Menu Protect
Off On
It can also be accessed if the [Enter], [Escape], and [Menu] keys are pressed in sequence when the printer is on line.
S1.Maint. Sheet S2.Color Chart S3.Maint. Clear S4.Clear All Mem. S5.Gamma Calib.
Fusing Unit Load Setting Default Setting-Old Setting-Current 1 bit/photo, 2 bit/photo, 300 dpi/1bit. 1 bit/Text, 2 bit/text, 300 dpi/2 bit Black Cyan Magenta Yellow Save Settings Before installation, this also can be accessed by sales staff by pressing the [w], [v] and [Menu] keys in sequence.
Mode Select
Print Sheet Gamma Select
S6.Printer ID S7.Brand
RICOH.EXP SAVIN nashuatec Rex-Rotary Gestetner RICOH.JPN
List Print
Config. Page Color Sample
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SERVICE TABLES
Controller SP Mode Functions

The controller SP mode adds special menu items to the Maintenance user menu.
Additional Maintenance menu

Menu Item Function/Use Directs the controller to read and print the engine firmware version and the following items from the NVRAM on the MCU: Image density Registration values Total counter values SC Logging ID sensor PWM value Etc. Prints out the image quality check chart (this chart is included in the controller software). Resets the maintenance counters for the fusing unit. Resets the parameters in the controller NVRAM to their default values.
S1. Maint. Page
S2. Color Chart S3. Maint. Clear S4. Clear All Memo S5. Gamma Calib. S6. Printer ID S7. Brand
Performs a service gamma () adjustment. It is possible to adjust service gamma () in both text and photograph modes for each color. Input this ID if the NVRAM on the controller board has been cleared or replaced. Sets the brand name. This ensures that the LCD display and the configuration page header show the correct model name. This must be done before the printer is passed to a customer.
The Controller SP mode adds special menu items to the user menu accessed from the [Media] (access by pressing the [Media] key, then scroll through the menu on the display) menu.
Media Menu ([Media] key)

Menu Item 3. Summary Function/Use Displays the currently installed versions of the controller system, emulation modules, and engine (MCU) firmware, and the amount of memory installed in the controller.
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SERVICE TABLES
4.1.4 MENUS AND DISPLAY

Navigate through the SP mode menu and operate the SP modes in the same way as for the user menu.
Key manipulation
[w] and [v] keys: Used to scroll through the menu. Pressing these keys for a numeral set-up menu item changes the displayed value in minimum increments. [Enter] key: When the selected item has a lower-level menu, use this key to enter the lower-level menu. When scrolling through a set of values, use this key to select the displayed setting. Used to move to a higher-level menu. When pressed before selecting a value with the [Enter] key, the old value remains valid. Exits the menu and returns to the online mode. This key can be used at any menu level.
Service Tables
[Escape] key:
[On Line] key:
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LCD display
Title Line Menu Item Line <System Menu> 1. Paper Tray Arrow Marks
Title line: Menu item line:
Shows the menu title, indicating your location in the menu hierarchy. Shows a menu item. Press the [w] or [v] key to scroll through the menu items. When the [w] or [v] key is pressed at the last menu item, the display wraps around to the first menu item. When displaying settings, the current setting is identified by an asterisk ( * ) to its left. When the [Enter] key is pressed, the item in the display is selected and the display goes up one level in the menu hierarchy. Scrolls through the menu items. These marks do not appear if the menu has only one menu item.
Arrow marks:
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SERVICE TABLES
4.1.5 SP MODE DETAILS

S1. Maintenance Sheet
The table below describes the contents of the engine maintenance list printout. The controller obtains the data from the engine (MCU).
Item MCTL version Registration Description The MCU board firmware version number. Side registrations from Optional tray can be adjusted with Maintenance. Menu by the operator. Leading edge registration can be done with engine SP mode (1. Margin). These values are stored in NVRAM on the MCU. Toner density can be adjusted by the operator via the Maintenance. Menu, by operators. Adjusted values are stored in NVRAM on the MCU. Indicates the total number of printouts. The counter is incremented when the paper exit sensor detects paper exit completion (regardless of paper size, type, and mono/color mode). Counter value printed in color mode. Counter value printed in mono color mode. PCU replacement is indicated when this value reaches 60000. This value is incremented by 4 in color mode printing and by 1 in Black mode printing, except for A3/DLT. When printing with A3/DLT, double counting occurs. Fusing unit replacement is indicated when this value reaches to 60000. This counter is incremented by 2 for A3/DLT size printing and by 1 for other size printing. Number of Fusing unit resets with controller SP mode (S3).
Toner density Total counter
Color Mono color PCU counter
Fusing unit/Counter reset time A3/DLT, A4/LT, LG, B4 and etc. Size counter Feed Jam, Transfer Jam and Eject Jam counter SC counter SC Logging Jam Logging
Number of each size paper that passed the exit sensor.
Number of paper jams in each section.
Processcontrol error Logging P sensor PWM
Number of SCs The most recent 3 SC codes. The most recent 10 jamming codes and the total counter value at the time. 000: At paper cassette 001: At paper pass 002: At paper exit The most recent 3 errors while process control and the total counter value at the time. Not all of the errors are indicated as SC errors. The value set with engine SP mode, 9: ID Sensor PWM.
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Fusing unit
SERVICE TABLES
S2. Color Chart

This prints a color test chart, so that the image quality can be tested for all colors at various densities. This chart can be printed on all paper sizes supported by the machine (the layout of the print pattern varies from paper size to paper size).
S3. Maintenance Clear

This mode resets the fusing unit counter (this counter is in the NVRAM on the MCU board). Use it after replacing the unit.
S4. Clear All Memory

Executing this function resets the following user settings, stored in the NVRAM on the controller, to their initial values: Initial set-up items with System Menu Printer ID Printer name on the network Gamma () calibration The Menu Reset clear function in the user menu only resets the Initial set-up items with System Menu to their initial values.
S5. Gamma () Calibration

This mode adjusts the gamma () tables used in text and photograph modes. NOTE: For problems with color quality and gradation, clean the engine and replace consumables and other parts first. Use this mode only when the customer insists on further fine adjustments (e.g., matching colors between machines) See Section 6.2.2 Service Gamma () Adjustment for the adjustment procedure.
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SERVICE TABLES
S6. Printer ID
Input this ID if the NVRAM on the controller board has been cleared or replaced. Follow the procedure given below to input the printer ID: 1. Select the first digit using the [w] and [v] keys. 2. Input the number by pressing the [Enter] key (you can use the [Escape] key to cancel the setting if you input an incorrect number). 3. Repeat these steps until the last digit is entered. Pressing the [Enter] key on the last digit to return to the S6. Printer ID menu. 4. Print a configuration page and verify that the correct printer ID is defined. 5. Turn the power off and on again to exit SP mode.
S7. Brand (Default Setting: RICOH.EXP)

Use this mode to specify the brand. This sets up the machine to display the correct model name on the LCD and in the configuration page header. NOTE: This must be done before delivering the printer to the customer.
Service Tables
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4.2 DETAILED SELF-DIAGNOSTICS MODE

Overview
In this mode, the controller tests components that are not tested during the powerup self-diagnostics. These are the memory, standard parallel interface, and options (optional interfaces 1 and 2, SIMM slots, DIMM slot, and Flash ROM card slot), if the devices are installed. The following special tools are required to execute this mode: Parallel Interface Loopback Connector
Part No. G0219350 Type of Interface For the standard parallel interface board For the optional parallel interface board Remarks If not used, the controller continues the test to the end, but flags a non-fatal error. If an interface board is installed but the loopback connector is not, the controller continues the test to the end, but flags a non-fatal error.
G0109350
NOTE: A decal with the part number is attached to each connector, to avoid confusing the two types.
Operating Procedure
[A]
[B]
G024O010.WMF
To enter the detailed self-diagnostics mode, make sure that the devices that you wish to test are installed. Then do the following. 1. Switch off the power. 2. Connect the loopback connector to the parallel port. If the optional additional parallel interface has been installed, connect the loopback connector for this port also. 3. Turn on the power while simultaneously pressing and holding down the [On Line] [A] and [Enter] [B] keys on the operation panel. Hold the keys down until all of the LEDs and the LCD turn off.
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Operation Panel Behavior During Detailed Self-diagnostics

Immediately after the power is turned on
The controller turns on all LEDs and the LCD.
During detailed self-diagnostics

When the controller starts self-diagnostics, it turns off all LEDs except the Power LED and causes the Power LED to blink. It displays the message Service diag on the LCD.
When the tests terminate normally

When an error does not occur during the self-diagnostic test, the controller causes the blinking Power LED to stay on and turns off all the other LEDs. The controller starts the system immediately afterward and prints out a list of settings in color mode.
When an error is detected

Service Tables
Errors are divided broadly into non-fatal errors and fatal errors. The controller takes different actions and provides different status information for different types of errors. When a non-fatal error is detected The controller turns the blinking Power LED on, turns off all of the other LEDs and the LCD, and restores the standby display. Since non-fatal errors do not adversely influence any print operation, the controller starts the system immediately after it takes these actions. The system turns on the Error LED and prints out a list of settings with error descriptions in monochrome mode (see Section 7.3.3 Controller User Errors for the error codes). After printing a list of settings, the system returns to the normal state and sets up all devices except the failed one. When a fatal error is detected Since there is no guarantee that the system can generate a list of settings after detecting a fatal error, the system turns off the Power LED and turns on the Error LED. At the same time, it displays an error message on the LCD until the power turns off. The first line of the LCD contains a 4-digit code that identifies the error and the second line contains an 8-digit code that gives details of the error for designers to debug the error (see Section 7.3.2 Controller Self-diagnostics Errors for a description of the error codes).
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Detailed Self-diagnostics Flow Chart

Turn On Power Fatal Error Detected
Code ROM sum check Tests the timer functions of the ROCKY F ASIC Read/write test Operation test Makes a loopback test on the standard Centronics interface Read/write test Font ROM sum check
Test Code ROM
Test Timer
Fatal Error Detected
Test Memory
Test CPU
Test ASIC
Test NV-RAM
Display error on panel
Test Font ROM
Flash ROM Card installed? Yes
No
Flash ROM card sum check (if card is installed)
Test Flash ROM Card
DIMM Installed?
No
Yes
DIMM (emulation module) sum check (if DIMM is installed)
Test DIMM
Optional Parallel I/F installed?
No
Optional parallel interface board loopback test (if board is installed)
Yes Test Optional Parallel I/F
Start System
Generate list of settings
G024O009.WMF
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Test Results Printout when No Fatal Errors Occur

If a non-fatal error occurred, the report is printed in black and white. The Error Log section at the bottom of the printout explains the non-fatal errors that occurred. If no error occurred, the report is printed in color. The Error Log section contains None.
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PERIODIC MAINTENANCE
5. PERIODIC MAINTENANCE
Refer to Section 5 Preventive Maintenance in the engine service manual.
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Periodic Maintenance

6.1 CONTROLLER BOARD REPLACEMENT
1. Remove the Printer Controller Board. Refer to section 6.5.1 Controller Board of the Engine Service manual for the replacement.
6.2 IMAGE ADJUSTMENT

6.2.1 OVERVIEW
The table below lists the adjustable image parameters, with their corresponding adjustment procedures.
Item Brightness, Contrast, Saturation, Color Balance Procedure In the Print Quality tab of the Windows printer properties, select the Custom button and click Setting. A range of adjustments are displayed. The driver and controller reflect the results of the adjustments in the image data processing. This can be adjusted by customers via the Maintenance Menu and stored in NVRAM on the MCU. The development bias is automatically adjusted by referring to stored value. This can be adjusted in Engine SP mode. Refer to SP mode in the Engine manual. Use controller SP mode S5 (Gamma Calib.). You can adjust each color for each gamma () table. The results of the adjustment are reflected in the gamma () correction done by the controller.
Density
Development Bias Transfer Bias
Service Gamma
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Replacement Adjustment
6.2.2 SERVICE GAMMA () ADJUSTMENT

NOTE: For problems related to color quality and gradation, clean the engine and replace supplies and other parts first. Use this mode only when the customer insists on further fine adjustments (e.g., matching colors between machines).
Adjustment Menu (Controller SP, S5. Gamma () Calibration)

The menu items under Gamma Calibration in controller SP mode are organized as shown below.
Layer 3 Load Setting Layer 4 Default Setting-Old Setting-Current 1 bit/Photo 2 bit/Photo 1 bit/Text 2 bit/Text 300 dpi/1 bit 300 dpi/2 bit Layer 5 Layer 6
Mode Select
Print Sheet Black Gamma Select Cyan Magenta Yellow Save Settings K/01th. [xxx] K/15the. [xxx] Same as above Same as above Same as above K/01th. = xxx/255 K/15th. = xxx/255 Same as above Same as above Same as above
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Adjustment Overview
To carry out this adjustment, select the print mode, to be adjusted then print out a color adjustment sheet. Make the gradation scales on the printout smooth from the lowest to the highest density. Adjust the CMY gradation scale at the top of the chart by balancing the density of the C, M, and Y gradation scales the CMY gray scale should change smoothly from minimum to maximum, and there should be no coloration. The color adjustment sheet is as follows.
[C] [B] [A]
G024O013.BMP
For each color, you can adjust 15 points (example [A]) between 0 (lowest density) [B] and 255 (highest density) [C]. For each point, you can adjust the density within 0 and 255. The gradation scales marked Default are printed according to the default gamma () settings in the flash ROM in the controller. The gamma adjustment changes the densities at the adjustable points in the gradation scale. The gradation scale marked Current shows the current settings. During the adjustment procedure, compare the Current gradation scale with the Default. Select the density for each of the 15 adjustable points, excluding points 0 and 255, from the Default gradation scale.
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The NVRAM holds three controller gamma () settings, those saved this time (Setting-Current), those saved in the preceding adjustment (Setting-Old), and the factory settings (Default).
Adjustment Procedure
1. Select Load Setting and load the settings that will serve as the basis for the adjustment. 2. Select Mode Select, and select the print mode that you are going to adjust. 3. To review the image quality for these settings, choose Print Select to print out a color adjustment sheet (Gamma () Calibration at the top of the page). 4. Select Gamma Setting. Then select a color (K, C, Y, or M). 5. Adjust the color density at each of the 15 points. NOTE: To decide what density value to input, do the following. 1. Look at the color adjustment sheet. 2. For the color you are adjusting, look at the gradation scale entitled Default. 3. Go along the scale until you reach the density that you wish to input. 4. Read off the value on the scale and store it in the machine. 5. Do the same for all 15 points. 6. When the density setting is complete for all colors, print out a color adjustment sheet again and make sure that the gradation scale for each printed color is smooth and that the CMY gradation scale is gray. Repeat the adjustment if there is an anomaly (normally, repeat this procedure 3 to 5 times). 7. If the adjustment results prove satisfactory, do the following: 1) Execute Save Settings. 2) Reset the controller (press the [Reset] key when the machine is off line) to use the new settings. NOTE: The new settings will not be saved in the controller NVRAM unless you reset the controller.
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6.2.3 SOFTWARE UPGRADE PROCEDURE

The controller, Ricoh-Script 2, the network interface board and the MCU have a flash ROM for storing control software. This allows version upgrades using a Flash ROM card. The engine's firmware cannot be upgraded using this procedure. Refer to the engine service manual for details regarding upgrading the MCU Firmware. NOTE: Before starting an upgrade procedure, make sure that the software in the Flash ROM card is newer than the software in the controller, Ricoh-Script 2, or network interface board. To check, do one of the following: Print out a configuration page (user mode). Enter controller SP mode and execute 3. Summary with the [Media] key. The software version is shown on the operation panel LCD. Follow the procedure shown below to upgrade the software: 1. Turn off the machine, and then unplug all cables from the parallel interface board(s) and network interface board, if connected. 2. Remove the right side (controller board) option cover. NOTE: If the network interface board is installed here remove it. 3. Next, remove the Flash ROM card cover (left side of printer). Now, carefully slide the Flash ROM card into the card slot (be sure to position the card "arrow" side into printer, "A" side of card away from printer). 4. Set DIP switch 1 on the controller board to ON. If you removed the network interface board earlier, reinstall it now. 5. Turn on the machine. The machine automatically copies the software from the Flash ROM card to the appropriate flash ROM (controller, Ricoh-Script 2, or network interface board).
CAUTION: 1) Do NOT turn off the machine while the software is being updated. Otherwise, the controller, NIB, or Ricoh-Script 2 module may be damaged.
For the controller or Ricoh-Script 2: The LCD display on the operation panel changes as shown below as the rewrite procedure proceeds. (MELT is displayed during the software upgrade for Ricoh-Script 2 since it involves a decompression process.)
(MELT ->) ERASE -> WRITE -> VERIFY -> OK!!OK!! The appearance of the message OK!!OK!! indicates that the controller has received the data from the Flash ROM card. However, note that it takes about 30 seconds to rewrite the data in the controller or Ricoh-Script 2 after this message is displayed. So, be sure to wait at least 30 seconds before proceeding.
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The message NG!!NG!! is displayed if an error occurs during the rewrite process. If this condition occurs, reinstall the Flash ROM card and turn the power off and on again.
For the network interface board: The appearance of the message DOWNLOAD OK. indicates that the controller has received the data from the Flash ROM card. However, note that it takes about 30 seconds to rewrite the data in the network interface board after this message is displayed.
DOWNLOAD -> ############ -> DOWNLOAD OK. The message DOWNLOAD NG. is displayed if an error occurs during the rewrite process. If this condition occurs, reinstall the Flash ROM card and turn the power off and on again. 6. When the rewrite ends, turn off the main unit, reset all DIP switches to OFF, and remove the Flash ROM card. 7. Replace the Flash ROM card cover. Turn the power on again and print the user mode configuration page. 8. Check the new software version and make sure that it matches the version on the Flash ROM card.
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TROUBLESHOOTING
7. TROUBLESHOOTING
7.1 TYPES OF PROBLEMS
The problems can be classified as follows:
Operation Printer-side Print Settings Printer-side Initial Settings Host-side Application Settings Faulty Engine
Main Unit Option Consumables Main Unit Option
Hardware
Faulty Controller
Hardware Limitations
Software
Bug in Controller ROM Bug in Emulation Module Software Controller Limitations Bug in Host-side Application Host-side Application Limitations Environment (power, temperature and humidity, dust, noise, vibration) Consumables
G024O014.WMF
Operating conditions
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7.2 TROUBLESHOOTING PROCEDURE

7.2.1 HARDWARE TESTS
1. Power-up self-diagnostics Turn on the power and check that an error code is not displayed. After the system starts, check for error messages on the configuration page that automatically prints. 2. Detailed diagnostic test See Section 4.2 Detailed Self-diagnostics Mode in this manual for the procedure. 3. Checking the configuration page output. Print out from the user menu: [Menu] [List Print] [Config. Page]. If error messages are included, check the relevant part of the machine and replace any defective components. 4. Connectivity test Make a test print from a computer. Check that the correct cable is used (and connected properly). Check the cable wire conduction Check the cable length (is it too long?). Do not connect the printer to the computer through a printer selector switch connect the printer to the computer directly. If the optional parallel interface is installed, connect the computer to the parallel interface board that is being tested.
7.2.2 OPERATION-RELATED TESTS

Check the print conditions and initial settings. Check the printer settings against the application settings. Check whether the current settings match the settings on the configuration page that the customer keeps. NOTE: Ask the customer to print a configuration page at some time when the controller is working normally, and keep it for reference.
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TROUBLESHOOTING
7.2.3 SOFTWARE-RELATED TESTS

Obtain information about the following: PC model OS type and version Configuration page Application software used, and the version Data file being printed when the problem occurred (if obtainable) Ricoh-Script 2 data file when the problem occurred Sample printouts when the error occurred and when the printer is normal Detailed operating procedure Controller system and emulation module version Engine firmware version
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7.3 ERROR MESSAGES

7.3.1 OVERVIEW
The error messages for this unit are classified as follows: 1. Controller Self-diagnostic Errors Errors detected while the unit performs power-up self-diagnostics/detailed selfdiagnostics on the controller hardware. 2. Controller User Errors Errors caused because the controller software cannot process the job because of, for example, insufficient memory. 3. Internal Errors Errors caused because the controllers control function fails to function normally. 4. Engine User Errors (Cautionary) Errors that do not require user intervention to continue printing (the printer can still communicate with the PC over the interface). However, for the best printing quality, the user should correct the problem as soon as possible. 5. Engine User Errors Severe errors that cause the unit to stop printing, requiring the user to fix the problem before printing again. 6. Engine Service Codes (SCs) Severe errors that cause the unit to stop printing, requiring a technician to fix the problem before printing again. Only one error message can be displayed at a time. There is an order of priority for displaying errors. This is as follows: (starting with the highest priority) Internal Errors, Controller Self-diagnostics Errors, Engine Service Codes (SCs), Engine User Errors, Engine User Errors (Cautionary), and Controller User Errors.
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TROUBLESHOOTING
7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS

When a controller self-diagnostics error occurs, the error code is displayed on the first line of the operation panel LCD. The second line contains an 8-digit code that gives details of the error for designers to debug. For a memory error, the second line of the LCD indicates the address where the error occurred. For errors other than memory errors, the second line always reads FFFFFFFF.
Code 00XX 0101 0201 0301/0401 Description Exception processing error Flash ROM sum check error Standard memory read/write error Optional memory read/write error Non-fatal error (printed as B0 in the error log.) CPU exception self-diagnostics error ASIC timer error ASIC Centronics interface error Non-fatal error (printed as B1 in the error log.) NVRAM error (Read/Write) Font ROM error (Sum) Flash ROM card error 1703 represents a non-fatal error (printed as B4 in the error log.) Optional Interface 1 Error Optional Interface 2 Error Optional parallel interface board error Non-fatal error (printed as B6 in the error log.) Optional emulation module error Non-fatal error (printed as B5 in the error log.) CPU error ASIC compression/decompression error FCI error Non fatal error (printed as B9) Location Controller Controller Controller Optional memory
060X 0D0X 11XX
Controller Controller Controller
1401 1601 170X
Controller Controller Flash ROM card/Controller
1B0X 1C0X 1D0X
Controller Controller Optional parallel interface board Emulation module/Controller Controller Controller Controller
Troubleshooting
250X
400X 450X 460X
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7.3.3 CONTROLLER USER ERRORS

Display 85: Error 86: Error 91: Error 94: Error A3: Error A6: Error A7: Error Error during library drawing A8: Error AB: Error B0: Error B1: Error B3: Error B4: Error B5: Error B6: Error B7: Error B9: Error Flash ROM card slot error Optional emulation module error Optional parallel interface board error Optional network interface board error FCI read/write error Print overrun Optional memory error Standard parallel interface error Invalid initial set-up setting Overflow during compression Error during drawing processing Description Graphics environment initialization error Invalid control code parameter Font/image environment initialization error Download data error Receive buffer overflow Location/action Optional memory/Controller Incorrect printer driver or incorrect cable installed Install additional memory. Incorrect total memory size setting in the driver Increase the I/O buffer size using the system menu (user mode) Install additional memory. Use a smaller font size or a less complex font, or replace the controller Switch the machine off/on. If that does not work, replace the controller. Install additional memory. Reinstall/replace optional memory. Interface cable/controller Reset the printer settings using Menu reset in the Maintenance menu (user mode). Controller/Flash ROM card Reset/replace emulation module. Reset/replace optional parallel interface board Reinstall/replace network interface board Controller
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7.3.4 INTERNAL ERRORS

When an internal error occurs, the message Power Off/On is displayed on the first line of the operation panel LCD. The internal error code is on the second line in the format Error XXYY-ZZZZZZZZ (XX denotes a classification code; YY denotes a process number, and ZZZZZZZZ indicates the program address where the error occurred). The classification code portions (XX) and their descriptions are shown below. The YY and ZZZZZZZZ portions are for designer use only (for debugging).
Code (XX) 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Description Error in the TLB user area. CPU TLB update exception CPU mismatch exception (load or fetch) CPU mismatch exception (store) CPU address error exception (load or fetch) CPU address error exception (store) CPU bus error exception (load or fetch) CPU bus error exception (store) CPU system call exception CPU break point exception CPU reserved instruction exception CPU coprocessor disabled exception CPU operation overflow exception CPU trap exception Coherency (instruction) error CPU floating-point operation exception CPU timer interrupt ROCKY level 4 interrupt (ART or Tim) ROCKY level 3 interrupt (CP) ROCKY level 2 interrupt (XINT1 or XINT0) ROCKY level 1 interrupt (CBE, DBE, Dtc0, Verr, Fin, Vdtc, Fout) ROCKY level 0 interrupt (Debug) Software interrupt Software interrupt Other CPU exceptions Memory allocation error Overflow error Frame allocation error Card eject error Printer engine error Option board error Session-to-network interface board communications error
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7.3.5 ENGINE USER ERRORS (CAUTIONARY)

Refer to the Troubleshooting section in Operating Instructions.
7.3.6 ENGINE SERVICE CODES

Refer to the Troubleshooting section in Engine Service manual.
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NETWORK INTERFACE BOARD TYPE 305
NOTE: This section describes elements specific to the Network Interface Board Type 305. For additional information, such as installation, firmware upgrades, etc., please refer to the controller section of the service manual and to the user's documentation
NETWORK INTERFACE BOARD
8. NETWORK INTERFACE BOARD

8.1 OVERVIEW
8.1.1 SPECIFICATIONS
Configuration: LAN Interface: Frame Type: Protocol: Network Cable: SNMP Support: Embedded 10BASE-T/100BASE-TX Ethernet II (*1), IEEE802.3, IEEE802.2, SNAP *1: Only Ethernet II for TCP/IP TCP/IP, EtherTalk (*2), IPX/SPX (NetBEUI is not supported) *2: Only possible when equipped with RICOH-SCRIPT2. STP (Shielded Twisted Pair)**, Category 5 IP and IPX SNMP support of MIB-II
8.1.2 BLOCK DIAGRAM
CPU MC68340PV 25.166MHz
FlashROM 2MB
Network Environment DRAM 2MB ASIC DISCII Bridge AG1001V
SRAM OPTION I/F EEPROM
MAC Am79C971
PHY ICS1890
RJ-45
Controller Board
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G024 Win
Network Interface Board Type 305
**NOTE: If UTP (Unshielded Twisted Pair) cable is used too much EMI (Electromagnetic Interference) is emitted exceeding the required emission standard. Also, the ferrite core must be properly installed to the STP cable. Refer to the Operating Instructions Manual for details.
31 March, 1999
8.2 COMPONENT LAYOUT

8.2.1 NETWORK INTERFACE BOARD DIAGRAM
Front
Rear
DRAM
Flassh ROM
Flassh ROM
CPU MC68340PV
ASIC DISCII
MAC Am79C971
PHY ICS1890
Bridge AG1001V
SRAM
SRAM
SW1
LED1 EEPROM RJ-45
LED3 (G)
LED4 (G)
G024O006.WMF
8.2.2 DEVICES
Device CPU Memory DRAM SRAM EEPROM ASIC Bridge MAC PHY Description MC68340PV25 (25.166MHz) Flash ROM MBM29F800B-90PFTN (1 MB x 2) TC5118160AJ-60 (2 MB x 1) CY7C199 (256kbit x 2) ST93C46CB1 (1kbit x 1) Gate array MBCG24243 (DISCII) AG1001V Am79C971KC "PCnet-FAST" ICS1890
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8.3 BASIC OPERATIONS

8.3.1 OVERVIEW
This network interface board can manage both 10BASE-T and 100BASE-Tx. It has a maximum data transfer speed of 100Mbps. The auto-negotiation function automatically switches the communication speed. The controller board supplies the power source (+5V) and provides the reset signal. The controller board communicates with the network interface board through the option I/F connectors.
8.3.2 LED FUNCTIONS

The LEDs on the network interface board show the operating state. 1. LED1: Displays the operating status. On: Ready Off: Busy This LED blinks while the firmware is downloading. 2. LED2: Not used. 3. LED3: Displays the LAN type. On: 100BASE-TX Off: 10BASE-T 4. LED4: Displays the link status. On: Link safe Off: Link failure or link disabled
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31 March, 1999
8.3.3 SWITCH FUNCTION

SW1 resets the NVRAM on the network interface board. NOTE: This board has the hardware to execute a "Summary Printout". However, it does not function on this printer due to controller specifications.
NVRAM Reset Procedure

This procedure resets all the network settings to the defaults. IP address, Subnet Mask, Default Gateway Address, Access Control Mask, Network Boot, Frame Type (NetWare), Active Protocol, and so on 1. Turn on the main switch while pressing SW1. Keep pressing SW1 for 15 seconds. 2. Release SW1 for 3 seconds, press it again for 3 seconds, and then release it. 3. Turn the main switch off/on to complete the NVRAM reset procedure. NOTE: There is a margin for error of less than 1 second. Use a watch to measure the time periods as accurately as possible. 4. Print out the configuration page, and then check the settings. If the procedure failed, the previous settings remain. Repeat the above procedure until the old settings have been cleared.
G024 Win
8-4
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8.3.4 NETWORK SETTING INFORMATION
G024O007.BMP
G024O007.BMP
Since the controller does not support the "Summary Printout" function for the network interface board, check the network setting information by printing out a user mode configuration page. NOTE: Even though NetBEUI parameters are displayed on the various configuration pages, the NetBEUI protocol is not supported on this unit.
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G024 Win
31Rev. 05/2000 March, 1999

NIB OPTION FIRMWARE MODIFICATION HISTORY
DESCRIPTION OF MODIFICATION Initial Production Release Corrects the following: On the web status monitor, the improper icon was used for Paper Empty. If the NIB received 5 simultaneous print jobs, additional print jobs would be lost. Corrects the following: The firmware was modified to support A250/B001. Corrects the following: One banner data page of NetWare was split into two pages when using NetWare 3.12 pserver mode. In NetWare remote printer mode, the NIB consumed a server connection license. To avoid this, the firmware has been modified to disconnect the NCP connection immediately after the remote printer has connected to the server. Corrects the following: On the web status monitor, the wording in German was incorrect. FreierSpeicher corrected to Freier Speicher. The Web status monitor displays No Tray/No Paper error when a tray is not closed completely. The message has been changed to Other Error. Disabling (Down) or enabling (Up) AppleTalk protocol from the operation panel sometimes did not take effect after the change. To avoid this, the firmware has been changed to save a new setting to the NVRAM immediately after a change. Corrects the following: When a printer error occurs, the printer information cannot be accessed using Macintosh printer utilities such as Apple Printer Utility. IPP (Internet Print Protocol) function has been added. FIRMWARE LEVEL G6785839B G6785839C SERIAL NUMBER Initial Production February 99 Production FIRMWARE VERSION 3.7.5 3.7.7
G6785839D
March 99 Production April 99 Production
3.8.6
G6785839E
3.8.7
G6785839F
June 99 Production
3.8.8
G6785839G
July 99 Production
3.9.2
G024 Win
8-6
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Rev. 07/2001

DESCRIPTION OF MODIFICATION FIRMWARE LEVEL G6785839H SERIAL NUMBER October 99 Production FIRMWARE VERSION 3.9.8
G6785839M
February 01 Production
4.0.7
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G024 Win
Corrects the following: The wording Config Reference has been changed to Riferim. Config for the Italian version of Web status. The wording Default Gateway Address has been changed to Direcci. Gateway for the Spanish version of Web status. A type of Cisco router caused a problem in browsing the NIB in an AppleTalk network. The cause of this was in the Cisco router but the NIB firmware has been modified to correct this. Corrects the following: PCL text filter support has been added. RICOH brand name has been deleted from several functions and reports. Corrects the following: HTTP access has been improved when multiple protocols are used at the same time (e.g. telnet, IPP and HTTP). Corrects the following: Bi-directional communication of "diprint" (using 9100 port of TCP/IP printing) is supported (required for DAZEL system). The "diprint direct [On/Off]" command using telnet has been implemented for supporting bi-directional communication of diprint (required for DAZEL system). PortNavi and Multidirect Print are not supported if bi-directional communication has been selected. The spelling of the command "retern" in the UNIX install shell has been corrected to "return". The DHCP of NetWare5 is supported. The DHCP relay agent is supported. (This has been confirmed only with Windows NT 4.0 relay agent at this time.) There may be some minor (character) display errors on the LCD while the NIB firmware is being upgraded. The firmware has been modified to prevent this. Corrects the following: Classless InterDomain Routing (CIDR) is supported. DHCP of Solaris 2.6 is supported.
G6785839J
4.0.0
G6785839K
April 00 Production
4.0.2
G6785839L
4.0.6
Rev. 12/2002

