g024_sm

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SERVICE MANUAL

000837MIU

G024/G047/G048

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RICOH GROUP COMPANIES

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G024 (ENGINE)/G047/G048

CONTROLLER AND NETWORKINTERFACE BOARD TYPE305

CONTROLLER AND NETWORKINTERFACE BOARD TYPE306

FIERY 500 CONTROLLER

SERVICE MANUAL


000837MIU

It is the reader's responsibility when discussing the information contained within thisdocument to maintain a level of confidentiality that is in the best interest of RicohCorporation 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 theirrespective companies.

They are used throughout this book in an informational or editorial fashion only and forthe benefit of such companies. No such use, or the use of any trade name, or website is intended to convey endorsement or other affiliation with Ricoh products.

2000 RICOH Corporation. All rights reserved.

The Service Manual contains information regardingservice techniques, procedures, processes andspare parts of office equipment distributed byRicoh Corporation. Users of this manual should beeither service trained or certified by successfullycompleting a Ricoh Technical Training Program.

Untrained and uncer t i f ied users ut i l iz inginformation contained in this service manual torepair or modify Ricoh equipment risk personalinjury, damage to property or loss of warrantyprotection.

Ricoh Corporation

WARNING

LEGEND

PRODUCT CODE COMPANYGESTETNER RICOH SAVIN

G024(WIN) C7005W AP305 SLP517cG024(PS) C7005P AP505 SLP517cp

G047/G048(WIN+)* C7006w/7006dw AP306/AP306D SLP624s/SLP624d

*Note: The two product codes and two model names refer to the simplex(manual duplex) and auto-duplex versions respectively.

DOCUMENTATION HISTORYREV. NO. DATE COMMENTS

* 6/99 Original Printing1 7/99 G024 Fiery 500 Controller Service

Manual Addition

2 9/2000 G047/G048 Service Manual Addition

⇒

Rev. 09/2000

SM I G024

TABLE OF CONTENTSENGINE

OVERALL MACHINE INFORMATION

1. OVERALL MACHINE INFORMATION ........................................ 1-11.1 SPECIFICATIONS.................................................................................... 1-11.2 MECHANICAL OVERVIEW ...................................................................... 1-3

1.2.1 IMAGE FORMATION PROCESS OVERVIEW ................................ 1-31.2.2 TRANSFER...................................................................................... 1-61.2.3 CHARGE CORONA UNIT VOLTAGES ........................................... 1-71.2.4 DEVELOPMENT UNIT BIAS VOLTAGES ....................................... 1-81.2.5 TRANSFER BIAS VOLTAGES ........................................................ 1-9

Primary transfer (from OPC belt to transfer belt).................................. 1-9Secondary transfer (from transfer belt to paper) .................................. 1-9

1.3 MAIN UNIT LAYOUT .............................................................................. 1-101.4 PARTS LAYOUT..................................................................................... 1-12

1.4.1 MECHANICAL COMPONENT LAYOUT........................................ 1-121.4.2 DRIVE LAYOUT............................................................................. 1-131.4.3 SENSORS ..................................................................................... 1-151.4.4 SWITCHES.................................................................................... 1-161.4.5 MOTORS, CLUTCHES, AND SOLENOIDS................................... 1-171.4.6 PCBS AND PSU ............................................................................ 1-181.4.7 THERMISTORS, HEATERS, AND FUSES.................................... 1-19

1.5 SYSTEM BLOCK.................................................................................... 1-201.5.1 BLOCK DIAGRAM ......................................................................... 1-20

1.6 ELECTRICAL COMPONENT LIST ......................................................... 1-211.6.1 SENSORS ..................................................................................... 1-211.6.2 SWITCHES.................................................................................... 1-211.6.3 MOTORS ....................................................................................... 1-221.6.4 SOLENOIDS.................................................................................. 1-221.6.5 CLUTCHES.................................................................................... 1-221.6.6 FANS ............................................................................................. 1-221.6.7 CIRCUIT BOARDS AND POWER SUPPLIES............................... 1-231.6.8 THERMISTORS............................................................................. 1-231.6.9 FUSES........................................................................................... 1-231.6.10 LAMPS......................................................................................... 1-23

DETAILED DESCRIPTIONS

2. DETAILED SECTION DESCRIPTIONS....................................... 2-12.1 PROCESS CONTROL.............................................................................. 2-1

2.1.1 OVERVIEW...................................................................................... 2-12.1.2 ID SENSOR ..................................................................................... 2-22.1.3 PROCESS CONTROL STEPS ........................................................ 2-3

G024 II SM

Step 1: ID sensor calibration ................................................................ 2-4Step 2: K development bias initialization.............................................. 2-4Step 3: Color development bias initialization........................................ 2-4Step 4: Charge grid bias voltage adjustment........................................ 2-5Step 5: Y, C, M, and K bias fine adjustment......................................... 2-5Step 6: Resetting the process control interval counter ......................... 2-5

2.2 PCU (PHOTOCONDUCTOR UNIT).......................................................... 2-62.2.1 OVERVIEW...................................................................................... 2-62.2.2 COMPONENTS ............................................................................... 2-72.2.3 DRIVE MECHANISMS..................................................................... 2-8

Belt drive .............................................................................................. 2-8Used toner collection drive ................................................................... 2-9Transfer belt revolutions....................................................................... 2-9Transfer belt speed ............................................................................ 2-10

2.2.4 TRANSFER VOLTAGE SUPPLY................................................... 2-112.2.5 CHARGE CORONA UNIT.............................................................. 2-122.2.6 OPC BELT ..................................................................................... 2-132.2.7 PRIMARY TRANSFER .................................................................. 2-14

Voltage application............................................................................. 2-14Transfer belt cleaning......................................................................... 2-15

2.2.8 USED TONER TANK..................................................................... 2-162.2.9 PCU DETECTION.......................................................................... 2-172.2.10 CHARGE CORONA UNIT DETECTION...................................... 2-172.2.11 BELT MARK DETECTION........................................................... 2-182.2.12 NEW PCU DETECTION .............................................................. 2-182.2.13 LUBRICANT APPLICATION MODE ............................................ 2-19

Lubricant application mode for a new PCU ........................................ 2-19Regular lubricant application mode .................................................... 2-20

2.3 VIDEO DATA PROCESSING ................................................................. 2-212.3.1 FLOW CHART ............................................................................... 2-212.3.2 GAMMA COMPENSATION ........................................................... 2-212.3.3 GRADATION PROCESSING......................................................... 2-222.3.4 AMDG (ADAPTIVE MULTI-DOT GAMMA) .................................... 2-222.3.5 LASER DIODE CONTROL ............................................................ 2-22

Modulation.......................................................................................... 2-22Smoothing .......................................................................................... 2-22

2.4 OPTICAL UNIT ....................................................................................... 2-232.4.1 OVERVIEW.................................................................................... 2-232.4.2 COMPONENTS ............................................................................. 2-242.4.3 LD UNIT ......................................................................................... 2-25

LD safety switch ................................................................................. 2-25LD unit configuration .......................................................................... 2-25Cylindrical lens ................................................................................... 2-26Polygon mirror.................................................................................... 2-26F-theta mirror ..................................................................................... 2-27BTL (Barrel Torroidal Lens)................................................................ 2-27Synchronization detection .................................................................. 2-28Synchronization detection error.......................................................... 2-28

2.4.4 APC (AUTO POWER CONTROL) ................................................. 2-29

SM III G024

Circuit ................................................................................................. 2-29LD error .............................................................................................. 2-29

2.4.5 LASER EXPOSURE CONTROL.................................................... 2-292.4.6 LASER EXPOSURE TIMING......................................................... 2-30

2.5 DEVELOPMENT UNIT ........................................................................... 2-312.5.1 OVERVIEW.................................................................................... 2-312.5.2 COMPONENTS ............................................................................. 2-322.5.3 REVOLVER DRIVE ....................................................................... 2-332.5.4 DEVELOPMENT UNIT DRIVE....................................................... 2-342.5.5 TONER AGITATION ...................................................................... 2-352.5.6 TONER TRANSPORT ................................................................... 2-362.5.7 DEVELOPMENT BIAS................................................................... 2-372.5.8 DTM (DEVELOPMENT TONER MAGAZINE) DETECTION.......... 2-382.5.9 TONER NEAR-END DETECTION ................................................. 2-392.5.10 DEVELOPMENT TIMING ............................................................ 2-40

2.6 PAPER TRANSFER UNIT ...................................................................... 2-412.6.1 OVERVIEW.................................................................................... 2-412.6.2 COMPONENTS ............................................................................. 2-422.6.3 CONTACT AND SEPARATION ..................................................... 2-432.6.4 BIAS............................................................................................... 2-44

2.7 PAPER FEED/REGISTRATION UNIT .................................................... 2-452.7.1 OVERVIEW.................................................................................... 2-452.7.2 COMPONENTS ............................................................................. 2-462.7.3 STANDARD TRAY......................................................................... 2-47

Drive................................................................................................... 2-47Paper feed/separation........................................................................ 2-48Tray lift ............................................................................................... 2-49Paper end detection ........................................................................... 2-50Paper size detection........................................................................... 2-51

2.7.4 BY-PASS FEED TABLE................................................................. 2-52Drive................................................................................................... 2-52Paper feed/separation........................................................................ 2-53Paper end detection ........................................................................... 2-53Paper size detection........................................................................... 2-54

2.7.5 REGISTRATION ............................................................................ 2-552.8 TRANSPORT/FUSING/PAPER EXIT UNIT............................................ 2-56

2.8.1 OVERVIEW.................................................................................... 2-562.8.2 COMPONENTS ............................................................................. 2-572.8.3 FUSING UNIT DRIVE .................................................................... 2-582.8.4 PAPER TRANSPORT.................................................................... 2-592.8.5 TEMPERATURE CONTROL ......................................................... 2-60

Fusing unit SC codes ......................................................................... 2-612.8.6 PRESSURE ROLLER.................................................................... 2-622.8.7 OIL END DETECTION................................................................... 2-632.8.8 OIL SUPPLY.................................................................................. 2-642.8.9 CLEANING..................................................................................... 2-652.8.10 PAPER EXIT COVER OPEN/CLOSED DETECTION.................. 2-65

2.9 OPEN COVER DETECTION .................................................................. 2-662.9.1 FRONT COVER OPEN/CLOSED DETECTION ............................ 2-66

G024 IV SM

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

INSTALLATION

3. INSTALLATION PROCEDURE.................................................... 3-13.1 ENVIRONMENT ........................................................................................3-13.2 MACHINE LEVEL......................................................................................3-23.3 MINIMUM SPACE REQUIREMENTS........................................................3-23.4 POWER REQUIREMENTS .......................................................................3-33.5 UNPACKING .............................................................................................3-33.6 MOVING....................................................................................................3-4

SERVICE TABLES AND PROCEDURES

4. SP MODE ..................................................................................... 4-14.1 OVERVIEW ...............................................................................................4-14.2 ENGINE SP MODE ...................................................................................4-1

4.2.1 OVERVIEW ......................................................................................4-1Entering engine SP mode .....................................................................4-1To exit engine SP mode........................................................................4-1Outline of the engine SP mode functions..............................................4-2

4.2.2 MENU OPERATION/DISPLAY.........................................................4-2Key operation........................................................................................4-2

4.2.3 MARGIN (REGISTRATION ADJUSTMENT) ....................................4-44.2.4 PARAMETER ...................................................................................4-64.2.5 CLEAR MEMORY.............................................................................4-64.2.6 SENSOR CHECK.............................................................................4-74.2.7 NIP WIDTH.......................................................................................4-94.2.8 RESET SC........................................................................................4-94.2.9 PROCESS CTRL............................................................................4-104.2.10 TEST PRINT.................................................................................4-114.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)....................4-114.2.12 IMAGE ADJUST ...........................................................................4-124.2.13 OUTPUT CHECK .........................................................................4-124.2.14 HIGHLIGHT ADJUSTMENT .........................................................4-144.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL

ADJUSTMENT).............................................................................4-144.2.16 BELT TRANSFER BIAS ADJUSTMENT ......................................4-15

PREVENTIVE MAINTENANCE

5. PREVENTIVE MAINTENANCE.................................................... 5-15.1 PM TASKS ................................................................................................5-1

5.1.1 REPLACEMENT...............................................................................5-15.1.2 CLEANING .......................................................................................5-15.1.3 INSPECTION....................................................................................5-1

Rev. 08/2000

SM V G024

5.2 PM TABLE ................................................................................................ 5-25.2.1 MAIN UNIT....................................................................................... 5-25.2.2 OPTIONAL PAPER FEED UNIT...................................................... 5-2

REPLACEMENT AND ADJUSTMENT

6. REPLACEMENT AND ADJUSTMENT........................................ 6-16.1 EXTERIOR ............................................................................................... 6-1

6.1.1 RIGHT COVER/OZONE FILTER COVER ....................................... 6-16.1.2 LEFT COVER .................................................................................. 6-26.1.3 BOTTOM FRONT COVER............................................................... 6-36.1.4 FRONT COVER AND OPERATION PANEL.................................... 6-36.1.5 TOP COVER AND TOP REAR COVER .......................................... 6-4

6.2 INSIDE THE MAIN UNIT .......................................................................... 6-56.2.1 GENERAL CAUTIONS .................................................................... 6-56.2.2 ID SENSOR ..................................................................................... 6-66.2.3 CALIBRATING THE ID SENSOR .................................................... 6-76.2.4 PCU SET SWITCH/CHARGE CORONA UNIT SET SWITCH/PCU RESET SENSOR/ USED TONER NSOR/ QUENCHING LAMP ......................................................................... 6-86.2.5 PULL-OUT SENSOR/PAPER END SENSOR ................................. 6-9

Pull-out sensor ..................................................................................... 6-9Paper end sensor................................................................................. 6-9

6.2.6 OIL END SENSOR/EXIT COVER SWITCH................................... 6-106.2.7 FRONT COVER SAFETY SWITCH, PCU MOTOR, MAIN MOTOR................................................................................ 6-116.2.8 TRANSFER BELT CLEANING SOLENOID/DEVELOPMENT DRIVE SOLENOID ........................................................................ 6-126.2.9 ADJUSTING THE DEVELOPMENT COUPLING JOINT................ 6-136.2.10 PCU DRIVE UNIT ........................................................................ 6-146.2.11 REVOLVER MOTOR ................................................................... 6-156.2.12 DTM UNIT.................................................................................... 6-16

6.3 LASER OPTICS SECTION..................................................................... 6-176.3.1 LD UNIT ......................................................................................... 6-176.3.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR ............ 6-19

6.4 FUSING SECTION ................................................................................. 6-226.4.1 FUSING UNIT ................................................................................ 6-226.4.2 OIL SUPPLY UNIT, PRESSURE ROLLER LAMP, HOT ROLLER LAMP, PRESSURE ROLLER THERMOFUSE, PRESSURE ROLLER THERMISTOR........................................... 6-23

Reinstallation...................................................................................... 6-266.4.3 OIL SUPPLY ROLLER, OIL SUPPLY SUB-ROLLER, BLADE ...... 6-276.4.4 PAPER EXIT SENSOR, CLEANING ROLLER .............................. 6-29

Paper exit sensor ............................................................................... 6-30Cleaning roller .................................................................................... 6-30

6.4.5 PRESSURE ROLLER, HOT ROLLER, HOT ROLLER THERMOFUSE, HOT ROLLER THERMISTOR ............................. 6-316.4.6 CHECKING AND ADJUSTING THE FUSING NIP WIDTH............ 6-33

G024 VI SM

Troubleshooting ..................................................................................6-346.5 ELECTRICAL WIRING ............................................................................6-35

6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR ..6-356.5.2 POWER SUPPLY UNIT..................................................................6-366.5.3 HIGH VOLTAGE SUPPLY UNIT ....................................................6-386.5.4 MCU ...............................................................................................6-396.5.5 UPGRADING THE MCU FIRMWARE ............................................6-40

6.6 PAPER FEED SECTION.........................................................................6-416.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR......6-416.6.2 PAPER WIDTH DETECTION BOARD ...........................................6-426.6.3 BY-PASS PAPER FEED ROLLER .................................................6-436.6.4 PAPER FEED ROLLER..................................................................6-446.6.5 PCU HOLDER ................................................................................6-456.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS

PAPER FEED CLUTCH, REGISTRATION CLUTCH, ANDTRANSFER ROLLER CLUTCH ....................................................6-46

Transfer roller position sensor.............................................................6-47By-pass paper feed clutch ..................................................................6-47Registration clutch ..............................................................................6-47Transfer roller clutch ...........................................................................6-47

6.6.7 TRANSFER ROLLER .....................................................................6-486.6.8 REGISTRATION ROLLER IDLER..................................................6-486.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE

ROLLER ..........................................................................................6-496.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH,

AND PULL-OUT/RELAY ROLLER CLUTCH ................................6-50Paper size switch ................................................................................6-50Paper feed clutch ................................................................................6-50Pull-out clutch .....................................................................................6-51Relay roller clutch ...............................................................................6-51

TROUBLESHOOTING

7. TROUBLESHOOTING ................................................................. 7-17.1 SC TABLES...............................................................................................7-1

7.1.1 TYPES OF SERVICE CALL .............................................................7-17.1.2 SC ERROR LIST ..............................................................................7-27.1.3 PROCESS CONTROL ERROR LIST ...............................................7-6

7.2 USER ERROR LIST ..................................................................................7-87.3 FIRMWARE HISTORY ............................................................................7-13

500-SHEET PAPER TRAY UNIT (G908)

1. OVERALL MACHINE INFORMATION.......................................... 8-11.1 SPECIFICATIONS.....................................................................................8-11.2 PARTS LAYOUT .......................................................................................8-2

Rev. 08/2000

SM VII G024

2. DETAILED SECTION DESCRIPTIONS........................................ 8-32.1 OVERVIEW .............................................................................................. 8-3

2.1.1 MECHANICAL LAYOUT .................................................................. 8-32.1.2 CONFIGURATION........................................................................... 8-4

2.2 MECHANISMS.......................................................................................... 8-52.2.1 DRIVE.............................................................................................. 8-52.2.2 PAPER FEED AND SEPARATION.................................................. 8-62.2.3 TRAY LIFT ....................................................................................... 8-72.2.4 PAPER END DETECTION............................................................... 8-72.2.5 SIZE DETECTION ........................................................................... 8-82.2.6 VERTICAL TRANSPORT ................................................................ 8-9

2.3 CIRCUITS............................................................................................... 8-102.3.1 BLOCK DIAGRAM ......................................................................... 8-10

3. REPLACEMENT AND ADJUSTMENT...................................... 8-123.1 PAPER FEED ROLLER.......................................................................... 8-123.2 FRICTION PAD AND PULL-OUT IDLE ROLLER ................................... 8-13

Friction pad ........................................................................................ 8-13Pull-out idle roller ............................................................................... 8-13

3.3 PAPER END SENSOR AND PULL-OUT SENSOR................................ 8-14Paper end sensor............................................................................... 8-14Pull-out sensor ................................................................................... 8-14

3.4 TOP COVER........................................................................................... 8-153.5 PAPER FEED CLUTCH AND PAPER SIZE SWITCH............................ 8-16

3.5.1 PAPER FEED CLUTCH................................................................. 8-16Paper size switch ............................................................................... 8-16

3.6 PULL-OUT DRIVE ROLLER................................................................... 8-173.7 TRAY MAIN MOTOR AND TRAY CONTROL BOARD........................... 8-18

Tray main motor ................................................................................. 8-18Tray control board .............................................................................. 8-18

8.3 BASIC OPERATIONS............................................................................... 8-38.3.1 OVERVIEW...................................................................................... 8-38.3.2 LED FUNCTIONS ............................................................................ 8-38.3.3 SWITCH FUNCTION ....................................................................... 8-4

NVRAM Reset Procedure .................................................................... 8-48.3.4 NETWORK SETTING INFORMATION ............................................ 8-5

�IMPORTANT SAFETY NOTICESPHYSICAL 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 evenif the main switch is turned off.

4. If an adjustment or operation check must be made requiring the removal oropening of the exterior covers while the main switch is on, keep hands awayfrom any electrically or mechanically driven components.

5. The printer drives some of its components when it completes the warm-upperiod. Keep hands away from mechanical and electrical components whenthe printer starts operation.

6. The interior and metal parts for the fusing unit become extremely hot whilethe 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 thespecified maintenance intervals.

3. Toner is non-toxic, but if it gets in your eyes by accident, it may causetemporary eye discomfort. Remove it with eye drops or flush eyes withwater. If this is unsuccessful, get medical attention immediately.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do NOT incinerate toner cartridges, development toner magazine (DTM) orused toner. Toner dust may ignite suddenly when exposed to an openflame.

2. Dispose of used toner bottle and photoconductor unit (PCU) in accordancewith local regulations. (These are non-toxic supplies.)

3. Dispose of replaced parts in accordance with local regulations.

LASER SAFETYThe Center for Devices and Radiological Health (CDRH) prohibits the repair oflaser-based optical units in the field. The optical unit can only be repaired in afactory or at a location with the requisite equipment. The laser subsystem is onlyreplaceable in the field by a qualified Customer Engineer. The laser chassis is notfield repairable. Customer engineers are therefore directed to return all chassis andlaser subsystems to the factory or service depot when the optical subsystemrequires replacement.

�WARNINGUse of controls, or adjustment, or performance of procedures other thanthose specified in this manual may result in hazardous radiation exposure.

�WARNINGWARNING: Turn OFF the main switch before attempting any of the

procedures in the Optical Unit section. Laser beams canseriously damage your eyes.

CAUTION MARKING:

Trademarks

Microsoft, Windows 98/95/3.1x, and Windows NT 4.0 are registered trademarks ofMicrosoft 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 betrademarks of their respective companies. We disclaim any and all rights in thosemarks.