DESCRIPTION OF MODIFICATION
FIRMWARE LEVEL G6785839N
SERIAL NUMBER August 01 Production
FIRMWARE VERSION 4.0.8
Corrects the following:
Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2.
G6785839P
SNMP security vulnerabilities reported by CERT on Feb.12, 2002 has been tested using the PROTOS c06-snmpv1 test suite and we have verified the fixes. -CERT :http://www.cert.org/advisories/CA-200203.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/pr otos/testing/c06/snmpv1/
July 02 Production
4.1.0
G024 Win
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G024 with FIERY 500 CONTROLLER SERVICE MANUAL
NOTE: This service manual is designed to be an addendum to the existing G024 engine (with base controller and Network Interface Board Type 305) service manual. As such, this service manual only details those areas that are unique to the G024 Fiery 500 version full-color laser printer. For any additional information, please refer to the G024 engine service manual. To differentiate this version of the G024 from the version with the base controller, this version will be referred to as the G024 PS.
G024 with FIERY 500 CONTROLLER SERVICE MANUAL

TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 SPECIFICATIONS.....................................................................................1-1 1.2 LAYOUT ....................................................................................................1-2
2. FUNCTIONAL OVERVIEW.......................................................... 2-1

2.1 BLOCK DIAGRAM AND FUNCTIONS ......................................................2-1 CPU ......................................................................................................2-1 Memory.................................................................................................2-1 DRAM ...................................................................................................2-2 SRAM ...................................................................................................2-2 NVRAM Functionality............................................................................2-2 Fiery Rip Chips (EFI ASICs) .................................................................2-3 Real Time Clock ...................................................................................2-3 2.2 PRINT DATA PROCESSING ....................................................................2-4 2.3 BUILT-IN COLOR MANAGEMENT ...........................................................2-5 2.4 PAPER FEED.............................................................................................2-6 2.4.1 PAPER SIZE DETECTION FOR TRAY 1..........................................2-6 2.4.2 PAPER SIZE DETECTION FOR THE BY-PASS TRAY ...................2-7
3. INSTALLATION........................................................................... 3-1 4. SERVICE TABLES AND PROCEDURES ................................... 4-1

4.1 DIAGNOSTICS MODE ..............................................................................4-1 4.1.1 OVERVIEW ......................................................................................4-1 Map of the Diagnostic Menu .................................................................4-1 4.1.2 RUNNING THE DIAGNOSTICS .......................................................4-2 Basic Procedure ...................................................................................4-2 Using the Custom Diagnostics Set .......................................................4-3 Diagnostic Test Result Display .............................................................4-4 Exit Custom Menu ................................................................................4-4 4.1.3 CONTENTS OF INDIVIDUAL DIAGNOSTIC TESTS .......................4-5 IDE Diagnostic Test ..............................................................................4-5 Ethernet Diagnostics.............................................................................4-6 RAM Diagnostics ..................................................................................4-7 Video Chip Diagnostics.........................................................................4-8 Boot ROM Diagnostics .........................................................................4-8 Firmware Diagnostics ...........................................................................4-8 I2CEEPROM diagnostics......................................................................4-8 4.2 ENGINE SP MODE ...................................................................................4-9 4.2.1 ENTERING ENGINE SP MODE........................................................4-9 4.2.2 KEY OPERATION ............................................................................4-9 4.3 BOOT ROM MENU .................................................................................4-10
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G024 PS
4.3.1 PURPOSE OF THE BOOT ROM MENU ........................................4-10 Entering the Boot ROM Menu.............................................................4-10 Contents of the Boot ROM Menu........................................................4-10 Exiting the Boot ROM Menu ...............................................................4-10 4.3.2 NAVIGATING THE MENU ........................................................4-11 Boot ROM menu map .........................................................................4-11 Key Usage in the Main Menu..............................................................4-12 Key Usage in each Menu Item............................................................4-12 4.3.3 DISPLAYING VERSION INFORMATION .......................................4-12 4.3.4 INSTALLING SOFTWARE UPGRADES ........................................4-13 Preparation .........................................................................................4-13 Procedure ...........................................................................................4-13 Recovery Mechanism .........................................................................4-13 4.3.5 FORMATTING THE HARD DISK ...................................................4-14 Procedure ...........................................................................................4-14 4.3.6 CHANGING THE ETHERNET MAC ADDRESS.............................4-14 Preparation .........................................................................................4-14 Procedure ...........................................................................................4-14 4.3.7 BRAND NAME SELECTION ..........................................................4-15 Preparation .........................................................................................4-15 Procedure ...........................................................................................4-15 4.3.8 CLEARING THE NVRAM PARAMETERS......................................4-15 Procedure ...........................................................................................4-15 4.4 SERVICE MODE .....................................................................................4-16 4.4.1 OVERVIEW ....................................................................................4-16 Password ............................................................................................4-16 Service Menu Map..............................................................................4-16 Entering the Service Menu..................................................................4-16 4.4.2 PRINT SERVICE INFORMATION LIST .........................................4-17 4.4.3 PRINT COLOR CHART..................................................................4-18 4.4.4 CLEAR FUSER CTR ......................................................................4-18
5. PERIODIC MAINTENANCE ........................................................ 5-1 6. REPLACEMENT AND ADJUSTMENT........................................ 6-1

6.1 CONTROLLER BOARD AND TEMPERATURE/HUMIDITY SENSOR REPLACEMENT .......................................................................................6-1
7. TROUBLESHOOTING................................................................. 7-1
7.1 TYPES OF PROBLEMS............................................................................7-1 7.2 TROUBLESHOOTING PROCEDURE.......................................................7-2 7.2.1 HARDWARE TESTS ........................................................................7-2 7.2.2 OPERATION-RELATED TESTS ......................................................7-2 7.2.3 SOFTWARE-RELATED TESTS .......................................................7-3 7.3 ERROR MESSAGES ................................................................................7-4 7.3.1 OVERVIEW ......................................................................................7-4 7.3.2 CONTROLLER DIAGNOSTICS ERRORS .......................................7-5 7.3.3 ENGINE USER ERRORS (CAUTIONARY)......................................7-7 7.3.4 ENGINE SERVICE CODES .............................................................7-7
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7.4 FIRMWARE HISTORY7-7
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G024 PS
IMPORTANT SAFETY NOTICES

PHYSICAL INJURY PREVENTION 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. Note that some printer components are supplied with electrical voltage even if the main switch is turned off. 4. If an adjustment or operation check must be made requiring the removal or opening of the exterior covers while the main switch is on, keep hands away from electrified or mechanically driven components. 5. The printer drives some of its components when it completes the warm-up period. Keep hands away from mechanical and electrical components when the printer starts operation. 6. The interior and metal parts for the fusing unit become extremely hot while the printer is operating. Do NOT touch these components with bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the printer without ozone filters installed. 2. Always replace the ozone filters with the specified replacement at the specified maintenance intervals. 3. Toner is non-toxic, but if it gets in your eyes by accident, it may cause temporary eye discomfort. Remove it with eye drops or flush eyes with water. If this is unsuccessful, get medical attention immediately. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do NOT incinerate toner cartridges, development toner magazine (DTM) or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner bottle and photoconductor unit (PCU) in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations.
Trademarks Microsoft, Windows 95/98, and Windows NT 4.0 are registered trademarks of Microsoft Corporation. Macintosh and EtherTalk are registered trademarks of Apple Computer, Inc. PostScript is a registered trademark of Adobe System Inc. PCL is a registered trademark of Hewlett-Packard Company. NetWare is a registered trademark of Novell, Inc. Ethernet is a registered trademark of Xerox Corporation. Token Ring is a registered trademark of IBM Corporation. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies. We disclaim any and all rights in those marks.
OVERALL INFORMATION
1.1 SPECIFICATIONS
Page Description Language: Printer Driver Platform: Resolution: Gradation Mode: Interface: Network Protocol: Adobe PostScript 3 PCL 5e/5c compatible Macintosh, Windows 95/98, Windows NT4.0 600 dpi 2 bits/pixel IEEE1284 Compatible, Nibble or ECP mode Ethernet 10BaseT/100BaseTX, 10Base 5 NetWare 3.10, 3.11, 4.X, IPX/SPX EtherTalk System 7 and later TCP/IP, SNMP, ARP, UDP (Token Ring is optional) 802.2, 802.3, SNMP, Ethernet-II, Ethernet SNMP LPD (Line Printer Daemon) Pserver (Print Server) PAP (Printer Access Protocol) SMB (Server Message Block) over TCP/IP Font: 136 PostScript fonts 35 Intelli fonts, 10 TrueType fonts, and 1 bitmap line printer font for PCL5c Memory: DIMM Slots: EIDE Interface: Options: Standard 32MB 2 (for optional memory) 1 (for optional HDD) 32/64MB DIMM 2.5-inch 1.6-GB hard disk drive
Frame Types: Printing Services:
NOTE: The G024 Fiery 500 Version alone and when equipped with the typical options (Paper Feed Units, Memory Units and Printer Hard Disk) meets the EMI requirements of the FCC rules part 15, class B. When configured with the Token Ring option, the product meets the EMI requirements of the FCC rules part 15, Class A.
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G024 PS
G024 Fiery 500 Service Manual
SPECIFICATIONS
Paper Size
Standard tray Short edge feed: 12" x 18", 11" x 17", 81/2" x 14", Others* (A3, 8" x 13", 81/4" x 13", 81/2" x 13", 13" x 18") Long edge feed: A4, 81/2" x 11", 71/4" x 101/2", Others* (51/2" x 81/2") By-pass feed tray* Short edge feed: A3, A6, B4 JIS, 11" x 17", 81/2" x 14", 8" x 13", 81/4" x 13", 81/2" x 13", 12" x 18", 13" x 18" Long edge feed: A4, A5, B5 JIS, 81/2" x 11", 51/2" x 81/2", 71/4" x 101/2" * Specify the paper size with the system menu (at the operation panel by the user).
LEGEND
Product Code G024 G908 G503 G690 N/A AP505 Paper Feed Unit Type 305 Memory Unit Type 505 (32MB&64MB) Printer Hard Disk Type 505 Fiery 500 Token Ring Kit RICOH SAVIN SLP517cp Paper Feed Unit Type 305 Memory Unit Type 505 (32MB&64MB) Printer Hard Disk Type 505 Fiery 500 Token Ring Kit GESTETNER C7005P Paper Feed Unit Type 305 Memory Unit Type 505 (32MB&64MB) Printer Hard Disk Type 505 Fiery 500 Token Ring Kit
N/A = Not Applicable NOTE: For additional specification information, refer to the G024 engine service manual.
G024 PS
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G024O011.WMF
1. Controller (Fiery 500) NOTE: For additional information refer to the G024 engine service manual and G024 engine component layout.
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G024 PS
1.2 LAYOUT
FUNCTIONAL OVERVIEW DETAILED DESCRIPTIONS
FUNCTIONAL OVERVIEW
2.1 BLOCK DIAGRAM AND FUNCTIONS

CPU MIPS R4700 Power Supervisor
On Board Flash ROM (Boot Code) Memory Controller ASIC (DX) SDRAM Flash ROM 4 DIMM Slots
PCI Connector
Token Ring Card (Option)
Video Control ASIC (VX)
Engine I/F Connector
IDE Controller
IDE HDD Connector
IEEE 1284 Connector I/F Control ASIC (IX) System I2C EEPROM
Ethernet RJ45 Connector Ethernet Controller Ethernet AUI Connector
G024C503.WMF
CPU
This product utilizes a MIPS R4700 (133 MHz) CPU.
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2. FUNCTIONAL OVERVIEW
BLOCK DIAGRAM AND FUNCTIONS
Memory
There is a proprietary memory ASIC that supports up to 8 DIMMs, up to 32 MB of boot PROM or flash memory. The ASIC can support burst accesses for 8 or 64 bit wide PROMs. However, this controller only supports 4 DIMMs. Three of these are for optional memory, and one is for the flash/mask ROM that holds the internal fonts.
DRAM
The Memory ASIC supports industry standard synchronous DRAM DIMMs for optional printer memory (see the previous page). The R4700 bus is 64 bits wide. Architecturally, the system can support up to 256 bytes of DRAM and 8 DIMM slots (64 MB DIMMs will be supported when commercially available).
SRAM
The SRAM is used for processing print data.
NVRAM Functionality
The NVRAM holds printer parameters that must be maintained across power cycles. NVRAM space is in the order of 32KB. The NVRAM consists of 1 MB of flash memory soldered to the motherboard.
G024 PS
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FUNCTIONAL OVERVIEW
The three ASICs (designed by EFI) are responsible for the high-speed and performance of the controller. They are as follows:
Memory ASIC (DX3)

The memory ASIC provides a high speed interface between the CPU, memory, and PCI bus. The DX3 supports 64-MB DRAM DIMMs.
IO ASIC (IX)
The IO ASIC supports the internal and external I/O interfaces including: PCI direct memory access User interface (front panel) IEEE 1284 compliant parallel port (Centronics, Nibble, ECP) Generic synchronous serial interface
Video ASIC (VX)

The video ASIC is responsible for: PCI direct memory access Decompression Video interface to the engine All three ASICs interface to a high speed PCI bus (64 bits wide) and comply Rev 2.1 of the PCI specification.
Real Time Clock

This controller does not utilize a real time clock.
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G024 PS
Fiery Rip Chips (EFI ASICs)
PRINT DATA PROCESSING
2.2 PRINT DATA PROCESSING

Drivers Connectivity IO/Print/ Device Mgr PDLs Compression Page Mgr Video Mgr
PostScript generation
Ethernet Spooling, PDL switching Parallel
DSC parsing PostScript
Page Compression Finishing, Engine loading Decomp, Video
PJL parsing PCL 5e/5c
Page Compression
PCL generation
G024C504.WMF
The key roles to each section of the print system are outlined below. The drivers are responsible for generating the page description on the host system and for transmitting data to the printer. The I/O manager mediates the connection between the parallel port or network interface and establishes a device or print manager connection. The print manager is responsible for spooling the job (if appropriate) and for feeding jobs to the correct PDL interpreter. The PDL interpreters are responsible for turning page descriptions into rendered pages and for parsing job management comments. The compression subsystem manages compressed pages in memory. The page manager coordinates pages to be sent to the engine for the most efficient printing, finishing, and accessory handling. The video subsystem is responsible for decompressing pages and feeding the engine with appropriate engine signals. The video subsystem also handles certain print quality processing functions.
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FUNCTIONAL OVERVIEW
This controller has a full complement of built-in color management processes.

Component PostScript color rendering dictionaries (CRDs) Press simulation control Device profiles Description CRDs optimized for photos, graphics, presentation objects; plain paper/transparency media types Lookup tables to simulate density characteristics of offset printing processes ColorSync 2/ICM profiles compatible with Macintosh and Windows color management systems Location/Platforms In controller ROM/Flash memory
Controller SRAM Macintosh/Windows 95
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2.3 BUILT-IN COLOR MANAGEMENT
PAPER FEED
2.4 PAPER FEED

2.4.1 PAPER SIZE DETECTION FOR TRAY 1
[A]
[B]
Paper size detection is based on the three paper size switches [A] located on the main unit. These switches detect the setting of the paper size dial [B] on the paper tray. The paper size dial has grooves and ridges on the side facing the paper size switches. A switch deactivates when it falls into a groove, and activates when a ridge presses against it. Paper size detection for tray 1
Dial No. 1 2 3 4 5 6 7 8 Paper Size 12" x 18" SEF Others 71/4" x 101/2" LEF 81/2" x 14" SEF 81/2" x 11 LEF A4 LEF 11" x 17" SEF No Cassette Sensor Status XNOB2 XNOB1 XNOB0 0 0 0 0 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 1 0 1 1 1
SEF: Short edge feed LEF: Long edge feed Others: SEF A3, 8" x 13", 81/4" x 13", 81/2" x 13", 13" x 18" LEF - 51/2" x 81/2"
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FUNCTIONAL OVERVIEW
[A]
A3 WIDE SEF B4 SEF B5 LEF EXE LEF
G024D410 WMF
A3 SEF A4 LEF DTL SEF LT LEF
A5 LEF HLT LEF LG SEF
A6 SEF B6 SEF
LEF: Long edge feed SEF: Short edge feed
G024D411. WMF
A contact plate (electrode plate) is connected to each of the two side fences [A]. The contact plates short the patterns on the paper size detection board [B]. Paper width is detected based on how the various patterns (strips) are shorted by the contacts on the side fences. Paper size detection for the by-pass feed tray
Paper Size A3 Wide LEF A4 LEF A3 SEF 81/2" x 11" LEF 11" x 17" SEF 71/4" x 101/2" LEF B5 JIS LEF B4 JIS SEF 81/2" x 14" SEF 51/2" x 81/2" SEF A5 LEF 8" x 13" SEF 81/4" x 13" SEF 81/2" x 13" SEF B6 JIS SEF A6 SEF XBIT0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 Sensor Status XBIT1 XBIT2 1 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 XBIT3 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1
NOTE: For additional paper feed information refer to the G024 engine service manual.
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2.4.2 PAPER SIZE DETECTION FOR THE BY-PASS TRAY
[B]
INSTALLATION
INSTALLATION
Refer to the following operation manuals. For the printer: Quick Installation Guide, Operating Instructions Printer Reference, Operating Instructions Getting Started and the Operating Instructions Users Guide. For options: Operating Instructions Printer Reference
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3. INSTALLATION
SERVICE TABLES
12 May, 1999
4.1 DIAGNOSTICS MODE

4.1.1 OVERVIEW
There are several sets of diagnostic tests. This section includes an outline of how to select, run, and stop a custom diagnostic test set and a brief description of the messages displayed on the front panel during and after the diagnostic test.
Map of the Diagnostic Menu

BEGIN
8]
START SELF-TEST
[ [MENU]
8]
[#ENTER]
[ ]/[ ] S C R O L L S T H R O U G H TESTS & GROUPS [MENU]

DIAGNOSTIC TESTS <TEST/GROUP NAME>
8 9
[ ]/[ ] S C R O L L S T H R O U G H TESTS & GROUPS
8 9
DIAGNOSTIC SETS CUSTOM
9]
[
8]
RUN UNTIL DONE <OTHER>
[#ENTER] [#ENTER] T O G G L E S S E L E C T I O N OF CURRENT TEST/GROUP
[MENU]
8]
[#ENTER]
RUN BOARD TESTS RUN CUSTOM TESTS
DIAGNOSTIC SETS FUNCTION
9]
[
[MENU]
8]
[CANCEL] [#ENTER]
DIAGNOSTIC SETS BURN-IN
RUN BURN-IN TESTS
9]
[
8]
[CANCEL]
9]
DIAGNOSTIC SETS START-UP
EXIT CUSTOM? [NO]/[YES]
[MENU]/[#ENTER]
RUN START-UP TESTS
[ ]/[ ] T O G G L E S SELECTION
8 9
[#ENTER]
END
G024C505.WMF
Using the diagnostics menu, you can use the printers operation panel to select one of several different diagnostic sets (Custom, Start-up, Burn-in, Function) and various test options.
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4. SERVICE TABLES AND PROCEDURES
DIAGNOSTICS MODE
12 May, 1999
4.1.2 RUNNING THE DIAGNOSTICS

Basic Procedure
1. To run a diagnostic test, switch the printer off and on again. By default, the power-up diagnostic self-test is run when the system is turned on. During the power-up diagnostics, optional components (such as hard disk drives) that are not installed will be reported on the front panel. 2. To run a different set of diagnostics, press and hold down the [V] key when START SELF-TEST appears on the front panel display. Release the [V] key when the DIAGNOSTIC SETS menu is displayed. From here a diagnostic set can now be selected. 3. Press the [V] or [W] buttons to scroll through the available diagnostic sets. These are Custom, Start-up, Functional, or Burn-in; see the notes at the end of the procedure for more information. 4. Press the [#Enter] button to select the displayed diagnostic set and exit this menu. Alternatively, the user may press the [MENU] button to select the start-up (default) diagnostic set and exit this menu. Custom: If this set is selected, a series of menus appears that allows you to specify which tests should be run. It also allows you to specify the conditions for the tests to stop (e.g., stop if an error is detected, or do all tests until the end). If any diagnostic set other than Custom is selected, it will begin immediately. Start-Up: If this set is selected, the default (power-up) diagnostic set is run. This is the same set of tests that is done every time the system is powered up. Functional: If this set is selected, a more comprehensive set of tests is run. These test the functionality of all the components. Burn-In: If this is selected, a set of tests is executed repeatedly to exercise all board functions. External connections are unnecessary.
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12 May, 1999
1. If CUSTOM was selected, you may select the individual diagnostic tests. You can view all the available tests by pressing the [V] or [W] buttons to scroll up or down. The tests in the menu are organized into groups of related tests. When scrolling through the menu, both groups and individual tests are displayed. A group is identified by a colon (:) after the group name (for example, IDE:). A test is identified by either a blank or + symbol before the test name (for example, +IDE), and this follows the group name. (The + symbol indicates that the test has been selected; see below.) 2. Initially, no group/test is selected. Select or deselect a group/test by pressing the [#Enter] button when the group/test name is displayed. NOTE: When a group is selected a + symbol may not be displayed. In this case after pressing [# Enter], press the [Menu] key as detailed in step 3 below. Be careful not to press [# Enter] twice or the group will be deselected. If a test is selected, the + symbol will be displayed before the test name. If a test is deselected, the + symbol will disappear. If a group is selected or deselected, all items in the group will be selected or deselected. 3. After selecting the tests to run, exit the Diagnostic Tests menu by pressing the [MENU] key. You are now presented with a menu that allows you to specify the condition which will cause the tests to terminate. This menu will display RUN UNTIL followed by either DONE, TIME..., FAILURE, or INTERRUPTED. 4. Cycle through the choices with [V] or [W]. 5. To select the currently displayed condition, press [#Enter]. If you select DONE or press the [MENU] button, each test that you selected will be run once. Selecting DONE will exit the menu and begin the tests. If you select FAILURE, the tests will repeat until a failure is detected. To stop the test, press [CANCEL]. If you select INTERRUPTED, the tests will run until you interrupt the tests by pressing the [CANCEL] button. If you select TIME..., the tests will run for a preset duration. NOTE: Selecting FAILURE, INTERRUPTED or TIME... will exit the menu.
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G024 PS
Using the Custom Diagnostics Set
DIAGNOSTICS MODE
12 May, 1999
Diagnostic Test Result Display

When executing each selected test, the message "TESTING:, followed by the name of the test will be displayed on the front panel. The green LED will be lit for the duration of each test. If the test fails, the red LED will turn on. At the end of the diagnostics, a summary error report is displayed in the event of any error(s). This error report consists of the message
TESTS FAILED UP/DOWN/CANCEL

After this report appears, view the names of the failed tests and the corresponding error code using the [V]/[W] buttons. Refer to section 4.1.3 of this manual for descriptions of the individual tests and section 7 of this manual for descriptions of the error codes. Exit this process at any time by pressing the [CANCEL] key.
Exit Custom Menu

If CUSTOM was selected in the DIAGNOSTIC SETS selection menu, a menu is presented after the tests have ended, asking the user if he wants to exit the custom tests. The user can toggle between the choices YES and NO using the [V]/[W] buttons, and accept the choice using the [#Enter] button. Selecting YES exits the Diagnostic Menu, while selecting NO presents the Custom Diagnostic Tests menu again.
G024 PS
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12 May, 1999
IDE Diagnostic Test

IDE CHIP
This is an IDE initialization and register test. All CMD 64X controller chips are located on the controller board. For each IDE controller chip, the following tests are performed: 1. The PCI configuration registers are initialized. 2. The programming interface of the CMD 64X chips is made ready. 3. The IDE controller (PCI I/O) bus mastering is disabled. 4. A base address is specified. Note that this address is recycled to prevent I/O address space exhaustion. The normal value is 0x11F0. 5. PCI I/O is enabled.
IDE HD
If an optional hard disk drive is not present, the front panel will display a message and these tests will be skipped. For a count of 128 (0 <= I <= 127). Set M to the last readable sector. Set buffer 1, buffer 2, buffer 3, buffer 4 to all zeros. Read sector 0+I into buffer 1. Read sector MI into buffer 2. Read sector 0+I into buffer 3. Read sector MI into buffer 4. Buffers 1 and 3 are compared. They should be equal, byte for byte, otherwise an error will result. Buffers 2 and 4 are compared. They should be equal, byte for byte, otherwise an error will result. Reading 128 alternating sectors from both ends of the disk will result in a 4second buzzer sounding as the heads go back and forth, giving an audible indication that they are working.
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4.1.3 CONTENTS OF INDIVIDUAL DIAGNOSTIC TESTS
DIAGNOSTICS MODE
12 May, 1999
Ethernet Diagnostics
ENET SLV REG (Slave register test)
This searches for the ethernet controller chip and performs an internal register test.
ENET INIT (Chip initialization test)

The ethernet chip is configured on the PCI bus. It can perform memory address recognition and bus mastering. It has the base address set and is compared to ensure the correct value was set. A speed detection error may occur if the external loopback plug is not plugged in. Internal loopback testing is not done because of hardware idiosyncrasies.
ENET READ (Packet read test)

256 packets on the network are captured at random. When these packets have been read without a single error, the test ends successfully. For this test, the network must be clean, and there must be no collisions, runts (incomplete packets), etc. It is important that all packets on the network must be free of errors, as this test assumes that any kind of packet error will result in a test failure.
ENET WRITE (Packet write test)

128 packets are transmitted. The packet type is set to 0xDEAD to ensure that other systems ignore it. When 128 packets transmit without a single error. The test passes successfully. Each packet has a 1 millisecond gap between it and the next packet. For this test, the network must be clean, and there must be no collisions, runts (incomplete packets), etc. It is important that all packets on the network must be free of errors, as this test assumes that any kind of packet error will result in a test failure.
G024 PS
4-6
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12 May, 1999
RAM diagnostics tests the DIMMs and the system paths to the DIMMs (I2 C and memory bus). These tests are running in memory without corrupting the diagnostics area. Before the memory test executes, it displays the test region on the serial port. All tests are performed in a cache (L2 where available).
MEM DIMM INFO

Determines whether the DIMM configuration can be detected via I2 C (serial presence detect). It is presumed that the bus works; otherwise, diagnostics would not be running in memory. However, transient conditions and any additional DIMMs will be tested.
MEM PATTERN
This test writes various patterns to the entire untested memory area, then confirms that they were written correctly.
MEM ADDRESS
This test writes the inverse of the address into the address. It then reads it back and verifies.
MEM GND BOUNCE

This diagnostic tests the ground bounce in the memory. Ground bounce occurs when there is excessive inductance on leads from the memory chip. If ground bounce causes the ground level on the chip to float to the logical 1 level, the chip will output a 1-level output when it should output a 0. The stress test for this condition is to read all 1s from the chip (maximizing the current flow through the leads), then read all 0s. This test writes alternating 64-bit words of all 1s and all 0s (i.e., 64-bits of 1, then 64-bits of 0, etc.) When written from or read into the processors internal cache, the chip will be stressed as described in the above paragraph.
MEM RANDOM
This diagnostic tests the memory by writing random data, reading it, and verifying.
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RAM Diagnostics
DIAGNOSTICS MODE
12 May, 1999
Video Chip Diagnostics

VX CHIP (VX Internal Register)
This test locates the VX chip and tests its register.
Boot ROM Diagnostics

BOOTROM (General Boot ROM Diagnostics)
This tests the Boot ROM to ensure that the checksum is valid, and that the parameter blocks are writable.
BOOTROM WRITE (Boot ROM Write Diagnostics)

This test writes various patterns to the parameter blocks in the Boot ROM. If these parameter blocks are full, the test will not occur and a failure will be reported.
Firmware Diagnostics
EFIDIMM (System DIMM diagnostics)
This test searches for the system DIMM, calculates and then verifies the checksum on the system DIMM.
I2CEEPROM diagnostics
This test reads the contents of the on-board I2C EEPROM at both sequential and random addresses to ensure that data is readable.
G024 PS
4-8
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12 May, 1999
4.2.1 ENTERING ENGINE SP MODE

To enter engine SP mode, hold down the [Online] [A] and [Menu] [B] keys on the operation panel and turn on the power. [A] [B]
On Line
Menu
Cancel
#Enter
Power
Error
Data in
G024C500.WMF
[A]
[B]
G024C501.WMF
4.2.2 KEY OPERATION

[Cancel] key: Pressing this key moves you to a higher level in the current menu. Before the specified value is confirmed by the [# Enter] key, pressing this key keeps the existing setting. NOTE: Refer to section 4 SP mode in the G024 engine service manual for additional information.
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G024 PS
4.2 ENGINE SP MODE
BOOT ROM MENU
12 May, 1999
4.3 BOOT ROM MENU

4.3.1 PURPOSE OF THE BOOT ROM MENU
[A]
On Line
[B]
Menu
Cancel
#Enter
Power
Error
Data in
G024C500.WMF
[A]
[B]
G024C501.WMF
Entering the Boot ROM Menu

During power-on, hold down the [ONLINE] [A] and [ ] [B] keys on the front panel until the LEDs turn off. The ROM menu will start after diagnostics (Self-Test).
Contents of the Boot ROM Menu

Currently there are 6 functions accessible from the front panel. Displaying the version information Installing software upgrades Formatting the hard disk drive Changing the Ethernet MAC address Selecting the brand name Clearing the NVRAM parameters
Exiting the Boot ROM Menu

Press the [CANCEL] key at the first level menu.
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4-10
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12 May, 1999
Boot ROM menu map

[ [
BOOTSTRAP V1.3.26 02/04/98
9]
[
[#ENTER]
VERSION INFO
9]
[
[MENU]
[MENU]/[#ENTER]
8]
SYSTEM CODE MAR 23 1999
9]
[
8]
BOOTCODE V1.3.26 02/04/98
[MENU]/ [#ENTER]
[MENU] [#ENTER]
INSTALL UPGRADES INSTALL: BOOT ROM
8]
[
[MENU]
Note 1 [MENU]
9]
INSTALL: SYSTEM CODE
8]
[
[MENU]
INSTALL: FILE SYSTEM
9]
[#Enter] Installs upgrade and returns [MENU] [#ENTER]

FORMAT DISK
[#Enter] Installs upgrade and returns [MENU] [ [
[#Enter] Installs upgrade and returns
[
FORMAT DISK: NO
9] 8]
FORMAT DISK: LOW LEVEL
9] 8
[MENU]
[ ] [#Enter] Formats hard disk drive and return
FORMAT DISK: HIGH LEVEL
[#ENTER]
Note 2
CHANGE ENET MAC ADDRESS
[MENU] [#ENTER]
ENET MAC ADDRESS 1234:5678:90AB
[MENU] Note2
CHANGE DEFAULT OEM
[#Enter] Saves the MAC address and returns [

DEFAULT OEM: RICOH *
[#ENTER]
8]/[9]
DEFAULT OEM: XXXX
[#ENTER]
[MENU]
CLEAR NVRAM PARAMETERS
[MENU] [#ENTER] [
CLEAR NVRAM: NO
8]/[9]
[
[MENU]
CLEAR NVRAM: YES
8]/[9]
[#Enter] Clears the NVRAM parameters and returns
Note 1: J10 must be shorted. Note 2: Short J8 to access these menus.
G024C506.WMF
SM
4-11
G024 PS
4.3.2 NAVIGATING THE MENU
BOOT ROM MENU
12 May, 1999
Key Usage in the Main Menu

Key [MENU] [CANCEL] [#Enter] Description Cycle through the functions in the menu. Exit the Boot ROM menu and continue system startup. Enter a menu.
Key Usage in each Menu Item

Key [MENU] [CANCEL] [#Enter] [ ]/[ ] Description Return to the main menu. Exit the Boot ROM menu and continue system startup. Select the current item in the menu or save the current value. Scroll through the list of items available. or change the value of the current item. Position the cursor to select the character/number to change.
8 9
[ ]/[ ]
4.3.3 DISPLAYING VERSION INFORMATION