G024OVERALL MACHINE INFORMATION

CONTROLLER OVERALL MACHINE INFORMATION

G024 Fiery 500 Version Service Manual


CONTROLLER DETAILED DESCRIPTIONS

INSTALLATION

CONTROLLER INSTALLATION


CONTROLLER SERVICE TABLES


CONTROLLER PERIODIC MAINTENANCE


CONTROLLER REPLACEMENT AND ADJUSTMENT

TROUBLESHOOTING

CONTROLLER TROUBLESHOOTING

500 - SHEET PAPER TRAY UNIT G908

CONTROLLER NETWORK INTERFACE BOARD TYPE

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Rev. 7/99

G047/G048

OVERALL INFORMATION

CONTROLLER DETAILED DESCRIPTIONS


CONTROLLER INSTALLATION

INSTALLATION

CONTROLLER SERVICE TABLES

SERVICE TABLES

CONTROLLER PERIODIC MAINTENANCE


CONTROLLER REPLACEMENT AND ADJUSTMENT


CONTROLLER TROUBLESHOOTING

TROUBLESHOOTING

CONTROLLER NETWORK INTERFACE BOARD

CONTROLLER OVERALL INFORMATION

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OVERALL INFORMATION

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SPECIFICATIONS

SM 1-1 G024

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS

Configuration Desk top

Print Process Dry electrostatic transfer system

Resolution 600 dpi

Paper Size Standard trayShort 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 (selectableby 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 labelsOHP transparency mode: OHP transparencies

First Printout Time Color: Less than 30 seconds (A4)Monochrome: Less than 14 seconds (A4)

Print Speed Color: 5 ppm (A4/81/2" x 11")Monochrome: 17 ppm (A4/81/2" x 11")

Warm-up Time Less than 450 seconds (at 23°C/73°F)

Paper Capacity 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.)

Paper OutputCapacity

250 sheets (A4/81/2" x 11" sized paper or less)100 sheets (Greater than A4/81/2" x 11"sized paper)

Output Method Face down

Power Supply 120 Vac, 60 Hz, 10 A220 to 240 Vac, 50/60 Hz, 5.2 A

Rev. 7/99

SPECIFICATIONS

G024 1-2 SM

Power Consumption Maximum: Less than 1200 WAverage during printing: Less than 750 WStandby mode: Less than 150 WEnergy saver mode: Less than 45 W

Noise Emission(Sound PowerLevel)

Stand-by: Less than 43 dBOperating: Less than 64 dB (without paper tray unit) Less than 66 dB (with paper tray unit)

Dimensions 660 x 625 x 475 mm (26" x 24.6" x 18.7")(without paper tray unit)

Weight Approximately 62kg (136.7lb.)

Toner(Type 305)

Black DTM (G756) EDP# - 400338Yellow DTM (G757) EDP# - 400341Magenta DTM (G758) EDP# - 400340Cyan DTM (G759) EDP# - 400339

Options Paper Feed Unit Type 305 (Paper Tray Unit) – up to two ofthese 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

Product Code RICOH SAVIN GESTETNER

G024 AP305 SLP517C C7005W

G908 Paper Feed UnitType 305

Paper Feed UnitType 305


G503 Ricoh-Script2Type 305

Ricoh-Script2Type 305

Ricoh-Script2Type 305

G678 Network InterfaceBoard Type 305

Network InterfaceBoard Type 305

Network InterfaceBoard Type 305

G660 IEEE 1284 Type 305 IEEE 1284 Type 305 IEEE 1284 Type 305

G688 Memory Unit Type204 (16 & 32MB)

Memory Unit Type204 (16 & 32MB)

Memory Unit Type204 (16 & 32MB)

Rev. 6/10/99

Rev. 7/99

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MECHANICAL OVERVIEW

SM 1-3 G024

1.2 MECHANICAL OVERVIEW

1.2.1 IMAGE FORMATION PROCESS OVERVIEW

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

G024V151.WMF

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MECHANICAL OVERVIEW

G024 1-4 SM

(1) OPC belt

The OPC (organic photoconductor) belt is the central part of the machine. This iswhere the laser beam "writes" an image of the original.

(2) Charge

In the dark, a negative corona discharge charges the OPC belt. The grid ensuresthe 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 andreaches the OPC belt. The beam discharges the areas of the OPC belt that itilluminates. Turning the laser beam on and off, and varying the intensity of thebeam, creates a latent image on the OPC belt.

(4) Development

The development section consists of four independent development units, one foreach color (Y, C, M, and K) and the structure necessary to support them. Thesemodules are known as DTMs (Development Toner Magazines).

This unit forms visual images by allowing toner to adhere to portions of the OPCbelt where negative potentials are lower than the development bias. In thismachine, monocomponent toner is used (there is no carrier).

In black single-color mode (1C), the image is developed in K only. In full colormode (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, aresuper-imposed onto each other on the transfer belt. The combined image is thentransferred to the paper.

(6) Transfer belt cleaning

A cleaning brush applies lubricant to the transfer belt to improve cleaning. Then, ablade 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 rollerat 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 ontothe paper.

(9) Belt transfer (primary transfer)

A charge applied to the bias roller attracts toner from the OPC belt onto the transferbelt.

(10) ID sensor

The ID sensor detects the density of the ID sensor pattern on the transfer belt. TheID sensor outputs determine the process control conditions.

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MECHANICAL OVERVIEW

SM 1-5 G024

(11) OPC belt cleaning

A cleaning brush applies lubricant to the OPC belt to improve cleaning. Then, ablade 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 redLED. This quenches the residual potential on the OPC belt, in preparation for thenext image.

MECHANICAL OVERVIEW

G024 1-6 SM

1.2.2 TRANSFER

An image is formed on the OPC belt in four colors, one color at a time. Theresulting 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 isfinally transferred to the paper.

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Forming a visualimage on the OPCbelt

Transferring theimage onto thetransfer belt

Turning the transferbelt

Depositing Ytoner on thebelt

Depositing Ctoner after Y

Depositing Mtoner after Yand C

Depositing Ktoner after Y,C, and M

Transferring the imageon the transfer belt ontothe paper (the papertransfer side is theopposite side from theOPC belt)

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MECHANICAL OVERVIEW

SM 1-7 G024

1.2.3 CHARGE CORONA UNIT VOLTAGES

The charge corona wire receives a constant current (C) of – 700 µA(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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OPC belt

Cleaning blade

Charge grid

Quenchinglamp

Charge corona unit

G = –600 V

C = –700 µA(About –5000 V)

MECHANICAL OVERVIEW

G024 1-8 SM

1.2.4 DEVELOPMENT UNIT BIAS VOLTAGES

Each development unit contains a supply roller and a development roller. Theserollers are conductive. The voltage applied to the supply roller (SB) depends on theprocess control results. The other voltages in turn all depend on SB, as describedbelow.

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.

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Supply roller

Developmentroller

OPC belt

Development blade

Toner

180 VAC equivalent

BL = –480 V

SB = –348 V

68 V

BL = –480 VAC180 V

(400 Vp-p)2 kHz

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MECHANICAL OVERVIEW

SM 1-9 G024

1.2.5 TRANSFER BIAS VOLTAGES

Primary transfer (from OPC belt to transfer belt)

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

Secondary transfer (from transfer belt to paper)

A constant +16 µA current (TC) is supplied to the paper transfer roller (at about 1.8kV) to attract the toner from the transfer belt.

The machine adjusts the transfer current automatically for variations intemperature, humidity, paper size, and paper thickness.

After a paper jam has occurred, the paper transfer roller must be cleaned. Positiveand negative currents are supplied alternately to repel any particles that may be onthe roller as a result of a paper jam.

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Paper transfer roller

TC– = –16 µA(About –1.1 kV)

Transfer belt

Toner

OPC belt

Bias roller

TC+ = +16 µA(About +1.8 kV)

TB = 800 V

MAIN UNIT LAYOUT

G024 1-10 SM

1.3 MAIN UNIT LAYOUT

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 traypaper feed mechanism

10. Development unit

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MAIN UNIT LAYOUT

SM 1-11 G024

(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 separationBy-pass tray: FRR method

(10) Development unit

• Development method: Monocomponent non-magnetic toner• Development unit changeover: Revolver method• Toner replenishment: DTM change

PARTS LAYOUT

G024 1-12 SM

1.4 PARTS LAYOUT

1.4.1 MECHANICAL COMPONENT LAYOUT

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

SM 1-13 G024

1.4.2 DRIVE LAYOUT

1. Main motor

2. Fusing drive input gear

3. Fusing drive gear

4. Transfer belt toner collection drivegear

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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PARTS LAYOUT

G024 1-14 SM

1. PCU pulley

2. PCU motor

3. OPC drive relay gear

4. OPC drive gear

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PARTS LAYOUT

SM 1-15 G024

1.4.3 SENSORS

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


12. Toner end sensor

13. Revolver H.P. sensor

14. Development toner magazine(DTM) set sensor

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PARTS LAYOUT

G024 1-16 SM

1.4.4 SWITCHES

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

SM 1-17 G024

1.4.5 MOTORS, CLUTCHES, AND SOLENOIDS

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


10. Relay roller clutch

11. By-pass feed clutch

12. Registration clutch


14. By-pass feed solenoid

15. Charge inlet fan

16. Inlet fan

17. Transport fans

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PARTS LAYOUT

G024 1-18 SM

1.4.6 PCBS AND PSU

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

SM 1-19 G024

1.4.7 THERMISTORS, HEATERS, AND FUSES

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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SYSTEM BLOCK

G024 1-20 SM

1.5 SYSTEM BLOCK

1.5.1 BLOCK DIAGRAM

PSU

CPU

ROM NVRAM DRAM

I/O

FIFO

PatternGeneration

MotorControl

Video I/FGAVD/PLLC

High VoltageSupply Board

ADC

PWM

FusingControl

FusingUnit

SolenoidsClutches

LDModulation

Control

PrinterController

RevolverMain MotorPCU Motor

ASIC

MCU

ID Sensor

OperationPanel

Selector

IC Card AMDG

Thermistor

HumiditySensor

D/A

Sensors

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ELECTRICAL COMPONENT LIST

SM 1-21 G024

1.6 ELECTRICAL COMPONENT LIST

1.6.1 SENSORS

Symbol Name Function Index No.S19 Exit sensor Detects exiting paper. 1S17 Oil end sensor Detects oil in the oil pan. 2

S14 Transfer belt H.P.sensor

Detects the marks on the transfer belt. 3

S11 Transfer rollerposition sensor

Detects when the transfer rollercontacts the transfer belt. 4

S2 Used toner sensor Detects when the used toner tank is full. 5

S4 PCU reset sensor Detects when a new PCU has just beeninstalled. 6

S5 Paper end sensor Detects when paper in the first tray hasrun out.

7

S8 ID sensor Detects the toner pattern density on thetransfer belt. 8

S6 Pull-out sensor Detects paper fed from the paper tray. 9

S10 By-pass paper endsensor

Detects paper in the by-pass tray. 10

S15 Registration sensor Detects paper at the registration roller. 11

S12 Toner end sensor Detects whether there is toner in theDTM.

12

S13 Revolver H.P.sensor

Detects when the revolver is at homeposition.

13

S16 DTM set sensor Detects whether a DTM has beeninstalled. 14

1.6.2 SWITCHES

Symbol Name Function Index No.SW1 Main switch Makes and breaks the 120/230 VAC

input power.1

SW2 Exit cover switch Detects when the exit cover isopened/closed. 2

SW3 Front cover safetyswitches

Makes and breaks 24 VDC and LD5V. 3

S7 Paper size switch Detects the paper size in the standardtray set on the dial by the user.

4

S1 PCU set switch Detects whether the PCU and usedtoner tank are installed. 5

S3 Charge corona unitset switch

Detects whether the charge corona unitis installed. 6

SW4 DTM cover switch Detects when the DTM cover isopened/closed.

7


G024 1-22 SM

1.6.3 MOTORS

Symbol Name Function Diag. No.

M4 Main motor Drives the paper feed mechanisms,fusing unit, and development roller.

4

M2 PCU motor Drives the OPC belt and transfer belt. 2M1 Revolver motor Drives the revolver (development). 5

M3 Polygon mirrormotor

Drives the polygon mirror. 6

1.6.4 SOLENOIDS


SOL1 By-pass feedsolenoid

Releases the by-pass tray pull-outroller.

14

SOL2Transfer beltcleaning solenoid

Moves the transfer belt cleaning unitinto contact and away from the transferbelt.

3

SOL3 Development drivesolenoid

Connects the development unit drivemechanism to the main motor.

7

1.6.5 CLUTCHES

Symbol Name Function Diag. No.CL5 Pull-out clutch Controls the pull-out roller drive. 8

CL2 Paper feed clutch Controls the first tray paper feed rollerdrive. 9

CL3 Relay roller clutch Controls the relay roller drive. 10

CL1 By-pass feed clutch Controls the by-pass tray paper feedroller drive. 11

CL4 Registration clutch Controls the registration roller drive. 12

CL6 Transfer rollerclutch

Moves the transfer roller into contactand away from the transfer belt.

13

1.6.6 FANS


FM2 Exhaust fan Expels air from inside the printer; ozoneis broken down by an ozone filter 1

FM5 Charge inlet fan Prevents ozone from being trapped inthe charge corona unit. 15

FM4 Inlet fan Ventilates and cools the printer. 16

FM1FM3

Transport fan Applies a downward draw to the backside of the paper after image transfer,guiding the paper to the fusing unitentrance.

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SM 1-23 G024

1.6.7 CIRCUIT BOARDS AND POWER SUPPLIES

Symbol Name Function Diag. No.PCB1 Power supply

unit (PSU)Supplies low-voltage power (5 VDC and 24VDC) and ac power to the fusing unit.

1

PCB8 Controller board Houses the controller, host interface,engine interface, and image generator. 2

PCB3 High voltagesupply board

Supplies high voltages for charge,development, and transfer. 3

S9 Temperature/humidity sensor

Detects temperature and humidity. 4

PCB2 Main control unit(MCU)

Houses the controller interface and enginecontroller. 5

PCB4 Lasersynchronizationdetector board

Detects the laser main scansynchronization beam from the polygonmirror.

6

L3 Quenching lamp Quenches the OPC by exposing it to light. 7PCB6 By-pass paper

width detectionboard

Detects the paper width in the by-passfeeder. 8

PCB5 Laser diode (LD)unit

Controls laser beam output. 9

PCB7 Operation panel Displays information and allows access tofunctions. 10

1.6.8 THERMISTORS


TH1 Pressure rollerthermistor

Detects the pressure roller temperature. 1

TH2 Hot rollerthermistor

Detects the hot roller temperature. 4

1.6.9 FUSES


TF2 Pressure rollerthermofuse

Provides protection against abnormalheating (250 VAC, 10 A, 167°C).

6

TF1 Hot rollerthermofuse

Provides protection against abnormalheating (250 VAC, 10 A, 167°C). 3

1.6.10 LAMPS


L2 Pressure rollerlamp

Heats the pressure roller (120/230 VAC,400 W)

2

L1 Hot roller lamp Heats the hot roller (120/230 VAC, 600 W) 5

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PROCESS CONTROL

SM 2-1 G024

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 controladjusts the following two parameters.

• Development bias (VB): This is adjusted to maintain a constant image density insolid areas

• Charge corona grid voltage (VG): This is adjusted to maintain a constant imagedensity in low image density (highlight) areas.

To monitor the machine's condition, only the ID sensor is used. There are no tonerdensity or potential sensors.

The ID sensor monitors the density of standard sensor patches made on thetransfer belt.

This printer uses a single-component (or mono-component) toner. Unlike printersbased on a two-component (or dual component) toner, this printer does not requireany toner density control system.

PROCESS CONTROL

G024 2-2 SM

2.1.2 ID SENSOR

The ID sensor consists of two separate sensors. For detecting the density of blacktoner patterns, there is a straight reflection sensor for K toner (this is the type ofsensor normally used in black-and-white copiers), and for colored toner there is adiffused light sensor. Both sensors share the same LED, but have separate lightreceivers for K and color toners. However, the LED current (light intensity) used fordetecting black toner is different from the one used to detect colored toner.

As shown in the diagram, the output from the straight reflection sensor decreasesas the amount of attached toner (M/A: mass/area or density) increases. This isbecause black toner is blocking the reflection of light back into the sensor from thetransfer belt (the transfer belt itself is black, but it is reflective). However, thediffused light sensor output increases for higher M/A, because colored toner isreflective.

The diffused light sensor is more accurate for detecting colored toner, no matterhow much or how little toner is present. However, if the amount of toner on thetransfer belt is small, the low level of reflected light means that without an initialcalibration, the error in detection could be very great.

The diffused light sensor cannot be used for black toner, because there is littledifference between the diffuse light reflected from black toner and from the transferbelt surface.

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Straight ref lect iondetect ion curve

Amount of at tached toner (M/A, mg/cm 2 )

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PROCESS CONTROL

SM 2-3 G024

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 uponwhich one of the seven events has occurred. The steps that are done for eachevent are given in the 'Steps done' column of the table below.

c ID sensor calibration

d K development bias initialization

e Color development bias initialization

f Charge grid bias voltage adjustment

g Y, C, M, and K bias fine adjustment

h Process control interval counter reset

Event Condition Steps doneForced processcontrol

When forced process control is done (engineSP mode 7. Process Ctrl - Initialize)

c through h

Process controlregular interval

When more than 100 sheets in 4C mode (oran equivalent number of sheets in anothermode) have been printed upon completion ofa job. (The interval can be changed withengine SP 7 Process Control – Interval Set)

c, f, g, h

Power on When the fusing temperature is 80°C or lowerjust after the power is turned on.

c, �, f throughh

Environmentalchange

When the change in the temperature/humiditysensor output since the previous processcontrol exceeds a certain value

c, �, f throughh

K-DTM(DevelopmentToner Magazine)replacement

This is done after clearing the K-DTM near-end state (i.e., when a new K-DTM is added).The machine idles and when the developmentroller stops for 10 seconds, indicating thatidling is over, process control occurs.

c, �, f

Color DTMreplacement

After the color toner end or near-end state isreset, the machine idles to transfer color tonerto the development unit. After idling, processcontrol occurs.

c through h

PCU replacement After a new PCU is detected, it is lubricated(new PCU lubricant application mode). Thenprocess control occurs.

c through h

PROCESS CONTROL

G024 2-4 SM

Step 1: ID sensor calibration

To calibrate the ID sensor, the light reflected from the bare transfer belt ismeasured. The LED current is adjusted until the sensor output is 2.5 V. Thedetector for black is used for the calibration. The LED current will be adjusted forcolor toner detection, based on the adjustment that was made during thecalibration for the black toner detection.

Calibrating the ID sensor in this way compensates for any changes in the sensor'sresponse caused by changes in transfer belt surface conditions or impurities in theID sensor light source/receiver.

Step 2: K development bias initialization

The machine creates a patch of black toner on thetransfer belt. The specifications for this pattern are asfollows.

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 isadjusted to obtain a M/A of 0.58 mg/cm2 on thetransfer belt for areas of maximum image density. Thisdevelopment bias is called VB.

This step is required when a new machine is installed,or when a black DTM is changed. This is because theamount of toner that adheres to the development rollervaries for each unit. This means that the amount oftoner transferred to the image for a certaindevelopment bias will not be the same.

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

Generate the toner patternon the transfer belt

Detect the density of thetoner pattern by the ID

sensor

Speci fy a development bias(VB ) that ensures a sol id

area toner amount of 0.58m g / c m2

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PROCESS CONTROL

SM 2-5 G024

Step 4: Charge grid bias voltage adjustment

Adjusting the development bias VB controls the density of solid areas on theprintout, and adjusting the charge grid bias VG controls the density of low imagedensity (highlight) areas. These two biases maintain a consistent γ (gamma) for theengine.

To adjust VG, the machine makes another pattern on the transfer belt. The IDsensor detects the density of this pattern. Based on the result, the machine adjuststhe grid bias voltage.

The figure on the right shows the pattern formed onthe transfer belt during this process. The pattern is20 mm (main scan) x 40 mm (sub scan), andconsists of a repeating pattern of two pixels madewith an LD intensity of 240 surrounded by pixels withno LD intensity, as shown in the opposite diagram.This is very pale, and suitable for calibrating the lowID point of the engine’s gamma.

If the density of low image areas is not acceptable, adjust the target ID sensoroutput for this sensor pattern with engine SP mode 12 (High-light adj). Then do aforced 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 tothe table at the beginning of this chapter, 2.1.3). Because of this, the solid areadensity, based on the VB obtained during initialization, may change as a result ofchanges inside the machine after a period of use, or because of environmentalchanges. To suppress these fluctuations, this step "fine-tunes" VB at regularintervals, or if the environmental conditions change. The method is describedbelow.

An ID sensor pattern is formed on the transfer belt based on the most recentlymeasured VB for each toner color. The ID sensor then reads the pattern formed.VB changes in accordance with the difference between the ID sensor outputsduring this process and during the initial calibration.

The change in VB is restricted to a certain range, so that the density does not varywidely after process control. However, this restriction does not apply to the processcontrol executed when fluctuations in the output from the temperature/humiditysensor 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. Thecounter is reset at the end of process control. If power is shut down or if the coveris opened during a process control operation, terminating the process controloperation, the process control restarts from the beginning upon recovery. Thecounter is not reset when process control is performed for K-DTM replacement.

0 0 0240 240 00 0 0

PCU (PHOTOCONDUCTOR UNIT)

G024 2-6 SM

2.2 PCU (PHOTOCONDUCTOR UNIT)

2.2.1 OVERVIEW

The PCU consists of an OPC* section, a primary (belt) transfer section, and a usedtoner 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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SM 2-7 G024

2.2.2 COMPONENTS

Section Component Overview

Cleaning unitThe main motor (a brushless DC motor)drives the used toner collection unit and thecleaning unit.

Drive mechanism

Belt driveThe PCU motor (an externally synchronizedbrushless DC motor) drives the OPC beltand the transfer belt.

OPC belt 292 mm in circumference.

Cleaning unit A counter blade scrapes the OPC belt toremove excessive toner.OPC

Lubricant bar This applies lubricant to the OPC surface toimprove toner removal.

Charge corona unitThe scorotron corona wire inside the chargecorona unit evenly charges the OPCsurface.Charge corona unit

Charge inlet fan The charge inlet fan blows air into thecharge corona unit to disperse ozone.

Transfer beltThe toner image on the OPC belt istransferred onto the transfer belt. Later it willbe transferred to the paper from the belt.

Transfer bias The transfer bias attracts the toner from theOPC to the transfer belt surface.

Cleaning unit A counter blade scrapes the transfer belt toremove toner.

ID sensorThe ID sensor detects the density of theblack and color patterns on the transfer beltsurface.

Primary transfersection

Lubricant barThis applies lubricant to the transfer beltsurface to improve toner separation from thebelt.

Used toner tank This collects the used toner from the OPCbelt and transfer sections.

Used tonerUsed toner sensor The used toner sensor detects when the

used toner tank is full.

Quenching Quenching lampLight from a red LED removes residualcharge from the OPC belt in preparation forreceiving the next image.