The version information for the bootstrap and the boot code can be displayed. The version number and the release date is shown. The version number can be different for the bootstrap and the boot code. For more information about bootstrap and boot code, refer to section 4.3.4 Installing Software Upgrades.
G024 PS
4-12
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12 May, 1999
The system software consists of three different elements: the Boot ROM, the system code and the file system. All of these elements can be upgraded through the parallel port. The files used for upgrades are bootrom.sys, system.sys and filesys.sys for the Boot ROM, system code and file system upgrades respectively. The file for recovering from a bad boot code is bootrom.rcy. The file formats are not interchangeable.
Preparation
To upgrade the Boot Rom first, power-off the printer then short the jumper pins together at J10 on the controller board. Next, power the printer back on and enter the Boot ROM menu.
Procedure
1. Use the [Menu] key to select Install Upgrades. Then press the [#Enter] key. 2. Use the [V]/[W] keys to select the item to upgrade (Boot ROM, system code, or file system). The options for the system code and the file system will not appear if a flash DIMM is not installed. 3. Press the [#Enter] key to start the upgrade process. 4. Start downloading the appropriate file through the parallel port. 5. Downloading from a PC can be done by issuing the command copy /b <file name> lpt1 The file size and the checksum automatically verify the file. The downloaded file is processed and stored. The front panel will display an error message if the upgrade fails. If an error occurred, press any key to acknowledge. 6. If the Boot ROM was upgraded, clear the NVRAM parameters. (See 4.3.8 Clearing NVRAM Parameters)
Recovery Mechanism
The software in the Boot ROM is divided into 2 sections: boot strap (located in the flash ROM) and boot code (located in the DIMM). The boot-strap is a small block of memory where essential initialization code resides. The system will continue to function properly even if the bootstrap is not upgraded. The boot code is the section where the diagnostics and ROM menu function resides. This is not locked and can always be updated when necessary. Since it is possible to accidentally erase the boot code, a disaster recovery mechanism is provided. This recovery mechanism can reload the Boot ROM if the bootstrap is
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G024 PS
4.3.4 INSTALLING SOFTWARE UPGRADES
BOOT ROM MENU
12 May, 1999
valid. This recovery mechanism should not be used as the procedure for upgrading the Boot ROM. 1. Hold down any key on the front panel while booting. 2. After all LEDs turn off, start downloading the recovery file (bootrom.rcy) through the parallel port. The front panel will display the progress of the recovery. Only the special recovery file will be loaded. If a recovery file is not detected, the system will continue to boot.
4.3.5 FORMATTING THE HARD DISK

This function will perform a low-level or a high-level format of the hard disk drive, creating a file system on the hard disk. This option will be available only if there is a hard disk drive installed in the system.
Procedure
1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys to select LOW LEVEL or HIGH LEVEL from the front panel. 2. Press the [#Enter] key to start formatting the hard disk drive. To return to the main menu without formatting the disk, either select NO with the [V]/[W] keys and press [#Enter], or press the [MENU] key. The front panel will report whether the disk drive formatted successfully. If it was unsuccessful, press any key to continue.
4.3.6 CHANGING THE ETHERNET MAC ADDRESS

It is possible to change a Ethernet MAC address. This is necessary if the customer wishes to use the same MAC address after the controller board has been replaced (the network interface is built into the controller).
Preparation
Prior to entering the Boot ROM menu, short the jumper pins together at J8 on the controller board to make this menu available.
Procedure
1. Once in the appropriate menu, refer to section 4.3.2, use the[ ]/[ ] keys to position the cursor at the digit to change, and the [V]/[W] keys to change the digit at the cursor. While changing the address, an asterisk (*) will be shown after the address when the current address is displayed. This is a reference, in case you forget the current MAC address during editing. 2. Press the [#Enter] key to save the Ethernet MAC address.
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12 May, 1999
4.3.7 BRAND NAME SELECTION

It is possible to change the machines brand name.
Preparation
Prior to entering the Boot ROM Menu, short the jumper pins together at J8 on the controller board to make this menu available.
Procedure
1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys to select the required brand name. 2. Press the [#Enter] key to save the Brand name.
4.3.8 CLEARING THE NVRAM PARAMETERS

User configurable settings are stored in the non-volatile memory within the boot ROM. Use the following procedure to clear these parameters. All data listed on the configuration sheet is erased, and these must be stored in the NVRAM again after clearing.
Procedure
1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys to select YES at the front panel. 2. Press the [#Enter] key to clear the non-volatile RAM parameters. To return to the main menu without clearing the non-volatile RAM parameters, either select NO with the [V]/[W] keys and press [#Enter], or press the [MENU] key. The front panel will report if the procedure was successful. If it is unsuccessful, press any key to continue.
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G024 PS
To return to the main menu without saving the MAC address, press the [MENU] key.
SERVICE MODE
12 Rev. 7/99 May, 1999
4.4 SERVICE MODE

4.4.1 OVERVIEW
Password
A special key combination is required to enter this menu. This is to prevent customers from accessing this menu.
Service Menu Map

SERVICE
[Enter]
Incorrect password
ENTER PASSWORD
Enter password
[Enter]
Exits menu and prints list
Correct password PRINT SERVICE INFORMATION LIST
[Enter]
Exits menu and prints chart
[ / ] key
89
PRINT COLOR CHART
[Enter]
Clears fuser counter and exits menu
[ / ] key
89
CLEAR FUSE CTR
G024C502.WMF
Entering the Service Menu

Press the [Menu] key, then use the [w] key until SERVICE MENU is displayed press [Enter] key. While the LCD displays ENTER PASSWORD, press the [ON LINE] and [ ] keys at the same time. To exit this menu, turn off the machine.
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12 May, 1999
The table below explains the contents of the engine maintenance list printout. The controller obtains the data from the engine (MCU).
Item MCU Firmware version Density Settings Margin Settings Description The MCU board firmware version number. Customers can adjust the toner density via the maintenance menu. Adjusted values are stored in the NVRAM on the MCU. Customers can adjust side-to-side registration from the optional tray with the Maintenance Menu. In addition, leading edge registration can be done with engine SP mode (1. Margin). These values are stored in the NVRAM on the MCU. Indicates the total number of printouts. The counter is incremented when the paper exit sensor detects paper exit completion (regardless of paper size, type, and mono/color mode). Counter value for printouts in color mode. Counter value for printouts in monochrome mode. PCU replacement is indicated when this value reaches 60000. This value increases by 4 in color mode printing and by 1 in black mode printing. When printing in A3/DLT, double counting occurs. Fusing unit replacement is indicated when this value reaches to 60000. This counter increases by 2 for A3/DLT size printing and by 1 for printing in other sizes. Number of fusing unit resets made with service mode. Number of sheets of each size of paper that passed the exit sensor.
Total
Color Print B/W color PCU
Fusing Unit Replacement A3/DLT, A4/LT, LG, B4 and etc. Size counter Feed Jam, Transfer Jam and Eject Jam SC SC Error History Jam History
Counters
Fusing unit
Process-control error History ID sensor PWM setting
Number of SCs The most recent 3 SC codes. The most recent 10 jam codes and the total counter value at the time. 000: Paper cassette 001: Paper feed path 002: Paper exit The most recent 3 errors during process control and the total counter value at the time. Not all of the errors are indicated as SC errors. The value set with engine SP mode, 9: ID Sensor PWM.
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G024 PS
4.4.2 PRINT SERVICE INFORMATION LIST
SERVICE MODE
12 May, 1999
4.4.3 PRINT COLOR CHART

This prints a color test chart, so that the image quality can be tested for all colors at various densities. This chart prints on A4/LTR or A3/DLT size paper or larger.
4.4.4 CLEAR FUSER CTR

This mode resets the fusing unit counter (this counter is in the NVRAM on the MCU board). Use this mode after replacing the fusing unit.
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Refer to Section 5 (Periodic Maintenance) in the engine service manual. Refer to Section 4 (Service Tables and Procedures Service Mode Clear Fuser Ctr) for details on how to clear the fusing unit counter after fusing unit replacement.
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5-1
G024
12 May, 1999
6.1 CONTROLLER BOARD AND TEMPERATURE / HUMIDITY SENSOR REPLACEMENT

[C] [E]
[A]
G024R551.WMF
[D]
[B]
G024R552.WMF
[F]
G024R553.WMF
NOTE: Print the Configuration Sheet (refer to the Operating Instructions Getting Started Manual) prior to replacing the controller board. This is required as the NVRAMs cannot be exchanged after replacement. The user must restore this data manually. 1. Remove the controller cover [A] (6 screws). 2. Remove the tray cover [B] (2 screws). 3. Remove the temperature/humidity sensor cover (1 screw) and sensor [C], (1 screw, 1 connector [D]). 4. If equipped, unplug the hard drive option connector from controller. 5. Remove the controller bracket [E] (5 screws and 2 screws at the Centronics parallel port). 6. Remove the controller board [F] (6 screws). 7. When installing the controller board make certain that the hard drive (if equipped) is properly reconnected and that the parallel port connector bail clips are positioned properly. After replacing the controller board, make sure that the brand name (and MAC address if required by the user) stored in the machine is correct. (See Section 4 Service Tables and Procedures - Boot ROM Menu.)
SM 6-1 G024
TROUBLESHOOTING
TYPES OF PROBLEMS

Printer-side Print Settings Printer-side Initial Settings Host-side Application Settings Faulty Engine
Operation
Main Unit Option Consumables Main Unit Option
Hardware
Faulty Controller
Hardware Limitations
Software
Bug in Controller ROM Bug in Emulation Module Software Controller Limitations Bug in Host-side Application Host-side Application Limitations Environment (power, temperature and humidity, dust, noise, vibration) Consumables
G024O014.WMF
Operating conditions
SM
7-1
G024 PS
7. TROUBLESHOOTING
TROUBLESHOOTING PROCEDURE

1. Start-up diagnostics Turn on the power and check whether the LCD displays an error code. 2. Custom diagnostic test See Section 4.1 Diagnostics Mode in this manual for the procedure. 3. Checking the configuration page output. Print out from the user menu. 4. Connectivity test Make a test print from a computer. Check that the correct cable is used (and connected properly). Check the cable wires continuity Check the cable length (Is it too long?). Do not connect the printer to the computer through a printer selector switch connect the printer to the computer directly.

Check the print conditions and initial settings. Check the printer settings against the application settings. Check whether the current settings match the settings on the configuration page that the customer keeps. If a normal configuration page is not available from the customer, ask the customer to print a configuration page at some time when the controller is working properly, and to always keep it for reference.
G024 PS
7-2
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TROUBLESHOOTING PROCEDURE
Obtain information about the following: PC model OS type and version Configuration page Application software used, and the version Data file being printed when the problem occurred (if obtainable) Sample printouts when the error occurred and when the printer is normal Detailed operating procedure Controller version (bootstrap, system code and boot code) Engine firmware version Printer driver version
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7-3
G024 PS
ERROR MESSAGES
7.3 ERROR MESSAGES

7.3.1 OVERVIEW
The error messages for this unit are classified as follows: 1. Controller Diagnostics Errors Errors detected while the unit performs start-up diagnostics/custom diagnostics on the controller hardware. 2. Engine User Errors (Cautionary) Errors that do not require user intervention to continue printing (the printer can still communicate with the PC over the interface). However, for the best printing quality, the user should correct the problem as soon as possible. 3. Engine Service Codes (SCs) Severe errors that cause the unit to stop printing, requiring a technician to fix the problem before printing again.
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ERROR MESSAGES
When a controller diagnostics error occurs, the first line of the operation panel LCD displays the name of the test that detected the error. The second line contains a 6-digit code following TYPE ID that gives error details for designers to use when debugging. IDE Test Error
Code 0x1001 0x1002 0x1003 Description IDE controller problems Hard disk problems or cable connection problem Unexpected return values of function calls Location IDE chip HDD or cable Chip or HDD
Ethernet Test Error

Code 0x400 0x401 0x2001 0x2002 0x2003 0x2004 0x2005 0x2006 0x2007 0x2008 0x2009 0x2010 0x2011 Description Cannot find Ethernet chip Internal register test failed Internal error Chip error Receive error Transmit error No net activity Fatal summary Lost carrier Transmit flow error No chip Interrupt error Low receive Location Replace the controller.
MEM Test Error

Code 0x0300 0x0301 0x0302 Description Bad memory information Bad memory Ground bounce test failed Location Replace the controller.
VX Test Error
Code 0x1801 Description Bad VX chip; registers cannot be programmed correctly Location Replace the controller.
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G024 PS
7.3.2 CONTROLLER DIAGNOSTICS ERRORS
ERROR MESSAGES
Boot ROM Test Error

Code 0x1811 0x1812 0x1813 0x1814 0x1815 0x1816 0x1817 0x1818 0x1819 Description Internal error Unknown boot flash type Incorrect chip installed Successive reads return different values Checksum failed for boot ROM Erasing boot ROM not completed successfully. Data written to the boot ROM cannot be verified correctly. Boot ROM write test not performed since parameter blocks are not empty Parameter blocks cannot be overwritten Location Replace the controller.
EFIDIMM Test Error

Code 0x1820 0x1821 Description System DIMM not found Cannot read from system DIMM properly, or system DIMM located in an incorrect slot Checksum for system code failed. Checksum for file system failed Checksum for system code and file system failed. Location Replace the controller.
0x1823 0x1824 0x1825
I2CEEPROM Test Error

Code 0x1100 Description Read error at I2CEEPROM Location Replace the controller.
G024 PS
7-6
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08/2001
FIRMWARE HISTORY
Refer to the Troubleshooting section in the Operating Instructions Printer Reference Manual.

Refer to the Troubleshooting section in the G024 engine service manual.

7.4.1 G024 FIRMWARE MODIFICATION HISTORY
DESCRIPTION OF MODIFICATION Corrects the following: 1. Wording change in RPS2 menu. Previous Changed to Bright Vivid Super Bright Super Vivid 2. Improving BG/UCR. 3. Cannot print out correctly from AcrobatReader4.0 when selecting 2 Byte font downloads. Corrects the following: 1. Item header "B" on the RPS2 menu has been omitted: Previous Changed to B. Job Timeout C. Job Timeout C. I/O Timeout D. I/O Timeout 2. No "Job Resetting..." display Corrects the following: 1. Overflow error in the coordinate variable. 2. An internal error appears when trying to cancel a job using the Reset key. FIRMWARE LEVEL G5035908 A SERIAL NUMBER April 2000 Production FIRMWARE VERSION 2.61
G5035908 B
3.10
G5035908 C
June 2001 Production
3.55
SM
7-7
G024 PS
G047/G048 SERVICE MANUAL
NOTE: This service manual is designed to be an addendum to the existing G024 engine (with base controller and Network Interface Board Type305) service manual. As such, this service manual only details those areas that are unique to the G047/G048 manual (simplex) and auto-duplex full-color laser printers. For any additional information, please refer to the G024 engine service manual.
G047/G048 SERVICE MANUAL

TABLE OF CONTENTS

1.1 1.2 1.3 1.4 SPECIFICATIONS .................................................................................... 1-1 MECHANICAL OVERVIEW ...................................................................... 1-3 MAIN UNIT LAYOUT................................................................................. 1-3 SYSTEM BLOCK ...................................................................................... 1-5 1.4.1 BLOCK DIAGRAM............................................................................ 1-5
2. DETAILED SECTION DESCRIPTIONS ....................................... 2-1
2.1 KEY DIFFERENCES FROM BASE MODEL (G024) ................................. 2-1 2.1.1 OVERVIEW ...................................................................................... 2-1 2.1.2 FUSING UNIT .................................................................................. 2-2 2.1.3 OPTICAL UNIT................................................................................. 2-2 2.1.4 PAPER FEEDING AND REGISTRATION ........................................ 2-3 2.1.5 PROCESS CONTROL ..................................................................... 2-3 2.1.6 ELECTRICAL COMPONENTS......................................................... 2-3 2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)............................. 2-4 2.2.1 OVERVIEW ...................................................................................... 2-4 Layout................................................................................................... 2-4 Electrical Components.......................................................................... 2-5 2.2.2 EXIT UNIT ........................................................................................ 2-7 Driving Mechanism ............................................................................... 2-7 Junction Gate ....................................................................................... 2-7 Exit Cover Open Detection ................................................................... 2-8 2.2.3 VERTICAL TRANSPORT UNIT ....................................................... 2-9 Driving Mechanism ............................................................................... 2-9 Paper Feed Detection........................................................................... 2-9 Vertical Transport Unit Cover Open Detection.................................... 2-10 2.2.4 DUPLEX UNIT................................................................................ 2-11 Driving Mechanism ............................................................................. 2-11 Reverse Mechanism ........................................................................... 2-11 Jogging Mechanism............................................................................ 2-12 Feed-out ............................................................................................. 2-12 Reverse Tray Detection ...................................................................... 2-12
SM
G047/G048
2.2.5 INTERLEAF.................................................................................... 2-13 Paper Path for Duplex Printing ........................................................... 2-13 Print Order for Duplex Black & White Printing .................................... 2-14 Print Order for Duplex Color Printing .................................................. 2-14
INSTALLATION
3. INSTALLATION PROCEDURE ................................................... 3-1
SERVICE TABLES
4. SP MODE .................................................................................... 4-1
4.1 OVERVIEW ............................................................................................... 4-1 4.2 ENGINE SP MODE ................................................................................... 4-1 4.2.1 OVERVIEW ...................................................................................... 4-1 To enter and exit engine SP mode ....................................................... 4-1 Outline of the engine SP mode functions.............................................. 4-1 4.2.2 MENU OPERATION/DISPLAY......................................................... 4-2 4.2.3 MARGIN (REGISTRATION ADJUSTMENT).................................... 4-2 4.2.4 PARAMETER ................................................................................... 4-3 4.2.5 CLEAR MEMORY ............................................................................ 4-3 4.2.6 SENSOR CHECK............................................................................. 4-4 4.2.7 NIP WIDTH....................................................................................... 4-5 4.2.8 RESET SC ....................................................................................... 4-5 4.2.9 PROCESS CTRL ............................................................................. 4-6 4.2.10 TEST PRINT .................................................................................. 4-6 4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION) ..................... 4-6 4.2.12 IMAGE ADJUST ............................................................................. 4-6 4.2.13 OUTPUT CHECK ........................................................................... 4-7 4.2.14 HIGHLIGHT ADJUSTMENT........................................................... 4-8 4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)........................ 4-8 4.2.16 PRIMARY BIAS ADJUSTMENT ..................................................... 4-9
5. PREVENTIVE MAINTENANCE ................................................... 5-1
5.1 PM TASKS ................................................................................................ 5-1 5.1.1 REPLACEMENT .............................................................................. 5-1 5.1.2 CLEANING ....................................................................................... 5-1 5.1.3 INSPECTION ................................................................................... 5-1 5.2 PM TABLE ................................................................................................ 5-2 5.2.1 MAIN UNIT ....................................................................................... 5-2 5.2.2 OPTIONAL PAPER FEED UNIT ...................................................... 5-2
G047/G048
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6. REPLACEMENT AND ADJUSTMENT (AUTO-DUPLEX MODEL) ........................................................... 6-1
6.1 EXTERIOR................................................................................................ 6-1 6.1.1 TOP OVER....................................................................................... 6-1 6.2 PAPER EXIT UNIT.................................................................................... 6-2 6.2.1 UPPER COVER ............................................................................... 6-2 6.2.2 LOWER COVER .............................................................................. 6-2 6.2.3 PAPER EXIT UNIT ........................................................................... 6-3 6.2.4 JUNCTION GATE SOLENOID ......................................................... 6-4 6.3 VERTICAL TRANSPORT UNIT ................................................................ 6-5 6.3.1 VERTICAL TRANSPORT UNIT COVER.......................................... 6-5 6.3.2 UPPER, LEFT AND RIGHT SIDE COVER....................................... 6-5 6.3.3 VERTICAL UNIT SENSOR .............................................................. 6-6 6.3.4 VERTICAL TRANSPORT MOTOR................................................... 6-6 6.3.5 VERTICAL TRANSPORT UNIT ....................................................... 6-7 6.4 DUPLEX UNIT........................................................................................... 6-8 6.4.1 DUPLEX TRAY ................................................................................ 6-8 6.4.2 REVERSE ROLLER ......................................................................... 6-9 6.4.3 DUPLEX FEED MOTOR/REVERSE MOTOR................................ 6-10 6.4.4 DUPLEX FEED SENSOR .............................................................. 6-10 6.4.5 JOGER HOME POSITION SENSOR ............................................. 6-11 6.4.6 JOGGER MOTOR/REVERSE SOLENOID .................................... 6-12 6.4.7 REVERSE SENSOR ...................................................................... 6-13 6.4.8 TEMPERATURE/HUMIDITY SENSOR .......................................... 6-13 6.4.9 RELAY MOTOR/RELAY ROLLER ................................................. 6-14 6.5 FUSING SECTION.................................................................................. 6-15 6.5.1 FUSING UNIT ................................................................................ 6-15 6.6 LASER SECTION.................................................................................... 6-16 6.6.1 CAUTION DECAL LOCATIONS..................................................... 6-16 6.6.2 OPTICAL HAUSING UNIT ............................................................. 6-17 6.7 ELECTRICAL COMPONENTS................................................................ 6-18 6.7.1 CONTROLLER BOARD ................................................................. 6-18 6.7.2 DUPLEX DC SUPPLY UNIT .......................................................... 6-19 6.7.3 POWER SUPPLY UNIT ................................................................. 6-20 6.7.4 HIGH VOLTAGE SUPPLY UNIT .................................................... 6-21 6.7.5 MCU ............................................................................................... 6-22 6.7.6 DUPLEX DRIVER BOARD............................................................. 6-22
SM
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G047/G048
Rev. 08/2001
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................ 7-1
7.1 SC TABLES...............................................................................................7-1 7.1.1 TYPES OF SERVICE CALL .............................................................7-1 Fusing Unit SC Errors .......................................................................7-1 7.1.2 SC ERROR LIST ..............................................................................7-2 7.1.3 PROCESS CONTRL ERROR LIST ..................................................7-6 7.2 USER ERROR LIST ...................................................................................7-8 7.3 FIRMWARE HISTORY ..7-10 7.3.1 G047 FIRMWARE MODIFICATION HISTORY...7-10
G047/G048
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G047/G048 CONTROLLER SERVICE MANUAL

TABLE OF CONTENTS

1.1 BASIC SPECIFICATIONS......................................................................... 1-1
2. DETAILED DESCRIPTIONS........................................................ 2-1
2.1 DIFFERENT POINT FROM BASE MODEL (G024) .................................. 2-1 2.1.1 SYSTEM SOFTWARE ..................................................................... 2-1 2.1.2 HARDWARE .................................................................................... 2-1 2.2 FUNCTIONAL OVERVIEW ....................................................................... 2-2 2.2.1 SYSTEM LAYOUT ........................................................................... 2-2 2.2.2 CONTROLLER BOARD LAYOUT .................................................... 2-3 2.2.3 FUNCTION OF EACH DEVICE........................................................ 2-4 2.3 PRINT DATA PROCESSING .................................................................... 2-5 2.3.1 GRADATION & PRINTABLE DATA ................................................. 2-5 2.3.2 IMAGE DATA PROCESSING FLOW ............................................... 2-6 IPDL-C (Intelligent Page Description Language for Color) ................... 2-7 CMS (Color Management System)....................................................... 2-8 Color Correction by the Driver .............................................................. 2-8 BG/UCR (Black Generation/Under Color Removal) ............................. 2-8 Gamma Correction ............................................................................... 2-8 Dither Processing ................................................................................. 2-9 Maximum Amount Toner Control.......................................................... 2-9 4 Bit Expansion..................................................................................... 2-9
INSTALLATION
3. INSTALLATION........................................................................... 3-1
3.1 BRAND SETTING ..................................................................................... 3-1
SERVICE TABLES
4. SERVICE TABLES ...................................................................... 4-1
4.1 CONTROLLER SP MODE ........................................................................ 4-1
SM i G047/G048
4.1.1 ENTERING AND EXITING CONTROLLER SP MODE .................... 4-1 4.1.2 MENUS AND DISPLAY.................................................................... 4-2 4.1.3 SP MODE MENU HIERARCHY ....................................................... 4-2 4.1.4 SP MODE DETAILS ......................................................................... 4-6 S1. Maintenance Sheet ........................................................................ 4-6 S2. Color Chart..................................................................................... 4-7 S3. Maintenance Clear ......................................................................... 4-7 S4. Clear All Memory............................................................................ 4-7 S5. Gamma () Calibration ................................................................... 4-7 S6. Printer ID ........................................................................................ 4-7 S7. Toner Limiter .................................................................................. 4-8 S8. Brand (Default Setting: RICOH.EXP) ............................................. 4-8 S9. Meter Click ..................................................................................... 4-8 IPDL-C Menu........................................................................................ 4-9 Media Menu ([Media] key) .................................................................... 4-9 4.2 POWER-UP SELF-DIAGNOSTICS......................................................... 4-10 4.3 POWER-UP SELF-DIAGNOSTICS FLOW CHART ................................ 4-10 4.4 DETAILED SELF-DIAGNOSTICS MODE ............................................... 4-11 4.5 DETAILED SELF-DIAGNOSTICS FLOW CHART .................................. 4-11
5. PERIODIC MAINTENANCE......................................................... 5-1

6. REPLACEMENT AND ADJUSTMENT ........................................ 6-1
6.1 CONTROLLER BOARD REPLACEMENT ................................................ 6-1 6.2 IMAGE ADJUSTMENT.............................................................................. 6-1 6.3 SOFTWARE UPGRADE PROCEDURE ................................................... 6-1
TROUBLESHOOTING
7. TROUBLESHOOTING................................................................. 7-1
7.1 TYPES OF PROBLEMS............................................................................ 7-1 7.2 TROUBLESHOOTING PROCEDURE ...................................................... 7-2 7.2.1 HARDWARE TESTS ........................................................................ 7-2 7.2.2 OPERATION-RELATED TESTS ...................................................... 7-2 7.2.3 SOFTWARE-RELATED TESTS ....................................................... 7-2 7.3 ERROR MESSAGES ................................................................................ 7-3 7.3.1 OVERVIEW ...................................................................................... 7-3 7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS ............................. 7-4 7.3.3 CONTROLLER USER ERRORS...................................................... 7-5 7.3.4 INTERNAL ERRORS ....................................................................... 7-6 7.3.5 ENGINE USER ERRORS (CAUTIONARY)...................................... 7-7
G047/G048 ii SM
Rev. 07/2001
7.3.6 ENGINE USER ERRORS.................................................................7-7 7.3.7 ENGINE SERVICE CODES .............................................................7-7

8. NETWORK INTERFACE BOARD (C4000 FERRET) .................. 8-1
8.1 OVERVIEW ...............................................................................................8-1 8.1.1 SPECIFICATIONS............................................................................8-1 8.1.2 BLOCK DIAGRAM............................................................................8-1 8.2 COMPONENT LAYOUT............................................................................8-2 8.2.1 NETWORK INTERFACE BOARD DIAGRAM...................................8-2 8.2.2 DEVICES..........................................................................................8-2 8.3 BASIC OPERATIONS ...............................................................................8-3 8.3.1 OVERVIEW ......................................................................................8-3 8.3.2 SWITCH FUNCTION ........................................................................8-4 NVRAM Reset Procedure .....................................................................8-4 8.4 FIRMWARE HISTORY ...............................................................................8-5 8.4.1 NIB FIRMWARE MODIFICATION HISTORY ....................................8-5
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G047/G048
!IMPORTANT SAFETY NOTICES

PHYSICAL INJURY PREVENTION 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. Note that some printer components are supplied with electrical voltage even if the main switch is turned off. 4. If an adjustment or operation check must be made requiring the removal or opening of the exterior covers while the main switch is on, keep hands away from electrically supplied or mechanically driven components. 5. The printer energizes some of its components when it completes the warmup period. Keep hands away from mechanical and electrical components when the printer starts operation. 6. The interior and metal parts for the fusing unit become extremely hot while the printer is operating. Do NOT touch these components with bare hands. HEALTH SAFETY CONDITIONS 1. Never operate the printer without ozone filters installed. 2. Always replace the ozone filters with the specified replacement at the specified maintenance intervals. 3. Toner is non-toxic, but if it gets in your eyes by accident, it may cause temporary eye discomfort. Cleanse the eyes using suitable eye drops or flush eyes with water. If this is unsuccessful, get medical attention immediately. SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do NOT incinerate toner cartridges, development toner magazine (DTM) or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner bottle and photoconductor unit (PCU) in accordance with local regulations. (These are non-toxic supplies.) 3. Dispose of replaced parts in accordance with local regulations.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is only replaceable in the field by a qualified Customer Engineer. The laser chassis is not field repairable. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when the optical subsystem requires replacement.
!WARNING
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous laser radiation exposure.
!WARNING
WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING:
OVERALL INFORMATION
SPECIFICATIONS
1.1 SPECIFICATIONS
Configuration: Print Process: Resolution: Paper Size: Desk top Dry electrostatic transfer system 600 dpi (1800dpi x 600dpi equivalent print quality) Standard tray Short edge feed (SEF): A3, 11" x 17", 81/2" x 14", Others* (B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13") Long edge feed (LEF): A4, 81/2" x 11", 71/4" x 101/2", Others* (B5 JIS, A5, 51/2" x 81/2") By-pass feed tray* Short edge feed: A3, A6, B4 JIS, B6 JIS, 12" x 18",11" x 17", 81/2" x 14", 8" x 13", 81/4" x 13", 81/2" x 13" Long edge feed: A4, A5, B5 JIS, 81/2" x 11", 51/2" x 81/2", 71/4" x 101/2" Custom size paper (Length: 148 to 457.2 mm, Width: 90 to 297 mm) * Specify the paper size with the system menu (at the operation panel by the user). Paper Weight: Standard and optional trays: 64 to 105 g/m2 (17 to 28 lbs.) By-pass feed tray: 64 to 160 g/m2 (17 lbs. to 43 lbs.) Plain paper mode: 64 to 105 g/m2 Thick paper mode: 105 to 160 g/m2, adhesive labels OHP transparency mode: OHP transparencies First Printout Time: Color: Less than 26 seconds (A4 A4/81/2" x 11" LEF) Monochrome: Less than 13 seconds (A4 A4/81/2" x 11" LEF) Simplex prints Color: 6 ppm (A4/81/2" x 11" LEF) Monochrome: 24 ppm (A4/81/2" x 11" LEF) Duplex prints Color: 5.5 ppm (A4/81/2" x 11" LEF) Monochrome: 21.7 ppm (A4/81/2" x 11" LEF) Less than 380 seconds (at 23C/73F) Standard tray: 250 sheets (80 g/m2, 20 lbs.) By-pass feed tray: 50 sheets (80 g/m2, 20 lbs.) Optional paper feed unit: 500 sheets each (80 g/m2, 20 lbs.)
Print Speed:
Warm-up Time: Paper Capacity:
SM
1-1
G047/G048
Overall Information
SPECIFICATIONS
Paper Output Capacity: Output Method: Power Supply:
250 sheets (A4/81/2" x 11" or less) 100 sheets (More than A4/81/2" x 11") Face down 120 V, 60 Hz, 10 A 220 to 240 V, 50/60 Hz, 5.2 A
Power Consumption: Maximum: Less than 1,200 W Average during printing: Less than 750 W Stand-by mode: Less than 150 W Energy saver mode: Less than 45 W Noise Emission: (Sound Power Level) Dimensions: Stand-by: Less than 43 dB Operating: Less than 65 dB Simplex model (G047) 660 x 575 x 475 mm (26 x 22.6 x 18.7) (without optional paper tray) Auto duplex model (G048) 660 x 652 x 610 mm (26 x 25.7 x 24) (without optional paper tray) Simplex model (G047) Approximately 62 kg (136.7 lbs.) (including consumables) Auto-Duplex model (G048) Approximately 82 kg (180.8 lbs.) (including consumables) Paper Feed Unit Type305 (G908) 500-Sheet Paper Tray Unit up to two of these units can be installed IEEE 1284 Parallel Type204 (G660) 32MB, 64MB or 128MB SDRAM Memory (see Note: 1) Network Interface Board Type306 (G678) Toner: Fuser Oil: Photo Conductor Unit: Type306 Black (G756), Type306 Cyan (G759), Type306 Magenta (G758), Type306 Yellow (G757) Type306 (G745) Type306 (G744)
Weight:
Option:
Note 1: These printers support the following memory modules: Printer Feature Expander Type185 32MB Printer Feature Expander Type185 64MB Memory Unit TypeA 128MB Additionally, approved SDRAM may be obtained from Delkin Devices Inc. (www.delkin.com).
G047/G048 1-2 SM
MECHANICAL OVERVIEW
Same as base model (G024). Refer to the G024 Engine Service Manual for details.
1.3 MAIN UNIT LAYOUT

13 1 2 12 11 10 9 8 3
4
G048V101.WMF
1. 2. 3. 4. 5. 6. 7.
Paper Transfer Unit Photoconductor Unit (PCU) Paper Tray/Paper Feed Mechanism Development Unit (DTM) Duplex Unit Optical Housing Unit Main Control Unit (MCU)
8. Vertical Transport Unit 9. High Voltage Supply Unit 10. DC Supply Unit 11. Controller Board 12. Power Supply Unit 13. Fusing Unit
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G047/G048
Overall Information
1.2 MECHANICAL OVERVIEW
MAIN UNIT LAYOUT
(1) Optical Housing Unit Optical system: 6-sided polygon mirror, F-theta mirror, BTL Resolution: 600 dpi Modulation method: PM+PWM (2) MCU CPU: XC68334 GFC16 Engine system control Process control Video interface (3) Vertical Transport Unit (Auto-duplex Model Only) Paper feeding for duplex printing by rollers (4) High Voltage Supply Unit Constant current: Paper transfer, charge corona wire Constant voltage: Charge corona grid, belt transfer, supply roller, development blade (5) DC Supply Unit (Auto-duplex Model Only) Outputs: +24 VDC supply for duplex unit (6) Controller Board Host interface Video interface Image processing Operation panel control (7) Power Supply Unit Outputs: +5 VDC, +24 VDC, 120/230 VAC (8) Fusing Unit Fusing method: Hot roller method Oil application: Application roller method Cleaning: Cleaning roller method Temperature detection: Thermistor Safety precaution: Thermofuse (9) Paper Transfer Unit Transfer: Transfer roller method (10) PCU A unit consisting of the OPC belt and the primary (belt) transfer section. OPC belt: 93-mm diameter Charging: Single scorotron charge corona wire Primary transfer: Transfer belt Cleaning: Counter blade Lubricant: Zinc stearate
G047/G048
1-4
SM
SYSTEM BLOCK
(12) Development Unit Development method: Monocomponent non-magnetic toner Development unit changeover: Revolver method Toner replenishment: DTM change (13) Duplex Unit Stack-less Paper side edge jogging
1.4 SYSTEM BLOCK

1.4.1 BLOCK DIAGRAM
ID Sensor Humidity Sensor
CPU D/A ADC PWM ROM NVRAM DRAM
High Voltage Supply Board
IC Card Sensors Vertical Transport Sensor PSU Fusing Control GAVD/PLLC I/O AMDG
ASIC
Pattern Generation Motor Control Expander
FIFO
Video I/F
Selector
MCU
Thermistor Fusing Unit Solenoids Clutches Interchange Solenoids LD Modulation Control Printer Controller Operation Panel Revolver Main Motor PCU Motor
DC Supply Unit
Sensor DDB Motor Solenoids G048V554.WMF
: Additional components on duplex model (G048)
SM
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G047/G048
Overall Information
(11) Tray/Transport Standard tray: Universal tray, friction pad separation By-pass tray: FRR method
KEY DIFFERENCES FROM BASE MODEL (G024)

2.1 KEY DIFFERENCES FROM BASE MODEL (G024)
2.1.1 OVERVIEW
The following points are different from the base model (G024). 1. Duplex printing: The following units were added to the Auto-duplex model (G048).
Paper Exit Unit Vertical Transport Unit Duplex Unit Located after fusing, switches the paper path to direct the sheet to exit or to the vertical transport unit. Used when duplex printing. Transports the sheet to duplex unit after fusing. This unit is located behind the main-body of the printer. This unit is located at the bottom of the main-body. In this unit, a sheet is turned, jogged and then fed to the main-body again. Sheets are fed into this unit onebyone.
Interleaf control is used for this model to increase the printing speed. 2. Printing Speed:
Printing Speed Black & White mode Color mode First Print Black & White mode Color mode G047/G048 24 ppm 6 ppm G047/G048 13 sec. 26 sec. Base Model (G024) 17 ppm 5 ppm Base Model (G024) 14 sec. 30 sec.
3. Image Quality Improvement: Increasing the line frequency in photograph and text mode improves the quality of the image. A new laser optical unit is used to increase the line frequency.
Line Frequency Photograph Graphics Text G047/G048 180 lpi 106 lpi 268 lpi Base Model (G024) 106 lpi 106 lpi 211 lpi
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G047/G048
2.1.2 FUSING UNIT

The following points differ from the base models (G024) fusing unit. 1. Pressure Roller: For duplex printing, the material used to make the pressure roller has been changed from Teflon to Silicon rubber to help improve duplex printing performance. 2. Heat Isolation: To maintain the fusing roller temperature, heat isolation bushings are mounted between the fusing roller bushing and drive gear. 3. Connector: All of the drawer connectors have been replaced with harness connectors. 4. Exit Cover Switch (Auto-duplex model only): The location of the paper exit cover switch has been moved from the fusing unit to the main-body of the machine.
2.1.3 OPTICAL UNIT

The following points differ from the base models (G024) optical unit. 1. Polygonal Mirror Motor: The speed of the polygonal mirror motor has been increased to allow for an increase in print speed.
Paper feed speed Mirror motor revolution speed G047/G048 121.54 mm/sec 28,706 rpm Base Model (G024) 101.27 mm/sec. 23,922 rpm
2. LD Unit: To improve the image quality, the diameter of the laser beam has been decreased and the power of the beam was increased.
Diameter of Beam LD Power G047/G048 69 m x 76 m 1.91 mW Base Model (G024) 76 m x 76 m 1.58 mW
3. Dust Prevention: To prevent the polygonal mirror and polygon mirror motor from collecting dust, two sponges have been added to the optical housing. One is above the polygon mirror motor and the other is on the side of the housing unit.
G047/G048
2-2
SM
2.1.4 PAPER FEEDING AND REGISTRATION

The following points differ from the G024 base model. 1. Paper size detection of bypass tray: Paper width detection mechanism on bypass tray is no longer necessary.
2. Pick-up roller: The composition of the pick-up roller has been changed to Silicon rubber to permit duplex printing from the bypass tray.
2.1.5 PROCESS CONTROL

The following points differ from the G024s process control method. 1. K-DTM Initialization: The image density target level has been lowered.
ID on sheet Volume of toner G047/G048 1.6 0.56 mg/cm2 Base Model (G024) 1.7 0.60 mg/cm2
2. Color-DTMs Initialization: The image density target level has been changed.
ID on sheet Volume of toner (C) Volume of toner (Y) Volume of toner (M) G047/G048 1.4 0.56 mg/cm2 0.54 mg/cm2 0.62 mg/cm2 Base Model (G024) 1.5 0.55 mg/cm2 0.55 mg/cm2 0.60 mg/cm2
3. Charge Grid Bias Compensation: Compensation control was changed because the number of lines in photo mode was changed from 106 to 180.
2.1.6 ELECTRICAL COMPONENTS

The following electrical components differ from those in the G024 base model. 1. Main Motor: The main motor has been changed to increase the print speed. The PCU motor was not changed, but the motor signals clock rate was changed. 2. MCU: The MCU has been changed to improve the efficiency of duplex printing by supporting the addition of new electrical components. 3. PSU: A different PCU has been used to increase the current level. A DC supply unit was added for the Auto-duplex model only.
SM 2-3 G047/G048
DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)
2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.1 OVERVIEW
Layout
10 1
8 2
3
G048D101.WMF
1. 2. 3. 4. 5.
Junction Gate Relay Roller Reverse Rollers Duplex Pick-up Roller Jogger Fence
6. Duplex Feed Rollers 7. Duplex Unit 8. Vertical Transport Rollers 9. Vertical Transport Unit 10. Exit Unit
G047/G048
2-4
SM
Electrical Components
18 17 16
1
2 3 4
15 14 5 6 7 13 9 10 12 11
G048D103.WMF
1. 2. 3. 4. 5. 6. 7. 8. 9.
Vertical Transport Entrance Sensor Vertical Transport Cover Switch Duplex DC Supply Unit Vertical Transport Unit Switch Vertical Transport Motor Temp./Hum. Sensor Duplex Driver Board Relay Motor Duplex Feed Sensor
10. Jogger HP Sensor 11. Jogger Motor 12. Reverse Solenoid 13. Reverse Sensor 14. Duplex Reverse Motor 15. Duplex Feed Motor 16. Vertical Transport Exit Sensor 17. Junction Gate Solenoid 18. Exit Cover Switch
Exit Unit: - A solenoid is used to position the junction gate. - A micro-switch is used to detect if the cover is open. Vertical Transport Unit: - The vertical transport rollers driven by the vertical transport motor feed paper to the duplex unit. - Two sensors detect paper fed in the entrance and out the exit of the unit. - Two micro-switches detect whether the vertical transport unit and cover are open.
SM 2-5 G047/G048
Auto-duplexing was not available in the base unit (G024). As a result the following components have been added to the G048 (only). Duplex Unit: - The duplex feed (transport) rollers and the reverse rollers drive the paper into the reverse tray of the duplex unit. - The jogger fences are positioned properly against the sheet in preparation for feeding the paper out of the reverse tray and into the printers main body. - The reverse, duplex pick-up (reverse transport idler roller), and relay roller feed paper into the main body for second-side printing. - The duplex feed sensor and reverse sensor detect paper jams.
G047/G048
2-6
SM
2.2.2 EXIT UNIT

Driving Mechanism
[E] [D]
[A]
[B]
[C]
G048D002.WMF
The fusing unit [A] and drive gears [B], powered by the main motor [C], drive the feed and exit rollers [D and E].
Junction Gate
[A]
[B]
G048D001.WMF
The junction gate [A] is located at the entrance of the exit unit. Paper is directed to the exit tray or to the vertical transport unit by this gate. This gate is positioned by solenoid [B]. When this solenoid activates, the paper is directed into the vertical transport unit.
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G047/G048
Exit Cover Open Detection
[A]
G048D003.WMF
The exit unit cover switch [A] is on the right side of the unit and is responsible for detecting if the exit unit cover is open. This switch interrupts a 24VDC line to the Main Control Board (PCB2).
G047/G048
2-8
SM
2.2.3 VERTICAL TRANSPORT UNIT

Driving Mechanism
[B] [D] [D] [A] [C]
Detailed Descriptions G047/G048
G048D501.WMF
The vertical transport motor [A] drives the vertical transport rollers [B] via gears [C] and timing-belts [D].
Paper Feed Detection

[A]
[B]
G048D010.WMF
Two sensors (photo-interrupters) detect paper presence in the vertical transport unit. The first is referred to as the vertical transport entrance sensor [A] and the second is referred to as the vertical transport exit sensor [B].
SM
2-9
Vertical Transport Unit Cover Open Detection
[A]
G048D008.WMF
[B]
G048D007.WMF
Two vertical transport safety switches are used to determine if the vertical transport unit or vertical transport unit cover is open. The vertical transport unit switch [B] detects if the vertical transport unit is open. The vertical transport unit cover switch [A] detects if the vertical transport unit cover is open. These switches are placed in series to one another on the same 24VDC line.
G047/G048
2-10
SM
2.2.4 DUPLEX UNIT

Driving Mechanism
[A] [B]
[C]
Overview The duplex feed motor [A] transports the paper arriving from the vertical transport unit through the first set of transport guides (which contain the duplex feed rollers). These transport guides are located in the duplex unit above the reverse tray. The duplex feed motor [B] continues to move the paper, via the reverse rollers, until it has been placed in the reverse tray. Next, the paper is driven out of the reverse tray by the action of the duplex reverse motor, reverse transport idler roller (referred to as the duplex pick-up roller) and reverse rollers, where it is driven up to the relay roller. Reverse Mechanism
First, paper is fed by the duplex feed rollers [A] (which function as transport rollers) and then by the reverse rollers [B]. When the reverse sensor [C] detects the leading edge of paper, the reverse solenoid [D] activates, lowering the duplex pick-up roller [F], and paper is fed into the reverse tray [E]. When the reverse sensor [C] detects the trailing edge of paper, the reverse solenoid deactivates and the duplex pick-up roller lifts slightly, pressing the sheet against the second reverse roller. [A]
[C]
[B] [F] [D]
[E]
SM 2-11
G048D015.WMF
G047/G048
Jogging Mechanism
When printing, the jogger fences [A] are moved to their standby position (10mm wider than the printed papers width). After the reverse rollers stop, the jogger motor [B] positions the jogger fences to their feed-out position (1mm narrower than the printed papers width). If, after completing the print job, no other sheets are to be duplexed, the fences return to their home position (determined when the tab on the front jogger fence enters the home position sensor [C]). [B]
[A]
[C]
G048D006.WMF
Feed-out
After jogging the paper, the reverse rollers turns counter-clockwise and the reverse solenoid activates. This feeds paper to the relay roller [A], which is driven by the relay motor [B].
[B] [A]
G048D009.WMF
Reverse Tray Detection

The reverse tray is connected to the duplex driver board [A] through drawer connectors [B]. When the tray is slid into the machine, these drawer connectors complete a loop back signal that helps to ensure that the tray is positioned properly into the machine.
[A]
[B]
G047/G048 2-12
G048D153.WMF
SM
2.2.5 INTERLEAF
An interleaf mechanism was added to increase duplex printing performance in black & white print mode. Also, this model only prints face down.
B/H
A-1 G F
A-2
G048D211.WMF
Paper Path for Duplex Printing A: Paper feed for back-side print ( -1: Standard tray -2: Optional tray) B: Secondary transfer for back-side print C: Fusing back-side print D: Junction E: Vertical transport F: Reverse G: Paper feed for front-side print H: Secondary transfer for front-side print I: Fusing for front-side print J: Junction K: Paper exit
SM
2-13
G047/G048
D/J
C/I
Print Order for Duplex Black & White Printing

The following example shows what happens when printing 8 sheets of A4/LTR size paper in duplex black & white mode. 4 sheets of A4/LTR size paper can be kept inside the machine during this print process.
10
12
14
16
11
13
15
G048D212.WMF
Print Order for Duplex Color Printing

The following example shows what happens when printing 8 sheets of A4/LTR size in duplex color mode.
2 sheets print
2 sheets print
2 sheets print
G048D214.WMF
G047/G048
2-14
SM
INSTALLATION
INSTALLATION PROCEDURE
3. INSTALLATION PROCEDURE
Refer to the following materials. For the printer: Quick Installation Guide For options: Setup Guide (one of the Operators Manuals) If the customer has a service contract with a meter click system, set up the counter as follows: 1. Enter Controller SP mode (refer to 4.1.1 ENTERING AND EXITING CONTROLLER SP MODE in the controllers section of this service manual for details).
Installation
2. Set Meter Click from the maintenance menu to the proper mode depending on the contract type (refer to 4.1.4 SP MODE DETAILS in the controllers section of this service manual for details). 3. Exit SP mode, and then confirm that display of both Color and Black is 0 by executing Show Counter. Use this procedure to specify the proper brand (SAVIN, NRG, Infotec, Gestetner, LANIER, RICOH.EXP, RICOH.JPN). The machine will then display the correct model name on the LCD panel and in the configuration page header. NOTE: This must be done before delivering the printer to the customers site. To modify the units brand, perform the following: 1. Ensure the printer is On Line (On Line indicator is lit.) 2. Using the operation panel, press the [!], ["], [Escape] and [Menu] keys in sequence. Do not let more than a second or two pass between button selections. 3. Select the appropriate brand name and press the [#Enter] key.
SM
3-1
G047/G048
SERVICE TABLES
OVERVIEW
4. SP MODE
4.1 OVERVIEW
This printer has two SP modes: 1) Engine SP mode 2) Controller SP mode The controller SP modes are described in the controllers section of this service manual. These two modes contain different functions.
4.2 ENGINE SP MODE

4.2.1 OVERVIEW
To enter and exit engine SP mode
Refer to this same section in the G024 Engine Service Manual for details.
Service Tables

The following table highlights the differences from the base model (G024).
Menu Item 1: Margin 2: Parameter 3: Clear Memory 4: Sensor Check 5: Nip Width 6: Reset SC 7: Process Ctrl 8: Test Print 9: ID Sensor PWM 10: Image Adjust 11: Output Check 12: Hi-light 13: Lub_Interval 14: BLT-TR BIAS Difference from the base model (G024) Duplex printing menu and two adjustable items were added. The secondary transfer bias can be adjusted individually for printing on the front side and for the other side of paper. Same as the base model (G024) Eight more sensors were added to the vertical transport and duplex units. Same as the base model (G024) Same as the base model (G024) Same as the base model (G024) Three menus were added for auto-duplex printing. Same as the base model (G024) Same as the base model (G024) 10 more components were added to the vertical transport and duplex units. Same as the base model (G024) Same as the base model (G024) Additional function to adjust the primary transfer bias.
SM
4-1
G047/G048
ENGINE SP MODE

Same as the base model (G024). Refer to this same section in the G024 Engine Service Manual for details.
4.2.3 MARGIN (REGISTRATION ADJUSTMENT)

NOTE: Items indicated in bold-italic are additional ones for this model.
Layer 1 Maintenance 1: Margin Layer 2 Margin Pattern Print Layer 3 Margin: Print Std. Paper Layer 4 Print: Std Tray 1 Tray 2 Tray 3 (D) Tray 1 (D) Tray 2 (D) Tray 3 By-pass Tray (D) shows duplex printing. Print: Thick By-pass Tray Print: Trans By-pass Tray Tray1: Left X.X Tray1: Top: 1st X.X It can be adjusted for tray 2, tray 3, and the by-pass tray in the same way as for tray1. Trans: Top: 1st X.X Back: Left X. X Back: Top X. X
Margin Adjust
Margin: Print Thick Paper Margin: Print Transparency Margin: Adjust Tray1: Left Margin: Adjust Tray1: Top: 1st
Margin: Adjust Trans: Top: 1st (For OHPs) Margin: Adjust Back: Left Margin: Adjust Back: Top
G047/G048
4-2
SM
ENGINE SP MODE
4.2.4 PARAMETER
NOTE: Items indicated in bold italic are additional ones for this model.
Layer 1 Maintenance 2: Parameter Layer 2 Parameter Std. Paper Layer 3 Std. Paper Transfer Bias Std. Paper (D) Transfer Bias Std. Paper Fusing Temp. Layer 4 Bias XXX% (D) Bias XXX% Temp. Low Temp. Normal Temp. High Same as Std. Paper Same as Std. Paper (D) not available
Parameter Thick Paper Parameter Transparency
Same as Std. Paper Same as Std. Paper (D) not available
4.2.5 CLEAR MEMORY

Same as the base model (G024). Refer to this same section in the G024 Engine Service Manual for details. NOTE: Counter values used for meter clicks are not cleared.
SM
4-3
G047/G048
Service Tables
ENGINE SP MODE
4.2.6 SENSOR CHECK

NOTE: Items indicated in bold-italic are additions to this model.
Sensor Name Name Display Paper End Sensor P End-1st (Tray 1) Paper End Sensor P End-By-pass (By-pass Tray) Paper End Sensor P End-2nd (Tray 2) Paper End Sensor P End-3rd (Tray 3) Registration Sensor Registration Exit Sensor Exit Paper Size Switch P Size-1st (Tray 1) Paper Size Switch P Size-2nd (Tray 2) Paper Size Switch P Size-3rd (Tray 3) By-pass Paper Width P Size-By-pass Detection Board PCU Set Switch PCU Set DTM Set Sensor CTC Set Toner End Sensor CTC Toner End Door Safety Switch Cvr Opn-F Exit Cover Switch Cvr Opn-EX Oil End Sensor Oil End (Fusing Unit) Fusing Set Used Toner Sensor Used Toner (Tray 2) Tray Set-2nd (Tray 3) Tray Set-3rd PCU Reset Sensor PCU Reset Revolver H.P. Sensor Revolver H.P. Transfer Roller Tfr Position Position Sensor Pull-out Sensor P Feed-2nd (Tray 2) Pull-out Sensor P Feed-3rd (Tray 3) ID Sensor ID Temperature/Humidity Humidity Sensor Temp DTM Cover Switch Cvr Opn-S Pull-out Sensor (Main Pick-up Body) Charger Corona Set Main Charger Switch Vertical transport Cvr Open-Duplex unit/cover switch Reverse sensor Reverse Sensor Sensor Status 0 Paper detected Paper detected Paper detected Paper detected Paper not detected Paper detected *1 *1 *1 *2 Detected Detected Not end Closed Closed End Detected Not full Not detected Not detected Old Home position Release Paper not detected Paper not detected *3 *4 *5 Open Paper detected Detected Open *6 Paper detected 1 Paper not detected Paper not detected Paper not detected Paper not detected Paper detected Paper not detected *1 *1 *1 *2 Not detected Not detected End Open Open Not end Not detected Full Detected Detected New Not home position Touch Paper detected Paper detected *3 *4 *5 Closed Paper not detected Not detected Closed *6 Paper not detected
G047/G048
4-4
SM
ENGINE SP MODE
Sensor Name Name Display Duplex Feed sensor P Feed-Duplex Jogger HP sensor Jogger H. P Duplex unit Duplex-Unit Set connection signal Duplex tray Duplex Tray Set connection signal Vertical transport V feed P1 entrance sensor Vertical transport V Feed P2 exit sensor Sensor Status 0 1 Paper not detected Paper detected Home position Not home position Not detected Detected *7 *7 Detected Not detected *8 *8 Paper detected Paper not detected Paper detected Paper not detected
*1: Paper size detection in Section 2 explains the status of the paper size switches for paper size detection. (0: Pressed, 1: Not pressed) *2: The indicated value is always 1f as there is no paper size detection mechanism on this model. *3: The displayed value indicates the K sensor output when the LED in the ID sensor is turned on. The specified output value (reference for normal operation) is 2.7 0.8 V. *4: The detection results are shown in the XXX YYY format. XXX indicates absolute humidity, and YYY indicates relative humidity. (Reference for normal operation: YYY should be between 5 and 95.) *5: The displayed value indicates the detected temperature. (Reference for normal operation: Between 8 and 42) *6: If either the vertical transport unit or vertical transport cover is open, 0 (open) is indicated. *7: The connection signal in between the MCU and the duplex driver board is checked. (10th pin of the CN254 on the MCU) *8: Loop back signal for the duplex driver board is checked. (13th pin of the CN896 on the Duplex driver board)
4.2.7 NIP WIDTH

4.2.8 RESET SC
SM
4-5
G047/G048
Service Tables
ENGINE SP MODE
4.2.9 PROCESS CTRL

4.2.10 TEST PRINT

Layer 1 Maintenance 8: Test Print Layer 2 Test Print Pattern 1 Test Print Pattern 2 Test Print Pattern 3 Test Print Pattern 1(D) Test Print Pattern 2(D) Test Print Pattern 3(D) Layer 3 Pattern 1 Tray X Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Layer 4 Printing Tray X Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Same as Pattern 1 Same as Pattern 1
4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)

4.2.12 IMAGE ADJUST

G047/G048
4-6
SM
ENGINE SP MODE
4.2.13 OUTPUT CHECK

Name By-pass Feed Clutch Pull-out Clutch Paper Feed Clutch Relay Roller Clutch Registration Clutch Transfer Roller Clutch Development Drive Solenoid By-pass Feed Solenoid Transfer Belt Cleaning Solenoid Quenching Lamp PCU Motor Display Bypass Feed Cl. Pick-up Cl. Feed Cl. Transport Cl. Regist. Cl. Tr. Roller Cl. Development Sol. Bypass Sol. Cleaning Sol. Quenching LED PCU Motor-slow PCU Motor-normal PCU Motor-fast PCU Motor-reverse Main Motor Main Mtr-normal Main Mtr-slow Polygon Mirror Motor Revolver Motor Tray Main Motor (for tray 2) Paper Feed Clutch (for tray 2) Tray Main Motor (for tray 3) Paper Feed Clutch (for tray 3) Vertical Transport Motor Duplex Feed Motor Duplex Reverse Motor Scanner Motor Revolver Motor OT1 Motor OT1 Feed Clutch OT2 Motor OT2 Feed Clutch V Feed motor Duplex Tray Mtr Rvrs Mtr Operation Continues for a certain time Continues until instructed to turn OFF Continues for a certain time Continues until instructed to turn OFF Continues until instructed to turn OFF Continues for a certain time Continues until instructed to turn OFF Continues for a certain time Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF Continues for a certain time Continues until instructed to turn OFF Continues for a certain time Continues until instructed to turn OFF Continues until instructed to turn OFF Continues until instructed to turn OFF
SM
4-7
G047/G048
Service Tables
ENGINE SP MODE Name Duplex Reverse Motor Reverse Solenoid Jogger (for H.P.) Jogger (jogger fences out) Jogger (jogger fences in) Relay Motor Junction Gate Solenoid Display Rvrs Mtr-rvrs Press Roller Sol Jogger HP Jogger Jogger reverse Pull Out Motor Divergence Sol. Operation Continues until instructed to turn OFF Continues until instructed to turn OFF Continues for a certain time Continues for a certain time Continues for a certain time Continues until instructed to turn OFF Continues until instructed to turn OFF
4.2.14 HIGHLIGHT ADJUSTMENT

4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)

G047/G048
4-8
SM
ENGINE SP MODE
4.2.16 PRIMARY BIAS ADJUSTMENT

This procedure is not found in the base model (G024). Use this menu to adjust the primary bias (belt transfer bias). The adjustment can be done in 100V steps between 800 V and 1,500 V. The default value is 1,200 V.
Layer 1 Maintenance 14: BLT-TR BIAS Layer 2 BLT-TR BIAS Cyan BLT-TR BIAS Magenta BLT-TR BIAS Yellow BLT-TR BIAS Black Layer 3 Cyan XXX Magenta XXX Yellow XXX Black XXX
SM
4-9
G047/G048
Service Tables
PREVENTIVE MAINTANENCE
PM TASKS
5. PREVENTIVE MAINTENANCE
5.1 PM TASKS
5.1.1 REPLACEMENT
Replace the PM parts every 100 K printouts as shown in the PM table on the next page. The fusing unit replacement interval is not determined in the same manner as the base machine. For details, see the note after the PM table. For the replacement procedures, refer to Chapter 6 Replacement and Adjustment in this manual and Chapter 3, Replacement and Adjustment in the Paper Feed Unit Type305 (G908) manual for the optional 500-sheet paper tray.
!CAUTION
When replacing components, be aware that the fusing unit may be hot. Handle it with care.
5.1.2 CLEANING
Clean the printer components when visiting the customer site. Refer to the PM table for the proper procedure to use when cleaning components. NOTE: Make sure that the charge corona unit cleaner is in the home position.
5.1.3 INSPECTION
Inspect the printer components when visiting the customers site. Visually inspect the components, and replace them if there is any damage.
!CAUTION
A high voltage is applied to bias electrodes. When inspecting any bias electrodes, ensure that the power switch is turned off.
SM
5-1
G047/G048
Preventive Maintenance
PM TABLE
5.2 PM TABLE
5.2.1 MAIN UNIT
Item Paper Feed Roller Registration Roller Friction Pad Bottom Plate Pad By-pass Feed Roller By-pass Pick up Roller By-pass Separation Roller Charge Corona Unit Quenching Lamp ID Sensor Dust Shield Glass Fusing Unit Exit roller-Exit Unit Feed roller-Exit Unit Feed rollers-Duplex Unit Vertical Transport Rollers Duplex Rollers Relay Roller EM C C C C C C C C*1 I C C*1 C C C C C C 60K 100K R R Note Alcohol or water Alcohol or water Water Water Alcohol or water Alcohol or water Alcohol or water Cleaner in the PCU Blower brush (if dirty) Dry cloth Cleaner brush (P/N: G0241533) Auto-duplex model only Auto-duplex model only Auto-duplex model only Auto-duplex model only Auto-duplex model only Auto-duplex model only
R*2
*1: This item is also a user maintenance item. *2: Regardless of the meter-click setting, the number of pages that the counter counts depends on the paper size: A3 or larger: 2 counts Smaller than A3: 1 count When the fusing unit counter reaches 60K, a message is displayed on the LCD only if No meter-click mode is selected. However, printing can still continue. NOTE: The following indication will NOT be shown on the display when one of the meter-click modes are selected even if the counter reaches the PM interval. Change Fusing Unit Change PCU Need Charger Unit The Charger unit and Fusing unit counter need to be manually cleared by Maintenance menu and controller SP mode (S4).
5.2.2 OPTIONAL PAPER FEED UNIT

Refer to the Paper Feed Unit (G908) section of the base model (G024) service manual.
G047/G048
5-2
SM
EXTERIOR
6. REPLACEMENT AND ADJUSTMENT (AUTO-DUPLEX MODEL)

6.1 EXTERIOR
6.1.1 TOP OVER
[D] [B]
[A] [C]
G048R810.WMF
1. Open the front cover [A] (by pressing the front cover release button). Next, open the paper exit unit [B] (by pressing the paper exit cover release button). 3. Remove the top cover [D] (2 screws). NOTE: There are five small L shaped tabs located on the bottom of the top cover to help secure the cover to the fusing unit. Prior to lifting the top cover off, carefully push the top cover slightly towards the back of the printer and then lift the cover off.
2. Open the vertical transport unit [C] (2 screws).
SM
6-1
G047/G048
PAPER EXIT UNIT
6.2 PAPER EXIT UNIT

6.2.1 UPPER COVER
[A] [B]
G048R829.WMF
1. Open the paper exit unit [A]. 2. Remove upper cover [B] (2 screws) NOTE: There are three L shaped tabs that help secure the upper cover to the exit unit. When removing the upper cover, carefully lift first from the back of the cover then lift the cover up and off.
6.2.2 LOWER COVER

[B]
[A]
G048R830.WMF
1. Remove the upper cover. (Refer to section 6.2.1.) 2. Open the vertical transport unit. 3. Remove the paper exit tray [A] (2 screws). NOTE: These screws can be loosened only. It is not necessary to remove the two screws completely. 4. Remove the lower cover [B] (2 screws).
G047/G048
6-2
SM
PAPER EXIT UNIT
6.2.3 PAPER EXIT UNIT

[A]
[B]
[D] [C]
G048R824.WMF
1. Remove the top cover. (Refer to section 6.1.1.) 2. Remove the lower cover. (Refer to section 6.2.2.) 3. Remove the stopper plate [A] (1 screw). NOTE: Removing the stopper plate will allow this unit to tip fully back. So, be careful. 4. Remove clips [B], detach springs [C] and remove the unit [D].
SM
6-3
G047/G048
PAPER EXIT UNIT
6.2.4 JUNCTION GATE SOLENOID

[A]
[C]
G048R827.WMF
[D]
[E] [B]
G048R840.WMF
G048R825.WMF
1. Remove the fusing unit. (Refer to section 6.5.1.) 2. Remove the paper exit unit. (Refer to section 6.2.3.) 3. Remove the guide plate [A] (4 screws). 4. Remove the clip [B] and the locking bar [C] while releasing the spring [D]. 5. Remove the solenoid [E] together with the bracket. 6. Remove the solenoid from bracket. NOTE: Be sure to note the original location of the screws securing the solenoid to the bracket.
G047/G048
6-4
SM
VERTICAL TRANSPORT UNIT
6.3 VERTICAL TRANSPORT UNIT

6.3.1 VERTICAL TRANSPORT UNIT COVER
[A] [B]
[C]
G048R802.WMF
1. Open the vertical unit cover [A]. 2. Remove a screw [B] at the joint arm and then remove the cover. NOTE: Refer to illustration above prior to removing the vertical unit cover. Observe that the hinge point of the cover is slotted [C].
6.3.2 UPPER, LEFT AND RIGHT SIDE COVER