G024 2-8 SM

2.2.3 DRIVE MECHANISMS

Belt drive

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 thesame speed.

The two couplings (for the transfer belt [G] and the OPC [H]) engage when the frontcover [I] is closed. When the front cover is closed, the two actuators [J] on the innerside of the cover push the coupling levers [K].

G024D602.WMF

G024D194.WMF

[A]

[B]

[C]

[D]

[E]

[D]

[G]

[H]

[I]

[J]

[K]

[F]

[K]

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SM 2-9 G024

Used toner collection drive

The main motor drives the used toner collection process. There are twomechanisms, 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 tonercollection 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 mmintervals (one full rotation of the transfer belt is 588 mm).

The number of transfer belt revolutions differs between single-color black (K) modeand 4C (YCMK) mode, as shown in the following table.

Print mode RevolutionsSingle-color black (K) (Paper length + 4 marks)/588

4C mode (YCMK) 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.

G024D604.WMF

[A]

[B]

[C]

[D]

[E]

[F]


G024 2-10 SM

Transfer belt speed

4C mode (color printing)

For color printing, the machine places two pages at a time on the transfer belt if theimage size is LT long edge feed or smaller (width: 216 mm to 148 mm), except forthe 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 atdouble speed to move the non-image area past the image transfer point (from OPCto transfer belt). This shortens the total printing time.

For printing on transparencies or on thick paper, the paper transfer and fusing unitspeeds 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 unitspeeds slow to 1/2 speed to improve paper transfer and fusing.

One revolut ion of the transfer belt(39.2 x 15 = 588)

LT long edge feed two- image pr int

A3 one- image pr int

LT long edge feed one- image pr int

Single-color black print

Double-speedrevolution

4 marks

216 40

376.8

506.8

Uni t : mm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1

G024D517.WMF

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SM 2-11 G024

2.2.4 TRANSFER VOLTAGE SUPPLY

The high voltage board [A] supplies the belt transfer voltage to the PCU throughthe connector [B], then the coil spring electrode [C] and finally the bias roller [D] tothe transfer belt [E].

Opening the front cover separates the coil spring electrode from the PCU.

G024D157.WMF

[A]

[B]

[C]

[D]

[E]


G024 2-12 SM

2.2.5 CHARGE CORONA UNIT

The charge corona unit [A] supplies a negative charge to the OPC using a singlescorotron corona wire. The coil spring electrode [B] supplies the voltage as soon asthe 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 wireand grid.

The high voltage board applies a constant current (-700 µA) to the charge coronawire. The grid (a stripe-pattern type grid) receives a constant voltage, whichdepends on the results of process control (the default setting is -600 V).

G024D605.WMF

G024D607.WMF

[A]

[B]

[C]

[D]

Electrode for the grid

Electrode for the wire

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SM 2-13 G024

2.2.6 OPC BELT

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] lubricatesthe OPC belt with zinc stearate, by using a spring to apply pressure to the lubricantbar [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 theused toner collection opening [G] in directions [H] and [I]. The toner then falls intothe used toner tank [J].

G024D156.WMF

G024D616.WMF

[A]

[B]

[C]

[D]

[E]

[F]

[G]

[H]

[I]

[J]


G024 2-14 SM

2.2.7 PRIMARY TRANSFER

Voltage application

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 andhumidity 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].

G024D155.WMF

[A]

[B]

[C]

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SM 2-15 G024

Transfer belt cleaning

When the cleaning brush [A] is moved into contact with the transfer belt [B], frictioncaused by the pressure from this contact turns the cleaning brush. The lubricantbar [C], due to its weight, presses against the cleaning brush which applieslubricant 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 bladesystem) removes the toner from the transfer belt.

The transfer belt toner collection auger [E] carries the removed toner to the left endof 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 imagesare forming. (In single-color black mode, the cleaning unit is in constant contactwith 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].

Prim ary transfer Solenoi d ON/OFF Cleaning u nitcontact/separation

Y OFF ContactC ON SeparatedM ON Separated

4C mode

K ON SeparatedSingle-color black

modeOFF Contact

G024D154.WMF

G024D153.WMF

[A]

[B]

[C]

[D]

[E]

[H]

[F]

[G]


G024 2-16 SM

2.2.8 USED TONER TANK

The used toner tank [A] has a shutter mechanism [B]. When the used toner tank isplaced in the PCU, a protrusion [C] on the PCU opens the shutter. When the tankis removed from the PCU, the spring (under tension) in the shutter cover pulls andcloses the shutter.

The toner collection auger (inside the tank) transports the toner falling into the usedtoner 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 themachine stops printing (used toner tank “full” condition).

G024D611.WMF

G024D612.WMF

[A][B]

[C]

[D]

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SM 2-17 G024

2.2.9 PCU DETECTION

The PCU set switch [A] is installed on the main unit (printer mainframe) under thebottom center of the PCU. The used toner tank (waste tank) case presses the PCUset switch and the presence of the PCU is detected. If the PCU is not detected, thedisplay indicates, "Reset PCU Correctly." Additionally, when the used toner tank isabsent, the PCU set switch detects that the used toner tank is missing anddisplays, "Reset Waste T Bottle Correctly."

2.2.10 CHARGE CORONA UNIT DETECTION

The main unit (printer mainframe) has a switch [A] to detect the presence of thecharge corona unit. If the charge corona unit [B] is installed in the PCU, the chargecorona unit activates this switch. The switch actually detects the sliding cleaner forthe grid and charge corona wire. So, if the user has not put the sliding cleaner fullyback into its home position, the LCD will display an error message.

G024D613.WMF

G024D158 WMF

[A]

[A]

[B]


G024 2-18 SM

2.2.11 BELT MARK DETECTION

There are 15 belt marks [A] on the right edge of the transfer belt. The transfer belthome position sensor [B] (a reflective photosensor) located on the front cover unitis used to detect these marks. This detection process is performed so as toproperly align the laser exposure start position in the sub-scan direction for the nextimage.

In 4C mode, when a printing phase is completed and the transfer belt returns to thewrite start position, the transfer belt moves forward one mark. Laser exposure inthe 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 OPCbelt is prevented.

2.2.12 NEW PCU DETECTION

On a new PCU, the new PCU detection lever [A] at the bottom right is pointingstraight down.

When the PCU reset sensor, located in the main unit, detects the new PCUdetection lever, the PCU counter resets. The main motor drives the new detectionlever via a gear [B] so as to release the sensor from the "new PCU" detection state.

G024D614.WMF

G024D615.WMF

[A]

[B]

[A]

[A]

[B]

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SM 2-19 G024

2.2.13 LUBRICANT APPLICATION MODE

Lubricant application mode for a new PCU

A new PCU does not have used toner on it. Without used toner to act as alubricant, rotation of a new PCU could result in scratches on the OPC belt, damageto the blade, and insufficient cleaning due to friction between the cleaning bladeand 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 transferbelt is also lubricated at this time. However, the transfer belt requires morelubrication than the OPC belt. Therefore, step 2 is done to lubricate the transfer beltwithout applying toner to the OPC.

This process takes place when the machine detects that a new PCU has beeninstalled.

Lubr icant appl icat ion modefor a new PCU

• Output a ful l -color A3 page using internal pattern #6.• Turn off the pr imary transfer bias.• Apply other bias vol tages using the process control values.• Turn off the transfer belt c leaning solenoid (cleaning brush contacts belt).

End

• Free run wi thout laser exposure (24 belt revolut ions - to simulate 6 ful l-color A3 sheets)• Turn off the transfer belt c leaning solenoid (cleaning brush contacts belt).

G024D521.WMF


G024 2-20 SM

Regular lubricant application mode

Lubricant is applied to the OPC and transfer belts when the lubricant applicationcounter reaches "A" (default: 100).

• If the regular lubricant application interval and the process control interval run outat the same time, process control is done first.

• Counting methodColor: 4 counts/printMonochrome: 1 count/print

The lubrication interval ("A" in the flow chart) can be adjusted with the followingengine SP mode:13: Lub_interval

Regular lubr icant appl icat ion mode

Reset the counter .Dr ive the PCU motor and main motor .

Turn of f everything af ter 30 seconds.

End

Lubr icantappl icat ion counter = A

N o

Yes

G024D522.WMF

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VIDEO DATA PROCESSING

SM 2-21 G024

2.3 VIDEO DATA PROCESSING

2.3.1 FLOW CHART

2.3.2 GAMMA COMPENSATION

The controller receives either 8-bit RGB or 8-bit CMYK data from the driver (in thecase of 8-bit RGB data, the controller has to convert this to 8-bit CMYK data beforeimage processing can start). Then, gamma compensation corrects the CMYK data(a combination of the controller gamma and service gamma is used; see DetailedDescriptions – Gamma Correction in the controller service manual).

G a m m acompensat ion

Gradat ionprocessing

VIDEO I /F

A M D G

GAVD I /F

H E M A

Control ler

Eng ine

G024D526.WMF

VIDEO DATA PROCESSING

G024 2-22 SM

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 withthe driver.

After dithering, the data is converted to 4-bit and sent to the engine through thevideo interface.

• 1-bit mode: The output for each pixel after dithering is either 0 or 1. Thisbecomes 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 becomeseither 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 isconverted 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 laserdiode 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 256gradations) to laser power levels.

Smoothing

Smoothing only occurs if the following settings have been made with the printerdriver.

• Resolution: 600 dpi• Color level: 1-bit• Smoothing: Auto

The LD controller smoothes the data to reduce jagged edges. Normally, the laserwrites the colored part of each pixel at the left side of the pixel. However, to smooththe 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

SM 2-23 G024

2.4 OPTICAL UNIT

2.4.1 OVERVIEW

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 DetectorBoard

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 acombination of laser power modulation (PM) and pulse width modulation (PWM).

G024D501.WMF

G024D502.WMF

2

1

345

6

7

8 9

10

11

OPTICAL UNIT

G024 2-24 SM

2.4.2 COMPONENTS

Section Component OverviewLD Wavelength 780 nm, rated power 10 mWLD control board Drives the LD.Collimating lens Makes the laser beams parallel.LD unit

Aperture Prevents the laser beams from expandingbeyond the required beam diameter.

Cylindrical lens Compensates for beam shape irregularities.Polygon mirror Revolving six-sided mirrorPolygon mirror motor Turns the mirror at 23,922 rpm.

F-theta mirror Compensates for dot position irregularitiesin the main scan direction.

BTL Compensates for leaning faces.Mirror Reflects the laser beams.

Laser opticalsystem

Dust shield glass Shields the optical system from dust andtoner.

Synchronizationdetection mirror

Reflects the laser beam to thesynchronization detection board.

Synchronizationdetection Synchronization

detection board

Detects the beam from the synchronizationdetection mirror, synchronizes the laserbeam’s main scan.

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OPTICAL UNIT

SM 2-25 G024

2.4.3 LD UNIT

LD safety switch

A safety switch is provided to prevent accidental laser emission while the frontcover is open for maintenance.

The safety switch is on the +5V DC line from the power supply unit to the LD unitvia the MCU.

When the front cover is opened, the safety switch shuts off the +5V DC line to theLD unit.

LD unit configuration

The LD unit consists of a laser diode (LD) [A], collimating lens [B], aperture [C], andLD control board [D]. The collimating lens focuses the laser beam into anaccurately parallel beam.

The aperture then prevents the beam from expanding beyond the required beamdiameter [E] on the OPC belt.

GND+5V

+24V

Power supplyunit LD unit

MCU+5V INT

+5V

Front cover switch

LD safetyswitch

To the paper exit coverswitch

Front coversafetyswitches

G024D518.WMF

G024D511.WMF

[A] [B][C]

[D]

E

OPTICAL UNIT

G024 2-26 SM

Cylindrical lens

The cylindrical lens concentrates the laser beam from the LD unit and forwards it tothe polygon mirror. The cylindrical lens determines the beam diameter in the sub-scan direction.

Polygon mirror

The polygon mirror [A] is a combined unit consisting of a polygon mirror motor anda mirror. The polygon mirror is six-sided. The mirror surfaces are precisely groundto prevent dot misalignments and to improve reflective efficiency. The polygonmirror motor turns the mirror at 23,922 rpm. Six main scans are performed perpolygon mirror motor revolution.

G024D503.WMF

Thick

Thin

[A]

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OPTICAL UNIT

SM 2-27 G024

F-theta mirror

The distance to the reflective face of the polygon mirror [A] is different at the centerand 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 anequal gap between pixels.

BTL (Barrel Torroidal Lens)

Irregularities in the perpendicular inclination of the mirror faces causes the laserbeam spacing in the sub-scan direction to fluctuate. The BTL compensates for this.

G024D504.WMF

Main scanLaser beamdot

After compensationBefore compensation

G024D505.WMF

Evenly spacedpixels

[B]

[A]

OPTICAL UNIT

G024 2-28 SM

Synchronization detection

A mirror deflects the laser beam from the polygon mirror to the synchronizationdetection board. The detection board responses are sent to the MCU laserexposure controller as synchronization signals for determining the LD exposurestart position across the main scan.

Synchronization detection error

If a synchronization detection signal is not detected within a certain period (about500 µs) after the LD turns on, the MCU assumes that there is a synchronizationdetection error. (SC 43 is displayed.)

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OPTICAL UNIT

SM 2-29 G024

2.4.4 APC (AUTO POWER CONTROL)

Circuit

The LD has a built-in photodiode to monitor the laser beam. The output signalsfrom the photodiode are input to the LD control board, which contains a feedbackcircuit to keep the laser beam at a constant intensity.

LD error

The LD control panel detects abnormal laser power output by monitoring thecurrent flowing in the LD. When the current exceeds 133 mA DC, the LD controlpanel 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 widthmodulation (PWM) and power modulation (PM).

At 600 dpi (if 1-bit mode was selected through the printer driver), the printersmoothes 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.

U1E M AControl s ignal

+5V

LDERR

LDOFF

PD

LD

G024D528.WMF

OPTICAL UNIT

G024 2-30 SM

2.4.6 LASER EXPOSURE TIMING

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 tothe 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 mirrormotor). When the machine is ready to print, the CPU waits for a certain number ofclock cycles. Then, the first time that the MARK goes high after this, FGATE goeshigh after a certain number of PMSYNC signals.

LGATE is generated from the LSYNC (laser main scan synchronization sensorsignal). The main scan registration value determines when LGATE goes high afterLSYNC is detected. Main scan registration adjustment changes the value of "A".

An engine SP mode adjustment (1: Margin) can adjust main scan and sub-scanregistration.

Laser exposure area

Laser exposure area

LGATE timing

FGATE timing

LGATE

LSYNC

Two-image output timing

MARK

PMSYNC

FGATE

FGATE timing

LGATE timing

A

START

G024D507.WMF

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DEVELOPMENT UNIT

SM 2-31 G024

2.5 DEVELOPMENT UNIT

2.5.1 OVERVIEW

1. Revolver motor

2. Revolver gear

3. Hopper

4. Development roller

The development unit consists of independent Y, C, M, and K units (known asdevelopment toner magazines or DTMs) combined with a support unit. Thedevelopment unit rotates clockwise (as seen from the left side of the printer) anddevelops images in the order of Y, C, M, and then K.

G024D169.WMF

1

2

3

4

DEVELOPMENT UNIT

G024 2-32 SM

2.5.2 COMPONENTS


Revolver drive The revolver motor turns the revolver unit.The MCU controls the rotational angle.

RevolverHome positionsensor

Detects when the revolver is at homeposition.

DTM Four colors (Y, C, M, and K)

DTM set sensor The DTM set sensor detects the presence ofa DTM.Toner supply

Toner end sensor The toner end sensor detects the presence oftoner.

Toner supplyThe supply roller supplies toner to thedevelopment roller. The blade forms a thinlayer of toner on the development roller.

DriveThe main motor only drives the developmentunit for the color that is at the developmentposition.

Development

Bias applicationBias is only applied to the development unitfor the color that is at the developmentposition.

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DEVELOPMENT UNIT

SM 2-33 G024

2.5.3 REVOLVER DRIVE

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 leftside. The home position sensor [D] located on the left side panel detects thisprotrusion.

The revolver turns 45 degrees and stops for Y color development, then turns 90degrees for C color development, then another 90 degrees for M colordevelopment. Then, the revolver turns 90 degrees once more for K colordevelopment. After completing development for all four colors, the revolver turns 45degrees to the home position.

G024D900.WMF

G024D529.WMF

YDevelopment

CDevelopment

MDevelopment

KDevelopment

45degrees

90degrees

90degrees

90degrees

45degrees

G024D513.WMF

[C]

[D]

[A]

[B]

DEVELOPMENT UNIT

G024 2-34 SM

2.5.4 DEVELOPMENT UNIT DRIVE

Gears and a coupling joint [A] transfers torque from the main motor [B] to drive thesupply [C] and development [D] rollers.

The coupling only engages while the development drive solenoid [E] is on.

G024D162.WMF

[B]

[C]

[D]

[A]

[E]

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DEVELOPMENT UNIT

SM 2-35 G024

2.5.5 TONER AGITATION

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 thedevelopment roller. When the hopper turns towards the bottom, the toner falls fromthe toner supply port (B). As the revolution continues, the toner is scooped backinto the toner supply port.

G024D167.WMF

A

B

BA

DEVELOPMENT UNIT

G024 2-36 SM

2.5.6 TONER TRANSPORT

The agitated toner passes from the hopper [A] to the supply and developmentrollers.

The supply roller flicker [B] regulates the amount of toner applied to the supplyroller. Then, the rotation of the supply roller [D] transports the toner to thedevelopment roller [C].

The development blade [E] forms an even layer of toner to a specified thickness onthe development roller surface. Negative bias applied to the development bladecharges the toner quickly. This negative charge is applied when the toner passesbetween the development blade and the development roller.

G024D161.WMF

[A]

[B]

[D]

[C]

[E]

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DEVELOPMENT UNIT

SM 2-37 G024

2.5.7 DEVELOPMENT BIAS

The electrode [A] on the main unit side supplies the voltages. The electrode isconnected only while development is in progress. When development for one colorfinishes, the bias transfers to the next color.

G024D166.WMF

G024D165.WMF

Development roller bias

Supply roller bias

Blade bias

KMCY

Revolver revolution

Blade AC bias

G024D514.WMFBias change-over

[A] [A]

Development roller bias: ASupply roller bias: BDevelopment blade bias: C

DEVELOPMENT UNIT

G024 2-38 SM

2.5.8 DTM (DEVELOPMENT TONER MAGAZINE) DETECTION

The DTM sensor [A] detects the presence of a DTM.

The DTM sensor outputs an error detection signal when a toner bottle is notpresent 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 therecovery procedure, ceasing the error condition.

G024D164.WMF

[A]

[B]

Rev. 7/99

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DEVELOPMENT UNIT

SM 2-39 G024

2.5.9 TONER NEAR-END DETECTION

Each toner hopper has a toner monitoring window [A] with two mirrors [B] at a 45-degree angle.

The toner end sensor (a reflective photosensor) [C] detects the toner between thetwo 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 thesensor 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 becomesunacceptable (there is no toner end condition).

G024D163.WMF

Emits l ightReceive l ight

Reflect ingBoard

G024D195.WMF

[A]

[B]

[D]

[C]

DEVELOPMENT UNIT

G024 2-40 SM

2.5.10 DEVELOPMENT TIMING

LT, long edge feed, two-image print mode

Belt mark

Laser exposure

Revolver

Developmentsolenoid

Developmentbias

Belt transfer bias

Change-over Change-over

Y C and M K

G024D515.WMF

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PAPER TRANSFER UNIT

SM 2-41 G024

2.6 PAPER TRANSFER UNIT

2.6.1 OVERVIEW

1. Transfer roller casing

2. Transfer roller springs

3. Transfer roller

4. Antistatic brush

5. Transfer roller position sensor


During the print process, the paper transfer unit makes and "breaks" contact withthe transfer belt.

G024D422.WMF

G024D426.WMF

1

23

4

5

6

PAPER TRANSFER UNIT

G024 2-42 SM

2.6.2 COMPONENTS


Transfer rollerCharges the back side of thepaper to attract toner from thetransfer belt.Transfer

Spring Presses the transfer rolleragainst the transfer belt.

Transfer roller clutchMoves the paper transfer unitinto contact and away fromthe transfer belt.

Contact/separationTransfer rollerposition sensor

Detects whether the papertransfer unit is in contact withor away from the transfer belt.

Bias terminal Connects the transfer roller tothe high-voltage supply board.

BiasConductive bearing

Enables an electricalconnection to the transferroller axle.

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PAPER TRANSFER UNIT

SM 2-43 G024

2.6.3 CONTACT AND SEPARATION

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 transferroller and the transfer belt. The transfer roller position sensor [D] detects thecontact and separation positions. The transfer roller is driven by contact with thetransfer belt.

If the transfer roller contacts the transfer belt (i.e., the transfer roller position sensoris on) just after the main switch is turned on or just after the door safety switch isturned on (i.e., the front cover is closed), the machine assumes a paper jam hasoccurred. The main motor is driven to engage and disengage the transfer rollerclutch, separating the transfer roller from the transfer belt (until the transfer rollerposition sensor is turned off).

G024D159.WMF

Registration clutch

Transfer roller clutch

Transfer bias

71.46 mm

31.5 mm

G024D516.WMF

[C] [B]

[D]

[A]

PAPER TRANSFER UNIT

G024 2-44 SM

2.6.4 BIAS

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 turnsand positive and negative currents are alternately applied. This removes any tonerthat 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 tworevolutions. Then, a positive bias drives the transfer roller for 0.9 revolutionsfollowed by a negative bias for another 0.9 revolutions. The positive/negative 0.9-revolution cycle is done 30 times.

G024D427.WMF

G024D157.WMF

[A]

[B]

[C]

[C]

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PAPER FEED/REGISTRATION UNIT

SM 2-45 G024

2.7 PAPER FEED/REGISTRATION UNIT

2.7.1 OVERVIEW

1. Friction pad


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


14. Registration rollers

G024D191.WMF

1 2

3

4

5

6

7

8

91011121314


G024 2-46 SM

2.7.2 COMPONENTS

Section Main function OverviewPaper feed/separation Friction pad separation methodPaper tray bottomplate pressure

Paper tray bottom plate lifts by a spring

Paper end detection Detection by a feeler and photo-interrupterPaper tray

Paper size detection User-specified by a dial; detected byswitches

Paper feed/separation FRR methodPaper end detection Detection by a feeler and photo interrupterBy-pass feed

tablePaper size detection Width detection by a circuit boardRegistration transport Drive transfer by electromagnetic clutchRegistration detection Detection by reflective photosensorRegistrationVertical transport Transport by roller

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SM 2-47 G024

2.7.3 STANDARD TRAY

Drive

Drive from the main motor is transferred from a timing belt to the paper feed drivegear [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 driveto the roller at the correct time.

G024D192.WMF

[A]

[B]

[C]


G024 2-48 SM

Paper feed/separation

The paper tray uses a friction pad [A].

A compressed spring [B] pushes the friction pad up from the bottom, providingconstant 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 thenfeeds the sheet to the registration roller. When the registration sensor detects thesheet, the machine feeds the paper another 28 mm, then the relay roller clutch isdisengaged to stop the paper.

G024D406.WMF

Mark detect ion

Paper feed clutch

Laser Exposure

Pull-out clutch

Pull-out sensor

Relay roller clutch

Registration sensor

Registration clutch

175

5 15

297

28

52427.88

G024D527.WMF

Timing for black, LT, long edge feed

[A]

[B]

[C]

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SM 2-49 G024

Tray lift

Tension springs [A] connect the bottom plate [B] of the paper tray to the paper trayarm [C].

When the paper tray is placed in the main unit (printer), the guide block [D] for themain unit base lifts the paper tray arm. The springs keep the top of the paper stackat the correct level.

Removing the paper tray extracts the paper tray arm from the guide block, loweringthe bottom plate.

G024D402.WMF

[A]

[B]

[C]

[D]


G024 2-50 SM

Paper end detection

The paper end sensor [A] is on the floor of the main unit (printer). When there is nopaper in the paper tray, the sensor actuator [B] falls into the notch in the bottomplate, causing the sensor to trip.

G024D403.WMF

[A]

[B]

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SM 2-51 G024

Paper size detection

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 sizeswitches. Each switch turns off when it falls into a groove, and turns on when aridge presses it.

Paper size detection for tray 1

Sensor StatusDial No. Paper Size

XNOB2 XNOB1 XNOB01 11" x 17" SEF 0 0 02 Others 0 1 13 71/4" x 101/2" LEF 0 0 14 81/2" x 14" SEF 1 0 05 81/2" x 11” LEF 1 0 16 A4 LEF 0 1 07 A3 SEF 1 1 08 No Cassette 1 1 1

SEF: Short edge feed LEF: Long edge feedOthers: SEF - B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13",

LEF - B5 JIS, A5, 51/2" x 81/2"

G024D404.WMF

[A]

[B]


G024 2-52 SM

2.7.4 BY-PASS FEED TABLE

Drive

Drive is transferred from the paper feed drive gear [A] to the by-pass paper feedclutch [B] and the shaft [C].

The by-pass feed solenoid allows the pick-up roller to drop onto the top sheet ofpaper (refer to the next page). The by-pass paper feed clutch controls the drivechange-over between the paper feed roller [D] and the pick-up roller [E]. (When theclutch 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.

G024D407.WMF

By-pass feed solenoid

By-pass paper feed c lutch

Registrat ion sensor

Registrat ion clutch

G024D523.WMF

Timing for black, LT, long edge feed

[A]

[B]

[C]

[D][E]

[F]

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SM 2-53 G024

Paper feed/separation

The paper feed/separation mechanism for the by-pass feed table is based on theFRR method.

A spring [A] pulls the pick-up roller [B] towards the paper. When the solenoid [C] isturned 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 inthe opposite direction.

The separation roller is driven in the opposite direction to the paper feed roller. Theseparation roller's axle utilizes a torque limiter made of a plastic coil spring. Whenthe applied load exceeds a certain limit, the separation roller is forced to turn in theforward direction (due to the friction of the paper).

Paper end detection

When there is no paper on the by-pass feed table, the actuator [A] falls into thenotch in the table. This actuates the paper end sensor (a photointerrupter) [B].

G024D408.WMF

G024D193.WMF

[A]

[B] [C][D]

[A]

[B]


G024 2-54 SM

Paper size detection

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]. Paperwidth is determined based upon which areas on the paper size detection board areconnected (shorted together).

Paper size detection for the by-pass feed traySensor Status

Paper SizeXBIT0 XBIT1 XBIT2 XBIT3

A4 LEF 1 1 0 0A3 SEF 1 1 0 081/2" x 11" LEF 1 1 0 011" x 17" SEF 1 1 0 071/4" x 101/2" LEF 1 1 0 1B5 JIS LEF 1 1 0 1B4 JIS SEF 1 1 0 181/2" x 14" SEF 1 0 0 151/2" x 81/2" SEF 1 0 0 1A5 LEF 1 0 0 18" x 13" SEF 1 0 0 181/4" x 13" SEF 1 0 0 181/2" x 13" SEF 1 0 0 1B6 JIS SEF 0 1 1 1A6 SEF 0 1 1 1

G024D411. WMF

GA3�

A4 �

DTL�

LT �

B4�

B5 �

EXE �A5 �

HLT �

LG �

A6 �

B6 �

�: Long edge feed �: Short edge feed

[A]

[B]

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SM 2-55 G024

2.7.5 REGISTRATION

The registration sensor [A] detects the paper fed from the relay rollers. The paperthen 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 torestart paper feeding at the correct time in order to synchronize with the leadingedge of the image on the transfer belt.

The registration brake [D] at the center of the registration roller [E] helps to stop theroller quickly and prevents the axle from flexing.

G024D414.WMF

G024D413.WMF

[A]

[B]

[C]

[D][E]

TRANSPORT/FUSING/PAPER EXIT UNIT

G024 2-56 SM

2.8 TRANSPORT/FUSING/PAPER EXIT UNIT

2.8.1 OVERVIEW

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)

G024D182.WMF

12345

6

7

8

109 11 12 13

15

16

14

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SM 2-57 G024

2.8.2 COMPONENTS


Transport fan

The transport fan creates an upward draw on thepaper to hold the paper against the transport belt.This allows the paper to move smoothly towardsthe entrance of the fusing unit.

Transport

Drive unit Gears transfer drive from the main motor.

Fusing unit Fuses the toner to the paper; has an oil supplymechanism.

Pressure unit Applies constant pressure using a lever andscrew mechanism.

Oil supply

The oil supply pad absorbs oil. The oil supplyroller applies a very small amount of oil to the hotroller via the oil supply sub-roller. The bladeevenly spreads the oil on the hot roller.

Heat detection The pressure roller thermistor and hot rollerthermistor detect temperature.

Fusing

CleaningThe cleaning roller for the hot roller removes thetoner attached to it. The scraper removes thetoner attached to the cleaning roller.

Paper exit detection The actuator and photointerrupter detect whenpaper exits the machine.Paper exit

Cover open detection The microswitch detects an open cover.


G024 2-58 SM

2.8.3 FUSING UNIT DRIVE

A gear train transfers drive from the main motor [A] to the fusing contact/separationgear [B].

Closing the front cover lowers the contact/separation lever [C] in direction [D]. Thislifts the fusing contact/separation gear, which engages with the fusing drive gear[E].

Opening the front cover lowers the fusing contact/separation gear, disengaging thegear train.

When the gears disengage, the knob for the fusing unit can be turned manually toremove paper jams.

For thick paper or transparencies, the main motor revolution slows to half-speed.

G024D182.WMF

G024D303.WMF

[C][B]

[E

[D]

[A]

[B]

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SM 2-59 G024

2.8.4 PAPER TRANSPORT

The transport fan creates an upward draw holding the paper (fed by the transferroller) against the transfer belt. The transfer belt then guides the paper to the fusingunit entrance guide plate. This prevents the side with toner from contacting theguide plate below the entrance to the fusing unit.

The transport fan turns on when the paper has been fed 101.89 mm since theregistration clutch turned on. The transport fan is turned off one second after theregistration sensor detects the paper’s trailing edge.

The paper exit sensor [A] is located at the exit of the fusing unit. The status of thepaper exit sensor is checked by the CPU at specific time intervals. This isperformed to detect jams.



Transport fan

Transfer rol ler clutch

101 .89 mm

1 secondlater

G024D525.WMF

G024D304.WMF

[A]


G024 2-60 SM

2.8.5 TEMPERATURE CONTROL

The hot roller [A] and pressure roller [B] have independent thermistors [C] tomonitor temperature.

The hot roller fusing lamp is easier to heat or cool than the pressure roller fusinglamp, and may overheat quickly if left on. Therefore, the reheat start temperaturefor the hot roller fusing lamp is 10°C higher than that for the pressure roller fusinglamp.

The hot roller and pressure roller fusing lamps are heated alternately. When afusing lamp reaches the reheat start temperature, the lamp is switched on and offalternately (the cycle is 1 second; for example, within this cycle, the printer mayswitch the lamp on for 0.6 s, and off for 0.4 s).

In level-1 energy-saving mode, the fusinglamps are turned off. In level-2 energy-saving mode, the fusing lamps areintermittently turned on to keep thepressure and hot roller temperature at120°C. The user can select which modeto use with the system menu in the usertools.

Fusing lamp statusFusing lamp

Below 130 °C 130°C 140°C 150°CHot roller Full power Full power On/off Off

Pressure roller Full power On/off On/off Off

The thermofuse [D] opens when it reaches 167°C, removing power from the fusinglamp (this prevents the fusing unit from overheating).

G024D305.WMF

150140130 c

b

a

°C

Time

G024D524.WMFa: Target temperature: 150°Cb: Hot roller temperature: Reheating starts at 150-10°C.c: Pressure roller temperature: Reheating starts at 150-20°C.

[A]

[B]

[C]

[D]

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SM 2-61 G024

Fusing unit SC codes

SC No. Name Condition

21 Pressure roller thermistor error The detected roller temperature has beenat 0°C for five seconds.

22 High pressure rollertemperature

The roller temperature has been at 190°Cfor three seconds.

23

Low pressure rollertemperature

Reheating has been done and the motor isnot running, or 60 seconds have passedafter the main motor halted. Then, theroller temperature has been below 130°Cfor 60 seconds.

24 Hot roller thermistor error The roller temperature has been at 0°C forfive seconds.

25 High hot roller temperature The roller temperature has been at 190°Cfor three seconds.

26

Low hot roller temperature Reheating has been done and the motor isnot running, or 60 seconds have passedafter the main motor halted. Then, theroller temperature has been below 130°Cfor 60 seconds.

49

Pressure roller reheat timeout When reheating, the roller temperaturedoes not reach the reheat starttemperature (target temperature -20°C)within five minutes.

50

Hot roller reheat timeout When reheating, the roller temperaturedoes not reach the reheat starttemperature (target temperature -10°C)within five minutes.

51

Pressure roller full-poweroperation error (beforereheating)

During full-power operation for reheating,the main motor is not running and thedifference between the temperatures nowand 60 seconds ago is 3°C or less.

52

Hot roller full-power operationerror (before reheating)

During full-power operation for reheating,the main motor is not running and thedifference between the temperatures nowand 60 seconds ago is 3°C or less.

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.


G024 2-62 SM

2.8.6 PRESSURE ROLLER

The hot roller [A] is made of silicone. The pressure roller [B] is made of siliconecovered with Teflon tubing.

A compression spring and a screw [C] press the pressure roller against the hotroller.NOTE: Do not turn the pressure screw except for when performing the nip width

adjustment. Nip width adjustment is necessary when the roller is replacedor uneven fusing across the page occurs.

G024D531.WMF

[A]

[B]

[C]

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SM 2-63 G024

2.8.7 OIL END DETECTION

A photointerrupter [A] detects the presence of oil. When there is no oil, the beamfrom the LED passes through to the phototransistor. However, if oil is present, thebeam 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 fusingoil near-end condition.

After near-end is detected, 200 sheets can be printed. Then, the machine detects afusing oil end condition and no printing can be done.

G024D307.WMF

[A]


G024 2-64 SM

2.8.8 OIL SUPPLY

Oil drips from the oil bottle [A] to the oil reservoir [B]. The oil is absorbed in the oilsupply pad [C], fed to the oil supply roller [D] by the oil supply sub-roller [E], andsupplied 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.

G024D306.WMF

[C]

[D]

[E]

[F]

[F]

[C]

[A]

[B]

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SM 2-65 G024

2.8.9 CLEANING

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 ordust drops into the recess [D] behind the scraper.

2.8.10 PAPER EXIT COVER OPEN/CLOSED DETECTION

The paper exit cover switch [A] detects when the paper exit cover [B] is opened orclosed.

This switch turns the 24 VDC power line on and off.

G024D313.WMF

G024D309.WMF

[A]

[D]

[B]

[C]

[A] [B]

OPEN COVER DETECTION

G024 2-66 SM

2.9 OPEN COVER DETECTION

2.9.1 FRONT COVER OPEN/CLOSED DETECTION

This feature ensures safety during maintenance and inspection while the frontcover [A] is opened.

Opening or closing the front cover vertically moves the lever in contact with theactuators of the door safety switches [B]. The safety switches disable the 5 VDCand 24 VDC power lines.

2.9.2 DTM COVER OPEN/CLOSED DETECTION

A contact switch is used to detect whether the DTMcover [A] is open or closed. This feature prevents themachine from working if the DTM cover wasaccidentally left open after DTM replacement.

This switch interrupts the 24 VDC supply.

G024D101.WMF

G024D172.WMF

[A]

[B]

[A]

INSTALLATION

ENVIRONMENT

SM 3-1 G024

Inst

alla

tion

3. INSTALLATION PROCEDURE

3.1 ENVIRONMENT

Recommended temperature and humidity

1. Temperature Range: 10°C to 32°C (50°F to 89°F)

2. Humidity Range: 20% to 80% RH

3. Ambient Illumination: 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 machinea) 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 sealevel.

7. Place the printer on a strong and level base.

8. Do not place the machine where it may be subjected to strong vibrations.

10ºC(50ºF)

15ºC(59ºF)

25ºC(77ºF)

32ºC(89.6ºF)

20

30

54

70

80

27ºC(80.6ºF)

40

% R H

Recommendedoperat ion range

Possib lerange

G024I502.WMF

MACHINE LEVEL

G024 3-2 SM

Inst

alla

tion

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.WMFA: 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")

POWER REQUIREMENTS

SM 3-3 G024

Inst

alla

tion

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.

3.5 UNPACKING

For unpacking and installation procedures, refer to the Operating Instructions andthe Quick Installation Guide.

TRANSPORTING

G024 3-4 SM

Inst

alla

tion

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 theprinter.

2. Keep the printer horizontal during transportation. (Do not concentrate the loadon any one part of the base.)

3. Before moving the printer, pack the printer using the factory-suppliedcushioning 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 AdjustmentProcedures), to remove the oilsupply unit of the fusing unit.Gradually tilt the oil sump to drainthe oil from the oil sump [A] to the oilbottle [B].

3) After draining the oil to the oil bottle,wipe the oil sump and oil bottle witha clean cloth.

�CAUTIONMake su re that no fusing oil re mains in the printer. Remo ve the oil andclean the oil sump and oil bottle as ex plaine d above. Otherwise, the oil m ayspread i nside the printer while mo ving it.

5. Insert cushioning material [E] betweenthe 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.

G024I500.WMF

G024I501.WMF

[A]

[B]

[C]

[D]

[E]

OVERVIEW

SM 4-1 G024

Ser

vice

Tab

les

4. SP MODE

4.1 OVERVIEW

This printer has two SP modes:1) Engine SP mode2) Controller SP mode

The various controller SP modes are detailed in the service manual for thecontroller.

These two modes perform different functions.

4.2 ENGINE SP MODE

4.2.1 OVERVIEW

Entering engine SP mode

To enter engine SP mode, hold down the [Online] [A] and [Menu] [B] keys on theoperation panel and turn on the power.

To exit engine SP mode

Turn off the unit.NOTE: Be sure to exit from SP mode when you are finished.

G024O015.WMF

G024O016.WMF

[A]

[B]

ENGINE SP MODE

G024 4-2 SM

Outline of the engine SP mode functions

The engine SP mode has the following menu items:

Menu Item Function and application1: Margin Independent vertical/horizontal registration adjustment for each

tray, and for OHP mode2: Parameter Independent adjustment of transfer bias and fusing temperature

for normal paper, thick paper, and OHPs3: Clear Memory Resets the counters and other values stored in NVRAM4: Sensor Check Sensor output check5: Nip Width Nip width measurement for fusing pressure adjustment6: Reset SC Resets fusing unit SC codes7: Process Ctrl Implementation of forced, normal, and color bias setting process

control and setting of execution intervals for periodic processcontrol

8: Test Print Prints internally generated patterns (4C overlay grids, 4x4 colorbelts, and solid-area color belts) for the print engine

9: ID Sensor PWM ID sensor output calibration10: Image Adjust Adjustment of image reproduction ratio in the main scan and sub-

scan directions11: Output Check Tests for motors, clutches, and solenoids12: Hi-light Fine adjustment of density for highlight (low-ID) areas.13: Lub_Interval Adjustment of lubricant application interval14: Soft Version Default “0”. Do not change.15: Belt-Tr Bias Adjustment of the Primary (Belt) Transfer Bias.

4.2.2 MENU OPERATION/DISPLAY

In the engine SP mode menu, you can move between menu levels, specifyparameters, 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 inEnglish only.

Key operation

[!] and ["] keys: Scroll through the menus. When either of these keys is pressedin a number setting menu, the displayed value changes by theminimum value.

[# Enter] key: When the selected item has a lower level menu, pressing thiskey moves you to the next lower level. At the lowest level, thiskey is used to determine the specified setting or execute theselected item.

[Escape] key: Pressing this key moves you to a higher level in the currentmenu. Before the specified value is confirmed by the [# Enter]key, pressing this key keeps the existing setting.

⇒⇒

Rev. 08/2000

ENGINE SP MODE

SM 4-3 G024

Ser

vice

Tab

les

LCD indications:

Title: The menu title is displayed to show the current menu level.

Selected item: The currently selected item on the menu is displayed. Pressingthe [▲] or [▼] key scrolls through the items at that level. Thescrolling is sequential and loops back to the beginning (i.e. thefirst item is again displayed after the last item). In the lowestlevel of the menu, the currently selected item/setting is prefixedwith an asterisk (*). To select an item/setting, press the [Enter]key while the target item is displayed. The item is then prefixedwith an asterisk (*) for 0.5 seconds, and the next highest levelmenu is displayed.

Arrow marks: The arrow marks indicate that the items can be scrolled. Thesearrow marks are not shown if there is only one item in themenu.

Maintenance V

1. Margin W

Title

Selected itemArrow marks

ENGINE SP MODE

G024 4-4 SM

4.2.3 MARGIN (REGISTRATION ADJUSTMENT)

The SP mode menu levels for registration adjustment are described below.

Layer 1 Layer 2 Layer 3 Layer 4Print: StdTray 1

Margin: PrintStd. Paper

It is also possible toprint from theoptional trays (tray2 & tray 3) and theby-pass tray asperformed fortray 1.

Margin: PrintThick Paper

Print: ThickBy-pass Tray

MarginPattern Print

Margin: PrintTransparency

Print: TransBy-pass Tray

Margin: AdjustTray1:Left

Tray1:LeftX.XTray1:Top:1stX.X

Margin: AdjustTray1:Top:1st

It is also possible toperform theadjustment for tray2, tray 3, and theby-pass tray in thesame way as fortray1.

Maintenance1:Margin

MarginAdjust

Margin: AdjustTrans:Top:1st(For OHPs)

Trans:Top:1stX.X

ENGINE SP MODE

SM 4-5 G024

Ser

vice

Tab

les

Follow the steps below to adjust registration in the “1. Margin” item of the engineSP mode menu:

1. From the Pattern Print menu, select the media type and paper tray. Then, printthe registration adjustment pattern (4C overlay grid pattern).

2. Measure the distance from the paper edge to the first vertical and horizontallines of the grid patterns (X and Y in the diagram).

3. Move to the Adjust menu to adjust the vertical and horizontal registration. Theadjustment range for the horizontal (Left) registration is between –2.0 and + 2.0mm in units of 0.4 mm. The adjustment range for the vertical (Top) registrationis 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 thehorizontal registration as "Left"and the vertical registration as"Top".

Y

X

Paper transport direct ion

G024P500.WMF

ENGINE SP MODE

G024 4-6 SM

4.2.4 PARAMETER

Use this menu to specify the paper transfer bias and fusing temperature for normalpaper, thick paper, and OHPs.

The paper transfer bias can be specified in 1% increments between 50% and200%. (Default: 100%)

The fusing temperature can be specified in three steps: Low, Normal, and High(Default: Normal = 150°C). The Low temperature is the Normal temperature minus15°C. The High temperature is the Normal temperature plus 15°C.

See the table below for Parameter menu details.

Layer 1 Layer 2 Layer 3 Layer 4Std. PaperTransfer Bias

BiasXXX%Temp.LowTemp.Normal

ParameterStd. Paper Std. Paper

Fusing Temp.Temp.High

ParameterThick Paper

Same as Std. Paper Same as Std. Paper

Maintenance2:Parameter

ParameterTransparency


4.2.5 CLEAR MEMORY

Use this menu to reset all the settings stored in NV-RAM in the MCU or to reset thejam 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 Layer 3 Layer 4Clear MemorySC

Clear: SCPress # to clear

ClearingSC

Clear MemoryJam

Clear: JamPress # to clear

ClearingJamMaintenance

3:Clear Memory Clear MemoryAllNOTE: Factory useonly.

Clear: ALLPress # to clear

ClearingALL

• 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

ENGINE SP MODE

SM 4-7 G024

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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 [▲] and [▼] arrowkeys. Then, manually change the sensor status and check the correspondingoutput.

After changing the sensor status, be sure to press the [Enter] key to update thedisplay.

See the table below for details of the Sensor Check menu.

Layer 1 Layer 2 Layer 3 Layer 4Maintenance4:Sensor Check

Sensor CheckXXX 0 or 1

The table below describes the relationship between the display values and thedetected output of the sensors.