[A]
[C]
[B]
G048R803.WMF
1. Open the vertical transport unit (2 screws). 2. Remove the upper cover [A] (3 screws). 3. If present, open the vertical transport unit cover. 4. Remove the left side cover [B] (2 screws) and right side cover [C] (2 screws).
SM
6-5
G047/G048
6.3.3 VERTICAL UNIT SENSORS

[B]
[A]
G048R801.WMF
1. Open the vertical transport unit 2. Remove the bracket [A]. (1 screw each) 3. Remove the harness connector from the sensor, then remove the sensor [B].
6.3.4 VERTICAL TRANSPORT MOTOR
[A]
G048R804.WMF
1. Remove the vertical transport cover. (Refer to section 6.3.1.) 2. Remove the upper and left side cover. (Refer to section 6.3.2.) 3. Remove the motor [A] (2 screws and 1 connector).
G047/G048
6-6
SM
6.3.5 VERTICAL TRANSPORT UNIT
[C]
[B] [A]
G048R823.WMF
1. Remove the vertical transport cover. (Refer to section 6.3.1.) 2. Remove the upper, left side and right side covers. (Refer to section 6.3.2.) 3. Disconnect connectors. NOTE: These two connectors (1 molex style and 1 in-line style) are located on the main-body of the printer (in a cable clamp) towards the right side. Remove the harness with these connectors first from the cable clamp and then carefully disconnect the connectors.
4. Disconnect the connector for the vertical transport motor then remove the clip [C] at the joint. NOTE: Be sure that the harness for the vertical transport motor is removed beforehand so the harness is not damaged. 5. Remove the hinge pins (brackets) on the left [A] and right side [B] (1 screw each). NOTE: The hinge pins (brackets) on the left and right side differ from each other. The left side hinge pin is longer than the other.
SM
6-7
G047/G048
DUPLEX UNIT
6.4 DUPLEX UNIT

6.4.1 DUPLEX TRAY
[B]
[A]
G048R828.WMF
1. First, pull the tray [A] out only about half-way. 2. Loosen the screw fixing the stopper plate [B]. 3. Move the stopper plate up and proceed to remove the duplex tray.
G047/G048
6-8
SM
DUPLEX UNIT
6.4.2 REVERSE ROLLER

[C] [A]
[B]
G048R811.WMF
[E] [H]
[D] [G] [F]
G048R813.WMF
G048R819.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Open the front and back set upper and lower guide plates [C]. 3. Remove the left [A] and right side covers [B] (4 screws each) 4. Remove the upper reverse plate [D] (2 screws). 5. Remove the lower reverse plate [E] (2 screws). NOTE: Be certain not to damage the Mylar sheet on the lower reverse plate when removing or re-installing the plate. Be sure to position the Mylar strips properly when re-installing the lower reverse plate. Do not set the plate down on the Mylar strips. Also note that the lower reverse plate is secured in the front by a small tab [H]. 6. Remove the reverse roller gears [F] by carefully prying up the gears locking tab, then remove the rollers [G] (4 clips and 4 bushings).
SM
6-9
G047/G048
DUPLEX UNIT
6.4.3 DUPLEX FEED MOTOR/REVERSE MOTOR

[A]
[B]
G048R815.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Remove the left and right side covers. (Refer to section 6.4.2.) 3. Remove the duplex feed motor [A] and duplex reverse motor [B] together with the brackets (2 screws each). NOTE: Be careful not to damage the motors harness when removing. Also note that the idle gear is not secured to the motors bracket. 4. Remove the motors from their brackets (2 screws and 1 connector each).
6.4.4 DUPLEX FEED SENSOR

[A] [B]
G048R817.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Remove the left and right side covers. (Refer to section 6.4.2.) 3. Remove the center plate [A] (2 screws). 4. Remove the duplex feed sensor [B] (1 connector). NOTE: Be sure not to damage the Mylar sheet when removing (or re-installing) the plate and sensor. When re-installing the center plate, be certain to position the sensor brackets guide plate properly.
G047/G048 6-10 SM
DUPLEX UNIT
6.4.5 DUPLEX UPPER UNIT AND JOGER HOME POSITION SENSOR

[B] [C]
[E] [A]
[F] [D]
G048R812.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Remove the left and right side covers. (Refer to section 6.4.2.) 3. Remove the center plate and duplex feed sensor connector [A]. (Refer to section 6.4.4.) Pass the sensors connector through the side frames cable guide (grommet). 4. Disconnect the feed [B] and reverse motor [C] connectors. NOTE: Be certain that all the wires of the motors harness are clear from the cable clamps. 5. Open the front set upper and lower guide plates and slowly slide the jogger fences [D] to the inside. When completed, close the upper and lower guide plates. 6. Disconnect the jogger H.P. sensor connector. 7. Remove the upper unit [E] (6 screws). 8. Remove the jogger H.P. sensor [F] (1 connector). NOTE: If replacement of only the jogger H.P. sensor is all that is required, the sensor may be removed alternatively by following only steps 1, 2, 5 and 6 above. Once completed, carefully push the sensor from its bracket using your fingers. When removing the sensor from its bracket, note the locking tabs on the sensor. Using this method, it is not necessary to remove the duplex upper unit.
SM
6-11
G047/G048
DUPLEX UNIT
6.4.6 JOGGER MOTOR/REVERSE SOLENOID

[D] [A]
[B]
G048R814.WMF
[C]
G048R816.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Carefully turn the tray over and remove the bottom cover [A] (6 screws). * NOTE: It is possible to remove the bottom cover by removing the 5 self-tapping screws on the bottom and then only loosening the side screw [D]. When turning the duplex tray over, be careful that none of the guide plates drop open. 3. Remove the jogger motor [B] together with bracket (3 screws). 4. Remove the motor from the bracket (2 screws and 1 connector). 5. Remove the reverse solenoid [C] (3 screws, 1 connector and 1 spring).
G047/G048
6-12
SM
DUPLEX UNIT
6.4.7 REVERSE SENSOR

[A]
G048R818.WMF
1. Remove the duplex tray. (Refer to section 6.4.1.) 2. Remove the bottom cover. (Refer to section 6.4.6.) 3. Remove the reverse sensor [A] together with bracket (1 screw). 4. Remove the sensor from the bracket (1 screw and 1 connector).
6.4.8 TEMPERATURE/HUMIDITY SENSOR
[A]
G048R808.WMF
1. Open the vertical transport unit. 2. Remove the temperature/humidity sensor [A] (1 screw and 1 connector).
SM 6-13 G047/G048
DUPLEX UNIT
6.4.9 RELAY MOTOR/RELAY ROLLER

[C] [D] [A]
[B]
G048R836.WMF
[C] [F] [G] [E]
G048R835.WMF
[J] [I]
G048R834.WMF
[H] 1. Remove the left and right side mainframe covers.
G048R839.WMF
2. Remove the vertical transport unit. (Refer to section 6.3.5.) 3. Remove the connector [A] and the grounding plate [B]. 4. Remove the 4 screws [C] that join the mainframe and the duplex unit, then separate them. 5. Remove the duplex tray. (Refer to section 6.4.1.) 6. Remove the temperature/humidity sensor. (Refer to section 6.4.8.) 7. Reverse the duplex unit and remove the unit frame [D] (8 screws). 8. Remove the gear [E] and motor bracket [F] (1 screw). 9. Remove the relay motor [G] (2 screws). 10. Remove the grounding plate [H] (1 screw). 11. Remove the relay roller drive gear [I] (1 clip). 12. Remove the relay roller [J] (2 clips and 2 bushings).
G047/G048 6-14 SM
FUSING SECTION
6.5 FUSING SECTION

6.5.1 FUSING UNIT
!CAUTION
1. The fusing unit may be hot. Handle it with care. (It is recommended to wait until the fusing unit is thoroughly cooled before servicing.) 2. Be very careful not to spill any silicone oil. 3. In the event of a fusing-related SC, replace the applicable components and execute 6: Reset SC from the engine SP menu to reset the SC. 4. When the fusing unit has been replaced, execute S3 Maintenance Clear from the controller SP menu to reset the fusing counter. [C]
[A]
[E] [B] [D]
G048R831.WMF
G048R832.WMF
1. Remove the top cover of mainframe. (Refer to section 6.1.1.) 2. Open the front cover and paper exit unit. 3. Open the oil bottle cover [A] and remove the bottle [B]. 4. Remove the harness cover [C] and detach connectors. 5. Using the grips provided, pivot the photoconductor unit forward. 6. Remove the grounding wire [D] (1 screw). 7. Remove the fusing unit [E] (3 green flat knob screws).
SM
6-15
G047/G048
LASER SECTION
6.6 LASER SECTION !WARNING

Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser light (radiation) can seriously damage your eyes.
6.6.1 CAUTION DECAL LOCATIONS

Two caution decals are located in the laser section as shown below.
G048R504A.WMF
LASER_PS1.WMF
LASER_PS2.WMF
G047/G048
6-16
SM
LASER SECTION
6.6.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR

[A]
[C]
G048R827.WMF
[D]
[B]
G048R826.WMF
Except for the removal of the screws on the backside of the optical housing unit, performing this removal procedure is the same as for the base model (G024). Refer to the G024s Service Documentation prior to and while performing this removal procedure. The steps below detail the procedure to use when removing the 2 screws securing the backside of the unit. 1. Remove the top cover. (Refer to section 6.1.1.) 2. Remove the paper exit unit. (Refer to section 6.2.3.) 3. Remove the guide plate [A] (4 screws). 4. Remove the clip [B] and the locking bar [C] with releasing the spring. 5. Remove the duct [D] (1 screw). 6. Remove 2 screws fixing the unit at backside.
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ELECTRICAL COMPONENTS
6.7 ELECTRICAL COMPONENTS

6.7.1 CONTROLLER BOARD
NOTE: Before replacing the controller, when possible, first print a list of the current settings. In the event of NV-RAM damage, it will be necessary to reconfigure all settings according to this list.
[A]
[C]
G048R805.WMF
[D] [B]
G048R806.WMF
1. Remove the top, left and right main-unit side covers. 2. If present, remove the vertical transport unit. (Refer to section 6.3.5.) 3. Remove the controller board cover [A] (12 screws). 4. Remove the RPS module [B] and RAM module [C]. 5. Remove the controller board [D] (4 screws, 2 screws on parallel connector and 1 board connector). NOTE: 1) If the customer has added optional expansion memory or a NIC, remove it before replacing the controller. Remember to install the memory or NIC on the new controller board. 2) To replace the controller boards, remove the NVRAM chip (IC23) on the old board, install it on the new board, then install the new board. The NVRAM chip stores user settings and service records. These settings will be lost if the NVRAM chip is not transferred.
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6.7.2 DUPLEX DC SUPPLY UNIT
!WARNING
To avoid the possibility of an electrical shock, unplug the power cable before replacing the power supply unit.
[A]
[B]
G048R807.WMF
1. Remove the controller board cover. (Refer to section 6.7.1.) 2. Remove the duplex dc supply unit [A] together with the bracket [B] (2 screws and 2 connectors). 3. Remove the dc supply unit from the bracket (4 screws).
Replacement and Adjustment SM 6-19 G047/G048
6.7.3 POWER SUPPLY UNIT
!WARNING
To avoid the possibility of an electrical shock, unplug the power cable before replacing the power supply unit. [A]
[B]
[C]
G048R820.WMF
G048R821.WMF
1. Remove the controller board. (Refer to section 6.7.1.) 2. Remove the duplex dc supply unit. (Refer to section 6.7.2.) 3. Remove the stay for the paper exit tray [A] (2 screws). 4. Remove the 8 screws holding the electrical wiring box [B], unplug 2 connectors, and release the single hook. Lift the left side of the electrical wiring box [B] upwards to swing it out part way . 5. Carefully unplug the connectors from the main-body to the power supply unit. When sufficiently free, swing the power supply unit further out. 6. Remove the power supply unit [C] (6 screws, remaining connectors and 2 hooks).
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6.7.4 HIGH VOLTAGE SUPPLY UNIT
[A]
[B]
G048R255.WMF
1. Swing the electrical wiring box [A] out. (Refer to section 6.7.3.) 2. Remove the high voltage supply unit [B] (6 screws, 8 connectors and 2 hooks).
!WARNING
Carefully connect the high-voltage wires as shown in the diagram below.
Blue connector: Supply roller
CN190
White connector: Belt transfer bias roller
White connector: Development roller
Yellow connector: Charge corona unit wire
White connector: Transfer roller
Yellow connector: Development blade
Blue connector: Charge corona unit grid
G048R512.WMF
NOTE: This symbol points to the back of the main-body. When viewing this supply unit installed in the printer, the arrow points to the backside of the printer main-body (towards rear of unit).
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6.7.5 MCU
[A]
G048R822.WMF
1. Swing the electrical wiring box out. (Refer to section 6.7.3.) 2. Remove the MCU [A] (2 screws and 22 connectors). NOTE: When replacing an MCU, remove the NVRAM chip (IC106) from the old board, install it on the new board, and then install the new board. In the event of NVRAM damage, install a new NVRAM chip, and contact your supervisor for additional steps. A forced process control will also be necessary (Engine SP mode 7: Process Control Initialize).
6.7.6 DUPLEX DRIVER BOARD
[B]
[A]
G048R833.WMF
1. Remove the duplex backside cover [A] (4 screws). 2. Remove connectors on the board. 3. Remove the duplex driver board [B] (6 screws).
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TROUBLESHOOTING
SC TABLES
7. TROUBLESHOOTING
7.1 SC TABLES
7.1.1 TYPES OF SERVICE CALL
For this printer engine, service calls and process control errors are classified into three types:
Service Call Type TYPE 1: Safety warning and immediate shutdown (Fusing unit errors) TYPE 2: Immediate shutdown TYPE 3: Log only (Process control errors) Results The printer stops immediately and the LCD displays an SC error message. The error is logged. The printer stops immediately and the LCD displays an SC error message. The error is logged. The printer does not stop. No SC error message is displayed. The error is only logged.
NOTE: In this section, additional or different codes from the base model (G024) are marked with an asterisk *.
Fusing Unit SC Errors

Fusing unit SC errors (Type 1 errors) can be released by executing the Reset SC item in the engine SP mode menu. They cannot be released by turning the main power switch off and on.
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Troubleshooting
SC TABLES
7.1.2 SC ERROR LIST

NOTE: The errors marked with an asterisk * are additional or changed codes for this model.
SC No. 20 Type 1 21 Type Type 2 Name Optional tray unit error Pressure roller thermistor error Occurrence conditions The detection signal for the 500-sheet paper tray unit is abnormal. The roller temperature has been at 0C for five seconds. Detection conditions Always monitored. Probable Cause The optional tray unit connector has a bad connection. Pressure roller thermistor, MCU
Type 1 22 Type 1
23
The roller temperature has been at 190C or higher for three seconds. Reheating has been done and the motor is not running, or 60 seconds have passed after the main motor halted. Then, the roller temperature has been below 130C for 60 seconds The roller temperature has been 0C for five seconds.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit. No detection in the event of SC or lack of fusing unit. No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit.
Pressure roller thermistor, MCU
Pressure roller thermistor, MCU, pressure roller lamp connector
Type 1 24
Type 1 25 Type 1
26
Type 2
Zero-cross cycle detection error
* 27
The roller temperature has been 190C or higher for three seconds. Reheat has been done and the motor is not running, or 60 seconds have passed after main motor halt. Then, the roller temperature has been below 130C for 60 seconds 50 Hz AC The number of zero-cross is detected less than 89 times or more than 111 times in one second for continuous 5 seconds. 60 Hz AC The number of zero-cross is detected less than 109 times or more than 131 times in one second for continuous 5 seconds.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit. No detection in the event of SC or fusing unit absence No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence.
Hot roller thermistor, MCU
Hot roller thermistor, MCU Hot roller thermistor, MCU, hot roller lamp connector
Frequency of the commercial AC power
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SC TABLES
SC No. Type Type 2 Name Paper transfer positive bias release error Occurrence conditions The PWM duty has been 50% or higher for 240 ms. Or, the paper transfer roller clutch does not operate. Detection conditions Detection starts 60 ms after control starts for this component. Probable Cause There is a disconnection in the paper transfer bias supply circuit. (Deformation of terminals or springs, dirty bearings.) When the contact/separation lever is normal: Bad transfer roller position sensor, harness, or MCU. When the contact/separation lever is faulty: Bad transfer roller clutch or MCU. There is a disconnection in the primary transfer bias supply circuit. (Dirty or deformed electrodes) There is a short circuit in the supply bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter). There is a short circuit in the blade bias supply circuit.
28
Type 2 29
Type 2
Supply bias error
31
Type 2
Blade bias error
32
Type 2 33
34
35 36
Type 2 Type 2
PCU motor, MCU
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Troubleshooting
Type 2
The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher. Continuous unlock for two seconds Continuous unlock for two seconds
There is disconnection in the charge corona unit bias supply circuit. (Dirty or deformed electrodes) There is a short circuit in the charge corona unit grid bias supply circuit (due to deformed terminals or electrodes or conductive foreign matters). Main motor, MCU
SC TABLES
SC No. Type Type 2 38 Name Revolver motor error Occurrence conditions Movement to the home position took four or more seconds. For black, movement to the home position took one second or longer. Continuous unlock for two seconds. The ID sensor output voltage is not between 0.1 V and 1.1 V while the ID sensor LED is off. No mark has been detected for 500 ms during PCU motor operation. LD error (abnormal laser power output). Synchronization detection error of the optical unit. A/D converted voltage has been 4.8 V or more for 240 ms. ID sensor calibration Detection conditions Probable Cause Revolver motor, MCU, or incorrect installation of color development unit
Polygon mirror motor, MCU ID sensor
Transfer belt H.P. sensor, MCU
42
During polygon mirror motor revolution. Detection starts 60 ms after control starts for this component.
45
Type 2
46
Type 2 47
Type 2
48
Type 1 49
When reheating, the roller temperature does not reach the reheat start temperature (target temperature 20C) within five minutes.
During re-heating.
LD, LD control board Synchronization detection board, LD control board There is a short circuit in the charge bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter). There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter). There is disconnection in the paper transfer bias supply circuit. (Dirty or deformed electrodes) There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter). Pressure roller thermistor, pressure roller lamp connector, MCU
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SC TABLES
SC No. Type Type 1 50 Name Hot roller reheat timeout Occurrence conditions When reheating, the roller temperature does not reach the reheat start temperature (target temperature 10C) within five minutes. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When an abnormal combination of print commands is received. 5 V (4.75 V) or more has continuously been detected for five seconds. 5 V (4.75 V) or more has continuously been detected for five seconds. Paper transfer position sensor does not detect the movement of roller. Detection conditions During reheating. Probable Cause Hot roller thermistor, hot roller lamp connector, MCU
Type 1
51
Type 1
52
Type 2 57 Type 2 59 Type 2 60 Type 2
*61
Type 2
Paper Transfer roller error
When the power is on, or the AC development bias is off. When the power is on, or the AC development bias is off. When the contact and separation of the roller need to be detected. When the power is on. During duplex printing.
Temperature sensor
Humidity sensor
*62
Type 2
*63
Auto-Duplex unit detection error. Jogger movement error
Auto-duplex unit is detected on the manualduplex model. Jogger home position sensor does not turn on.
Transfer roller position sensor MCU Harness Transfer roller clutch MCU
Jogger motor Jogger HP sensor MCU DDB
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Troubleshooting
SC TABLES
7.1.3 PROCESS CONTROL ERROR LIST

PE No. Type Name K ID sensor error 103 Type 3 Occurrence conditions While the LED is off, the ID sensor output does not meet the standard voltage (between 0.05 V and 1.5 V). Detection conditions ID sensor (K) calibration Probable Cause When the output meets the standard voltage: MCU, harness When the output does not meet the standard: K ID sensor K ID sensor, MCU, transfer belt error, transfer belt surface unevenness, incorrect ID sensor installation K ID sensor, MCU, transfer belt error, transfer belt surface unevenness
104
Type 3
ID sensor output error (rough adjustment)
105
Type 3
ID sensor output error (fine adjustment)
ID sensor pattern error (Cyan) 110 Type 3
The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal 0.4 V). The difference in ID sensor outputs when the transfer belt is read and when the LED is off does not meet the standard voltage (Vbkcal 0.1 V). The slope M of the line representing the relationship between the C development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the M development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the Y development bias and attached toner amount is not between 0.01 and 0.0005. The slope M of the line representing the relationship between the K development bias and attached toner amount is not between 0.01 and 0.001.
ID sensor pattern error (Magenta) 111 Type 3
ID sensor pattern error (Yellow) 112 Type 3
ID sensor pattern error (K) 116 Type 3
Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect color DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect K DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization
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SC TABLES
PE No. Type Name ID sensor pattern read error (K) 118 Type 3 Occurrence conditions The difference in ID sensor outputs when the ID sensor pattern is read and when the background surface of the transfer belt is read is 0.8 V or less. The slope M of the line representing the relationship between the DTM bias and attached toner amount is not between 0.01 and 0.001. Detection conditions K-DTM bias initialization Probable Cause Incorrect DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization Incorrect DTM installation, incorrect PCU installation, development bias error, MCU, LD control malfunction, loss of synchronization
ID sensor pattern error (K) 123 Type 3
K-DTM bias control
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Troubleshooting
USER ERROR LIST
7.2 USER ERROR LIST

This table only details those items that have been added to, and that are different from, the base model (G024).
Error Add Toner: xx Operation after error Printing stops. Detection conditions The PCU counter is increased to 100 after toner near-end is detected. Toner near-end detection is enabled two seconds after the development drive solenoid turns on until it turns off. The toner near-end message is displayed when toner end is detected five times. Release method Replace the DTM. Remarks This error is shown when Stop is selected in the Toner Empty menu. When near-end is detected, closing the front cover initiates recovery. If the toner near-end status is cleared, it is not detected during recovery. In singlecolor (black-and-white) continuous output, toner near-end is detected during process control. Counting (upon exit) A3/DLT or smaller K single-color: Plus 1 Full color: Plus 4 For sizes larger than A3/DLT, counting doubles. This is not shown if meter-click mode is selected. A3 or larger: Number of sheets that have passed x 2 Smaller than A3: Number of sheets that have passed This is not shown if meter-click mode is selected. This is not shown if meter-click mode is selected.
Low on : x,x,x
Replace the DTM.
Change PCU
The CPU counter reaches 72,000.
Replace the PCU to reset the counter.
Change Fusing Unit
The fusing unit counter reaches 60,000.
Manually release the message using Maintenance Clear in controller SP mode.
Need Charger
Printing can be done. Printing is disabled.
Charger counter reaches 24 K. Always monitored.
Vertical Transport Unit Cover Open
Replace charger unit and reset the charger counter. Close the cover.
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USER ERROR LIST

Error Duplex-tray Jam Operation after error Printing is disabled. Detection conditions <Case 1> The duplex feed sensor does not detect paper 3.2 seconds after the vertical transport exit sensor detects paper. <Case 2> The reverse sensor does not detect paper 3.2 seconds after the duplex feed sensor detects paper. <Case 3> The reverse sensor does not detect paper 0.5 seconds after the duplex reverse motor turns on. The vertical transport entrance sensor does not detect paper 3.2 seconds after the paper exit sensor in fusing unit detects paper. Or The vertical transport exit sensor does not detect paper 2.8 seconds after the vertical entrance sensor detects paper. The pull-out sensor for the main frame does not detect paper 0.9 seconds after the relay motor turns on. Release method Remove the jammed paper. Remarks
Vertical Transport Unit Jam
Remove the jammed paper by opening the vertical transport unit.
Duplex Unit Exit Jam
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Troubleshooting
FIRMWARE HISTORY
Rev.08/2001

DESCRIPTION OF MODIFICATION Corrects the following: 1. Item header "B" on the RPS2 menu has been omitted: Previous Changed to B. Job Timeout C. Job Timeout C. I/O Timeout D. I/O Timeout Corrects the following: 1. Overflow error in the coordinate variable. 2. An internal error appears when trying to cancel a job using the Reset key. FIRMWARE LEVEL G5035921 B SERIAL NUMBER November 2000 Production FIRMWARE VERSION 3.10
G5035921 C
3.55
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G047/G048 CONTROLLER AND NETWORK INTERFACE BOARD TYPE306 SERVICE MANUAL
NOTE: The first section of this part of the Service Manual refers to the Controller. The second section details the Network Interface Board Type 306.
OVERALL INFORMATION

1.1 BASIC SPECIFICATIONS
Page Description Language: Printer Driver:
Resolution: Color Mode: Gradation Mode Toner Saving: Color Correction: Interface:
IPDL-C (Intelligent Page Description Language for Color) RICOH-SCRIPT2 IPDL-C: Windows 95/98/2000/NT 4.0 RICOH-SCRIPT2: Windows 95/98/2000/NT 4.0, Macintosh (PPD for LaserWriter 8) 600 dpi (1800dpi x 600dpi equivalent print quality)
Color, B&W 1 or 2 bits/pixel On/Off (printer driver setting) Default Setting: Disabled On/Off (printer driver setting) Default setting: Enabled
Standard: Parallel port (IEEE1284: Compatible/Nibble/

ECP mode supported) Option: Parallel port (IEEE1284: only Compatible mode supported), Ethernet (100 BASE-TX, 10 BASE-T) RICOH-SCRIPT2: 39 Roman fonts Standard: 32 MB (simplex model), 64 MB (duplex model) Up to 256 MB can be installed (2 SDRAMS). 2 2 (for optional network I/F board and optional parallel I/F)
Fonts Memory SDRAM DIMM Slot Option Bus Interface Options
32 MB Memory 64 MB Memory 128 MB Memory Network Interface Board Type306 IEEE1284 Parallel Interface Type204 Paper Feed Unit Type305
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Overall Information
2. DETAILED DESCRIPTIONS
2.1 KEY DIFFERENCES FROM BASE MODEL (G024)
2.1.1 SYSTEM SOFTWARE
1. Automatic duplex printing is available for the duplex model. 2. Manual duplex printing (printing on the reverse side) is available for the simplex model. 3. The appropriate electric counter can be selected depending on the type of maintenance contract for meter click charge. A new User mode, Show Counter, has been added to display the Color and B/W counter values. 4. If the printer driver has been installed, the printer keeps a record of the number of pages printed out under each registered User Code (Up to 100). 5. This printer has a job log which shows the time, number of pages and current status of each print job. Up to 64 User IDs (User Codes) can be set. 6. The bypass tray can be used as a manual tray. If it is set to Manual, the paper size selected by the printer driver takes priority over the size selected on the operation panel. 7. The printer can be set so that it will either stop or continue printing when toner has run out. 8. 300-dpi mode is not supported. 9. It is possible to enter SP mode without turning the machine off and on. 10. The optional network interface board (C4000 Ferret) supports PortNavi.
2.1.2 HARDWARE
1. CPU NEC VR4310-177 2. ASIC Rocky-R, which is compatible with SDRAM. FCI2.5C was removed because 300-dpi mode is not supported. Therefore, toner saving mode is controlled by firmware. 3. SDRAM The type of SDRAM used has been changed from SIMM to DIMM. 4. NVRAM The capacity of the NVRAM has been expanded to 8 KB to store the Job and Print Logs. 5. DIP Switches Dip switches do not require resetting when upgrading firmware.
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2.2 FUNCTIONAL OVERVIEW

2.2.1 SYSTEM LAYOUT
Controller Board
IC Card I/F SDRAM SDRAM I/F SDRAM SDRAM I/F IEEE1284 I/F Option Bus I/F
IC Card
Program ROM I/F
RPS2
Host Network I/F Board
Video I/F
Host
G048O701.WMF
G047/G048
2-2
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Detailed Descriptions Option RAM I/F IEEE1284 I/F
G048O702.WMF
2.2.2 CONTROLLER BOARD LAYOUT
NVRAM DIP SW Standard/Option RAM I/F IC Card I/F Option Bus I/F
Flash ROM
Program ROM I/F
CPU R4310 Option Bus I/F
ASIC ROCKY R
Font ROM
Flash ROM
Video I/F
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2.2.3 FUNCTION OF EACH DEVICE

Device CPU ASIC ROCKY R Function VR4310-177 (177 MHz) This ASIC controls the following:
Memory mapping Reset DRAM Data received from the parallel Video DMA PvDMA Interrupt Serial communication with engine IEEE1284 interface Timer I/O Port
FLASH ROM NVRAM FONT ROM Program ROM DIP SW
1 2 3 4 5 6 7 8
Stores program (2 MB) The flash ROM is programmable via an IC card. Stores the initial settings and printer parameters. (8 KB EEPROM) Stores internal printer fonts. (One 64-Mbit mask ROM) RICOH-SCRIPT2 Emulation Module The emulation module is programmable by IC card.
OFF
SW No. 1 2 3-8 Setting OFF ON OFF
G048O708.WMF
Content Do not touch these switches in the field.
Video I/F IEEE1284 I/F Option Bus I/F
Option RAM I/F IC Card
Interface the controller with the printer engine. Provides an interface that connects to a local host (IEEE1284 compliant). Two slots; each can hold either an optional network interface or a parallel interface board. You cannot install two boards of the same type. A slot for accommodating the memory. Accommodates an IC card to upgrade firmware.
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2.3 PRINT DATA PROCESSING

2.3.1 GRADATION & PRINTABLE DATA
The image can be printed with 1 bit or 2 bits (Default) in 600 dpi. However, a page cannot be printed and the job is automatically canceled if the memory for image processing overflows while converting the image data to bitmap format. This may happen depending on the mode selected or the images data size. If the memory overflows, try changing the gradation settings in the driver by selecting a different print mode, or using a Custom setting (Print Quality tab in drivers interface).
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2.3.2 IMAGE DATA PROCESSING FLOW
IPDL-C Driver CMS RGB 8bit
PS Driver RGB 8bit CMYK 8bit
Controller
BG/UCR RPS2 Module (including CMS)
CMYK 8bit CMYK 8bit Gamma Correction CMYK 8bit Maximum Amount Toner Control Gamma Correction Table Maximum Amount Value (for service) 1/2bit Text/Photo Dither
BG/UCR
Manual Gamma Correction
Dithering CMYK 1/2bit 4bit Expansion CMYK 4bit
MCU Printer Engine
Operation Panel
G048O706.WMF
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Banding processing (Converted to IPDL-C) Band pool memory
IPDL-C (Intelligent Page Description Language for Color)

First, the image data received from an application is separated into three elements: text, graphics, and images. Then, the data for each element is converted to IPDL-C. The data converted is not done for the whole page at once. Each band (area specified) is independently processed (banding processing) for the data conversion as shown in the figure. The IPDL-C conversion from each element is stored in free memory and converted to bitmap data. Bitmap data is compressed and stored in the band pool memory, DRAM. After data processing is complete, the controller sends the decompressed data to the printer engine and the engine starts printing.
APPLICATION
What is IPDL-C....
GDI
TEXT
What is IPDL-C....
DRIVER
IPDL-C
IMAGE IPDL-C
GRAPHICS IPDL-C
CONTROLLER
Free Memory
Converted from IPDL-C to bitmap format
Compression
Compressed bitmap data
G048O707.WMF
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CMS (Color Management System)

CMS works to optimize the color print quality using a color profile which is based on the characteristics of the printer. In RICOH-SCRIPT2, CMS functions similar to IPDL-C; but the RGB conversion is done in the controller. CMS is used whenever the color profile setting in the printer driver is set to any value other than Off.
Color Correction by the Driver

The driver adjusts the following parameters in accordance with the driver settings made by the users: Brightness, Contrast, Saturation and Color Balance The driver does not perform RGB to CMYK conversion.
BG/UCR (Black Generation/Under Color Removal)