Sensor Name Sensor StatusName Display 0 1

Paper End Sensor(Tray 1)

P End-1st Paper detected Paper not detected

Paper End Sensor(By-pass Tray)

P End-By-pass Paper detected Paper not detected


P End-2nd Paper detected Paper not detected


P End-3rd Paper detected Paper not detected

Registration Sensor Registration Paper not detected Paper detectedExit Sensor Exit Paper detected Paper not detectedPaper Size Switch(Tray 1)

P Size-1st *1 *1

Paper Size Switch(Tray 2)

P Size-2nd *1 *1


P Size-3rd *1 *1

By-pass Paper WidthDetection Board

P Size-By-pass *2 *2

PCU Set Switch PCU Set Detected Not detectedDTM Set Sensor CTC Set Detected Not detectedToner End Sensor CTC Toner End Not end EndDoor Safety Switch Cvr Opn-F Closed OpenExit Cover Switch Cvr Opn-EX Closed OpenOil End Sensor Oil End End Not end(Fusing Unit) Fusing Set Detected Not detectedUsed Toner Sensor Used Toner Not full Full(Tray 2) Tray Set-2nd Not detected Detected(Tray 3) Tray Set-3rd Not detected DetectedPCU Reset Sensor PCU Reset Old NewRevolver H.P. Sensor Revolver H.P. Home position Not home position

ENGINE SP MODE

G024 4-8 SM


Transfer RollerPosition Sensor

Tfr Position Release Touch

Pull-out Sensor(Tray 2)

P Feed-2nd Paper not detected Paper detected


P Feed-3rd Paper not detected Paper detected

ID Sensor ID *3 *3Humidity *4 *4Temperature/Humidity

Sensor Temp *5 *5DTM Cover Switch Cvr Opn-S Open ClosedPull-out Sensor (MainBody)

Picup Paper detected Paper not detected

Charger Corona SetSwitch

Main Charger Detected Not detected

*1: “Paper size detection” in Section 2 explains the status of the paper sizeswitches for paper size detection. (0: Pressed, 1: Not pressed)

*2: The table below shows the correspondence between the paper guide positionsand displayed values.

Guide position A3W A3/A4 B4/B5 A5 B6 A6Display 20 04 22 12 0b 0b

Guide position 12 11 10½ 8½ 8¼ 8Display 20 04 22 12 12 12

*3: The displayed value indicates the K sensor output when the LED in the IDsensor is turned on. The specified output value (reference for normaloperation) is 2.7 ± 0.8 V.

*4: The detection results are shown in the XXX YYY format. XXX indicatesabsolute humidity, and YYY indicates relative humidity. (Reference for normaloperation: YYY should be between 5 and 95.)

*5: The displayed value indicates the detected temperature. (Reference for normaloperation: Between 8 and 42)

ENGINE SP MODE

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4.2.7 NIP WIDTH

Use this to re-adjust the fusing pressure, which is required when the pressureadjustment screw for the fusing unit is loosened. This function feeds atransparency from the by-pass feed tray, then stops and resumes feed through thefusing unit three times, and finally ejects the transparency. This operation produceswhite cloudy patches on the transparency due to heating. For details of theoperation, see “Replacement and Adjustment - Checking and Adjusting the FusingNip Width”.

The table below shows the details of the Nip Width menu.

Layer 1 Layer 2 Layer 3 Layer 4Maintenance5:Nip Width

Nip WidthPress # to start

Executing

4.2.8 RESET SC

For safety purposes, fusing system SCs cannot be reset by turning the power offand on. Use this menu to reset a fusing system SC.

The table below shows the details of the Reset SC menu.

Layer 1 Layer 2 Layer 3 Layer 4Maintenance6:Rest SC

Rest SCPress # to reset

Reseting*Fusing SC

*As displayed in LCD

ENGINE SP MODE

G024 4-10 SM

4.2.9 PROCESS CTRL

Use this menu either:

• To execute process control after performing maintenance work that affectsprocess 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 theparameters that are adjusted are different for each. (For a list of the steps in aprocess control operation, see ‘Detailed Section Descriptions – Process Control’.

• Initialize: Forced process control to initialize the machine. This does all sixsteps of the process control procedure.

• Normal: This forced process control adjusts the process control parametersin the same way as the periodic process control self check

• Color Bias: Process control for setting color development bias. Only the colordevelopment bias initialization step is done.

• PCU Getting OK: Complete process control followed by belt lubricationroutine for a new PCU

After the end of each process control, “Finish” is displayed with the final statusfollowing 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 isdone.

The interval for process control can be specified in units of 50 sheets between 0and 250 sheets (default: 100 sheets).NOTE: Specifying 0 for the interval disables all process controls.

Layer 1 Layer 2 Layer 3 Layer 4Process Ctrl.Initialize

InitializePress # to start

Executing

Process Ctrl.Normal

NormalPress # to start

Executing

Process Ctrl.Color Bias

Color BiasPress # to start

Executing

Process Ctrl.PCU Getting OK

PCU Getting OKPress # to start

Executing

Maintenance7:Process Ctrl

Process Ctrl.Interval Set

Interval SetPress # to start

ENGINE SP MODE

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4.2.10 TEST PRINT

Use this menu to check print quality. This function prints a pattern that is internallygenerated 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 Layer 3 Layer 4Test PrintPattern 1

Pattern 1Tray X

PrintingTray X

Test PrintPattern 2

Same as Pattern 1 Same as Pattern 1Maintenance8:Test Print

Test PrintPattern 3

Same as Pattern 1 Same as Pattern 1

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 Layer 2 Layer 3 Layer 4Maintenance9:ID Sensor PWM

ID Sensor PWMXXX

ENGINE SP MODE

G024 4-12 SM

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 of0.1% within ±1%.

Layer 1 Layer 2 Layer 3 Layer 4Image AdjustMain Scanning

Main ScanningXXXMaintenance

10:Image adjust Image AdjustSub-scanning

Sub-scanningXXX

4.2.13 OUTPUT CHECK

Use this menu to check the operation of the clutches, motors, and solenoidsindividually.NOTE: Before testing the PCU, main, or revolver motors, remove the load

beforehand (to do this, remove the motor from the machine, but keep itconnected).

The table below shows the Output Check menu details.

Layer 1 Layer 2 Layer 3 Layer 4Maintenance11:Output Check

Out Put CheckXXXXXXXX

XXXXXXXXON (OFF)

Name Display OperationBy-pass feed clutch Bypass Feed Cl. Operating for a certain

timePull-out clutch Pick-up Cl. Operating until inputting

OFFPaper feed clutch Feed Cl. Operating for a certain

timeRelay roller clutch Transport Cl. Operating until inputting

OFFRegistration clutch Regist. Cl. Operating until inputting

OFFTransfer roller clutch Tr. Roller Cl. Operating for a certain

timeDevelopment drive solenoid Development Sol. Operating until inputting

OFFBy-pass feed solenoid Bypass Sol. Operating for a certain

timeTransfer belt cleaning solenoid Cleaning Sol. Operating until inputting

OFF

ENGINE SP MODE

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Name Display OperationQuenching lamp Quenching LED Operating until inputting

OFFPCU Motor-slow Operating until inputting

OFFPCU Motor-normal Operating until inputting

OFFPCU Motor-fast Operating until inputting

OFF

PCU motor

PCU Motor-reverse Operating until inputtingOFF

Main Mtr-normal Operating until inputtingOFF

Main motor

Main Mtr-slow Operating until inputtingOFF

Polygon mirror motor Scanner Motor Operating until inputtingOFF

Revolver motor Revolver Motor Operating until inputtingOFF

Tray main motor (for tray 2) OT1 Motor Operating until inputtingOFF

Paper feed clutch (for tray 2) OT1 Feed Clutch Operating for a certaintime

Tray main motor (for tray 3) OT2 Motor Operating until inputtingOFF

Paper feed clutch (for tray 3) OT2 Feed Clutch Operating for a certaintime

ENGINE SP MODE

G024 4-14 SM

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 Layer 3 Layer 4Hi-light adjcyan

cyan1 to 7

Hi-light adjmagenta

Same as cyan

Hi-light adjyellow

Same as cyanMaintenance12:Hi-light adj

Hi-light adjblack

Same as cyan

4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVALADJUSTMENT)

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 monochromemode.)

The default value is 100 transfer belt revolutions.

This mode is helpful when insufficient toner is transferred to the printout, especiallyon text and/or line images. This can occur when a machine is used heavily. (Theexpected 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 machineperformance.

Layer 1 Layer 2 Layer 3 Layer 4Maintenance13:Lub_Interval

M IntervalXXX

ENGINE SP MODE

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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. Thedefault setting is 800V.

Increasing this parameter can print vertical lines more sharply but white dots mayappear on solid image areas. Therefore, this mode should only be used whenblurry vertical lines appear.

Layer 1 Layer 2 Layer 3 Layer 4BLT-BIAS adjCyan

Cyan /#XXXX

BLT-BIAS adjMagenta

Magenta /#XXXX

BLT-BIAS adjYellow

Yellow /#XXXX

Maintenance15: BLT-TR BIAS

BLT-BIAS adjBack

Back /#XXXX

NOTE: This mode is available starting from ROM version 2.23 (applied toNovember 1999 production.)

⇒

Rev. 08/2000

PM TASKS

SM 5-1 G024

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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 nextpage.

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 andAdjustment” in this manual and Chapter 3, “Replacement and Adjustment” in themanual for the optional 500-sheet paper tray.

�CAUTIONWhen 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.

5.1.3 INSPECTION

Inspect the printer components when visiting the customer’s site.

• Visually inspect the components, and replace the components if there is anydamage.

�CAUTIONA high voltage is applied to bias electrodes. To inspect a bias electrode,ensure that the power switch is turned off.

PM TABLE

G024 5-2 SM

5.2 PM TABLE

5.2.1 MAIN UNIT

C: Clean R: Replace I: Inspect

item EM 60k 100k NotePaper feed roller C R Alcohol or waterRegistration roller C Alcohol or waterFriction pad C R WaterBottom plate pad C WaterBy-pass feed roller C Alcohol or waterPull-out roller C Alcohol or waterBy-pass separation roller C Alcohol or waterCharge corona unit C*1 Cleaner in the PCUQuenching lamp I Blower brush (if dirty)ID sensor C Dry clothDust shield glass C*1 Cleaner brush (P/N: G0241533)Fusing unit 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 EM 60k 100k NotePaper feed roller C R Alcohol or waterFriction pad C R WaterBottom plate pad C Water

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6. REPLACEMENT AND ADJUSTMENT

6.1 EXTERIOR

6.1.1 RIGHT COVER/OZONE FILTER COVER

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].

4. Remove the ozone filter [B].

G024R151.WMF

[C]

[A]

[B]

EXTERIOR

G024 6-2 SM

6.1.2 LEFT COVER

1. Open the Front cover

2. Open the oil bottle cover [A].

3. Remove the left cover [B] (three screws).

G024R152.WMF

[A]

[B]

EXTERIOR

SM 6-3 G024

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6.1.3 BOTTOM FRONT COVER

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

1. Open the By-pass Tray [A].

2. Remove the two front cover screws [B] and carefully move the front cover awayfrom the printer. NOTE: The display's harness does not allow for muchmovement.

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 hooksretaining the operation panel [D] and carefully "tilt" the operation panel toremove.

NOTE: The surface of the operation panel circuit board is not insulated. If turningon the printer while the operation panel is removed from the front cover isrequired, be careful not to short-circuit this board.

[A]

[C]

[D]

[B]

[B]

[C]

[A]

[B]

[B]

EXTERIOR

G024 6-4 SM

6.1.5 TOP COVER AND TOP REAR COVER

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).

G024R167.WMF

G024R251.WMF

[A]

[B]

[C]

INSIDE THE MAIN UNIT

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6.2 INSIDE THE MAIN UNIT

6.2.1 GENERAL CAUTIONS

CAUTION: When replacing the components inside the main unit, follow theinstructions below.

1. When placing the PCU outside of the printer, cover the photosensitive face witha 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 touchthe 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, setthe 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 cleaningcontact/separation lever to release the cleaner if the cleaning unit is contactingthe belt.)

G024R500.WMF

[A]

[B]

[A][C]


G024 6-6 SM

6.2.2 ID SENSOR

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.

G024R106.WMF

[A]

[B]


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6.2.3 CALIBRATING THE ID SENSOR

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 theengine SP mode.)

2. Select “9: ID Sensor PWM” in the engine SP menu. Specify 150 as the PWMvalue. Press # Enter, an asterisk (*) is displayed next to the value. Next, Pressthe [Escape] or [Menu key].

3. Select “7: Process Ctrl” in the engine SP menu. Execute “Color Bias.” (Thisstarts (executes) the process control for the color development bias settings.)Wait until "Finish OK" is displayed and the printer finishes cycling. Then, pressthe [Escape] or [Menu] key.

4. Select “8: Test Print” in the engine SP menu. Execute “Pattern 3” to printpattern 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 aretoo pale, return to step 2 and decrease the PWM value by one. Then, repeatsteps 3 to 5.

6. If the YCM solid area density is good, select “7: Process Ctrl” in the engine SPmenu and execute “Initialize.” (This executes a complete forced process controlself-check.)

7. After the forced process control self-check is completed, restart the printer innormal mode.

ID sensor calibrationflowchart

SP "9: ID Sensor PWM"Set 150 as PWM.

SP "7: Process Ctr l"Execute "Color Bias."

SP "8: Test Print"Print "Pattern 3."

Is the density good?

SP "7: Process Ctr l"Execute "Init ial ize."

Restart the printer innormal mode.

SP "9: ID Sensor PWM"Dark : PWM → +1Pale : PWM → -1

Yes

No

G024R510.WMF


G024 6-8 SM

6.2.4 PCU SET SWITCH/CHARGE CORONA UNIT SETSWITCH/PCU RESET SENSOR/ USED TONERSENSOR/QUENCHING LAMP

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 theconnector.

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).

G024R107A.WMF

[A]

[B]

[C]

[D]

[E]

[F]


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6.2.5 PULL-OUT SENSOR/PAPER END SENSOR

Pull-out sensor

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

1. Remove the paper end sensor bracket [C] (one screw).

2. Remove the paper end sensor [D] (four hooks, one connector [E]).

G024R275.WMF

G024R900.WMF

[A]

[C]

[D]

[E]

[B]


G024 6-10 SM

6.2.6 OIL END SENSOR/EXIT COVER SWITCH

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.

G024R108B.WMF

[A]

[B]

[C]

[D]


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6.2.7 FRONT COVER SAFETY SWITCH, PCU MOTOR, MAIN MOTOR


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).

G024R161.WMF

G024R115.WMF

G024R162.WMF

[B]

[D]

[E]

[A]

[C]


G024 6-12 SM

6.2.8 TRANSFER BELT CLEANING SOLENOID/DEVELOPMENTDRIVE SOLENOID


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 cleaningsolenoid [G].

6. After replacing the development drive solenoid, adjust the development jointposition (see the procedure on the next page).

NOTE: When putting back the bearing, hold the shaft in order to place the bearingbetween the revolver gear and side plate.

G024R163A.WMF[A]

[B]

[C]

[D]

[E]

[E]

[F]

[G]


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6.2.9 ADJUSTING THE DEVELOPMENT COUPLING JOINT

Performing this procedure is required after replacing the development drivesolenoid.

1. Remove the left cover. (See Left Cover Removal.)


3. Remove the PCU and properly protect it from light exposure.

4. Remove the main motor. (See Main Motor Removal.)

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 thedevelopment drive solenoid. (See Section 4, Output Check.)

9. Set the adjustment tool (P/N: G0249310) [F] between the developmentcoupling joint [E] and right side plate [D]. (For this step, the part of the toolcontaining 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 thearrow in the diagram), and tighten the two screws [B].

11. Extract the adjustment tool. Place the other part of the adjustment tool (withoutthe hole) between the coupling joint and the side plate. If there is no frictionbetween the adjustment tool and the development joint, the adjustment iscompleted. If there is any friction, repeat from step (7).

G024R516.WMF

G024R518.WMF

[A]

[B][C]

[D]

[E]

[F]


G024 6-14 SM

6.2.10 PCU DRIVE UNIT


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 pressuresprings [C] between the pressure arm protrusion and the bracketembossment.After the PCU drive unit is retained, check that the belt is given sufficienttension from the tension springs [D] before tightening the tightener screws.

G024R111.WMF

[B]

[C]

[C]

[A]

[D]

[A]

[D]


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6.2.11 REVOLVER MOTOR


2. Remove the revolver motor unit [A] (three screws, one connector [B]).

G024R901.WMF

[B]

[A]


G024 6-16 SM

6.2.12 DTM UNIT

1. Turn off the printer.

2. Open the DTM cover [A] and remove the DTM unit [B]. Refer to the QuickInstallation Guide and Operating Instructions.

NOTE: 1) Be careful not to drop toner onto the floor. (Before placing the DTMunit on the floor, lay several clean sheets of paper first.)

2) After installing a new DTM unit, remove the seal. Then, close the DTMcover and turn on the printer to enter setup mode. Set up thesubsequent DTM units according to the instructions displayed on thepanel.For details of installing cartridges in setup mode, refer to the OperatingInstructions.

G024D164A.WMF[A]

[B]

LASER OPTICS SECTION

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6.3 LASER OPTICS SECTION

6.3.1 LD UNIT



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 theDTM units to the removal position.

4. Loosen the support stopper screw [C]. Lift the support stopper [D] andtemporarily tighten the screw. Then, remove the support [E].NOTE: After putting back the support, remember to lower the support stopper

and tighten the screw.

G024R266.WMF

G024R267.WMF

[B]

[C]

[A]

[D]

[E]


G024 6-18 SM

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].

G024R258.WMF

G024R259A.WMF

[A]

[B]

[D]

[C]

[E]

[E]


SM 6-19 G024

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6.3.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR

�WARNINGTurn off the main switch and unplug the machine before attempting any ofthe procedures in this section. Laser beams can seriously damage youreyes.

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 LeftCover Removal), rear top cover (see Top Cover Removal), bottom front cover(see Bottom Front Cover Removal), and tray cover (see Controller BoardRemoval).

2. Remove the fusing unit. (See Fusing Unit Removal.)

3. Remove the PCU reset sensor from the bracket. (See PCU Reset SensorRemoval.)

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 stayforward.

G024R269.WMF

G024R270.WMF

[A] [A][B]

[C]

[D]

[D]

[B]


G024 6-20 SM

9. Remove the duct [E] for the exhaust fan (one screw).

10. Remove the optical housing unit [G] (four screws, two connectors [H]), lifting itin 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.

G024R522.WMF

G024R504A.WMF

LASER-3.WMFCAUTN-V.WMF

[H]

[E]

[G]


SM 6-21 G024

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polygon mirror faces.

12. Remove the polygon mirror motor [J] (four screws).

G024R263.WMF

G024R506A.WMF

[J]

[I]

FUSING SECTION

G024 6-22 SM

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 componentsand execute “6: Reset SC” in the engine SP menu to release the SC.

4. When the fusing unit has been replaced, execute “S3 MaintenanceClear” in the controller SP menu to reset the fusing counter.

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 thebottom of the fusing unit stay even when they are fully loosened.

G024R168.WMF

[A]

[B]

[C]

FUSING SECTION

SM 6-23 G024

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6.4.2 OIL SUPPLY UNIT, PRESSURE ROLLER LAMP, HOTROLLER LAMP, PRESSURE ROLLER THERMOFUSE,PRESSURE ROLLER THERMISTOR

NOTE: If the pressure spring retaining screw has been turned while replacing thepressure or hot roller, adjust the nip width. See “Checking and Adjustingthe 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]).

G024R169A.WMF

G024R170.WMF

[A][B][C]

[D]

[D]

FUSING SECTION

G024 6-24 SM

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, threeconnectors). Make note of all connector locations prior to unplugging.

G024R172.WMF

G024R173.WMF

[A]

[B]

FUSING SECTION

SM 6-25 G024

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7. Remove the holder [A] for the left fusing lamp terminals (two screws, fiveconnectors). 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].

G024R174.WMF

G024R175.WMF

[B]

[C]

[A]

FUSING SECTION

G024 6-26 SM

ReinstallationMake sure that the cables are connected to their correct places. Refer to yourobservations made during removal and the illustrations below.

• Pressure roller lamp connector [a], [A]

• Hot roller lamp connector [b], [B]

• Pressure roller thermofuse connector [c], [C]

• Hot roller thermofuse connector [d], [D]

G024R174.WMF

G024R173.WMF

[a]

[b]

[c]

[d]

[A]

[B]

[C]

[D]

FUSING SECTION

SM 6-27 G024

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6.4.3 OIL SUPPLY ROLLER, OIL SUPPLY SUB-ROLLER, BLADE

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 theprinter.

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 oilsupply 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].

G024R176.WMF

[A]

[B]

[C]

[E][C]

[D]

FUSING SECTION

G024 6-28 SM

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).

G024R177.WMF

G024R178.WMF

[D]

[A]

[B]

[C]

FUSING SECTION

SM 6-29 G024

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6.4.4 PAPER EXIT SENSOR, CLEANING ROLLER

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.

G024R309.WMF

G024R171A.WMFG024R521.WMF

[A]

[B]

[C]

[D]

[E]

[F]

[G] [H]

FUSING SECTION

G024 6-30 SM

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 twobearings).

G024R179.WMF

[A]

[B]

FUSING SECTION

SM 6-31 G024

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6.4.5 PRESSURE ROLLER, HOT ROLLER, HOT ROLLERTHERMOFUSE, HOT ROLLER THERMISTOR

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 foradjusting the inlet path in the event of wrinkling or other similar feedproblems.

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).

G024R180.WMF

G024R181.WMF

[A]

[B]

[C]

[D]

[E]

[E]

[F]

FUSING SECTION

G024 6-32 SM

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).

G024R182.WMF

G024R183.WMF

[A]

[B][D]

[C]

FUSING SECTION

SM 6-33 G024

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6.4.6 CHECKING AND ADJUSTING THE FUSING NIP WIDTH

NOTE: 1) Wait five minutes or longer after completion of warm-up before startingthe 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 thenarrowest width near the three points above.

3. Obtain an average of the right and left widths of the three bands. Check thatthe average meets the following standard.

L (left): 6.5 ±0.2 mmR (right): (L+0.25) ± 0.15 mm

10 mm 10 mm

L1

L2

L3

R1

R2

R3

Alterationbelt

G024R520.WMF

FUSING SECTION

G024 6-34 SM

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.

G024R314.WMF

[A]

ELECTRICAL WIRING

SM 6-35 G024

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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 settingsaccording to this printed list.

1. Remove the tray cover [A]. (twoscrews).

2. Remove the temperature/humiditysensor cover [B] (one screw).

3. Remove the temperature/humiditysensor [C] (one screw, one connector[D]).NOTE: If the customer has added the

optional expansion memory ora NIC, remove it beforecontroller replacement.Remember to install thememory or NIC on the newcontroller board.

4. Remove the controller cover [E] (16screws, including 2 screws at the parallelport connector).

5. Remove the controller board [F] with thebracket [G] attached to it (six screws, oneconnector [H]).

6. Remove two screws and one bracket [G]from the controller board.

NOTE: To replace controller boards, remove theNVRAM chip (IC23) on the old board,install it on the new board, then install thenew board. The NVRAM chip stores usersettings and service records. Thesesettings will be lost if the NVRAM chip isnot transferred.

G024R164.WMF

G024R184.WMF

G024R166.WMF

[A]

[B]

[C]

[D]

[E]

[F]

[G]

[H]

ELECTRICAL WIRING

G024 6-36 SM

6.5.2 POWER SUPPLY UNIT

�WARNINGTo avoid the risk of electric shock, unplug the power cable before startingpower supply unit replacement.

1. Remove the fusing unit (see Fusing UnitRemoval) and the controller board (seeController Board Removal).

2. Remove the bracket [A] (two screws).

3. Remove the eight screws retaining theelectrical wiring box [B], unplug twoconnectors, and release the two hooks.Lift the left side of the electrical wiringbox [B] upwards c to swing it out d.

G024R253.WMF

G024R252.WMF

[A]

[B]

ELECTRICAL WIRING

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4. Remove the power supply unit [C] (sixscrews, six connectors).

G024R254.WMF

[C]

ELECTRICAL WIRING

G024 6-38 SM

6.5.3 HIGH VOLTAGE SUPPLY UNIT

1. Remove the right cover (see Right Cover Removal), left cover (see Left CoverRemoval), controller board (see Controller Board Removal), and power supplyunit (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, eightconnectors).

�CAUTIONCarefully connect the high-voltage wires as shown in the diagram below.

G024R255.WMF

CN190

G024R512.WMFWhite connector:Belt transfer biasroller

Yellow connector:Development blade

White connector:Development roller

Blue connector:Supply roller

Yellow connector:Charge corona unitwire

Blue connector: Charge corona unit grid

White connector:Transfer roller

[A]

[B]

ELECTRICAL WIRING

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6.5.4 MCU

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 oldboard, install it on the new board, then install the new board.In the event of NVRAM damage, install a new NVRAM chip, and contactyour supervisor for additional steps. A forced process control will also haveto be done (engine SP mode 7: Process Control – Initialize).

G024R256.WMF

[A]

ELECTRICAL WIRING

G024 6-40 SM

6.5.5 UPGRADING THE MCU FIRMWARE

NOTE: Turn off the printer before inserting or removing the IC card. (Otherwise theIC card may be damaged.)


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 theMCU. The side with ‘A’ on it must be facing upwards.

4. Turn on the printer. (Check that the following is displayed on the operationpanel.)

5. Check that the firmware versions are correct. (Make sure that the firmware inthe 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 followingsequence:

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 fromthe beginning.)


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, whichis displayed immediately after power-on. (If the firmware version differs from theIC card firmware version displayed in step 3, repeat from step 1.)

R Vxxx C VxxxEnter On L ine KEY

G024R514.WMF

FLASH DWLOADINGERASE! !

FLASH DWLOADINGWRIT ING

FLASH DWLOADINGOK!! OK! !

G024R513.WMF

Current Firmwareversion

Version of Firmwarein the IC card

⇒

Rev. 02/00

PAPER FEED SECTION

SM 6-41 G024

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6.6 PAPER FEED SECTION

6.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR

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]).

G024R154.WMF

[A] [B]

[C]

[D]

PAPER FEED SECTION

G024 6-42 SM

6.6.2 PAPER WIDTH DETECTION BOARD


2. Remove the by-pass feed table unit [A] (two snap rings, two hooks, oneconnector [B]).

3. Remove the auxiliary tray [C] (two hooks), from the cover [D] for the by-passfeed table.

4. Remove the table [E] (two hooks).

5. Remove the paper width detection board [F] (one screw).

G024R155.WMF

G024R156.WMF

G024R105.WMF

[A]

[C]

[E]

[D][F]

[B]

[D]

[B]

PAPER FEED SECTION

SM 6-43 G024

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6.6.3 BY-PASS PAPER FEED ROLLER


2. Remove the paper end sensor bracket. (See By-pass Paper End SensorRemoval.)

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).

G024R157A.WMF

G024R158.WMF

[A]

[B]

[C]

[D]

[E]

PAPER FEED SECTION

G024 6-44 SM

6.6.4 PAPER FEED ROLLER

1. Remove the paper feed tray.

2. If necessary, carefully pull the front bottom cover forward slightly. Slide thelever [A] in the direction of the arrow in the diagram, and remove the paper feedroller [B].

G024R408.WMF

[A]

[B]

PAPER FEED SECTION

SM 6-45 G024

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6.6.5 PCU HOLDER

�CAUTIONBefore remo ving the torsion springs [ C] in the foll owing pr ocedure, makesure that the front co ver is cl osed (to re lease the p ressu re).If the springs are removed while pressure is applie d to them, the y mayjump out and cause injur y.

1. Remove the sensor bracket [A] (twoscrews, two connectors).

2. Remove the bracket [B] (twoscrews). Remove the right and lefttorsion springs [C]. Remove theright and left caps [D] (one screweach).

3. Open the paper feed frame and unplugthe ID sensor connector. Pull out theright and left rotation shafts [F] until thePCU holder [E] can be removed.

NOTE: Do not entirely pull out therotation shafts, or the paperfeed frame will drop. Hold thePCU holder with one hand,and gradually pull out therotation shafts with the otherhand. To remove the PCUholder, lift it with the front sidepanel kept vertical.When installing the PCUholder, keep the front sidepanel vertical and lower it straight down between the printer sidepanels. (There is a toothed section [G] below the left side panel of theholder, which engages the damper gear [H].)

G024R409.WMF

G024R410.WMF

[A]

[C]

[B]

[D]

[E]

[F]

[G]

[H]

PAPER FEED SECTION

G024 6-46 SM

6.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS PAPERFEED CLUTCH, REGISTRATION CLUTCH, AND TRANSFER ROLLER CLUTCH

1. Remove the right inner cover [A] (three screws).


G024R159.WMF

[A]

PAPER FEED SECTION

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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]).

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.

G024R519.WMF

G024R160.WMF

[A]

[C]

[D]

[E]

[F]

[G]

[H]

[B]

[I]

PAPER FEED SECTION

G024 6-48 SM

6.6.7 TRANSFER ROLLER


2. Remove the right inner cover (three screws). See Transfer Roller PositionSensor Removal.

3. Remove the transfer roller [A] (three E rings, one gear, and two bearings).

6.6.8 REGISTRATION ROLLER IDLER


2. Remove the right inner cover (three screws). See Transfer Roller PositionSensor Removal.

3. Remove the grounding plate [A] (one screw).

4. Remove the registration roller idler [B] and guide plate [C] (two E rings, twobearings, and two springs).

G024R265.WMF

G024R406.WMF

[A]

[A]

[B]

[C]

PAPER FEED SECTION

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6.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVEROLLER

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).

G024R407A.WMF

[A][C]

[D]

[B]

[E]

PAPER FEED SECTION

G024 6-50 SM

6.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH, ANDPULL-OUT/RELAY ROLLER CLUTCH

1. Remove the front bottom cover (see Front Bottom Cover Removal) and thepaper 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 thetray 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.

G024R273.WMF

G024R274.WMF

[A]

[B]

[C]

[D]

[E] [F]

[G]

[H]

PAPER FEED SECTION

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Pull-out clutch

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

6. Remove the relay roller clutch [D] (one hook, one connector [E]).

G024R271.WMF

G024R272.WMF

[A]

[B]

[C]

[D]

[E]

TROUBLESHOOTING

SC TABLES

SM 7-1 G024

Tro

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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 intothree types:

TYPE 1: Safety warning andimmediate shutdown(Fusing unit errors)

The printer stops immediately and the LCD displaysan SC error message. The error is logged.

TYPE 2: Immediate shutdown The printer stops immediately and the LCD displaysan SC error message. The error is logged.

TYPE 3: Log only(Process control errors)

The printer does not stop. No SC error message isdisplayed. The error is only logged.

Fusing unit SC errors

Fusing unit SC errors (type 1 errors) can be released by executing the Reset SCitem in the engine SP mode menu. They cannot be released by turning the mainswitch off and on.

SC TABLES

G024 7-2 SM

7.1.2 SC ERROR LIST

SCNo. Type Name Occurrence conditions Detection conditions Cause

20Type 2 Optional tray

unit errorThe detection signal forthe 500 sheet paper trayunit is abnormal.

Always monitored. The optional trayunit connector has abad connection.

21

Type 1 Pressurerollerthermistorerror

The roller temperaturehas been at 0°C for fiveseconds.

No detection in theevent of a jam/dooropen, SC, unitabsence, energy-saving mode, or lackof fusing unit.

Pressure rollerthermistor, MCU.

22

Type 1 Highpressurerollertemperature

The roller temperaturehas been at 190°C orhigher for three seconds.

No detection in theevent of SC or nofusing unit installed.


23

Type 1 Lowpressurerollertemperature

Reheating has been doneand the motor is notrunning, or 60 secondshave passed after themain motor halted. Theroller temperature hasbeen below 130ºC for 60seconds.

No detection in theevent of a jam/dooropen, SC, unitabsence, energy-saving mode, or lackof fusing unit .

Pressure rollerthermistor, MCU,pressure roller lampconnector.

24

Type 1 Hot rollerthermistorerror

The roller temperaturehas been 0°C for fiveseconds.


Hot roller thermistor,MCU.

25Type 1 High hot

rollertemperature

The roller temperaturehas been 190°C or higherfor three seconds.

No detection in theevent of SC or fusingunit absence.


26

Type 1 Low hotrollertemperature

Reheat has been doneand the motor is notrunning, or 60 secondshas passed after mainmotor halt. The rollertemperature has beenbelow 130ºC for 60 secs.

No detection in theevent of a jam/dooropen, SC, unitabsence, energy-saving mode, orfusing unit absence.

Hot roller thermistor,MCU, hot rollerlamp connector.

27

Type 1 AC Powerzero-crossdetectionerror

No zero-cross signal canbe detected when thefusing heaters turn on.

NOTE: From main enginefirmware ver. 2.21 orlater, this SC can bereleased by turning theunit OFF then ON.


60HZ ACThe number of zero-cross cycles isdetected less than109 times or morethan 131 times for 5continuous seconds.

⇒

Rev. 09/2000

SC TABLES

SM 7-3 G024

Tro

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sho

oti

ng


28

Type 2 Papertransferpositive biasrelease error

The PWM duty has been50% or higher for 240ms. Or, the paper transferroller clutch does notoperate.

Detection starts 60ms after control startsfor this component.

There is a dis-connection in thepaper transfer biassupply circuit.(Deformation ofterminals or springs,dirty bearings)When the contact /separation lever isnormal: Bad transferroller positionsensor harness, orMCU. When thecontact/separationlever is faulty: Badtransfer roller clutchor MCU.

29

Type 2 Primarytransfer biasopen

The PWM duty has been50% or higher for 240ms.


There is adisconnection in theprimary transfer biassupply circuit. (Dirtyor deformedelectrodes.)

31

Type 2 Supply biaserror

The voltage has beenhigher than theappropriate controlvoltage for the targetvoltage for 240 ms.However, detection isdisabled when thecalculated control voltageis 5 V or higher.


There is a shortcircuit in the supplybias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter.)

32

Type 2 Blade biaserror



There is a shortcircuit in the bladebias supply circuit.

33

Type 2 Chargecorona unitbias open



There isdisconnection in thecharge corona unitbias supply circuit.(Dirty or deformedelectrodes.)

34

Type 2 Chargecorona unitgrid biaserror



There is a shortcircuit in the chargecorona unit grid biassupply circuit (dueto deformedterminals orelectrodes orconductive foreignmatters).

35 Type 2 Main motorerror

Continuous unlock fortwo seconds.

Main motor, MCU.

36 Type 2 PCU motorerror


PCU motor, MCU.

Rev. 09/2000

⇒

SC TABLES

G024 7-4 SM


38

Type 2 Revolvermotor error

Movement to the homeposition took four or moreseconds. For black,movement to the homeposition took one secondor longer.

Incorrect installationof colordevelopment unit,revolver motor,MCU defective.

39Type 2 Polygon

mirror motorerror


Polygon mirrormotor, MCU.

40

Type 2 ID sensorerror

The ID sensor outputvoltage is not between0.1 V and 1.1 V while theID sensor LED is off.

ID sensor calibration. ID sensor.

41

Type 2 Transfer beltH.P. sensorerror

No mark has beendetected for 500 msduring PCU motoroperation.

Transfer belt H.P.sensor, MCU.

42 Type 2 Laser diodeerror

LD error (abnormal laserpower output)

LD, LD controlboard

43Type 2 Synchronizat

ion detectionerror

Synchronization detectionerror of the optical unit

During polygon mirrormotor revolution

Synchronizationdetection board, LDcontrol board

45

Type 2 Charge biasshort

A/D converted voltagehas been 4.8 V or morefor 240 ms.


There is a shortcircuit in the chargebias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter)

46

Type 2 Papertransferpositivecurrent error

A/D converted voltagehas been 0.2 V or less for240 ms.


There is a shortcircuit in the papertransfer bias supplycircuit (due todeformed terminalsor electrodes orconductive foreignmatter)

47

Type 2 Papertransfernegative biasopen

The PWM duty has been50% or greater for 240ms.


There isdisconnection in thepaper transfer biassupply circuit. (Dirtyor deformedelectrodes)

48

Type 2 Papertransfernegativecurrent error




49

Type 1 Pressureroller reheattimeout

When reheating, theroller temperature doesnot reach the reheat starttemperature (targettemperature -20°C) withinfive minutes.

During reheating Pressure rollerthermistor, pressureroller lampconnector, MCU

Rev. 09/2000

⇒

SC TABLES

SM 7-5 G024

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50

Type 1 Hot rollerreheattimeout


During reheating Hot roller thermistor,hot roller lampconnector, MCU

51

Type 1 Pressureroller lampfull-poweroperationerror

When full-poweroperation occurs duringreheating, the main motoris not running and thedifference between thecurrent temperature andthat of 60 seconds ago is18°C or less.


Pressure rollerthermistor, pressureroller lampconnector, MCU

52

Type 1 Hot rollerlamp full-poweroperationerror



Hot roller thermistor,hot roller lampconnector, MCU

57Type 2 Print

commanderror

When an abnormalcombination of printcommands is received.

59

Type 2 Temperaturesensor error

5 V (4.75 V) or more hascontinuously beendetected for five seconds.

When the power ison, or the ACdevelopment bias isoff.

Temperature sensor

60

Type 2 Humiditysensor error



Humidity sensor

Rev. 09/2000

⇒

SC TABLES

G024 7-6 SM

7.1.3 PROCESS CONTROL ERROR LIST

PENo. Type Name Occurrence conditions Detection

conditions Cause

103

Type 3 K ID sensorerror

While the LED is off, theID sensor output does notmeet the standardvoltage (between 0.05 Vand 1.5 V).

ID sensor (K)calibration

When the outputmeets the standardvoltage: MCU, harnessWhen the output doesnot meet the standard:K ID sensor

104

Type 3 ID sensoroutput error(roughadjustment)

The difference in IDsensor outputs when thetransfer belt is read andwhen the LED is off doesnot meet the standardvoltage (Vbkcal±0.4 V).


K ID sensor, MCU,transfer belt error,transfer belt surfaceunevenness, incorrectID sensor installation

105

Type 3 ID sensoroutput error(fineadjustment)

The difference in IDsensor outputs when thetransfer belt is read andwhen the LED is off doesnot meet the standardvoltage (Vbkcal±0.1 V).


K ID sensor, MCU,transfer belt error,transfer belt surfaceunevenness

110

Type 3 ID sensorpattern error(Cyan)

The slope γM of the linerepresenting therelationship between theC development bias andattached toner amount isnot between –0.01 and –0.0005.

Color DTMinitialization

Incorrect color DTMinstallation, incorrectPCU installation,development biaserror, MCU, LD controlmalfunction, loss ofsynchronization

111

Type 3 ID sensorpattern error(Magenta)

The slope γM of the linerepresenting therelationship between theM development bias andattached toner amount isnot between –0.01 and –0.0005.



112

Type 3 ID sensorpattern error(Yellow)

The slope γM of the linerepresenting therelationship between theY development bias andattached toner amount isnot between –0.01 and –0.0005.



116

Type 3 ID sensorpattern error(k)

The slope γM of the linerepresenting therelationship between theK development bias andattached toner amount isnot between –0.01 and –0.001.


Incorrect K DTMinstallation, incorrectPCU installation,development biaserror, MCU, LD controlmalfunction, loss ofsynchronization

118

Type 3 ID sensorpattern readerror (K)

The difference in IDsensor outputs when theID sensor pattern is readand when thebackground surface ofthe transfer belt is read is0.8 V or less.

K-DTM biasinitialization

Incorrect DTMinstallation, incorrectPCU installation,development biaserror, MCU, LD controlmalfunction, loss ofsynchronization

SC TABLES

SM 7-7 G024

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PENo. Type Name Occurrence conditions Detection

conditions Cause

123

Type 3 ID sensorpattern error(K)

The slope γM of the linerepresenting therelationship between theDTM bias and attachedtoner amount is notbetween –0.01 and –0.001.

K-DTM bias control Incorrect DTMinstallation, incorrectPCU installation,development biaserror, MCU, LD controlmalfunction, loss ofsynchronization

USER ERROR LIST

G024 7-8 SM

7.2 USER ERROR LIST

Error Operation aftererror

Detectionconditions Release method Remarks

Add Toner: xx Printing can bedone.

Toner near-enddetection is enabledtwo seconds afterthe developmentdrive solenoid turnson until it turns off.The toner near-endmessage isdisplayed whentoner end isdetected five times.

Replace the DTM. When near-end isdetected, closing thefront cover initiatesrecovery. If the tonernear-end status iscleared, it is notdetected duringrecovery. In single-color (black-and-white) continuousoutput, toner near-end is detectedduring processcontrol.

Loadxx(By-pass feedtable)

Printing is disabledwhen the by-passpaper feed table isspecified. If paperend is detected forthe second imagein double-imagemode, the printerstops after the firstsheet is printed.

Paper end isdetected by the by-pass feed paper endsensor.

Supply paper. Double-image mode:Two images on thetransfer belt at thesame time.

Loadxx(Tray 1)

Printing is disabledwhen the papertray is specified. Ifpaper end isdetected for thesecond image ofthe double-imagemode, the printerstops after the firstsheet is printed.

Paper end isdetected by thepaper end sensor ofthe first paper tray.

Supply paper.

Loadxx(Tray 2)

Printing is disabledwhen the secondpaper tray isspecified. If paperend is detected forthe second imageof the double-image mode, theprinter stops afterthe first sheet isprinted.

Paper end isdetected by thepaper end sensor ofthe second papertray.

Supply paper.

Loadxx(Tray 3)

Printing is disabledwhen the thirdpaper tray isspecified. If paperend is detected forthe second imagein double-imagemode, the printerstops after printingthe first sheet.

Paper end isdetected by thepaper end sensor ofthe third paper tray.

Supply paper.

USER ERROR LIST

SM 7-9 G024

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Paper SizeError

Printing isdisabled.

The specified papersize for the by-passfeed table differsfrom that detected.Or the paper size inthe tray differs fromthe paper size dialsetting by ±40 mm.

Open the door.

Change PCU Printing can bedone.

The CPU counterreaches 60,000.

Replace the PCU toreset the counter.

Counting (upon exit)A3/DLT or smallerK single-color: Plus1Full color: Plus 4For sizes larger thanA3/DLT, countingdoubles.

ChangeFusing Unit

Printing can bedone.

The fusing unitcounter reaches60,000.

Manually release theerror using‘Maintenance Clear’in controller SPmode.

A3 or larger:Number of sheetsthat have passed x2Smaller than A3:Number of sheetsthat have passed

Waste TonerNearly Full

20 sheets can beprinted.

The used tonerbottle is detected as“full”’ for 10 seconds.

Replace the usedtoner bottle.

The near-full statusis reset if the fullused toner bottlestatus is notdetectedcontinuously for 10seconds.

Waste Toneris Full


20 sheets have beenprinted in the usedtoner near-fullstatus.

Replace the usedtoner bottle.

The near-full statusis reset if the fullused toner bottlestatus is notdetectedcontinuously for 10seconds.

Add Fuser Oil 200 sheets can beprinted after thefusing oil near-endmessage isdisplayed.

Oil end iscontinuouslydetected for 10seconds.

Supply fusing oil. The oil near-endstatus is reset whenoil end is notdetectedcontinuously for 10seconds.

Fuser Oil isLow


200 sheets havebeen printed in thefusing oil near-endstatus.

Supply fusing oil. The oil near-endstatus is reset whenoil end is notdetectedcontinuously for 10seconds.

Reset PCUCorrectly


The PCU set sensordetects no PCUwhen the mainswitch is turned onor the cover isclosed.

Set the PCU.

USER ERROR LIST

G024 7-10 SM



Reset ChargerCorrectly


The charge coronaunit set switch doesnot detect the wirecleaner for thecharge corona unitwhen the mainswitch is turned onor the cover closed.

Install the chargecorona unit correctly.Return the wirecleaner to the homeposition.

Reset FusingUnit Correctly


Disconnection isdetected for both thehot and pressureroller thermistorswhen the mainswitch turns on.

Install the fusing unitcorrectly.

Reset TrayCorrectly

Printing is disabledwhen the no traymessage isdisplayed for thespecified tray

None of the papersize switches for thattray detect anything.

Install the traycorrectly.

Reset TonerCorrectly


The DTM sensordoes not detect aDTM when the mainswitch is turned onor the front coverclosed.

Install the DTMcorrectly.

USER ERROR LIST

SM 7-11 G024

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Detection conditions Releasemethod Remarks

Error Operationafter error Paper

tray

Paperfeedclutch topull-outsensor

Paper feedclutch toregistrationsensor (1 st)

Paper feedclutch toregistrationsensor (2 nd

in double-image mode

Tray 1 0.9 s 3.24 s 3.82 s

Removethejammedpaper andclose thefront cover.

Tray 2(Option)

0.9 s 3.9 s 4.08 s


Paperfeedjam


Tray 3(Option)

0.9 s 5.14 s 5.31 s


The paperfeed jamcounterincreases by1.

Double-image mode:Two imageson thetransfer beltat the sametime.

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.