The RGB data sent to the controller is converted to CMYK data. During CMYK conversion, some CMY data is replaced with K data by the BG/UCR algorithm.
Gamma Correction
The gamma curve can be adjusted in SP mode. For information pertaining to the adjustment procedure, see Section 6: Replacement and Adjustments in the controller service manual for the base model (G024). For CMYK, the density can be adjusted every 15 points from 0 to 100% (0,15, 30, etc.). The corrected gamma data is stored in NVRAM memory. The controller performs the gamma correction, RGB/CMYK conversion and dithering.
1/2bit 4bit Expansion
8bit
Controller
Printer Driver BG/UCR Gamma Correction Dithering
Printer Engine
Process Control
Manual Gamma Correction
Image Density Adjustment in Solid Areas
Image Density Adjustment in Highlight Area
G048O709.WMF
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Dither Processing
The dither pattern is prepared for the photo, text, graphic and thin lines independently for 1- and 2-bit modes. These dither patterns help to create the illusion of 256 gradations for high quality prints. The optimum dither pattern is automatically selected based on the Text, Photographic and Image elements on the pages.
Maximum Amount Toner Control

The maximum toner amount is controlled in order to prevent toner from being scattered around text or printed lines. The maximum amount values are prepared independently for text and photo. They can be adjusted by the SP mode
Default: 300% Adjustable range: 100% to 400% (step: 10%)

4 Bit Expansion
When the controller sends the data to the printer engine, the controller expands the data to 4 bits to meet the image-processing algorithm of the printer engine. When expanding 1/2 bit to 4 bit, add some of the same data to the original data as shown in the figure. Even when the data is expanded, dithering remains the same.
1bit 2bit
b0
b1
b0
4bit Expansion
b0
b0
b0
b0'
4bit Expansion
b1
b0
b1'
b0'
G048O710.WMF
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INSTALLATION
INSTALLATION
3. INSTALLATION
Refer to the following materials. For the printer: Quick Installation Guide For options: Setup Guide
Installation 3-1 G047/G048
3.1 BRAND SETTING

Brand (Default Setting: RICOH.EXP)
Use this mode to specify the proper brand (SAVIN, NRG, Infotec, Gestetner, LANIER, RICOH.EXP, RICOH.JPN). The machine will then display the correct model name on the LCD panel and in the configuration page header. NOTE: This must be done before delivering the printer to the customers site. To modify the units brand, perform the following: 1. Ensure the printer is On Line (On Line indicator is lit.) 2. Using the operation panel, press the [!], ["], [Escape] and [Menu] keys in sequence. Do not let more than a second or two pass between button selections. 3. Select the appropriate brand name and press the [#Enter] key.
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SERVICE TABLES
SERVICE TABLES
4. SERVICE TABLES
4.1 CONTROLLER SP MODE
When accessing controller SP mode, the SP mode menu is added to the Job Timeout, Maintenance and Media menus.
4.1.1 ENTERING AND EXITING CONTROLLER SP MODE

[A] [B]
[C]
G048O015.WMF
[A]
[B]
[C]
G048O016.WMF
To enter controller SP mode: There are two ways to enter SP mode.
Turn on the printer while holding down the [On Line] [A] and [Reset] [B] keys on
the operation panel. Hold the keys down until all of the LEDs and the LCD turn off. Then, after the printer completes its cycling, press the [Menu] key. When on-line, first press [Reset] [B], [On Line] [A] and then press [Enter] [C] sequentially (dont take more than a few seconds to press each key). To exit controller SP mode: There are two ways to exit controller SP mode.
Turn the main switch off and, after a brief period, back on. Follow the procedure for entering SP mode.
NOTE: When accessing controller SP mode, SP is displayed on the display. Do not forget to exit SP mode after servicing. If inadvertently left in controller SP mode, users could change settings or clear all settings by accident.
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Service Tables
SERVICE TABLES
4.1.2 MENUS AND DISPLAY

Same as the base model (G024). Refer to the G024 controller and network interface board section of the G024 engine service manual for details.
4.1.3 SP MODE MENU HIERARCHY

The table below shows the controller SP mode menu hierarchy. The individual layers in the table below can be accessed while in controller SP mode by pressing the [#Enter] key. When in SP mode, S1 to S9 are added to the Maintenance menu.
Layer 1 Show Counter Layer 2 Color: xxxxxxx Black: xxxxxxx 1. Job Timeout 2. I/O Timeout 3. MinLineWidth 4. Toner Usage RPS2 Menu (displayed if RPS2 is selected.) 1. Color Level 2. Color Mode 3. Color Set Layer 3 Layer 4 It can be accessed if the meter click mode is selected.
IPDL-C Menu (displayed if IPDL-C is selected.)
Off 0 999 seconds 0 999 seconds 1 4 dots Off On 1 bit 2 bit Color Black & White Off Vivid Super Vivid Fine Super Fine Photograph Presentation Solid Color Off On Auto Photographic Text Plain Paper OHP Thick Paper Plain (Duplex Backside) Thick (Duplex Backside) On Off Off On Long Edge Short Edge Off0 999 seconds 0 999 seconds
It can also be accessed in SP mode. Same as above
4. ColorProfile
5. TonerSaving 6. Dithering
7. Paper Type
8. Auto Tray SW 9. Duplex Print A: Duplex Bind B: Job Timeout C. I/O Timeout
G047/G048
4-2
SM
SERVICE TABLES
Layer 1 RPS2 Menu (displayed if RPS2 is selected.) Layer 2 D: Feed Timeout E: Print Errors F: Ktalk Mode G: Parallel IF1 Layer 3 60 seconds 0 999 seconds Off On Not available System Default ACK Inside ACK Outside System Default ACK Inside ACK Outside Tray 1 By-pass Tray 2 Tray 3 8.5 x 13 A5 B4 JIS B5 JIS 8.5 x 5.5 8 x 13 8.25 x 15 Manual Auto Tray 16 KB 32 KB 64 KB 128 KB 256 KB 512 KB Off 5 minutes 15 minutes 30 minutes 45 minutes 60 minutes Level 1 Level 2 Auto Manual Hi-speed Normal ACK inside ACK outside STB down ACK inside ACK outside STB down Original Mode Standard On Off IPDL-C RPS Layer 4
H: Parallel IF2
System Menu
1. Paper Tray
2. Tray Size [*]
3. Bypass Use 4. I/O Buffer
5. Energy Saver
6. Energy Level 7. PDL Sensing 8. Transfer 9. Parallel 1
10. Parallel 2
11. Bi-direction 12. OHP Slip 13. Printer Language
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4-3
G047/G048
Service Tables
Displayed if an optional parallel interface board is installed. Tray 2 and 3 are displayed if an optional paper feed unit is installed.
SERVICE TABLES
Layer 1 System Menu Layer 2 14. Language Layer 3 English French German Italian Dutch Spanish Japanese Layer 4
32. IP ADDRESS to 39. Active PTL. Maintenance 1. Reinstall 2. Toner Select Charger Cyan Magenta Yellow Black Byps.: Vert. Bypass/Thick: V Tray: Vert. Dup.: Vert. Tray1: Horiz. Tray2: Horiz. Tray3: Horiz. Continue Stop Off On
Displayed if an optional network interface board is installed.
3. Toner level 4. Registration
Tray 2 and 3 are displayed if an optional paper feed unit is installed.
5. Toner Empty 6. Menu Reset 7. Menu Protect
8. Log Protect 9. Log Clear
Off On
It can also be accessed if the [Enter], [Escape], and [Menu] keys are pressed in sequence when the printer is on line. It is always displayed in SP mode. Same as above If Menu Protect is selected, it is not displayed. It can also be accessed if the [Enter], [Escape], and [Menu] keys are pressed in sequence if the printer is on line and an optional network interface board is installed. It is always displayed in SP mode.
10. Ethernet
Auto 10 Mbps 100 Mbps
S1. Maint. Page S2. Color Chart S3. Maint. Clear S4. Clear All Mem.
Fusing Unit
G047/G048
4-4
SM
SERVICE TABLES
Layer 1 Maintenance Layer 2 S5. Gamma Calib. Layer 3 Load Setting Layer 4 Default Setting-Old Setting-Current 1 bit/photo, 2 bit/photo 1 bit/Text, 2 bit/text Black Cyan Magenta Yellow Save Settings
Mode Select Print Sheet Gamma Select
S6. Printer ID S7. Toner Limiter S8. Meter Click
Not used Text Photo Off Print/Japan Develop. Count Print Count Print/Japan: D Dev.Count: D Print Count: D
List Print
Select PDL
1. Config. Page 2. Color Sample 3. Job Log 4. Statistics IPDL-C OPTION#1 RPS2
SM
4-5
G047/G048
Service Tables
SERVICE TABLES
4.1.4 SP MODE DETAILS

S1. Maintenance Sheet
The table below explains the contents of the engines maintenance list printout. The controller obtains the data from the printer engine (MCU).
Item MCU version Toner density Registration Description The MCU board firmware version number. Toner density can be adjusted via the Maintenance. Menu by customers. Adjusted values are stored in NVRAM on the MCU. Side registrations from Optional tray can be adjusted with Maint. Menu by customers. And leading edge registration can be done with engine SP mode (1. Margin). These values are stored in NVRAM on the MCU. Indicates the total number of printouts. The counter is incremented when the paper exit sensor detects paper exit completion (regardless of paper size, type, and mono/color mode). Counter value printed in color mode. Counter value printed in black mode. PCU replacement is indicated when this value reaches 72000. This value is incremented by 4 in color mode printing and by 1 in Black mode printing except A3/DLT. When printing with A3/DLT, double counting occurs. Fusing unit replacement is indicated when this value reaches to 60000. This counter is incremented by 2 for A3/DLT size printing and by 1 for other size printing. Number of Fusing unit resets with controller SP mode (S3).
Total counter
Color Mono color PCU counter
Fusing unit
Fusing unit/Counter reset time Charger Counter Charger Reset Counter A3/DLT, A4/LT, LG, B4 and Other Size counter Feed Jam, Transfer Jam and Exit Jam counter Feed Jam, Transfer Jam and Exit Jam counter (Duplex) SC counter Meter Click Count by developments Count by prints Count by developments (A3/DLT double) Count by prints (A3/DTL double)
Charger replacement is indicated when this value reaches to 24000. Number of Charger resets with controller UP mode. Number of each size paper that passed the exit sensor.
Number of paper jams in each section for duplex printing.
Number of SCs Type of counting method for meter click mode Number of developments. This counter increases by 1 when a print of any size is made. Number of prints. This counter increases by 1 for any size printing. Number of developments. This counter increases by 2 for A3/DLT size printing and by 1 for all other sizes. Number of prints. This counter increases by 2 for A3/DLT size printing and by 1 for all other sizes.
G047/G048
4-6
SM
SERVICE TABLES
Item Count by prints (Japan) Count by prints (Japan:A3/DTL double) SC Logging Jam Logging Description Not used. Not used.
Process-Control Error Logging ID sensor PWM
The most recent 3 SC codes. The most recent 10 jamming codes and the total counter value at the time. 000: At paper cassette 001: At paper pass 002: At paper exit The most recent 3 errors while process control and the total counter value at the time. Not all of the errors are indicated as SC errors. The value set with engine SP mode, 9: ID Sensor PWM. Service Tables 4-7 G047/G048
S2. Color Chart

S3. Maintenance Clear

S4. Clear All Memory

Executing this function resets the following user settings, stored in the NVRAM on the controller, to their default values: System Menu Printer ID Printer name on the network Gamma () calibration Brand
S5. Gamma () Calibration

S6. Printer ID
Not used with this model. NOTE: This is used for controller identification when installing fonts for RICOHSCRIPT2 onto the hard disk. However, since it is not possible to install the hard disk in this model, it is not necessary to set the printer ID.
SM
SERVICE TABLES
S7. Toner Limiter

The maximum toner values can be adjusted from 100 to 400% for both Text and Photo Modes. The default value for both is 300%. If this value is set high, the printed image appears more true to the original data. However, since a greater amount of toner is used, it is easy to scatter the toner around lines and text areas. If the value is set low, the color balance of low-density areas varies, however toner does not scatter as easily. NOTE: The values for the maximum toner amount are fixed for the base model (G024), but are adjustable for the G047/48.
S8. Meter Click

In this mode, the counting method can be selected based on the type of Service Contract. When the mode is activated: 1. A new user mode, Show Counter displays the counter values. 2. The printer will stop printing when toner has run out. In addition, Toner Empty disappears from the Maintenance menu. 3. The configuration sheet includes the value for the counting method selected in Meter Click mode, not the total counter value. Both counter values are included in the engine maintenance sheet. 4. After selecting meter clock mode, the counter value for the selected counting method is automatically set to 0. However, it cannot be reset to 0 after the machine begins counting. 5. All developments/prints are counted at paper exit.
G047/G048
4-8
SM
SERVICE TABLES
6. Counting method: 1) By developmentBlack Full color Black and white +1 1C +1 2C +2 3C +3 Full color +3 +1
NOTE: If the meter click mode is set to Dev. Count: D, it is incremented by 2 for A3/DLT size. 2) By printBlack Full color Black and white +1
Service Tables
1C +1
2C +1
3C +1
Full color +1
If the meter click mode is set to Print Count: D, it is incremented by 2 for A3/DLT size. 7. The following are not counted: 1) A sheet of paper that is placed between printed transparencies in OHP Slip Mode. 2) The final page when printing an odd number of pages in duplex mode. 3) The engine maintenance sheet, color chart and gamma calibration sheets in controller SP mode. 4) All sheets printed out in engine SP mode. 5) The Low-Memory Error Sheet. 6) A list of settings (B/W) if a non-fatal error is detected during Self-Diagnostics. 8. Change Fuser, Change PCU, and Need Charger are not displayed.
IPDL-C Menu
Item 3. MinLineWidth 4. Toner Usage Description Adjusts the minimum line width within 1 to 4 dots. Displays the toner usage independently for each color when printing the page. (Number of dots on the page/ maximum number of dots)
Media Menu ([Media] key)

Controller SP mode adds special menu items to the user menu accessed from the [Media] (access by pressing the [Media] key, then scroll through the menu on the display) menu.
Menu Item 3. Summary Function/Use Displays the currently installed versions of the controller system, emulation modules, and engine (MCU) firmware, and the amount of memory installed in the controller.
SM
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G047/G048
SERVICE TABLES
4.2 POWER-UP SELF-DIAGNOSTICS

4.3 POWER-UP SELF-DIAGNOSTICS FLOW CHART

Turn on power Diagnostic Code ROM sum check Test Code ROM Fatal Error Detected
Read/write test
Test Standard RAM
Frequency check
Test CPU
Test of timer functions of Rocky R
Test Timer
Operation Test
Test FPU
Font ROM sum check
Test Font ROM
DIMM (RPS2) sum check
Test DIMM
Display Error on LCD
Start System
Non-fatal Error (user error) No
Yes Print List of Settings (Black/white)
Standby Condition
G048O711.WMF
G047/G048
4-10
SM
SERVICE TABLES
4.4 DETAILED SELF-DIAGNOSTICS MODE

4.5 DETAILED SELF-DIAGNOSTICS FLOW CHART

Turn on power Diagnostic Code ROM sum check Test Code ROM Fatal Error Detected
Read/write test
Test Standard RAM
Frequency check
Test CPU
Test of timer functions of Rocky R
Test Timer
Read/write test
Test Optional RAM
Operation test
Test FPU
Loop back test on the standard parallel interface
Test Parallel Interface
Read/write test
Test NVRAM
Font ROM sum check
Test Font ROM
DIMM (RPS2) sum check
Test DIMM
Display Error on LCD
Start System
Non-fatal Error No Print List of Settings (Color)
Yes
Print List of Settings (Black/white)
Standby Condition
G048O712.WMF
SM
4-11
G047/G048
Service Tables
Refer to Section 5 - Periodic Maintenance in the base model (G024) engine service manual.
SM
5-1
G047/G048
Periodic Maintenance

6.1 CONTROLLER BOARD REPLACEMENT
Refer to section 6.7.1 Controller Board of the G047/G048 engine service manual for the replacement procedure.
6.2 IMAGE ADJUSTMENT

6.3 SOFTWARE UPGRADE PROCEDURE

The controller, RICOH-SCRIPT 2 and network interface boards have a flash ROM for storing control software. This allows version upgrades using an IC card. NOTE: The G024s controller manual refers to this card as a Flash ROM Card. The term IC card and flash ROM card are synonymous. The engines firmware cannot be upgraded using this procedure. Refer to the base engines (G024) service manual for details on how to upgrade the MCU firmware. NOTE: Before starting an upgrade procedure, make sure that the software in the IC card is newer than the software in the controller, RICOH-SCRIPT2 or network interface board. To check, do one of the following: Print out a configuration page (user mode). Enter controller SP mode and execute 3. Summary with the [Media] key. The software version is shown on the operation panel LCD. Follow the procedure shown below to upgrade the software: 1. Turn off the machine, and then unplug all cables from the parallel interface boards and network interface board(s), if connected. 2. For the duplex model only: Open the vertical transport unit (2 screws). 3. Remove the controller board cover. 4. Install the upgrade IC card carefully into the card slot. (Be sure to position the card arrow side to IC card slot, A side of card away from printer.) 5. Turn on the machine. The machine automatically copies the software from the IC card to the appropriate IC (located on the controller, RICOH-SCRIPT2 or network interface board). CAUTION: Do NOT turn off the machine while the software is being updated. Otherwise, the controller, NIB, or RICOH-SCRIPT2 module may be damaged.
SM 6-1 G047/G048 Replacement and Adjustment
For the controller or RICOH-SCRIPT2: The LCD display on the operation panel changes as shown below as the rewrite procedure proceeds. (MELT is displayed during the software upgrade for RICOH-SCRIPT2 since it involves a decompression process.) (MELT ->) ERASE -> WRITE -> VERIFY -> OK!!OK!! The appearance of the message OK!!OK!! indicates that the controller has received the data from the IC card. However, note that it takes about 30 seconds to rewrite the data in the controller or Ricoh-Script 2 after this message is displayed. The message NG!!NG!! is displayed if an error occurs during the rewrite process. If this condition occurs, reinstall the IC card and turn the power off and on again. For the network interface board: The appearance of the message DOWNLOAD OK. indicates that the controller has received the data from the IC card. However, note that it takes about 30 seconds to rewrite the data in the network interface board after this message is displayed. DOWNLOAD -> ############ -> DOWNLOAD OK. The message DOWNLOAD NG. is displayed if an error occurs during the rewrite process. If this condition occurs, reinstall the IC card and turn the power off and on again. 1. When the rewrite ends, turn off the main unit, and remove the IC card. 2. Re-install the controller board cover (6 screws). 3. For the duplex model only: Close and secure the vertical transport unit. 4. Turn the power on again and print the user mode configuration page. 5. Print a Configuration Page to ensure the new software version is installed and make sure that it matches the version on the IC card.
G047/G048
6-2
SM
TROUBLESHOOTING
TROUBLESHOOTING
7. TROUBLESHOOTING
Printer-side Print Settings Printer-side Initial Settings Host-side Application Settings Faulty Engine Main Unit Option Consumables Hardware Faulty Controller Main Unit Option Hardware Limitations
Operation
Software Fault in Controller ROM Software Fault in Emulation Module Software Software Controller Limitations Software Fault in Host-side Application Host-side Application Limitations Operating conditions Environment (power, temperature and humidity, dust, noise, vibration) Consumables
G048O014.WMF
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G047/G048
Troubleshooting
TROUBLESHOOTING



G047/G048
7-2
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TROUBLESHOOTING
7.3 ERROR MESSAGES

7.3.1 OVERVIEW
The error messages for this unit are classified as follows: 1. Controller Self-diagnostic Errors Errors detected while the unit performs power-up self-diagnostics/detailed selfdiagnostics on the controller hardware. 2. Controller User Errors Errors caused because the controller software cannot process the job because of, for example, insufficient memory. 3. Internal Errors Errors caused because the controllers control function fails to function normally. 4. Engine User Errors (Cautionary) Errors that do not require user intervention to continue printing (the printer can still communicate with the PC over the interface). However, for the best print quality, the user should correct the problem as soon as possible. 5. Engine User Errors Severe errors that cause the unit to stop printing, requiring the user to fix the problem before printing again. 6. Engine Service Codes (SCs) Severe errors that cause the unit to stop printing, requiring a technician to fix the problem before printing again. Only one error message can be displayed at a time. There is an order of priority for displaying errors. This is as follows, starting with the highest priority: Internal Errors, Controller Self-diagnostics Errors, Engine Service Codes (SCs), Engine User Errors, Engine User Errors (Cautionary), and Controller User Errors.
Troubleshooting SM 7-3 G047/G048
TROUBLESHOOTING
7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS

When a controller self-diagnostics error occurs, the error code is displayed on the first line of the operation panel LCD. The second line contains an 8-digit code that gives details of the error for designers to debug. For a memory error, the second line of the LCD indicates the address where the error occurred. For errors other than memory errors, the second line always reads FFFFFFFF.
Code 00XX 0101 0201 0301/0401 060X 0D0X 0EXX 110X 1401 160X 1B0X 1C0X 1D0X 250X 400X Description Exception processing error Code ROM sum check error Standard memory read/write error Optional memory read/write error Non-fatal error (printed as B0 in the error log.) CPU exception self-diagnostics error ASIC timer error AISIC operation panel interface error ASIC Centronics interface error Non-fatal error (printed as B1 in the error log.) NVRAM error (Read/Write) Font ROM error (Sum) Optional Interface 1 Error Optional Interface 2 Error Optional parallel interface board error Non-fatal error (printed as B6 in the error log.) DIMM (emulation module) error Non-fatal error (printed as B5 in the error log.) FPU error Location Controller Controller Controller Optional memory Controller Controller Controller Controller Controller Controller Controller Controller Optional parallel interface board Emulation module/Controller Controller
G047/G048
7-4
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TROUBLESHOOTING
7.3.3 CONTROLLER USER ERRORS

Display 85: Error 86: Error 91: Error 94: Error A3: Error A6: Error A7: Error Error during library drawing A8: Error AB: Error B0: Error B1: Error B3: Error B4: Error B5: Error B6: Error B7: Error IC card slot error Optional emulation module error Optional parallel interface board error Optional network interface board error Print overrun Optional memory error Standard parallel interface error Invalid initial set-up setting Description Graphics environment initialization error Invalid control code parameter Font/image environment initialization error Download data error Receive buffer overflow Overflow during compression Error during drawing processing Location/action Optional memory/Controller Incorrect printer driver or incorrect cable installed Install additional memory. Incorrect total memory size setting in the driver Increase the I/O buffer size using the system menu (user mode) Install additional memory. Use a smaller font size or a less complex font, or replace the controller Switch the machine off/on. If that does not work, replace the controller. Install additional memory. Reinstall/replace optional memory. Interface cable/controller Reset the printer settings using Menu reset in the Maintenance menu (user mode). Controller/IC card Reset/replace emulation module. Reset/replace optional parallel interface board Reinstall/replace network interface board
Troubleshooting SM 7-5 G047/G048
TROUBLESHOOTING
7.3.4 INTERNAL ERRORS

When an internal error occurs, the message Power Off/On is displayed on the first line of the operation panel LCD. The internal error code is on the second line in the format Error XXYY-ZZZZZZZZ (XX denotes a classification code; YY denotes a process number, and ZZZZZZZZ indicates the program address where the error occurred). The classification code portions (XX) and their descriptions are shown below. The YY and ZZZZZZZZ portions are for designer use only (for debugging).
Code (XX) 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Description Error in the TLB user area. CPU TLB update exception CPU mismatch exception (load or fetch) CPU mismatch exception (store) CPU address error exception (load or fetch) CPU address error exception (store) CPU bus error exception (load or fetch) CPU bus error exception (store) CPU system call exception CPU break point exception CPU reserved instruction exception CPU coprocessor disabled exception CPU operation overflow exception CPU trap exception Coherency (instruction) error CPU floating-point operation exception CPU timer interrupt ROCKY level 4 interrupt (ART or Tim) ROCKY level 3 interrupt (CP) ROCKY level 2 interrupt (XINT1 or XINT0) ROCKY level 1 interrupt (CBE, DBE, Dtc0, Verr, Fin, Vdtc, Fout) ROCKY level 0 interrupt (Debug) Software interrupt Software interrupt Other CPU exceptions Memory allocation error Overflow error Frame allocation error Card eject error Printer engine error Option board error Session-to-network interface board communications error
G047/G048
7-6
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TROUBLESHOOTING

The unit can continue printing even when one of the messages listed below is encountered.
Display Change Fuser Change PCU Need Charger Low on: XXX Description Fusing unit replacement time arrived. Photoconductor unit replacement time arrived Charger replacement time arrived. Toner near end XXX denotes the color name (CMYK or their combination). Fusing oil near end Waste toner bottle is nearly full. Number of sheets until warning state Information only Information only Information only 100
Add Fusing Oil Waste T Full
100 20
NOTE: Change Fuser, Change PCU and Need Charger are not displayed if meter click mode is selected by SP mode.
7.3.6 ENGINE USER ERRORS

The unit can no longer continue printing when this error message is displayed. Refer to the Troubleshooting section in the Setup Guide (an operators manual).

Troubleshooting
Refer to the Troubleshooting section in the base model (G024) engine service manual.
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G047/G048
NETWORK INTERFACE BOARD Type306 (C4000 FERRET)
NOTE: This section describes elements specific to the Network Interface Board Type306. For additional information, such as installation, firmware upgrades, etc., please refer to the controller section of the service manual and to the user's documentation.
OVERVIEW
8. NETWORK INTERFACE BOARD TYPE306 (C4000 FERRET)

8.1 OVERVIEW
8.1.1 SPECIFICATIONS
Configuration: LAN Interface: Frame Type: Protocol: SNAP: Embedded 100BASE-TX/10BASE-T Ethernet II, IEEE802.3, IEEE802.2, SNAP TCP/IP, AppleTalk, NetWare, NetBEUI MIB-II, PrinterMIB, HostResourceMIB, RicohPrivateMIB
8.1.2 BLOCK DIAGRAM
CPU
Flash ROM 1MB
Option Bus I/F
Controller Board
ASIC
SDRAM 8MB (64Mb)
Ethernet Controller
EEPROM 1Kb
Filter Module Network Interface Board

G048O713.WMF
LAN I/F
Network Environment
SM
8-1
G047/G048
COMPONENT LAYOUT
8.2 COMPONENT LAYOUT

8.2.1 NETWORK INTERFACE BOARD DIAGRAM
CPU HD6417612 ASIC MB87L1231
RJ-45
Flash ROM
LED4(G) LED3(G)
SDRAM
Ethernet Controller AM79C973
EEPROM LED1(Y) SW2
G048O705.WMF
8.2.2 DEVICES
Device CPU ASIC Flash ROM SDRAM EEPROM Ethernet Controller Description HD6417612RF MB87L1231 MBM29LV800BA-70PFTN (8 Mbit) 64Mbit: 100MHz M93C46-WMN6 (1kbit) AM79C973KC/W
G047/G048
8-2
SM
BASIC OPERATIONS
8.3 BASIC OPERATIONS

8.3.1 OVERVIEW
This network board can manage both 100BASE-TX and 10BASE-T. It has a maximum data transfer speed of 100Mbps. The auto-negotiation function automatically switches the communication speed. The controller board supplies the power source (+5V) and provides the reset signal. The controller board communicates with the network interface board through the option I/F connector. The function of LED and SW is as follows;
Functions LED1 LED2 LED3 LED4 Displays the operating status. ON: Ready, OFF: Busy Not used Displays the LAN Type. ON: 100 BASE-TX, OFF: 10 BASE-T Displays the link status. ON: Link safe, OFF: Link failure or Link disable Resets the NVRAM on the network interface board. NOTE: This board has the capability (i.e. required hardware) to execute a Summary Printout. However, Summary Printout does not function on this printer due to the controllers specifications.
SW1
SM
8-3
G047/G048
Network Interface Board
BASIC OPERATIONS
8.3.2 SWITCH FUNCTION

SW1 resets the NVRAM on the network interface board. NOTE: This board has the capability (i.e. required hardware) to execute a "Summary Printout." However, Summary Printout does not function on this printer due to controllers specifications.
NVRAM Reset Procedure

This procedure resets all the network settings to the defaults.
IP address, Subnet Mask, Default Gateway Address, Access Control Mask,

Network Boot, Frame Type (NetWare), Active Protocol, and so on 1. Turn on the main switch while pressing SW1. Keep pressing SW1 for 15 seconds. 2. Release SW1 for 3 seconds, press it again for 3 seconds, and then release it. 3. Turn the main switch off/on to complete the NVRAM reset procedure. NOTE: There is a margin of less than 1 second for error. Use a watch to measure the time periods as accurately as possible. 4. Print out the configuration page, and then check the settings. If the procedure failed, the previous settings remain. Repeat the above procedure until the old settings have been cleared.
G047/G048
8-4
SM
Rev. 12/2002
FIRMWARE HISTORY

8.4.1 NIB FIRMWARE MODIFICATION HISTORY
NIB FIRMWARE MODIFICATION HISTORY
DESCRIPTION OF MODIFICATION Initial Production
First release for G062 and B017/B018
FIRMWARE LEVEL G6785847 D G6785847 E
SERIAL NUMBER First Production Sept. 00 Production
FIRMWARE VERSION 4.8.2 5.0.2
Corrects the following: Classless InterDomain Routing (CIDR) is

supported.
Corrects the following: The spelling of the command retern in the Corrects the following: DHCP of Solaris 2.6 is supported. Corrects the following: SNMP Trap IP address is set to 11.22.33.44
G6785847 F
Oct. 00 Production Feb. 01 Production Aug. 01 Production
5.0.4
UNIX install shell has been corrected to return.
G6785847 G G6785847 H
5.0.7 5.1.0
incorrectly before the NIB is assigned the IP address from the DHCP server Disconnects from NetWare Servers that uses relatively old CPUs (i486)
Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2. Corrects the following: SNMP security vulnerabilities reported by CERT
on Feb.12, 2002 has been tested using the PROTOS c06-snmpv1 test suite and we have verified the fixes. -CERT :http://www.cert.org/advisories/CA-200203.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testi ng/c06/snmpv1/
G6785847 J
July 02 Production
5.1.2
SM
8-5
G047/G048
TECHNICAL SERVICE BULLETINS
TECHNICAL SERVICE BULLETIN

BULLETIN NUMBER: G024 - 001 10/04/99 APPLICABLE MODEL: GESTETNER C7005W/700SP RICOH AP305/505 SAVIN SLP517C/517CP SUBJECT: GENERAL:
The following Harnesses are being changed to reduce Electro-Magnetic Interference (EMI). The following parts updates are being issued for all G024 Parts Catalogs. Please update your Parts Catalogs with the following information. REFERENCE PAGE ITEM 39 10 43 6 37 13 37 12
HARNESSES !
Note: This copy is intended as a master original for reproduction of additional bulletins.
PARTS
OLD PART NO. G0245114 G0245118 G0245130 G0245132
NEW PART NO. G0245121 G0245106 G0245105 G0245104
DESCRIPTION Fusing Harness Toner Sensor Harness Right Main Harness Main Input Harness
QTY 1 1 1 1
INT 1 1 1 1
UNITS AFFECTED:
G024 Serial Number cut-in not available at time of publication.
INTERCHANGEABILITY CHART:\
0 1 3/S
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines. 2 NEW machines. OLD parts can be used in OLD and NEW machines. NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines. 3 OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually.
CONTROL NO. 054
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U +NFH#h#NNF ENfFEfMM %440-'%&0)#13()0 ####+)78)82)6#h#'KNNI9 ####6-'3,#h#%4INI ####7%:-2#h#704IEK%
SUBJECT:
GRADATION IMAGE PRINTING WITH PCL DRIVER
COPY QUALITY
SYMPTOM:
When documents containing gradation images are printed with the PCL driver, the gradation may not be smooth. Patchy red or green dots may appear depending on the colors contained in the image and the density of the gradation.
CAUSE:
In Toner Reduction Mode, a Dither Pattern control error will occur when the total index value of the CMYK color exceeds the following values. Either 170% with 2 colors or 250% in total.
SOLUTION:
Use a PS driver instead of the PCL driver If this is not accepted by the customer, update the controller firmware to the following version or later.
System code: Aug 6 1999
To update the firmware, system.sys and filesys.sys files need to be updated. This version is applied to production from Aug. 99 production onwards. NOTE: This problem only occurs when gradation patterns are present in the image.
CONTROL NO. 389
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U +NFH#h#NNG ENfFEfMM %440-'%&0)#13()0 ####+)78)82)6#h#'KNNI9 ####6-'3,#h#%4INI ####7%:-2#h#704IEK%
SUBJECT: BOOT ROM RECOVERY MECHANISM

SOFTWARE
GENERAL:
The Recovery Mechanism for failure of upgrading Boot ROM by using Boot ROM.rcy is explained in the Field Service Manual (4.3.4 Installing Software Upgrades). This recovery mechanism is NOT available on above listed PS models. If any failure occurs during upgrading Boot ROM, please try to recover the system by retrying to download the bootcode file named bootrom.sys through a PC WITHOUT SWITCHING OFF THE UNIT. If the unit does not recover using these methods, then the Controller Board (G0245321) or Flash DIMM (G0245323) needs to be replaced. NOTE: During the downloading of files to these PS models from a PC, the progress is indicated with = bars on the LCD of the unit. Do not switch off the unit until the status returns to INSTALL: #### on the LCD display.
CONTROL NO. 389

BULLETIN NUMBER: G024 004 1/11/2000 APPLICABLE MODEL: GESTETNER C7005W RICOH AP305 SAVIN SLP517C SUBJECT: GENERAL:
SERVICE MANUAL
SERVICE MANUAL - CORRECTION
The Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 1 set of replacement pages. The versions displayed on the Engine Firmware (section 6.5.5) are reversed. The version on the left side shows the current Firmware version and the other is the version contained in the IC card.