USER ERROR LIST

G024 7-12 SM

Error Operationafter error Detection conditions Release

method Remarks

Transportjam


The exit sensor does notdetect paper 3.14 secondsafter the registration clutchactivates. (6.28 seconds fortransparencies and thickpaper)

Remove thejammed paperand close thefront cover.

The transportjam counterincreases by 1.

Exit jam Printing isdisabled.

The exit sensor detectspaper 2.18 seconds afterthe registration sensor de-activates.The following conditionsare regarded as roll-injams, however, an exit jammessage is displayed:• The exit sensor is de-

activates less than twoseconds after theregistration clutch turnsoff. (Four seconds orlonger fortransparencies andthick paper)

• When the exit sensor isturned off before theregistration sensorturns off.

Remove thejammed paperand close thefront and exitcovers.

The exit jamcounterincreases by 1.

Front coveropen


Always monitored Close thecover.

Exit/DTMcover open


Always monitored Close thecover.

FIRMWARE HISTORY

SM 7-13 G024

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7.3 FIRMWARE HISTORY

7.3.1 G024 FIRMWARE MODIFICATION HISTORY

G024 FIRMWARE MODIFICATION HISTORY

DESCRIPTION OF MODIFICATION FIRMWARELEVEL

SERIALNUMBER

FIRMWAREVERSION

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.

G0245500 H June ’99Production

2.16

Corrects the following:• Change the Transfer Current value on OHP

mode.

G0245500 J July ’99Production

2.17

Corrects the following:• Change the Transfer Current value on OHP mode

to optomize with FOLEX.• Set Setup status flag when detecting DTM cover

sheet.

G0245500 K September ’99Production

2.18

Corrects the following:• SC98 may occur while continuous B/W printing

depending upon the timing.• SC28 may occur while continuous color printing

depending upon the timing.• SC41 may occur if paper end is detected and

paper is added on the tray during half print speed.(Thick paper or OPC Transparency mediaprinting)

G0245500 L October ’99Production

2.20

Corrects the following:• Condition for SC105 detection.• Additional SP mode menu for Primary Transfer

Bias “15-BLT-TR BIAS”.• Secondary Bias Control error may occur during

initialization.

G0245500 N November ’99Production

2.23

Corrects the following:• Auto pattern printing after PCU replacement.

G0245500 Q February ‘00Production

2.26

Corrects the following:• Change timing for turning on the Revolver Motor

when detecting paper end as the countermeasurefor SC38 detection error.

• Skip the K-DTM process control procedure oncolor DTM replacement to thin vertical lines.

• The development roller is rotated twice on DTMreplacement to prevent thin vertical lines.

• Change the timing for turning off the charge biaswhen printing images wider than letter size inB/W mode.

G0245500 S April ‘00Production

2.30

⇒

Rev. 08/2000

500-SHEET PAPER TRAY UNIT(SECOND AND THIRD TRAYS)

G908

SPECIFICATIONS

SM 8-1 G024

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1.1 SPECIFICATIONS

Paper Feed Method Friction pad

Configuration Front loading

Paper Capacity 500 sheets (80 g/m2, 20 lbs.)

Paper Size 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 64 to 105 g/m2 (17 to 28 lbs.)

Power DC 24V, DC 5V (supplied by the main unit)

Dimensions 580 x 465 x 138 mm (22.8” x 18.3” x 5.4”)

Tray Weight 6.0 kg.

PARTS LAYOUT

G024 8-2 SM

1.2 PARTS LAYOUT

1. Pull-out sensor

2. Paper end sensor



5. Tray main motor

6. Tray control board

G908D801.WMF

1

2

3

4 5

6

OVERVIEW

SM 8-3 G024

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2.1 OVERVIEW

2.1.1 MECHANICAL LAYOUT

1. Tray bottom plate

2. Friction pad

3. Paper lift arm


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

G908D802.WMF

1 2

3

4

10 9 8 7 56

OVERVIEW

G024 8-4 SM

2.1.2 CONFIGURATION

Function Main function OverviewPaper feed/separation Friction pad separation methodTray bottom plate pressure Paper tray bottom plate pressurized by a

spring under tensionPaper end detection Detection by actuator and photo interrupter

Paper feed

Paper size detection User-specified by a dial; detected byswitches.

Drive Motor drive Stepper motor

MECHANISMS

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2.2 MECHANISMS

2.2.1 DRIVE

Gears and the paper feed clutch [A] transfer drive from the tray main motor [B] tothe 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.

G908D803.WMF

[B]

[C]

[A]

[D]

MECHANISMS

G024 8-6 SM

2.2.2 PAPER FEED AND SEPARATION

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].

G908D805.WMF

[A]

[B]

MECHANISMS

SM 8-7 G024

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2.2.3 TRAY LIFT

A spring [A] under tension connects the bottom plate [B] of each tray to the papertray arm [C].

When the paper tray is placed in the main unit, the guide block [D] on the main unitbase lifts the paper tray arm. The spring connected to the bottom plate keeps thetop of the paper at the correct level for paper feed.

2.2.4 PAPER END DETECTION

The paper end sensor [A] is installed in the main body of the 500-sheet paper trayunit. When the sensor feeler [B] falls into the notch in the bottom plate [C], paperend is detected.

G908D806.WMF

G908D807.WMF

[A]

[B]

[C]

[D]

[A]

[B]

[C]

MECHANISMS

G024 8-8 SM

2.2.5 SIZE DETECTION

Paper size detection is based on the three paper size switches [A] on the mainbody of the 500-sheet paper tray unit, which detect the setting of the paper sizedial [B] on the tray.

The paper size dial has grooves and ridges on the side facing the paper sizeswitches. Each switch is turned off when it falls into a groove, and is turned onwhen a ridge presses it.

Paper size detection for tray 2 and 3Sensor Status

Dial No. Paper Size J9(SPS2)

J10(SPS1)

J11(SPS0)

1 11" x 17" SEF 0 0 02 A3 SEF 1 1 03 A4 LEF 0 1 04 81/2" x 11” LEF 1 0 15 81/2" x 14" SEF 1 0 06 71/4" x 101/2" LEF 0 0 17 Others 0 1 08 No Cassette 1 1 1

SEF: Short edge feed LEF: Long edge feedOthers: SEF - B4 JIS, 8" x 13", 81/4" x 13", 81/2" x 13" LEF - B5 JIS, A5, 51/2" x 81/2"

G908D808.WMF

[A][B]

MECHANISMS

SM 8-9 G024

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2.2.6 VERTICAL TRANSPORT

A sheet fed from the paper feed roller[A] for the third tray actuates the pull-out sensor [B]. The pull-out roller [C]then sends the sheet upwards in thedirection of the second tray.

When the pull-out sensor for the thirdtray is actuated, the pull-out roller [D]for the second tray starts rotating.

The pull-out roller for the second trayfeeds the sheet arriving from the thirdtray to the pull-out roller [E] for themain unit.

The pull-out roller rotates insynchronization with the drive motor.

G908D809A.WMF


Main motor (3rd tray)

Paper feed clutch(3rd tray)

Pull-out switch (3rd tray)

Main motor (2nd tray)

Pull-out clutch

Pull-out switch (2nd tray)


Timin g chart for o p tional tra ys

G908D810.WMF

[A]

[B]

[C]

[E]

[D]

CIRCUITS

G024 8-10 SM

2.3 CIRCUITS

2.3.1 BLOCK DIAGRAM

2nd 500-sheet paper tray

UpperCN860

LowerCN863

Main

3rd 500-sheet paper trayUpper

CN860

Tray control board

CN501

CN503

CN504

CN505

CN507

CN502

LowerCN863

Paperswitch

CN506

Papersensor

Pull-outsensor

Mainmotor

Paperfeed

clutch

6 7

6 7

Tray control board

CN501

CN503

CN504

CN505

CN507

CN502

Paperswitch

CN506

Papersensor

Pull-outsensor

Mainmotor

Paperfeed

clutch

6 7

6 7

G908D811.WMF

CIRCUITS

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Combinations of signals from the J6 (XSPST0) and J5 (XSPST1) pins on theCN860 connector indicate the presence of a 500-sheet paper tray unit (second orthird tray).

CN860 (Tray 2) StatusJ6 J5

No tray detected H HTray 2 detected L HTray 2 and 3 detected L LError H L

The J4 (SPSEL) pin of connector CN860 determines which of the two trays theCPU is controlling or detecting signals from.

J4 (SPSEL) of CN860 SelectionL Tray 2H Tray 3

G908D804.WMF

CN863

CN860

PAPER FEED ROLLER

G024 8-12 SM


3.1 PAPER FEED ROLLER

1. Remove the tray.

2. Push the paper feed roller lever [A] toward the right side, and remove the paperfeed roller [B].

G908R604.WMF

[A]

[B]

FRICTION PAD AND PULL-OUT IDLE ROLLER

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3.2 FRICTION PAD AND PULL-OUT IDLE ROLLER

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 thefront cover [B] forward, then lift it to remove it from the protrusion [C] on eachside.

2. Remove the two springs [D] from the bearings.

3. Remove the pull-out idle roller [E] (two bearings).

G908R601.WMF

[A]

[B]

[D]

[C]

[E]

PAPER END SENSOR AND PULL-OUT SENSOR

G024 8-14 SM

3.3 PAPER END SENSOR AND PULL-OUT SENSOR

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).

G908R605.WMF[A]

[B]

TOP COVER

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3.4 TOP COVER

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).

G908R602.WMF

[A]

PAPER FEED CLUTCH AND PAPER SIZE SWITCH

G024 8-16 SM

3.5 PAPER FEED CLUTCH AND PAPER SIZE SWITCH

3.5.1 PAPER FEED CLUTCH


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 rollershaft [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 oneclamp).

NOTE: When installing the paper feed clutch, put the stoppers in the two holes inthe top cover before inserting the shaft.

Paper size switch

1. Remove the paper size switch [D] (two hooks, one connector).

G908R606.WMF

[A]

[B]

[C]

[D]

PULL-OUT DRIVE ROLLER

SM 8-17 G024

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3.6 PULL-OUT DRIVE ROLLER


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 twobearings [C]).

NOTE: Be careful not to deform the grounding plate.

G908R607.WMF

[A]

[B]

[C]

[D]

[C]

TRAY MAIN MOTOR AND TRAY CONTROL BOARD

G024 8-18 SM

3.7 TRAY MAIN MOTOR AND TRAY CONTROL BOARD

Tray main motor

1. Remove the top cover. (See Top Cover.)


3. From the bracket [A], remove the motor [B] (two screws, one connector).

Tray control board


2. Remove the board [C] (two stud locks, two screws, seven connectors, and agrounding wire).

G908R603.WMF

[A]

[B]

[C]

G024

CONTROLLERAND

NETWORK INTERFACE BOARDTYPE 305

SERVICE MANUAL

NOTE: The first section of this part of the Service Manualrefers to the Controller. The second section details theNetwork Interface Board Type 305.

To differentiate this version from the G024 Fiery 500Controller Version (G024 PS), when equipped withthis controller the G024 is generally referred to as theG024 Win.

SM I G024

TABLE OF CONTENTSCONTROLLER

1. OVERALL MACHINE INFORMATION ......................................... 1-11.1 SPECIFICATIONS.....................................................................................1-11.2 LAYOUT ....................................................................................................1-2

2. DETAILED DESCRIPTIONS ........................................................ 2-12.1 FUNCTIONAL OVERVIEW .......................................................................2-1

2.1.1 BLOCK DIAGRAM............................................................................2-12.1.2 PRINT DATA PROCESSING ...........................................................2-2

CMS (Color Management System) .......................................................2-3Color Adjustment by the Driver .............................................................2-3Color Conversion, and Gamma Correction by the Controller................2-3

2.1.3 GAMMA CORRECTION...................................................................2-3Controller gamma (γ) (not adjustable)...................................................2-3Service gamma (γ) ................................................................................2-3

2.2 FUNCTIONAL DESCRIPTION ..................................................................2-41.2.1 CONTROLLER LAYOUT..................................................................2-41.1.2 FUNCTIONS OF COMPONENTS ....................................................2-5

2.3 POWER-UP SELF-DIAGNOSTICS...........................................................2-71.3.1 OPERATION PANEL DISPLAY DURING POWER-UP SELF- DIAGNOSTICS.....................................................................2-7

Immediately after turning the power on.................................................2-7During power-up self-diagnostics..........................................................2-7If the test terminates normally...............................................................2-7If an error is detected............................................................................2-7Non-fatal error detected........................................................................2-8Fatal error detected ..............................................................................2-8

2.4 POWER-UP SELF-DIAGNOSTICS FLOW CHART ..................................2-9

3. INSTALLATION............................................................................ 3-1

4. SERVICE TABLES ....................................................................... 4-14.1 SP MODES ...............................................................................................4-1

4.1.1 OVERVIEW ......................................................................................4-14.1.2 ENGINE SP MODE ..........................................................................4-14.1.3 CONTROLLER SP MODE................................................................4-1

Entering and Exiting Controller SP Mode..............................................4-1SP Mode Menu Hierarchy.....................................................................4-2Controller SP Mode Functions ..............................................................4-4

4.1.4 MENUS AND DISPLAY....................................................................4-5Key manipulation ..................................................................................4-5LCD display ..........................................................................................4-6

G024 II SM

4.1.5 SP MODE DETAILS .........................................................................4-7S1. Maintenance Sheet ........................................................................4-7S2. Color Chart .....................................................................................4-8S3. Maintenance Clear .........................................................................4-8S4. Clear All Memory............................................................................4-8S5. Gamma (γ Calibration.....................................................................4-8S6. Printer ID ........................................................................................4-9S7. Brand (Default Setting: RICOH.EXP) .............................................4-9

4.2 DETAILED SELF-DIAGNOSTICS MODE ...............................................4-10Overview.............................................................................................4-10Operating Procedure ..........................................................................4-10Operation Panel Behavior During Detailed Self-diagnostics ...............4-11Detailed Self-diagnostics Flow Chart ..................................................4-12Test Results Printout when No Fatal Errors Occur .............................4-13

5. PERIODIC MAINTENANCE ......................................................... 5-1

6. REPLACEMENT AND ADJUSTMENT......................................... 6-16.1 CONTROLLER BOARD REPLACEMENT ................................................6-16.2 IMAGE ADJUSTMENT..............................................................................6-1

6.2.1 OVERVIEW ......................................................................................6-16.2.2 SERVICE GAMMA (γ ADJUSTMENT...............................................6-2

Adjustment Menu (Controller SP, S5. Gamma (γ Calibration) ..............6-2Adjustment Overview............................................................................6-3Adjustment Procedure ..........................................................................6-4

6.2.3 SOFTWARE UPGRADE PROCEDURE...........................................6-5

7. TROUBLESHOOTING.................................................................. 7-17.1 TYPES OF PROBLEMS............................................................................7-17.2 TROUBLESHOOTING PROCEDURE.......................................................7-2

7.2.1 HARDWARE TESTS ........................................................................7-27.2.2 OPERATION-RELATED TESTS ......................................................7-27.2.3 SOFTWARE-RELATED TESTS .......................................................7-3

7.3 ERROR MESSAGES ................................................................................7-47.3.1 OVERVIEW ......................................................................................7-47.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS .............................7-57.3.3 CONTROLLER USER ERRORS......................................................7-67.3.4 INTERNAL ERRORS........................................................................7-77.3.5 ENGINE USER ERRORS (CAUTIONARY)......................................7-87.3.6 ENGINE SERVICE CODES .............................................................7-8

8. NETWORK INTERFACE BOARD TYPE 305............................... 8-18.1 OVERVIEW ...............................................................................................8-1

8.1.1 SPECIFICATIONS............................................................................8-18.1.2 BLOCK DIAGRAM............................................................................8-1

8.2 COMPONENT LAYOUT............................................................................8-28.2.1 NETWORK INTERFACE BOARD DIAGRAM...................................8-28.2.2 DEVICES..........................................................................................8-2

SM III G024

8.3 BASIC OPERATIONS ...............................................................................8-38.3.1 OVERVIEW ......................................................................................8-38.3.2 LED FUNCTIONS.............................................................................8-38.3.3 SWITCH FUNCTIONS......................................................................8-48.3.4 NETWORK SETTING FUNCTION ...................................................8-5

8.4 FIRMWARE HISTORY ..............................................................................8-6

Rev. 05/2000

OVERALL INFORMATION


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1.1 SPECIFICATIONS

Page DescriptionLanguage

IPDL-CRicoh-Script 2 (Option)

Printer Driver IPDL-C: Windows 98/95/3.1x/NT4.0Ricoh-Script 2: Windows 98/95/NT4.0, Macintosh (PPD

for LaserWriter 8)

Resolution Controller: 600/300 dpi

Color Mode Color (4 color mode only)/Monochrome (black only)Set by the printer driver

Gradation Mode 2 or 1 bit/pixel

Smoothing Auto/Off (by a printer driver setting)

Toner Saving On/Off (by a printer driver setting)

Color Correction On/Off (by a printer driver setting)Default setting: Enabled

Interface Standard: Bi-directional Parallel (IEEE1284: compatibleand nibble mode supported)

Option: Parallel (IEEE1284: only compatible modesupported), Ethernet (100Base-TX/10Base-T)

Network Protocol IPX/SPX, TCP/IP, AppleTalk (with Ricoh-Script 2)

Fonts IPDL-C: Japanese fonts only - not used

Ricoh-Script 2: 39 fonts

Memory Standard: 32 MBOptional upgrades: 16 MB SIMM, 32 MB SIMM

SIMM Slot 2 (for optional memory)

DIMM Slot 1 (for optional Ricoh-Script 2)

Option Interface 2 (for optional network I/F board and optional parallelI/F)

Options 16 MB Memory

32 MB Memory

Network Interface Board

IEEE1284 Parallel Interface

Ricoh-Script 2 Emulation Module

OVERALL MACHINE INFORMATION 31 March, 1999

G024 Win 1-2 SM

1.2 LAYOUT

1. Controller

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2. DETAILED DESCRIPTIONS

2.1 FUNCTIONAL OVERVIEW

2.1.1 BLOCK DIAGRAM

The functions and characteristics of the various blocks in the controller aredescribed 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 networkinterface).

Print Image Generator Block

1. Converts the data received from the host into a print image and writes thisimage into the memory (the image conversion method depends on thecontroller's settings).

Operat ion Panel

Printer Hardware

M C UPrinter Engine Controller

Control Block

Host InterfaceBlock

Print ImageGenerator Block

Engine InterfaceBlock

Control ler Printer Engine

LD Uni tSynch.

Detector

Printer

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Engine Interface Block

1. After converting the image data into 4-bit data, sends the image data in parallelon a 4-bit/pixel basis in synchronization with the synchronization signal andclock 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 thediagram represent function blocks and the text next to the arrows indicates the datatype. The diagram is followed by a brief description of color processing by theprinter driver.

IPDL-C Ricoh-Script

Application

GDI

Printer Driver

Controller

Printer Engine

RGB 8bit

RGB 8bit

RGB 8bit

CMYK 2 or 1 bit

CMS *

Application

Printer Driver

Controller

Printer Engine

RGB 8bit

RGB 8bit

CMYK 2 or 1 bit

Ricoh-Script(including CMS*)

CMYK 8bit

CMYK 8bit

CMYK 8bit

* CMS: Color Management System

Conversion to4-bit data

Conversion to4-bit data

CMYK 8bit

CMYK 8bit

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CMS (Color Management System)

The CMS adjusts the RGB values of the colors in the application data inpreparation for RGB to CMYK conversion, which is done in the controller.

A file known as a ‘profile’ is automatically installed in the \windows\system\folderwith the file name extension ‘.rcm’ (unique to this printer) during the printer driverinstallation. This file contains instructions for the CMS on how to compensate thecolors in the print data produced by the application.

CMS is used whenever the color correction setting in the printer driver is set to anyvalue other than “Off”.

Color Adjustment by the Driver

The driver adjusts the following parameters in accordance with the driver settingsmade 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 (γ) correction.

2.1.3 GAMMA CORRECTION

Gamma correction in this model has two components: controller gamma (γ) (non-adjustable) and service gamma (γ) (adjustable).

Controller gamma ( γγ) (not adjustable)

This gamma is programmed into the flash ROM in the controller. If there has beenno service gamma (γ) adjustment in the machine since installation, the controllergamma (γ) is the only gamma that is used (i.e., service gamma (γ) = 0).

Service gamma ( γ)

This gamma is stored in the NVRAM in the controller. It can be adjusted using thecontroller SP mode (S5. Gamma Calibration). See “Section 6.2.2 Service GammaAdjustment,” for the adjustment procedure.

The controller combines the service gamma (γ) (the default setting is zero) with thecontroller gamma (γ) when doing gamma correction.


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2.2 FUNCTIONAL DESCRIPTION

2.2.1 CONTROLLER LAYOUT

DIP

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2.2.2 FUNCTIONS OF COMPONENTS

Device Description/Function

CPU • VR4310-177 MHz

ASIC ROCKY F

• DRAM control

• Timeout monitoring

• Parallel interface

• Timer control

• I/O port control

• Engine interface serial communications control

• Image data decompression

• Interrupt control

FLASH ROM• For storing programs (2 MB)

• Programmable via a Flash ROM card.

NVRAM• Stores initial set-up settings and printer parameters.

• Uses a 2 KB EEPROM.

ASIC FCI2.5C• Smoothing

• Toner saving

FONT ROM• Uses two 32-Mbit mask ROMs (8 MB total).

• Stores internal printer fonts (Japanese fonts only - not used).

DRAM • Sixteen 16-Mbit DRAMs are installed as standard (32 MBtotal).

DIP SW

1 2 3 4

O F F

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VIDEO I/F • Interfaces the controller with the printer engine.

SW No. Setting Purpose

OFFThe controller boots from the flashROM located on the board (normalsetting).

1

ON

The controller boots from the FlashROM card (when upgrading thecontroller, NIB, or Ricoh-Script 2software).

2 to 4 Always set to OFF. For designers’use only.


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Device Description/Function

PARALLEL I/F • Provides an interface that connects to a local host(IEEE1284 compliant).

OPTION I/F 1,2

• Two slots; each can hold either an optional network interfaceor a parallel interface board. You cannot install two boardsof the same type.

• The optional board type can be identified from the unique IDbuilt into it.

DIMM SLOT

• A 72-pin slot for accommodating the optional Ricoh-Script 2emulation module.

• The emulation module is a programmable flash ROM.

SIMM SLOT

• Two slots for optional expansion memory boards.