G024R514.WMF
PAGE:
6-40
Updated Information
An arrow has highlighted the revised areas .
CONTROL NO 011ABW
ELECTRICAL WIRING
Rev. 12/99
6.5.5 UPGRADING THE MCU FIRMWARE

NOTE: Turn off the printer before inserting or removing the IC card. (Otherwise the IC card may be damaged.) 1. Remove the left cover. (See Left Cover Removal.) 2. Remove the bracket to the bottom left of the revolver unit (one screw). 3. Insert the IC card that contains the MCU software into the IC card slot of the MCU. The side with A on it must be facing upwards. 4. Turn on the printer. (Check that the following is displayed on the operation panel.)

G024R514.WMF
5. Check that the firmware versions are correct. (Make sure that the firmware in the IC card is later than the current one.) Press the On Line key. 6. Check that the messages on the operation panel change in the following sequence:
FLASH DWLOADING ERASE!!
FLASH DWLOADING WRITING
FLASH DWLOADING OK!! OK!!

G024R513.WMF
7. Upon the OK!! OK!! message, the MCU flash ROM has been updated. (If the NG message is displayed, try performing the upgrade procedure again from the beginning.) 8. Turn off the printer. 9. Remove the IC card. 10. Put back the bracket and the left cover. 11. Start the printer in engine SP mode. Check the engine firmware version, which is displayed immediately after power-on. (If the firmware version differs from the IC card firmware version displayed in step 3, repeat from step 1.)
G024
6-40
SM

BULLETIN NUMBER: G024 - 005 12/23/99 APPLICABLE MODEL: GESTETNER C7005P RICOH AP505 SAVIN SLP517CP SUBJECT: GENERAL:
! New PS and PCL printer drivers are released with the new drivers addressing the following issues: Title1/Title2 Print Image /PCL driver Driver setup /PCL driver ! Problem Name Patterned areas in certain colors are not correctly reproduced Editing the Font Substitution Table Description Patterned areas in pink are printed with plain red. No substitution font appears in the pull down menu of editing fonts in other language versions of Windows than English. OS Win95/98
UPDATING THE PRINTER DRIVER "

SOFTWARE
WinNT4.0
The CRD names follows: Old Photos Text Illustrations
on the ColorWise tab of the printer properties for both PS and PCL are renamed as New CRD Images Text Graphics
Continued
RICOH GROUP COMPANIES CONTROL NO. 007CLR
Tech Service Bulletin No. G024 005 Page 2 of 2 ! The updated files for each driver.
OS Windows95/98 PS Driver Windows95/98 PCL Driver Windows NT PCL Driver
Old File Name (Version No.) EFER5010.DLL (1.71.30) EFGNPCLG.DRV (2.0.0065) EFGNDLGG.DLL (1.60.80) EFGNPCL9.DLL (2.0.0048) EFGNRES9.DLL (1.59.10)
New File Name (Version No.) EFER5010.DLL (1.71.60) EFGNPCLm.DRV (2.0.0069) EFGNDLGm.DLL (1.61.50) EFGNPCLm.DLL (2.0.0069) EFGNRESm.DLL (1.61.30)
NOTE: How to print the Test Page: 1. 2. 3. 4. Select the Setting menu from the Windows Start menu. Select Printers and open the icon for the printer, which you have updated. Select Properties from file menu. Click the Print Test Page button on the General tab.
INSTALLATION NOTES:
When updating the printer driver, do the following steps to remove the previously installed printer driver. Otherwise, the previously installed printer driver remains installed in the PC, even though it may not function properly. If the currently installed printer settings are special, it is necessary to write down each setting of the printer properties before deleting the printer icon. 1. Delete the printer icon for the currently installed printer version and confirm removal of old files before installing the new ones. 2. Install the new printer driver by using the Add Printer in the Printers window. 3. After installation, confirm the version number of the updated files by printing the test page. If any settings were special, use the settings that were recorded prior to deleting the original printer driver and reenter them.
UNITS AFFECTED:
The new driver CD-ROM is applied to the production from October 1999 starting with S/N P07910#####.

BULLETIN NUMBER: G024 - 006 01/17/2000 APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: GENERAL:
The Service Manual page listed below must be replaced with the page supplied. Each bulletin package contains 1 set of replacement pages. PAGES: The revised area has been highlighted by an arrow .
SERVICE MANUAL - INSERT
!
SERVICE MANUAL
Legend
Updated Information (Legend)
CONTROL NO. 008CLR
Rev. 01/2000
LEGEND
PRODUCT CODE G024(WIN) G024 (PS) GESTETNER C7005W C7005P COMPANY RICOH AP305 AP505 SAVIN SLP517c SLP517cp
DOCUMENTATION HISTORY
REV. NO. * 1 DATE 6/99 7/99 COMMENTS Original printing G024 Fiery 500 Controller Service Manual Addition

BULLETIN NUMBER: G024 - 007 02/22/2000 APPLICABLE MODEL: GESTETNER C5007W/C5007P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: GENERAL:
The Service Manual page listed below must be replaced with the page supplied. Each bulletin package contains 1 set of replacement pages. PAGES: The revised areas have been highlighted by an arrow .
!
SERVICE MANUAL
7-2
Updated Information (SC 27)
CONTROL NO. 014CLR
SC TABLES
Rev. 02/2000
7.1.2 SC ERROR LIST

Type 1 22 Type 1
23
Type 1 24
Type 1 25 Type 1
26
Type 2 27 Type 2
AC Power zero-cross detection error Paper transfer positive bias release error
The roller temperature has been 190C or higher for three seconds. Reheat has been done and the motor is not running, or 60 seconds has passed after main motor halt. The roller temperature has been below 130C for 60 secs. No zero-cross signal can be detected when the fusing heaters turn on. The PWM duty has been 50% or higher for 240 ms. Or, the paper transfer roller clutch does not operate.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit . No detection in the event of SC or fusing unit absence. No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence. No detection in the event of SC or fusing unit absence. Detection starts 60 ms after control starts for this component.
AC power conditions.
28
There is a disconnection in the paper transfer bias supply circuit. (Deformation of terminals or springs, dirty bearings) When the contact / separation lever is normal: Bad transfer roller position sensor harness, or MCU. When the contact/separation lever is faulty: Bad transfer roller clutch or MCU.
G024
7-2
SM

BULLETIN NUMBER: G024 008 REISSUE ! 02/25/2000 APPLICABLE MODEL: GESTETNER C5007W/C5007P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: BANDING !
! SYMPTOM:
42 mm Pitch Horizontal Banding occurs on printed pages.
COPY QUALITY
! CAUSE:
Lines on the Development Roller have been caused by prolonged contact with the Development Blade during storage.
! SOLUTION:
The lines will fade as pages are printed. This symptom will disappear after approximately 300 pages are printed. Switching the Energy Saver Mode to level 2 will automatically run the Development Roller every 70-minutes. This will help to reduce the reoccurrence of this symptom.
CONTROL NO. 014CLR

BULLETIN NUMBER: G024 - 009 04/14/2000 APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: JAPANESE FONTS USING MICROSOFT INTERNET EXPLORER 5.x !
SOFTWARE
SYMPTOM:
When you browse the G024 printer with Microsoft Internet Explorer 5.x (IE 5.x), IE 5.x requires installing a Japanese font even if the HTML does not have a Japanese font. I.e., if browsing the http://Printer IP Address/en/cgi-bin/sts_index.cgi, the following message appears;
!
FIRMWARE
The message maybe different because of minor variations in the IE version or Windows OS. The above message appears when using IE 5.00.2920.0000 on Windows 2000. In this case, IE requires the Japanese font every time. IE 5.00.2314.10003 on Windows NT 4.0 is shown the below. In this case, IE requires the Japanese font after browsing the NIB (Network Interface Board).
NOTE: The NIB works properly by canceling messages stating that the Japanese font is required. Continued 2000 RICOH Corporation. All rights reserved.
CONTROL NO. 021CLR
Tech Service Bulletin No. G024 009 Page 2 of 2
CAUSE:
There is a problem in the HTML code of the NIB version 3.8.7 or earlier.
SOLUTIONS:
Countermeasure 1
If the NIB version is 3.8.7 or earlier, please upgrade to the latest NIB firmware and install the new one to the NIB. Check the NIB version by printing the configuration page (Menu button " <Menu> List Print " <List Print> Config. Page). The configuration page shows the Network Version line as follows: Network Version ELAND99 3.7.5 (0003)- 3.60f9
This line shows that the NIB version is 3.7.5.
Countermeasure 2
Install a Japanese font in Windows. There are a few ways to install a Japanese font. 1. If IE 5.x is pre-installed on Windows 2000, Windows 2000 CD-ROM has Japanese fonts. The customer should insert the CD-ROM and click the OK button. 2. Use Windows update from the Start up Menu in Windows and install the Japanese font.

BULLETIN NUMBER: G024 - 010 04/26/2000 APPLICABLE MODEL: GESTETNER C5007W/C5007P RICOH AP305/AP505 SAVIN SLP517C/SLP517CP SUBJECT: SYMPTOM:
Horizontal yellow or rainbow color bands occur on printed page at a 98 mm pitch internal. NOTE: For other banding Issues please refer to Technical Service Bulletin G024-008 Reissue !, Dated 02/25/2000.
98-MILLIMETER PITCH HORIZONTAL BANDING !
COPY QUALITY
CAUSE:
An unstable rotation of the OPC Idle Roller in PCU Unit, causing misalignment of the colored toners in which a horizontal yellow or rainbow bands to occur on the printed page.
SOLUTION:
The material, diameter, and accuracy of the OPC Idle Roller was changed from February 2000 production. NOTE: PCU Unit produced before February 2000 was modified. A modified PCU Unit will contain a Red Dot next to the serial number on both the outside carton and on the PCU Unit. NOTE: On the PCU Unit, the serial number is located by the left green handle.
UNITS AFFECTED:
The PCU Unit serial number "cut in" is 0002XXXX or after (00 = 2000, 02 = February) For serial number 0001XXXX and below these units have been modified and they have a red dot next to the serial number. NOTE: 9912XXXX (99 =1999, 12 = December). The PCU Unit inside the Printer has been changed to the new type since February 2000. The cut-in machine serial numbers are: C5007W/SLP517C/AP305 (EDP#400332): P080020001 or after C5007P/SLP517CP/AP505 (EDP#400356): P070020001 or after NOTE: If the PCU Unit before the serial number cut-in above has a red dot by the serial number on the carton box, it has new type PCU UNIT installed. 2000 RICOH Corporation. All rights reserved.
CONTROL NO. 024CLR

BULLETIN NUMBER: G024 - 011 05/19/2000 MODEL: APPLICABLE MODEL: GESTETNER - C7005W RICOH - AP305 SAVIN - SLP517c SUBJECT: GENERAL:
The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. PAGES: The revised areas have been highlighted by an arrow .
!
SERVICE MANUAL
Controller TOC III 8-6,7
Updated Information (Controller Table of Contents) Updated Information (Firmware History)
CONTROL NO. 036ABW
Rev. 05/2000
8.3 BASIC OPERATIONS ...............................................................................8-3 8.3.1 OVERVIEW ......................................................................................8-3 8.3.2 LED FUNCTIONS.............................................................................8-3 8.3.3 SWITCH FUNCTIONS......................................................................8-4 8.3.4 NETWORK SETTING FUNCTION ...................................................8-5 8.4 FIRMWARE HISTORY ..............................................................................8-6
SM
III
G024
31Rev. 05/2000 March, 1999

DESCRIPTION OF MODIFICATION Initial Production Release Corrects the following: On the web status monitor, the improper icon was used for Paper Empty. If the NIB received 5 simultaneous print jobs, additional print jobs would be lost. Corrects the following: The firmware was modified to support A250/B001. Corrects the following: One banner data page of NetWare was split into two pages when using NetWare 3.12 pserver mode. In NetWare remote printer mode, the NIB consumed a server connection license. To avoid this, the firmware has been modified to disconnect the NCP connection immediately after the remote printer has connected to the server. Corrects the following: On the web status monitor, the wording in German was incorrect. FreierSpeicher corrected to Freier Speicher. The Web status monitor displays No Tray/No Paper error when a tray is not closed completely. The message has been changed to Other Error. Disabling (Down) or enabling (Up) AppleTalk protocol from the operation panel sometimes did not take effect after the change. To avoid this, the firmware has been changed to save a new setting to the NVRAM immediately after a change. Corrects the following: When a printer error occurs, the printer information cannot be accessed using Macintosh printer utilities such as Apple Printer Utility. IPP (Internet Print Protocol) function has been added. FIRMWARE LEVEL G6785839B G6785839C SERIAL NUMBER Initial Production February 99 Production FIRMWARE VERSION 3.7.5 3.7.7
G6785839D
March 99 Production April 99 Production
3.8.6
G6785839E
3.8.7
G6785839F
June 99 Production
3.8.8
G6785839G
July 99 Production
3.9.2
G024 Win
8-6
SM
Rev. 05/2000

DESCRIPTION OF MODIFICATION Corrects the following: The wording Config Reference has been changed to Riferim. Config for the Italian version of Web status. The wording Default Gateway Address has been changed to Direcci. Gateway for the Spanish version of Web status. A type of Cisco router caused a problem in browsing the NIB in an AppleTalk network. The cause of this was in the Cisco router but the NIB firmware has been modified to correct this. Corrects the following: PCL text filter support has been added. RICOH brand name has been deleted from several functions and reports. Corrects the following: HTTP access has been improved when multiple protocols are used at the same time (e.g. telnet, IPP and HTTP). FIRMWARE LEVEL G6785839H SERIAL NUMBER October 99 Production FIRMWARE VERSION 3.9.8
G6785839J
4.0.0
G6785839K
April 00 Production
4.0.2
SM
8-7
G024 Win

BULLETIN NUMBER: G024 - 012 05/26/2000 APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517C/SLP517CP SUBJECT: GENERAL:
The following Parts corrections and additions are being issued for all G024 Parts Catalog. Please correct your Parts Catalog as follows. 14-Brand Name Seal-Win RIC
G024(WIN) PARTS CATALOG UPDATE / G024(PS) UPDATE !

PARTS
RICOH COLOR LASER AP305
15-Decal-Aficio
16-Decal-OHP
OLD PART NO. G0241550 G0241548 G0245313 G0241548
NEW PART NO. G0241501 G0241551 G0241330 G0241551 G0241554 G0296845 G0241552
DESCRIPTION Front Cover Decal - Paper Main Control Board Decal - Paper Brand Name Seal Win RIC Decal Aficio Decal - OHP
QTY 1 1 1 1 1 1 1
REFERENCE PAGE ITEM 3 15 3 18 35 10 63 4 63 14* 63 15* 63 16*
* Denotes New Item
Continued...
CONTROL NO. 037ABW
Publications Bulletin No. G024 - 012 Page 2 of 3
18-Decal-Fiery Driven 17-Decal-Controller Manual
The following table lists the differences between the G024WIN and the G024PS.
G024WIN G0243282 G0243292 G0245613 G0245614 G0241524 G9083186 G9083186 G9083184 G9083184 G0243292 G9083186 G9083186 G0248607 G0248650 G0248697 G0241554 G5336600 G5336610
G024PS G0243382 G0243392 G0245611 G0245612 G0241514 G0243093 G0243096 G0243091 G0243094 G0243392 G0243093 G0243096 G0248637 G0248651 G0248652 G0241556 G5446600 G5446610
DESCRIPTION By-pass Feed Table Assy- PS Decal Paper Size - PS Operation Panel Assy PS NA Operation Panel Assy PS EU Left Cover PS Decal Paper Size Dail PS NA Decal Paper Size Dail PS EU Paper Size Dial Assy PS NA Paper Size Dial Assy PS EU Decal Paper Size PS Decal Paper Size Dial PS NA Decal Paper Size Dial PS EU Printer Reference PS NA Printer Reference PS SVN Printer Reference PS GES Brand Name Seal PS RIC Brand Name Seal PS SVN Brand Name Seal PS GES
QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
REFERENCE PAGE ITEM 3 1 3 6 3 17 3 17 5 4 13 1 13 1 13 17 13 17 63 9 63 12 63 12 63 13 63 13 63 13 63 14 63 14 63 14
Continued...
Publications Bulletin No. G024 - 012 Page 3 of 3
The following table lists the items exclusive to the G024PS.

G024WIN G024PS G0245321 G0245323 G0245324 G0241485 G0241495 G0241496 G0241487 G0241499 03530060W 04513006B G0248667 G0248647 G0241453 G0241455 G0241456 G0241457 G0241463 G0241464 G0241467 G5448637 G5448651 G5448652 G0246830 DESCRIPTION Controller-PS w/o ROM RAM FLASH DIMM-PS SDRAM-PS Connector Cover PS Controller Board Bracket - -PS Controller Board Angle PS Board Cover PS Control Board Cover PS Philips Pan Head Screw M3x6 Tapping Screw M3x6 Users Guide PS Getting Started PS Ground Plate Stay Rear Lower Gasket 337 Gasket 186 Retainer-PS Gasket 20 Gasket 30 Tape GND Decal Controller Manual RIC Decal Controller Manual SVN Decal Controller Manual GES Decal Fiery Driven QTY 1 1 1 1 1 1 1 1 REFERENCE PAGE ITEM 35B 51 35B 51 35B 51 35B 52 35B 53 35B 54 35B 55 35B 56 35B 151 35B 152 63 13 63 13 35B 57 35B 58 35B 59 35B 60 35B 62 35B 63 35B 64 63 17 63 17 63 17 63 18
1 1 1 2 2 1 2 1 1 1 1 1 1

BULLETIN NUMBER: G024 - 013 08/22/2000 MODEL: APPLICABLE MODEL: GESTETNER - C7005W/C7005P RICOH - AP305/AP505 SAVIN - SLP517c/SLP517cp SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
IV, VI 4-2 4-15 7-13
Updated Information (Table of Contents) Updated Information (Engine SP Mode Functions) Updated Information (Primary Transfer Bias Adjustment) Updated Information (Firmware History)
CONTROL NO. 031CLR
Rev. 08/2000
2.8.2 DTM COVER OPEN/CLOSED DETECTION..................................2-66
INSTALLATION
3. INSTALLATION PROCEDURE.................................................... 3-1
3.1 3.2 3.3 3.4 3.5 3.6 ENVIRONMENT ........................................................................................3-1 MACHINE LEVEL ......................................................................................3-2 MINIMUM SPACE REQUIREMENTS........................................................3-2 POWER REQUIREMENTS .......................................................................3-3 UNPACKING .............................................................................................3-3 MOVING ....................................................................................................3-4

4. SP MODE ..................................................................................... 4-1
4.1 OVERVIEW ...............................................................................................4-1 4.2 ENGINE SP MODE ...................................................................................4-1 4.2.1 OVERVIEW ......................................................................................4-1 Entering engine SP mode .....................................................................4-1 To exit engine SP mode........................................................................4-1 Outline of the engine SP mode functions..............................................4-2 4.2.2 MENU OPERATION/DISPLAY .........................................................4-2 Key operation........................................................................................4-2 4.2.3 MARGIN (REGISTRATION ADJUSTMENT) ....................................4-4 4.2.4 PARAMETER ...................................................................................4-6 4.2.5 CLEAR MEMORY.............................................................................4-6 4.2.6 SENSOR CHECK .............................................................................4-7 4.2.7 NIP WIDTH .......................................................................................4-9 4.2.8 RESET SC........................................................................................4-9 4.2.9 PROCESS CTRL............................................................................4-10 4.2.10 TEST PRINT.................................................................................4-11 4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)....................4-11 4.2.12 IMAGE ADJUST ...........................................................................4-12 4.2.13 OUTPUT CHECK .........................................................................4-12 4.2.14 HIGHLIGHT ADJUSTMENT .........................................................4-14 4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT).............................................................................4-14 4.2.16 BELT TRANSFER BIAS ADJUSTMENT ......................................4-15
5. PREVENTIVE MAINTENANCE.................................................... 5-1
5.1 PM TASKS ................................................................................................5-1 5.1.1 REPLACEMENT...............................................................................5-1 5.1.2 CLEANING .......................................................................................5-1 5.1.3 INSPECTION....................................................................................5-1
G024 IV SM
Rev. 08/2000
Troubleshooting ..................................................................................6-34 6.5 ELECTRICAL WIRING ............................................................................6-35 6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR ..6-35 6.5.2 POWER SUPPLY UNIT..................................................................6-36 6.5.3 HIGH VOLTAGE SUPPLY UNIT ....................................................6-38 6.5.4 MCU ...............................................................................................6-39 6.5.5 UPGRADING THE MCU FIRMWARE ............................................6-40 6.6 PAPER FEED SECTION .........................................................................6-41 6.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR......6-41 6.6.2 PAPER WIDTH DETECTION BOARD ...........................................6-42 6.6.3 BY-PASS PAPER FEED ROLLER .................................................6-43 6.6.4 PAPER FEED ROLLER..................................................................6-44 6.6.5 PCU HOLDER ................................................................................6-45 6.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS PAPER FEED CLUTCH, REGISTRATION CLUTCH, AND TRANSFER ROLLER CLUTCH ....................................................6-46 Transfer roller position sensor.............................................................6-47 By-pass paper feed clutch ..................................................................6-47 Registration clutch ..............................................................................6-47 Transfer roller clutch ...........................................................................6-47 6.6.7 TRANSFER ROLLER .....................................................................6-48 6.6.8 REGISTRATION ROLLER IDLER ..................................................6-48 6.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE ROLLER ..........................................................................................6-49 6.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH, AND PULL-OUT/RELAY ROLLER CLUTCH ................................6-50 Paper size switch ................................................................................6-50 Paper feed clutch ................................................................................6-50 Pull-out clutch .....................................................................................6-51 Relay roller clutch ...............................................................................6-51
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................. 7-1
7.1 SC TABLES...............................................................................................7-1 7.1.1 TYPES OF SERVICE CALL .............................................................7-1 7.1.2 SC ERROR LIST ..............................................................................7-2 7.1.3 PROCESS CONTROL ERROR LIST ...............................................7-6 7.2 USER ERROR LIST ..................................................................................7-8 7.3 FIRMWARE HISTORY ............................................................................7-13
500-SHEET PAPER TRAY UNIT (G908)

1. OVERALL MACHINE INFORMATION.......................................... 8-1
1.1 SPECIFICATIONS.....................................................................................8-1 1.2 PARTS LAYOUT .......................................................................................8-2
G024 VI SM
ENGINE SP MODE
Rev. 08/2000

The engine SP mode has the following menu items:
Menu Item 1: Margin 2: Parameter 3: Clear Memory 4: Sensor Check 5: Nip Width 6: Reset SC 7: Process Ctrl Function and application Independent vertical/horizontal registration adjustment for each tray, and for OHP mode Independent adjustment of transfer bias and fusing temperature for normal paper, thick paper, and OHPs Resets the counters and other values stored in NVRAM Sensor output check Nip width measurement for fusing pressure adjustment Resets fusing unit SC codes Implementation of forced, normal, and color bias setting process control and setting of execution intervals for periodic process control Prints internally generated patterns (4C overlay grids, 4x4 color belts, and solid-area color belts) for the print engine ID sensor output calibration Adjustment of image reproduction ratio in the main scan and subscan directions Tests for motors, clutches, and solenoids Fine adjustment of density for highlight (low-ID) areas. Adjustment of lubricant application interval Default 0. Do not change. Adjustment of the Primary (Belt) Transfer Bias.
8: Test Print 9: ID Sensor PWM 10: Image Adjust 11: Output Check 12: Hi-light 13: Lub_Interval 14: Soft Version 15: Belt-Tr Bias

In the engine SP mode menu, you can move between menu levels, specify parameters, and view LCD indications in the same way as with the user menu. The different menu items are described on the following pages. All menus are in English only.
Key operation
[!] and ["] keys: Scroll through the menus. When either of these keys is pressed in a number setting menu, the displayed value changes by the minimum value. [# Enter] key: When the selected item has a lower level menu, pressing this key moves you to the next lower level. At the lowest level, this key is used to determine the specified setting or execute the selected item. Pressing this key moves you to a higher level in the current menu. Before the specified value is confirmed by the [# Enter] key, pressing this key keeps the existing setting.
4-2 SM
[Escape] key:
G024
Rev. 08/2000
ENGINE SP MODE
4.2.16 PRIMARY (BELT) TRANSFER BIAS ADJUSTMENT
This mode is used to adjust The Primary (Belt) Transfer Bias.

This value can be specified in 100V increments, between 800V and 1500V. The default setting is 800V. Increasing this parameter can print vertical lines more sharply but white dots may appear on solid image areas. Therefore, this mode should only be used when blurry vertical lines appear.
Layer 1 Layer 2 BLT-BIAS adj Cyan BLT-BIAS adj Magenta BLT-BIAS adj Yellow BLT-BIAS adj Back Layer 3 Cyan XXXX Magenta XXXX Yellow XXXX Back XXXX /# /# /# /# Layer 4
Maintenance 15: BLT-TR BIAS
NOTE: This mode is available starting from ROM version 2.23 (applied to November 1999 production.)
SM
4-15
G024
Service Tables
Rev. 08/2000
FIRMWARE HISTORY
7.3.1

DESCRIPTION OF MODIFICATION FIRMWARE LEVEL G0245500 H SERIAL NUMBER June 99 Production FIRMWARE VERSION 2.16
Corrects the following: No communication between controller while SC

error is issued due to defective Transfer Roller.
Improve Fusing Control Unit. Change the Toner Near End detection method for
black toner.
The process control counter value change on

printing over LT. Size images.
Transfer Bias applied to the paper between OHP

tranparency on OHP slip mode.
Corrects the following: Change the Transfer Current value on OHP

mode.
G0245500 J
July 99 Production September 99 Production
2.17
Corrects the following: Change the Transfer Current value on OHP mode
to optomize with FOLEX.
G0245500 K
2.18
Set Setup status flag when detecting DTM cover

sheet.
Corrects the following: SC98 may occur while continuous B/W printing
G0245500 L
2.20
SC28 may occur while continuous color printing

SC41 may occur if paper end is detected and

paper is added on the tray during half print speed. (Thick paper or OPC Transparency media printing)
Corrects the following: Condition for SC105 detection. Additional SP mode menu for Primary Transfer
Bias 15-BLT-TR BIAS.
G0245500 N
2.23
Secondary Bias Control error may occur during

initialization.
Corrects the following: Auto pattern printing after PCU replacement. Corrects the following: Change timing for turning on the Revolver Motor
when detecting paper end as the countermeasure for SC38 detection error. Skip the K-DTM process control procedure on color DTM replacement to thin vertical lines. The development roller is rotated twice on DTM replacement to prevent thin vertical lines. Change the timing for turning off the charge bias when printing images wider than letter size in B/W mode.
G0245500 Q G0245500 S
February 00 Production April 00 Production
2.26 2.30 Troubleshooting G024
SM
7-13

BULLETIN NUMBER: G024 - 014 09/11/2000 MODEL: APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
7-2 through 5
Updated Information (SC Error List)
CONTROL NO. 033CLR
SC TABLES
Rev. 09/2000
7.1.2 SC ERROR LIST

Type 1 22 Type 1
23
Type 1 24
Type 1 25 Type 1
26
27
Type 1
AC Power zero-cross detection error
The roller temperature has been 190C or higher for three seconds. Reheat has been done and the motor is not running, or 60 seconds has passed after main motor halt. The roller temperature has been below 130C for 60 secs. No zero-cross signal can be detected when the fusing heaters turn on. NOTE: From main engine firmware ver. 2.21 or later, this SC can be released by turning the unit OFF then ON.
No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or lack of fusing unit . No detection in the event of SC or fusing unit absence. No detection in the event of a jam/door open, SC, unit absence, energysaving mode, or fusing unit absence. No detection in the event of SC or fusing unit absence.
60HZ AC The number of zerocross cycles is detected less than 109 times or more than 131 times for 5 continuous seconds.
G024
7-2
SM
Rev. 09/2000
SC TABLES
Name Paper transfer positive bias release error Occurrence conditions The PWM duty has been 50% or higher for 240 ms. Or, the paper transfer roller clutch does not operate. Detection conditions Detection starts 60 ms after control starts for this component. Cause There is a disconnection in the paper transfer bias supply circuit. (Deformation of terminals or springs, dirty bearings) When the contact / separation lever is normal: Bad transfer roller position sensor harness, or MCU. When the contact/separation lever is faulty: Bad transfer roller clutch or MCU. There is a disconnection in the primary transfer bias supply circuit. (Dirty or deformed electrodes.) There is a short circuit in the supply bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter.) There is a short circuit in the blade bias supply circuit.
SC No.
Type Type 2
28
Type 2 29
Type 2
Supply bias error
31
Type 2
Blade bias error
32
Type 2 33
Type 2
34
35 36
Type 2 Type 2
PCU motor, MCU.
SM
7-3
G024
Troubleshooting
The voltage has been higher than the appropriate control voltage for the target voltage for 240 ms. However, detection is disabled when the calculated control voltage is 5 V or higher. Continuous unlock for two seconds. Continuous unlock for two seconds.
There is disconnection in the charge corona unit bias supply circuit. (Dirty or deformed electrodes.) There is a short circuit in the charge corona unit grid bias supply circuit (due to deformed terminals or electrodes or conductive foreign matters). Main motor, MCU.
SC TABLES
Rev. 09/2000
Name Revolver motor error Occurrence conditions Movement to the home position took four or more seconds. For black, movement to the home position took one second or longer. Continuous unlock for two seconds. The ID sensor output voltage is not between 0.1 V and 1.1 V while the ID sensor LED is off. No mark has been detected for 500 ms during PCU motor operation. LD error (abnormal laser power output) Synchronization detection error of the optical unit A/D converted voltage has been 4.8 V or more for 240 ms. ID sensor calibration. Detection conditions Cause Incorrect installation of color development unit, revolver motor, MCU defective. Polygon mirror motor, MCU. ID sensor.
SC No.
Type Type 2
38
Transfer belt H.P. sensor, MCU.
42
During polygon mirror motor revolution Detection starts 60 ms after control starts for this component.
45
Type 2
46
Type 2 47
Type 2
48
Type 1 49
When reheating, the roller temperature does not reach the reheat start temperature (target temperature -20C) within five minutes.
During reheating
LD, LD control board Synchronization detection board, LD control board There is a short circuit in the charge bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) There is disconnection in the paper transfer bias supply circuit. (Dirty or deformed electrodes) There is a short circuit in the paper transfer bias supply circuit (due to deformed terminals or electrodes or conductive foreign matter) Pressure roller thermistor, pressure roller lamp connector, MCU
G024
7-4
SM
Rev. 09/2000
SC TABLES
Name Hot roller reheat timeout Occurrence conditions When reheating, the roller temperature does not reach the reheat start temperature (target temperature -10C) within five minutes. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When full-power operation occurs during reheating, the main motor is not running and the difference between the current temperature and that of 60 seconds ago is 18C or less. When an abnormal combination of print commands is received. 5 V (4.75 V) or more has continuously been detected for five seconds. 5 V (4.75 V) or more has continuously been detected for five seconds. Detection conditions During reheating Cause Hot roller thermistor, hot roller lamp connector, MCU
SC No.
Type Type 1
50
Type 1
51
Type 1
52
Type 2 57 Type 2 59 Type 2 60
When the power is on, or the AC development bias is off. When the power is on, or the AC development bias is off.
Temperature sensor
Humidity sensor
SM
7-5
G024
Troubleshooting

BULLETIN NUMBER: G024 - 015 09/11/2000 MODEL: APPLICABLE MODEL: GESTETNER C7005W RICOH AP305 SAVIN SLP517C SUBJECT: GENERAL:
The following parts updates are being issued for all G024 Parts Catalogs.
PARTS CATALOG UPDATES !
PARTS
UPDATE 1:
Bushing 20.2 To facilitate assembly, the Bushing 20.2 is being changed. The following part update is being issued for all G024 Parts Catalogs.
OLD PART NO. 11060459
NEW PART NO. G0241473
DESCRIPTION Bushing 20.2
QTY 1
INT 0
REFERENCE PAGE ITEM 7 107
UPDATE 2:
Spring Plate Seal The Spring Plate is no longer required.. The following part update is being issued for all G024 Parts Catalogs.
OLD PART NO. G0243084
NEW PART NO. -
DESCRIPTION Spring Plate Seal
QTY 1!0
INT -
REFERENCE PAGE ITEM 13 16 Continued
CONTROL NO. 033CLR
UPDATE 3:
Seal 7x15x15 The Seal 7x15x15 is being removed to prevent horizontal white lines. This modification has been in production since December 1999. The following part update is being issued for all G024 Parts Catalogs.
NEW PART NO. -
DESCRIPTION Seal 7x15x15
QTY 1!0
UNITS AFFECTED:
All G024 printers manufactured after December 1999 will have the Seal 7x15x15 removed during production.
UPDATE 4:
Friction Pad To prevent noise during paper feed, a new style Friction Pad is being installed during production. This modification has been in production since January 2000. The following part update is being issued for all G024 Parts Catalogs.
DESCRIPTION Friction Pad
QTY 1
INT 1
UNITS AFFECTED:
All G024 printers manufactured after January 2000 will have the new style Friction Pad installed during production. Continued
UPDATE 5:
Pressure Spring To improve secondary transfer, a new style Pressure Spring for the left side is being installed during production. This modification has been in production since March 2000. The following part update is being issued for all G024 Parts Catalogs.
DESCRIPTION Pressure Spring Pressure Spring Left
QTY 2!1 1
REFERENCE PAGE ITEM 9 10 9 28 *
* Denotes new item number.
UNITS AFFECTED:
All G024 printers manufactured after March 2000 will have the new style Pressure Spring - Left installed during production.
INTERCHANGEABILITY CHART:
0 1 3/S

BULLETIN NUMBER: G024 016 09/15/2000 MODEL: APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: GENERAL:
The Front Lower Cover Assembly (P/N G0243336) will no longer be available. The Front Lower Cover Assembly consisted of the following parts listed below which will be available individually as spare parts. The individual parts which are listed below, need to be ordered when replacing the Front Lower Cover Assembly.
FRONT LOWER COVER ASSEMBLY !

PARTS
OLD PART NO. G0243336 G0243337 H5164095 G0243344
NEW PART NO. -
G0246830 G0296845
DESCRIPTION Front Lower Cover Assy Front Lower Cover Decal Energy Saver Spring 4mm Decal Fiery Driven Decal Aficio
QTY 10 1 1 1 1 1
REFERENCE PAGE ITEM 3 20 3 14 3 19 3 21 3 22 3 23
CONTROL NO. 034CLR

BULLETIN NUMBER: G024 - 017 09/15/2000 MODEL: APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517c/SLP517cp SUBJECT: GENERAL:
The diameter of the base of the Driving Gear Shaft was changed from 10 mm to 20 mm to prevent the Shaft from being bent when removing paper jams from the Fusing Unit. The following part update is being issued for all G024 Parts Catalogs.
FUSING UNIT RIGHT SIDE PLATE !

PARTS
This diameter was changed to 20 mm from 10 mm.
DESCRIPTION Right Side Plate
QTY 1
INT 1
UNITS AFFECTED:
All G024 printers manufactured starting in September 1999 will have the new style Right Side Plate installed during production.
0 1 3/S
CONTROL NO. 034CLR

BULLETIN NUMBER: G024 - 018 12/13/2000 MODEL: APPLICABLE MODEL: GESTETNER C7005W/C7005P RICOH AP305/AP505 SAVIN SLP517C/SLP517CP SUBJECT: SYMPTOMS:
1) Acoustic noise coming from the Upper Cover around the Fusing Unit. 2) Tightener Gear Assembly (G0241808) may be damaged (No Fusing Unit drive).
FUSING UNIT GEAR !

MECHANICAL
CAUSE:
The force between the Fusing Contact/Separation Gear and the Fusing Drive Gear is too great.
SOLUTION:
FIELD COUNTERMEASURE: Place a Fusing Stay Spacer (P/N: G0249001) on the Fusing Unit Stay as shown in the illustration below.
PARTS
Spacer Fusing Stay (P/N: G0249001)
VIEW FROM TOP
Line up the right side edge
Continued 2000 RICOH Corporation. All rights reserved.

CONTROL NO. 043CLR
PRODUCTION COUNTERMEASURE: The shape of Tightener Gear Assembly Bracket that contains the Contact/Separation Gear was changed, to prevent too much thread engagement between the gears.
Modified Shape of Bracket
GENERAL:
The following part addition is being issued for all G024 Parts Catalogs.
NEW PART NO. DESCRIPTION G0249001 Spacer Fusing Stay *DENOTES NEW ITEM NUMBER
QTY 0-1
REFERENCE PAGE ITEM 47 16*
UNITS AFFECTED:
All G024 printers manufactured after the Serial Numbers listed below will have the new style Tightener Gear Assembly Bracket installed during production. MODEL NAME Gestetner C7005W / C7005P Ricoh AP305 / AP505 Savin SLP517C / SLP517CP SERIAL NUMBER January 2000, Production

BULLETIN NUMBER: G024WIN 019 01/31/2001 MODEL: APPLICABLE MODEL: GESTETNER NETWORK INTERFACE BOARD FOR C7005w RICOH NETWORK INTERFACE BOARD FOR AP305 SAVIN NETWORK INTERFACE BOARD FOR SLP517c SUBJECT: GENERAL:
The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. PAGES:
!
SERVICE MANUAL
8-7
Updated Information (G024 NIB OPTION FIRMWARE HISTORY)
An arrow has highlighted the revised areas .
CONTROL NO. 044CLR
Rev. 01/2001

DESCRIPTION OF MODIFICATION Corrects the following: The wording Config Reference has been changed to Riferim. Config for the Italian version of Web status. The wording Default Gateway Address has been changed to Direcci. Gateway for the Spanish version of Web status. A type of Cisco router caused a problem in browsing the NIB in an AppleTalk network. The cause of this was in the Cisco router but the NIB firmware has been modified to correct this. Corrects the following: PCL text filter support has been added. RICOH brand name has been deleted from several functions and reports. Corrects the following: HTTP access has been improved when multiple protocols are used at the same time (e.g. telnet, IPP and HTTP). Corrects the following:
FIRMWAR E LEVEL G6785839H
SERIAL NUMBER October 99 Production
G6785839J
4.0.0
G6785839K
April 00 Production
4.0.2
Bi-directional communication of "diprint" (using 9100 port of TCP/IP printing) is supported (required for DAZEL system). The "diprint direct [On/Off]" command using telnet has been implemented for supporting bi-directional communication of diprint (required for DAZEL system). PortNavi and Multidirect Print are not supported if bi-directional communication has been selected. The spelling of the command "retern" in the UNIX install shell has been corrected to "return". The DHCP of NetWare5 is supported. The DHCP relay agent is supported. (This has been confirmed only with Windows NT 4.0 relay agent at this time.) There may be some minor (character) display errors on the LCD while the NIB firmware is being upgraded. The firmware has been modified to prevent this.
G6785839L
4.06
SM
8-7
G024 Win

BULLETIN NUMBER: G024/G047/G048 020 07/25/2001 MODEL: APPLICABLE MODEL: GESTETNER C7006W/7006DW RICOH AP306/306D SAVIN SLP624s/624d ! SUBJECT:
VERTICAL STREAKS ON PRINTS
COPY QUALITY
SYMPTOM:
Vertical streaks appear on prints.
CAUSE:
The customer has not performed periodic charger cleaning.
!
FIRMWARE
SOLUTION:
To ensure that vertical streaks do not appear on prints, the engine and controller firmware has been modified. The new versions include a display message reminding customers to perform a periodic charger cleaning. The message is displayed every 5K developments. Controller firmware version: Engine firmware version: 3.20 or later 2.00 or later
For this feature, a Charger Clean Counter and Charger Clean Reset Counter have been added. These counter values are shown on the Engine Maintenance Sheet.
NOTE: Errors and Limitations Controller Firmware: Ver. 3.20 or newer Engine Firmware: Ver. 2.00 or newer No errors of any kind. Older than ver. 3.20 SC error indicated after the first 5K developments. The only way to clear this condition is to update the controller firmware to ver 1.09 or newer. No functional error, but no periodical alert is indicated.
Older than ver. 2.00
No functional errors, but no periodic alert is indicated.
NOTE: When updating the engine firmware to version 2.00 or newer, the controller firmware also needs to be updated to version 3.20 or newer.
The firmware revision can be downloaded through the Technology Solution Center FTP Site http://tsc.ricohcorp.com. NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the FTP Internet Web Site and EPROM/Flash Card Exchange program.

CONTROL NO. 053CLR
Tech Service Bulletin No. G024/G047/G048 020 Page 2 of 2
GENERAL:
To distinguish between service parts containing the different firmware versions, the printer control board and MCU board were changed as follows. The following parts updates are being issued for all G047/G048 Parts Catalogs.
OLD PART NO. G0475768 G0475303
NEW PART NO. G0475769 G0475306
DESCRIPTION Printer Control Board Main Control Board (MCU)
QTY 1 1
INT -
REFERENCE PAGE ITEM 84A * 79 *
NOTE: After the engine firmware has been updated with this version, a C v123 is indicated instead of C v200.
UNITS AFFECTED:
The above firmware changes have been applied the G047/G048 from the November 2000 production.
PROCEDURE:
! Turning off the Clean Charger message

You can set the Clean Charger message not to display by following the steps below. 1. 2. 3. 4. 5. Press [Menu]. Press the ["] or [#] to display Maintenance and then press [Enter]. Press the ["] or [#] to display 8. Disp.Cl.Chgr. and then press {Enter]. Press the ["] or [#] to display Off, and then press [Enter]. Press [On Line]. The Ready message appears in the display panel.
NOTE: Printouts may appear dirty when you continue using the printer with the charger not cleaned. Follow the steps in the User Manual for Cleaning the Charger.

BULLETIN NUMBER: G024/G047/G048 021 07/25/2001 MODEL: APPLICABLE MODEL: GESTETNER C7005W RICOH AP305 SAVIN SLP517c ! SUBJECT:
VERTICAL STREAKS ON PRINTS
COPY QUALITY
SYMPTOM:
Vertical streaks appear on prints.
CAUSE:
The customer has not performed periodic charger cleaning.
SOLUTION:
To ensure that vertical streaks do not appear on prints, the engine and controller firmware has been modified. The new versions include a display message reminding customers to perform a periodic charger cleaning. The message is displayed every 5K developments. Controller firmware version: Engine firmware version: 1.09 or later 3.01 or later
FIRMWARE
For this feature, a Charger Clean Counter and Charger Clean Reset Counter have been added. These counter values are shown on the Engine Maintenance Sheet. Refer to the following table for the new display items (#6, 7) that reset the alert indication and to disable this function. The service manual page for the new Maintenance Table is supplied. Please update your G024 Service Manual with the new page 4-3. Maintenance 1.Toner Select Cyan Magenta Yellow Black
2. Toner level 3. Menu Reset 4. Registration (Only when optional tray is installed.) 5. Menu Protect
Off On
6. Reinstall 7. Disp.Cl.Chgr
Clean Charger On Off
It can also be accessed if the [Enter], [Escape], and [Menu] keys are pressed in sequence while the printer is on line. Press # key Default : On

CONTROL NO. 053CLR
Tech Service Bulletin No. G024/G047/G048 021 Page 2 of 2
NOTE: Errors and Limitations Controller Firmware: Engine Firmware: Ver. 3.01 or newer Ver. 1.09 or newer No errors of any kind. Older than ver. 1.09 SC error indicated after the first 5K developments. The only way to clear this condition is to update the controller firmware to ver 1.09 or newer. No functional error, but no periodical alert is indicated.
Older than ver. 3.01 " "
No functional errors, but no periodic alert is indicated.
When updating the engine firmware to version 3.01 or newer, the controller firmware needs to be updated to version 1.09 or newer. Do not use this Engine Firmware version on the G024-17/27 (PostScript version), otherwise an SC error occurs.
The latest firmware can be downloaded through the Technology Solution Center FTP Site http://tsc.ricohcorp.com. NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the FTP Internet Web Site and EPROM/Flash Card Exchange program.

BULLETIN NUMBER: G024/G047/G048 022 07/25/2001 MODEL: APPLICABLE MODEL: GESTETNER C7006w/7006dw RICOH AP306/306D SAVIN SLP624s/624d SUBJECT: SYMPTOM:
Incomplete toner fusing or reduced glossiness may occur with the first print made after the machine recovers from Energy Saver Mode. This tends to occur more often with plain or standard paper that is relatively thick.
INCOMPLETE TONER FUSING !
COPY QUALITY
CAUSE:
When the machine starts printing after coming out of Energy Saver Mode, the hot roller temperature is not high enough to ensure proper fusing for the first print.
SOLUTION:
A special version of the MCU firmware (Version 9.00) has been released. With this version, the hot roller temperature for the first print coming out of Energy Saver Mode is increased by 10C over the original temperature. NOTE: 1. It takes slightly longer to get the first print with this firmware version because of the increased temperature. 2. This MCU firmware contains the Charger Cleaning Alert feature. Therefore, the controller firmware also needs to be updated to version 3.20 or newer. Please refer to TSB G024/G047/G048 0020.
The latest firmware can be downloaded through the Technology Solution Center FTP Site http://tsc.ricohcorp.com. NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the FTP Internet Web Site and EPROM/Flash Card Exchange program.
CONTROL NO. 053CLR

BULLETIN NUMBER: G024/G047/G048 023 08/07/2001 MODEL: APPLICABLE MODEL: GESTETNER NETWORK INTERFACE BOARD for C7005W RICOH - NETWORK INTERFACE BOARD for AP305 SAVIN - NETWORK INTERFACE BOARD for SLP517C SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
The Service Manual page listed below must be replaced with the page supplied. Each bulletin package contains 1 set of replacement pages. PAGES: The revised areas have been highlighted by an arrow .
8-7
Updated Information (NIB Firmware Modification History)
Copyright 2001 RICOH Corporation. All rights reserved.
CONTROL NO. 055CLR
Rev. 07/2001

DESCRIPTION OF MODIFICATION FIRMWARE LEVEL G6785839H SERIAL NUMBER October 99 Production FIRMWARE VERSION 3.9.8
G6785839M
February 01 Production
4.0.7
SM
8-7
G024 Win
Corrects the following: The wording Config Reference has been changed to Riferim. Config for the Italian version of Web status. The wording Default Gateway Address has been changed to Direcci. Gateway for the Spanish version of Web status. A type of Cisco router caused a problem in browsing the NIB in an AppleTalk network. The cause of this was in the Cisco router but the NIB firmware has been modified to correct this. Corrects the following: PCL text filter support has been added. RICOH brand name has been deleted from several functions and reports. Corrects the following: HTTP access has been improved when multiple protocols are used at the same time (e.g. telnet, IPP and HTTP). Corrects the following: Bi-directional communication of "diprint" (using 9100 port of TCP/IP printing) is supported (required for DAZEL system). The "diprint direct [On/Off]" command using telnet has been implemented for supporting bi-directional communication of diprint (required for DAZEL system). PortNavi and Multidirect Print are not supported if bi-directional communication has been selected. The spelling of the command "retern" in the UNIX install shell has been corrected to "return". The DHCP of NetWare5 is supported. The DHCP relay agent is supported. (This has been confirmed only with Windows NT 4.0 relay agent at this time.) There may be some minor (character) display errors on the LCD while the NIB firmware is being upgraded. The firmware has been modified to prevent this. Corrects the following: Classless InterDomain Routing (CIDR) is supported. DHCP of Solaris 2.6 is supported.
G6785839J
4.0.0
G6785839K
April 00 Production
4.0.2
G6785839L
4.0.6

BULLETIN NUMBER: G024/G047/G048 024 08/20/2001 MODEL: APPLICABLE MODEL: GESTETNER NETWORK INTERFACE BOARD for C7006W/7006dw RICOH - NETWORK INTERFACE BOARD for AP306/306D SAVIN - NETWORK INTERFACE BOARD for SLP624s/624d SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
iii 8-5
Updated Information (Table of Contents - NIB) Updated Information (NIB Firmware Modification History)
CONTROL NO. 057CLR
Rev. 07/2001
7.3.6 ENGINE USER ERRORS.................................................................7-7 7.3.7 ENGINE SERVICE CODES .............................................................7-7

8. NETWORK INTERFACE BOARD (C4000 FERRET) .................. 8-1
8.1 OVERVIEW ...............................................................................................8-1 8.1.1 SPECIFICATIONS............................................................................8-1 8.1.2 BLOCK DIAGRAM............................................................................8-1 8.2 COMPONENT LAYOUT............................................................................8-2 8.2.1 NETWORK INTERFACE BOARD DIAGRAM...................................8-2 8.2.2 DEVICES..........................................................................................8-2 8.3 BASIC OPERATIONS ...............................................................................8-3 8.3.1 OVERVIEW ......................................................................................8-3 8.3.2 SWITCH FUNCTION ........................................................................8-4 NVRAM Reset Procedure .....................................................................8-4 8.4 FIRMWARE HISTORY ...............................................................................8-5 8.4.1 NIB FIRMWARE MODIFICATION HISTORY ....................................8-5
SM
iii
G047/G048
Rev. 07/2001
FIRMWARE HISTORY
8.4
FIRMWARE HISTORY


supported.
Corrects the following: The spelling of the command retern in the

G6785847 F
Oct. 00 Production Feb. 01 Production
5.0.4
Corrects the following: DHCP of Solaris 2.6 is supported.
G6785847 G
5.0.7
SM
8-5
G047/G048

BULLETIN NUMBER: G024/G047/G048 025 09/24/2001 09/14/2001 MODEL: APPLICABLE MODEL: GESTETNER C7005W RICOH COLOR PRINTER AP305 SAVIN SLP517C SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. An arrow has highlighted the revised areas . PAGES:
iii
77
Updated Information Table Of Contents Updated Information Firmware Modification History
Copyright
CONTROL NO 060CLR
08/2001
7.4 FIRMWARE HISTORY7-7
SM
iii
G024 PS
08/2001
FIRMWARE HISTORY
Refer to the Troubleshooting section in the Operating Instructions Printer Reference Manual.

Refer to the Troubleshooting section in the G024 engine service manual.

DESCRIPTION OF MODIFICATION Corrects the following: 1. Wording change in RPS2 menu. Previous Changed to Bright Vivid Super Bright Super Vivid 2. Improving BG/UCR. 3. Cannot print out correctly from AcrobatReader4.0 when selecting 2 Byte font downloads. Corrects the following: 1. Item header "B" on the RPS2 menu has been omitted: Previous Changed to B. Job Timeout C. Job Timeout C. I/O Timeout D. I/O Timeout 2. No "Job Resetting..." display Corrects the following: 1. Overflow error in the coordinate variable. 2. An internal error appears when trying to cancel a job using the Reset key. FIRMWARE LEVEL G5035908 A SERIAL NUMBER April 2000 Production FIRMWARE VERSION 2.61
G5035908 B
3.10
G5035908 C
3.55
SM
7-7
G024 PS

BULLETIN NUMBER: G024/G047/G048 - 026 09/24/2001 09/14/2001 MODEL: APPLICABLE MODEL: GESTETNER C7006W RICOH AFICIO COLOR AP306 SAVIN SLP624S SUBJECT: GENERAL: SERVICE MANUAL - INSERT
!
SERVICE MANUAL
The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages.
An arrow has highlighted the revised areas . PAGES:
TOC IV
7-10
Updated Information (table of contents) Updated Information (Firmware Modification History)
Copyright
CONTROL NO 060CLR
Rev. 08/2001
TROUBLESHOOTING
7. TROUBLESHOOTING ................................................................ 7-1
7.1 SC TABLES...............................................................................................7-1 7.1.1 TYPES OF SERVICE CALL .............................................................7-1 Fusing Unit SC Errors .......................................................................7-1 7.1.2 SC ERROR LIST ..............................................................................7-2 7.1.3 PROCESS CONTRL ERROR LIST ..................................................7-6 7.2 USER ERROR LIST ...................................................................................7-8 7.3 FIRMWARE HISTORY ..7-10 7.3.1 G047 FIRMWARE MODIFICATION HISTORY...7-10
G047/G048
iv
SM
FIRMWARE HISTORY
Rev.08/2001

DESCRIPTION OF MODIFICATION Corrects the following: 1. Item header "B" on the RPS2 menu has been omitted: Previous Changed to B. Job Timeout C. Job Timeout C. I/O Timeout D. I/O Timeout Corrects the following: 1. Overflow error in the coordinate variable. 2. An internal error appears when trying to cancel a job using the Reset key. FIRMWARE LEVEL G5035921 B SERIAL NUMBER November 2000 Production FIRMWARE VERSION 3.10
G5035921 C
3.55
G047/G048
7-10
SM

BULLETIN NUMBER: G024/G047/G048 - 027 11/15/2001 APPLICABLE MODEL: GESTETNER C7005W/C7005P/C7006W/C7006DW RICOH AP305/AP505/AP306/AP306D SAVIN SLP517C/SLP517CP/CLP624S/SLP624D
SUBJECT: CHARGE CORONA UNIT
GENERAL:
The charge unit has been registered as a service part. The following parts addition is being issued for all AG024/G047/G048 Parts Catalogs.
PARTS
NEW PART DESCRIPTION NUMBER G0473580 Charge corona Assembly *DENOTES NEW ITEM NUMBER
QTY 1
REFERENCE PAGE
G024 G047/ G048
ITEM 21*
11
CONTROL NO. 066CLR

BULLETIN NUMBER: G024/G047/G048 028 12/03/2002 APPLICABLE MODEL: GESTETNER C7005W RICOH AP305 SAVIN SLP517C
SUBJECT: NETWORK INTERFACE BOARD
GENERAL:
The Network Interface Board has been registered as a service part for the G024 Win Parts Catalog. The following part update is being issued for all G024 Win Parts Catalogs.
PARTS
PART NUMBER G6785714
DESCRIPTION Network Interface Board
QTY 1
REFERENCE PAGE ITEM 35 13 *
* DENOTES NEW ITEM NUMBER

BULLETIN NUMBER: G024/G047/G048 029 12/04/2002 APPLICABLE MODEL: GESTETNER C7005W RICOH AP305 SAVIN SLP517C SUBJECT: GENERAL: SERVICE MANUAL INSERT
!
SERVICE MANUAL
8-8
Updated Information (NIB Firmware History)
Copyright
Rev. 12/2002

DESCRIPTION OF MODIFICATION
FIRMWARE LEVEL G6785839N
SERIAL NUMBER August 01 Production
Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2.
G6785839P
SNMP security vulnerabilities reported by CERT on Feb.12, 2002 has been tested using the PROTOS c06-snmpv1 test suite and we have verified the fixes. -CERT :http://www.cert.org/advisories/CA-200203.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/pr otos/testing/c06/snmpv1/
July 02 Production
4.1.0
G024 Win
8-8
SM

BULLETIN NUMBER: G024/G047/G048 030 12/06/2002 APPLICABLE MODEL: GESTETNER C7006W/C7006DW RICOH AP306/AP306D SAVIN CLP624S/SLP624D SUBJECT: GENERAL: SERVICE MANUAL INSERT
!
SERVICE MANUAL
8-5
Updated Information (NIB Firmware History)
Copyright
Rev. 12/2002
FIRMWARE HISTORY


supported.
Corrects the following: The spelling of the command retern in the Corrects the following: DHCP of Solaris 2.6 is supported. Corrects the following: SNMP Trap IP address is set to 11.22.33.44
G6785847 F
Oct. 00 Production Feb. 01 Production Aug. 01 Production
5.0.4
G6785847 G G6785847 H
5.0.7 5.1.0
incorrectly before the NIB is assigned the IP address from the DHCP server Disconnects from NetWare Servers that uses relatively old CPUs (i486)
Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2. Corrects the following: SNMP security vulnerabilities reported by CERT
on Feb.12, 2002 has been tested using the PROTOS c06-snmpv1 test suite and we have verified the fixes. -CERT :http://www.cert.org/advisories/CA-200203.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testi ng/c06/snmpv1/
G6785847 J
July 02 Production
5.1.2
SM
8-5
G047/G048

BULLETIN NUMBER: G024/G047/G048 031 03/12/2003 APPLICABLE MODEL: GESTETNER C7005W/C7005P/C7006W/C7006DW RICOH AP305/AP505/AP306/AP306D SAVIN SLP517C/SLP517CP/CLP624S/SLP624D SUBJECT: PARTS CATALOG UPDATES
PARTS Note: This copy is intended as a master original for reproduction of additional bulletins.
GENERAL:
The following parts updates are being issued for all G047 Parts Catalogs.
UPDATE 1:
Fusing Unit To increase the durability of the hot roller, the material of the roller surface (silicone rubber) has been changed.
OLD PART NO. G0474504 G0474505 G0484504 G0484505 G0474600
NEW PART NO. G0474507 G0474508 G0484507 G0484508 G0474608
DESCRIPTION Fusing Unit - 120V (G047) Fusing Unit - 230V (G047) Fusing Unit - 120V (G048) Fusing Unit - 230V (G048) Hot Roller
QTY 1 1 1 1 1
INT 1 1 1 1 1
REFERENCE PAGE ITEM 29 14 29 14 29 14 29 14 35 15
UNITS AFFECTED:
All G024/G047/G048 printers manufactured after the serial numbers listed below will have the new style Fusing Unit installed during production.
MODEL NAME Gestetner C7006w Gestetner C7006dw Ricoh Color Laser AP306 Ricoh Color Laser AP306D Savin SLP624s Savin SLP624d
SERIAL NUMBER P33204xxxxx P34204xxxxx P33204xxxxx P34204xxxxx P33204xxxxx P34204xxxxx
Continued
Tech Service Bulletin No.G024/G047/G048 031 Page 2 of 3
UPDATE 2:
Bias Terminal Assembly To ensure a proper contact between the development bias terminal and revolver, the contact angle has been changed and the thickness of the terminal has been increased. This will also ensure that CMYK bands do not appear on printouts.
DESCRIPTION Bias Terminal Assembly
QTY 1-1
INT 1
UNITS AFFECTED:
All G024/G047/G048 printers manufactured after the serial numbers listed below will have the new style Bias Terminal Assembly installed during production.
MODEL NAME Gestetner C7006w Gestetner C7006dw Ricoh Color Laser AP306 Ricoh Color Laser AP306D Savin SLP624s
SERIAL NUMBER P33201xxxxx P34201xxxxx P33201xxxxx P34201xxxxx P33201xxxxx
UPDATE 3:
Ball Bearing To ensure that the drive gear does not wear down prematurely, lock or cause noise, grease has been attached to the Ball Bearing.
OLD PART NO. AE030024
NEW PART NO. 08053380
DESCRIPTION Ball Bearing - 25X37X7MM
QTY 1
INT 1
UNITS AFFECTED:
All G024/G047/G048 printers manufactured after the serial numbers listed below will have the new style Ball Bearing installed during production.
SERIAL NUMBER P33204xxxxx P34204xxxxx P33204xxxxx P34204xxxxx P33204xxxxx P34204xxxxx Continued
Tech Service Bulletin No.G024/G047/G048 031 Page 3 of 3
UPDATE 4:
Inlet Fan The Inlet Fan Motor has been changed to ensure the proper temperature around the DTM and PCU. As the temperature rises it can cause toner blocks inside the DTM, and scratches on the development roller surface or damage to the DTM drive gear.
NOTE: In addition to this new motor, Inlet Fan Motor #AX640071 can also be used on this machine since these two parts are identical.
OLD PART NO. AX640099
NEW PART NO. AX640140
DESCRIPTION Fan Motor - DC24V 1.92W Fan Motor - DC24V 4.08W
QTY 1
INT 1
UNITS AFFECTED:
All G024/G047/G048 printers manufactured after the serial numbers listed below will have the new style Inlet Fan Motor installed during production.
SERIAL NUMBER P33206xxxxx P34206xxxxx P33206xxxxx P34206xxxxx P33206xxxxx P34206xxxxx
0 1 3/S

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G024/G047/G048 SERVICE MANUAL

RICOH GROUP COMPANIES

RICOH GROUP COMPANIES

2000 RICOH Corporation. All rights reserved.

2.8.2 DTM COVER OPEN/CLOSED DETECTION..................................2-66

SERVICE TABLES AND PROCEDURES

REPLACEMENT AND ADJUSTMENT

500-SHEET PAPER TRAY UNIT (G908)

2. DETAILED SECTION DESCRIPTIONS........................................ 8-3

3. REPLACEMENT AND ADJUSTMENT...................................... 8-12

IMPORTANT SAFETY NOTICES

CONTROLLER OVERALL MACHINE INFORMATION

CONTROLLER DETAILED DESCRIPTIONS

CONTROLLER SERVICE TABLES

CONTROLLER PERIODIC MAINTENANCE

CONTROLLER REPLACEMENT AND ADJUSTMENT

CONTROLLER NETWORK INTERFACE BOARD TYPE

500 - SHEET PAPER TRAY UNIT G908

REPLACEMENT AND ADJUSTMENT

SERVICE TABLES AND PROCEDURES

G024 OVERALL MACHINE INFORMATION

OVERALL INFORMATION CONTROLLER DETAILED DESCRIPTIONS

DETAILED DESCRIPTIONS CONTROLLER INSTALLATION

INSTALLATION CONTROLLER SERVICE TABLES

SERVICE TABLES CONTROLLER PERIODIC MAINTENANCE

REPLACEMENT AND ADJUSTMENT CONTROLLER TROUBLESHOOTING

CONTROLLER OVERALL INFORMATION

Paper Output Capacity Output Method Power Supply

Overall Machine Information

1. OVERALL MACHINE INFORMATION

Rev. 7/99 Rev. 6/10/99

Product Code G024 G908 G503 G678 G660 G688 AP305

1.2.1 IMAGE FORMATION PROCESS OVERVIEW

Overall Machine Information

1.2 MECHANICAL OVERVIEW

Depositing Y toner on the belt

Depositing C toner after Y

Depositing M toner after Y and C

Depositing K toner after Y, C, and M

Charge grid C = 700 A (About 5000 V) Quenching lamp

Charge corona unit

Overall Machine Information

1.2.3 CHARGE CORONA UNIT VOLTAGES

1.2.4 DEVELOPMENT UNIT BIAS VOLTAGES

Toner Development blade

BL = 480 V 180 VAC equivalent (400 Vp-p) 2 kHz

Primary transfer (from OPC belt to transfer belt)

Secondary transfer (from transfer belt to paper)

Overall Machine Information

1.2.5 TRANSFER BIAS VOLTAGES

MAIN UNIT LAYOUT

1.3 MAIN UNIT LAYOUT

MAIN UNIT LAYOUT

Overall Machine Information

1.4 PARTS LAYOUT

Overall Machine Information

1.4.2 DRIVE LAYOUT

Overall Machine Information

Overall Machine Information

1.4.5 MOTORS, CLUTCHES, AND SOLENOIDS

1.4.6 PCBS AND PSU

Overall Machine Information

IMPORTANT SAFETY NOTICES