• SIMM specifications: 16 MB or 32 MB SIMM, 60 ns accessspeed

FLASH ROMCARD SLOT

• For accommodating a Flash ROM card for upgrading thesoftware.


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2.3 POWER-UP SELF-DIAGNOSTICS

2.3.1 OPERATION PANEL DISPLAY DURING POWER-UP SELF-DIAGNOSTICS

The controller starts power-up self-diagnostic tests when the printer power isturned 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 PowerLED, which it causes to blink. It displays the message “Warming UP” on the lowerline of the LCD.

If the test terminates normally

If an error is not detected during the self-diagnostic test, the controller turns theblinking Power LED on and turns off all the other LEDs. The controller starts thesystem immediately afterwards.

If an error is detected

Errors are divided broadly into fatal and non-fatal errors. The controller takesdifferent actions and gives different status information for different types of errors.

See “Section 7.3.2 Controller Self-Diagnostics Errors” for tables of the differenttypes of errors.


G024 Win 2-8 SM

Non-fatal error detected

The controller causes the blinking Power LED to stay on, turns off all of the otherLEDs and the LCD, and restores the standby display state. Since non-fatal errorsdo not adversely affect any print operation, the controller starts the systemimmediately after it takes these actions.

The system turns on the Error LED and prints out a list of settings with errordescriptions, 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 andenables all devices except the failed one.

Fatal error detected

Since there is no guarantee that the system can generate a list of settings whenthe error detected is fatal, the system turns off the Power LED and turns on theError LED. At the same time, it displays and keeps an error message on the LCDuntil 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).


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2.4 POWER-UP SELF-DIAGNOSTICS FLOW CHART

Turn on power

Flash ROM cardinstal led?

Test Code ROM

Test Timer

Test CPU

Test ASIC

Test Font ROM

Start System

DIMM Instal led?

Test DIMM

Non-fatal Error(user error)?

TestFlash ROM card

Display Error onPanel

Generate List ofSett ings

Start System

Fatal ErrorDetected

Fatal ErrorDetected

Fatal ErrorDetected

Fatal ErrorDetected

Fatal ErrorDetected

N O

N O

N O

Y E S

Y E S

Y E S

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Code ROM sum check

Tests the timer functionsof the ROCKY F ASIC

Operation check

Tests the engine interfacefunctions of the ROCKY F ASIC

Font ROM sum check

Flash ROM card sumcheck, if Flash ROM cardis installed

DIMM (emulation module)sum check, if DIMM isinstalled

INSTALLATION

INSTALLATION

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3. INSTALLATION

Refer to the following materials.

• For the printer: Quick Installation Guide• For options: Operating Instructions

SERVICE TABLES

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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 modesThis 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 SPmodes.

4.1.3 CONTROLLER SP MODE

Entering and Exiting Controller SP Mode

To enter controller SP mode: Turn on the printer while holding down the [OnLine] [A] and [Reset] [B] keys on the operator panel. Hold the keys down until allof 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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[A] [B]

[A] [B]

SERVICE TABLES

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SP Mode Menu HierarchyThe table below shows the controller menu hierarchy. The menus in the table canbe accessed in the controller SP mode. When in SP mode, S1 to S7 are added tothe Maintenance menu.

Layer 1 Layer 2 Layer 3 Layer 41.Job Timeout Off

0 – 999 secondsIPDL-C Menu

2.I/O Timeout 0 – 999 seconds1.Paper Tray Tray 1

BypassTray 2Tray 3

“Tray 2 and 3” areselectable if anoptional paper feedunit is installed.

2. Tray Size [*] 8.5 x 13A5B4 JISB5 JIS5.5 x 8.58 x 138.25 x 15

3.I/O Buffer 16 kB32 kB64 kB128 kB256 kB512 kB

4.Energy Saver Off5 minutes15 minutes30 minutes45 minutes60 minutes

5. Energy Level Level 1Level 2

6.Transfer Hi-speedNormal

7.Image Memory OffOn

8.Parallel 1 ACK insideACK outsideSTB down

9.Parallel 2 ACK insideACK outsideSTB down

10.Bi-direction Original ModeStandard

11. OHP Slip ONOFF

System Menu

12. Printer Language IPDL-COption

Emulation name isdisplayed if anemulation module isinstalled.

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Layer 1 Layer 2 Layer 3 Layer 413.Language English

FrenchGermanItalianDutchJapanese

System Menu

32.IP ADDRESSto 39.Active PTL.

Displayed if anoptional networkinterface board isinstalled.

1.Toner Select CyanMagentaYellowBlack

2. Toner level3.Menu Reset4. Registration (Onlywhen optional tray isinstalled.)5. Menu Protect Off

OnIt can also beaccessed if the[Enter] , [Escape] , and[Menu] keys arepressed in sequencewhen the printer is online.

S1.Maint. SheetS2.Color ChartS3.Maint. Clear Fusing UnitS4.Clear All Mem.

Load Setting DefaultSetting-OldSetting-Current

Mode Select 1 bit/photo, 2 bit/photo,300 dpi/1bit.1 bit/Text, 2 bit/text,300 dpi/2 bit

Print Sheet

S5.Gamma Calib.

Gamma Select BlackCyanMagentaYellowSave Settings

S6.Printer ID

Maintenance

S7.Brand RICOH.EXPSAVINnashuatecRex-RotaryGestetnerRICOH.JPN

Before installation, thisalso can be accessedby sales staff bypressing the [▼], [▲]and [Menu] keys insequence.

List Print Config. PageColor Sample

SERVICE TABLES

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Controller SP Mode Functions

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

Additional Maintenance menuMenu Item Function/Use

S1.Maint. Page

Directs the controller to read and print the engine firmware version andthe following items from the NVRAM on the MCU:

• Image density• Registration values• Total counter values• SC Logging• ID sensor PWM value• Etc.

S2.Color Chart

Prints out the image quality check chart (this chart is included in thecontroller software).

S3.Maint. Clear

Resets the maintenance counters for the fusing unit.

S4.Clear AllMemo

Resets the parameters in the controller NVRAM to their default values.

S5.GammaCalib.

Performs a service gamma (γ) adjustment. It is possible to adjustservice gamma (γ) in both text and photograph modes for each color.

S6.Printer ID

Input this ID if the NVRAM on the controller board has been cleared orreplaced.

S7.Brand

Sets the brand name. This ensures that the LCD display and theconfiguration page header show the correct model name. This must bedone before the printer is passed to a customer.

The Controller SP mode adds special menu items to the user menu accessed fromthe [Media] (access by pressing the [Media] key, then scroll through the menu onthe display) menu.

Media Menu ([Media] key)

Menu Item Function/Use

3. SummaryDisplays the currently installed versions of the controllersystem, emulation modules, and engine (MCU) firmware, andthe amount of memory installed in the controller.

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4.1.4 MENUS AND DISPLAY

Navigate through the SP mode menu and operate the SP modes in the same wayas for the user menu.

Key manipulation

[▼] and [▲] keys: Used to scroll through the menu. Pressing these keys for anumeral set-up menu item changes the displayed value inminimum increments.

[Enter] key: When the selected item has a lower-level menu, use this key toenter the lower-level menu. When scrolling through a set ofvalues, use this key to select the displayed setting.

[Escape] key: Used to move to a higher-level menu. When pressed beforeselecting a value with the [Enter] key, the old value remainsvalid.

[On Line] key: Exits the menu and returns to the online mode. This key can beused at any menu level.

SERVICE TABLES

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LCD display

Title line: Shows the menu title, indicating your location in the menuhierarchy.

Menu item line: Shows a menu item. Press the [▼] or [▲] key to scroll throughthe menu items. When the [▼] or [▲] key is pressed at the lastmenu item, the display wraps around to the first menu item.When displaying settings, the current setting is identified by anasterisk ( * ) to its left. When the [Enter] key is pressed, theitem in the display is selected and the display goes up one levelin the menu hierarchy.

Arrow marks: Scrolls through the menu items. These marks do not appear ifthe menu has only one menu item.

Title Line

Menu Item LineArrow Marks

<System Menu>

1. Paper Tray

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4.1.5 SP MODE DETAILS

S1. Maintenance Sheet

The table below describes the contents of the engine maintenance list printout. Thecontroller obtains the data from the engine (MCU).

Item DescriptionMCTL version The MCU board firmware version number.Registration 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 Toner density can be adjusted by the operator via the Maintenance. Menu, byoperators. Adjusted values are stored in NVRAM on the MCU.

Total counter Indicates the total number of printouts. The counter is incremented when thepaper exit sensor detects paper exit completion (regardless of paper size, type,and mono/color mode).

Color Counter value printed in color mode.Mono color Counter value printed in mono color mode.

PCU counter PCU replacement is indicated when this value reaches 60000. This value isincremented 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 Fusing unit replacement is indicated when this value reaches to 60000. Thiscounter is incremented by 2 for A3/DLT size printing and by 1 for other sizeprinting.

Fusingunit/Counterreset time

Number of Fusing unit resets with controller SP mode (S3).

A3/DLT,A4/LT, LG, B4and etc. Sizecounter

Number of each size paper that passed the exit sensor.

Feed Jam,Transfer Jamand Eject Jamcounter

Number of paper jams in each section.

SC counter Number of SCsSC Logging The most recent 3 SC codes.Jam Logging The most recent 10 jamming codes and the total counter value at the time.

000: At paper cassette001: At paper pass002: At paper exit

Process-control errorLogging

The most recent 3 errors while process control and the total counter value atthe time.Not all of the errors are indicated as SC errors.

P sensorPWM

The value set with engine SP mode, 9: ID Sensor PWM.

SERVICE TABLES

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S2. Color Chart

This prints a color test chart, so that the image quality can be tested for all colors atvarious densities. This chart can be printed on all paper sizes supported by themachine (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 MCUboard). Use it after replacing the unit.

S4. Clear All Memory

Executing this function resets the following user settings, stored in the NVRAM onthe controller, to their initial values:

• Initial set-up items with System Menu• Printer ID• Printer name on the network• Gamma (γ) calibrationThe “Menu Reset” clear function in the user menu only resets the Initial set-upitems with System Menu to their initial values.

S5. Gamma (γγ) ) CalibrationThis mode adjusts the gamma (γ) 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 thecustomer insists on further fine adjustments (e.g., matching colors betweenmachines)

See “Section 6.2.2 Service Gamma (γ) Adjustment” for the adjustment procedure.

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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 [▼] and [▲] keys.

2. Input the number by pressing the [Enter] key (you can use the [Escape] key tocancel the setting if you input an incorrect number).

3. Repeat these steps until the last digit is entered. Pressing the [Enter] key onthe 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 correctmodel 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 power-up 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), ifthe devices are installed.

The following special tools are required to execute this mode:

Parallel Interface Loopback Connector

Part No. Type of Interface RemarksG0219350 For the standard parallel

interface boardIf not used, the controller continues thetest to the end, but flags a non-fatalerror.

G0109350 For the optional parallelinterface board

If an interface board is installed but theloopback connector is not, the controllercontinues the test to the end, but flags anon-fatal error.

NOTE: A decal with the part number is attached to each connector, to avoidconfusing the two types.

Operating Procedure

To enter the detailed self-diagnostics mode, make sure that the devices that youwish 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 additionalparallel interface has been installed, connect the loopback connector for thisport also.

3. Turn on the power while simultaneously pressing and holding down the [OnLine] [A] and [Enter] [B] keys on the operation panel. Hold the keys down untilall of the LEDs and the LCD turn off.

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[A] [B]

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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 PowerLED and causes the Power LED to blink. It displays the message “Service diag” onthe LCD.

When the tests terminate normally

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

When an error is detected

Errors are divided broadly into non-fatal errors and fatal errors. The controller takesdifferent actions and provides different status information for different types oferrors.

• When a non-fatal error is detectedThe controller turns the blinking Power LED on, turns off all of the other LEDsand the LCD, and restores the standby display. Since non-fatal errors do notadversely influence any print operation, the controller starts the systemimmediately after it takes these actions.

The system turns on the Error LED and prints out a list of settings with errordescriptions in monochrome mode (see “Section 7.3.3 Controller User Errors” forthe error codes).

After printing a list of settings, the system returns to the normal state and sets upall devices except the failed one.

• When a fatal error is detectedSince there is no guarantee that the system can generate a list of settings afterdetecting a fatal error, the system turns off the Power LED and turns on the ErrorLED. At the same time, it displays an error message on the LCD until the powerturns off.

The first line of the LCD contains a 4-digit code that identifies the error and thesecond line contains an 8-digit code that gives details of the error for designersto debug the error (see “Section 7.3.2 Controller Self-diagnostics Errors” for adescription of the error codes).

SERVICE TABLES

G024 Win 4-12 SM

Detailed Self-diagnostics FlowChart

Turn On Power

Tes t Code ROM

Test T imer

Tes t Memory

Tes t CPU

Test ASIC

Tes t NV-RAM

Test Font ROM

Flash ROMCard insta l led?

Test F lash ROM Card

DIMM Insta l led?

Tes t D IMM

Optional Paral le lI /F instal led?

Test Opt ional Paral le l I /F

Star t System

Generate l ist ofsett ings

Display error on panel

Fatal Error Detected





N o

Yes

Yes

N o

N o

Yes

G024O009.WMF

Code ROM sum check

Tests the timer functions ofthe ROCKY F ASIC

Read/write test

Operation test

Makes a loopback test on thestandard Centronics interface

Read/write test

Font ROM sum check

Flash ROM card sumcheck (if card isinstalled)

DIMM (emulation module)sum check (if DIMM isinstalled)

Optional parallel interfaceboard loopback test (if boardis installed)

SERVICE TABLES

SM 4-13 G024 Win

Ser

vice

Tab

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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 “ErrorLog” section at the bottom of the printout explains the non-fatal errors thatoccurred.

If no error occurred, the report is printed in color. The “Error Log” section contains“None”.

PERIODIC MAINTENANCE


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5. PERIODIC MAINTENANCE

Refer to Section 5 Preventive Maintenance in the engine service manual.


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6.1 CONTROLLER BOARD REPLACEMENT

1. Remove the Printer Controller Board. Refer to section 6.5.1 Controller Board ofthe Engine Service manual for the replacement.

6.2 IMAGE ADJUSTMENT

6.2.1 OVERVIEW

The table below lists the adjustable image parameters, with their correspondingadjustment procedures.

Item ProcedureBrightness, Contrast,Saturation, Color Balance

In the Print Quality tab of the Windows printer properties,select the ‘Custom’ button and click ‘Setting’. A range ofadjustments are displayed. The driver and controller reflectthe results of the adjustments in the image dataprocessing.

DevelopmentBias

This can be adjusted by customers via the MaintenanceMenu and stored in NVRAM on the MCU. Thedevelopment bias is automatically adjusted by referring tostored value.Density

Transfer Bias This can be adjusted in Engine SP mode.Refer to SP mode in the Engine manual.

Service Gamma

Use controller SP mode S5 (Gamma Calib.). You canadjust each color for each gamma (γ) table. The results ofthe adjustment are reflected in the gamma (γ) correctiondone by the controller.


G024 Win 6-2 SM

6.2.2 SERVICE GAMMA (γ) ADJUSTMENT

NOTE: For problems related to color quality and gradation, clean the engine andreplace supplies and other parts first. Use this mode only when thecustomer insists on further fine adjustments (e.g., matching colors betweenmachines).

Adjustment Menu (Controller SP, S5. Gamma ( γγ) ) Calibration)

The menu items under Gamma Calibration in controller SP mode are organized asshown below.

Layer 3 Layer 4 Layer 5 Layer 6DefaultSetting-Old

Load Setting

Setting-Current1 bit/Photo2 bit/Photo1 bit/Text2 bit/Text300 dpi/1 bit

Mode Select

300 dpi/2 bitPrint Sheet

K/01th. [xxx] K/01th. = xxx/255↓ ↓Black

K/15the. [xxx] K/15th. = xxx/255Cyan Same as above Same as aboveMagenta Same as above Same as aboveYellow Same as above Same as above

Gamma Select

Save Settings


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Adjustment Overview

To carry out this adjustment, select the print mode, to be adjusted then print out acolor adjustment sheet. Make the gradation scales on the printout smooth from thelowest to the highest density. Adjust the CMY gradation scale at the top of the chartby balancing the density of the C, M, and Y gradation scales – the CMY gray scaleshould change smoothly from minimum to maximum, and there should be nocoloration.

The color adjustment sheet is as follows.

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 within0 and 255.

The gradation scales marked ‘Default’ are printed according to the default gamma(γ) settings in the flash ROM in the controller. The gamma adjustment changes thedensities at the adjustable points in the gradation scale. The gradation scalemarked “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 0and 255, from the ‘Default’ gradation scale.

G024O013.BMP

[A]

[B]

[C]


G024 Win 6-4 SM

The NVRAM holds three controller gamma (γ) settings, those saved this time(Setting-Current), those saved in the preceding adjustment (Setting-Old), and thefactory settings (Default).

Adjustment Procedure

1. Select “Load Setting” and load the settings that will serve as the basis for theadjustment.

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 outa color adjustment sheet (Gamma (γ) 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 adjustmentsheet again and make sure that the gradation scale for each printed color issmooth and that the CMY gradation scale is gray. Repeat the adjustment ifthere 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 youreset 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 aflash ROM for storing control software. This allows version upgrades using a FlashROM card.

The engine's firmware cannot be upgraded using this procedure. Refer to theengine 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-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 interfaceboard(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, carefullyslide 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 networkinterface board earlier, reinstall it now.

5. Turn on the machine. The machine automatically copies the software from theFlash ROM card to the appropriate flash ROM (controller, Ricoh-Script 2, ornetwork 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 bedamaged.

For the controller or Ricoh-Script 2:The LCD display on the operation panel changes as shown below as the rewriteprocedure proceeds. (‘MELT’ is displayed during the software upgrade forRicoh-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 hasreceived the data from the Flash ROM card. However, note that it takes about30 seconds to rewrite the data in the controller or Ricoh-Script 2 after thismessage is displayed. So, be sure to wait at least 30 seconds beforeproceeding.


G024 Win 6-6 SM

The message NG!!NG!!” is displayed if an error occurs during the rewriteprocess. If this condition occurs, reinstall the Flash ROM card and turn thepower off and on again.

For the network interface board:The appearance of the message “DOWNLOAD OK.” indicates that thecontroller has received the data from the Flash ROM card. However, note that ittakes about 30 seconds to rewrite the data in the network interface board afterthis message is displayed.

DOWNLOAD -> ############ -> DOWNLOAD OK.

The message “DOWNLOAD NG.” is displayed if an error occurs during therewrite process. If this condition occurs, reinstall the Flash ROM card and turnthe 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.

TROUBLESHOOTING

31 March, 1999 TROUBLESHOOTING

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7. TROUBLESHOOTING

7.1 TYPES OF PROBLEMSThe problems can be classified as follows:

Operat ion

Hardware

Sof tware

Operat ingcondi t ions

• Printer-side Print Sett ings• Printer-side Init ial Sett ings• Host-s ide Appl icat ion Sett ings

• Faul ty Engine

• Faulty Control ler

• Hardware Limi tat ions

• Main Uni t

• Opt ion

• Consumab les

• Main Uni t

• Opt ion

• Bug in Contro l ler ROM

• Bug in Emulat ion Module Sof tware

• Control ler Limitat ions

• Bug in Host-s ide Appl icat ion

• Host-s ide Appl icat ion Limitat ions

• Environment (power, temperature and humidi ty , dust, noise, vibrat ion)• Consumab les

G024O014.WMF

TROUBLESHOOTING 31 March, 1999

G024 Win 7-2 SM

7.2 TROUBLESHOOTING PROCEDURE

7.2.1 HARDWARE TESTS

1. Power-up self-diagnosticsTurn on the power and check that an error code is not displayed.After the system starts, check for error messages on the configuration pagethat automatically prints.

2. Detailed diagnostic testSee “Section 4.2 Detailed Self-diagnostics Mode” in this manual for theprocedure.

3. Checking the configuration page output.Print out from the user menu: [Menu] → [List Print] → [Config. Page] . If errormessages are included, check the relevant part of the machine and replace anydefective components.

4. Connectivity testMake 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 thecurrent settings match the settings on the configuration page that the customerkeeps.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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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


G024 Win 7-4 SM

7.3 ERROR MESSAGES

7.3.1 OVERVIEW

The error messages for this unit are classified as follows:

1. Controller Self-diagnostic ErrorsErrors detected while the unit performs power-up self-diagnostics/detailed self-diagnostics on the controller hardware.

2. Controller User ErrorsErrors caused because the controller software cannot process the job becauseof, for example, insufficient memory.

3. Internal ErrorsErrors caused because the controller’s control function fails to functionnormally.

4. Engine User Errors (Cautionary)Errors that do not require user intervention to continue printing (the printer canstill communicate with the PC over the interface). However, for the best printingquality, the user should correct the problem as soon as possible.

5. Engine User ErrorsSevere errors that cause the unit to stop printing, requiring the user to fix theproblem before printing again.

6. Engine Service Codes (SCs)Severe errors that cause the unit to stop printing, requiring a technician to fixthe problem before printing again.

Only one error message can be displayed at a time. There is an order of priority fordisplaying errors. This is as follows: (starting with the highest priority) InternalErrors, Controller Self-diagnostics Errors, Engine Service Codes (SCs), EngineUser Errors, Engine User Errors (Cautionary), and Controller User Errors.


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7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS

When a controller self-diagnostics error occurs, the error code is displayed on thefirst line of the operation panel LCD.

The second line contains an 8-digit code that gives details of the error for designersto debug. For a memory error, the second line of the LCD indicates the addresswhere the error occurred. For errors other than memory errors, the second linealways reads “FFFFFFFF”.

Code Description Location00XX Exception processing error Controller0101 Flash ROM sum check error Controller0201 Standard memory read/write error Controller

0301/0401 Optional memory read/write errorNon-fatal error (printed as B0 in the errorlog.)

Optional memory

060X CPU exception self-diagnostics error Controller0D0X ASIC timer error Controller11XX ASIC Centronics interface error

Non-fatal error (printed as B1 in the errorlog.)

Controller

1401 NVRAM error (Read/Write) Controller1601 Font ROM error (Sum) Controller170X Flash ROM card error

1703 represents a non-fatal error (printedas B4 in the error log.)

Flash ROM card/Controller

1B0X Optional Interface 1 Error Controller1C0X Optional Interface 2 Error Controller1D0X Optional parallel interface board error

Non-fatal error (printed as B6 in the errorlog.)

Optional parallel interfaceboard

250X Optional emulation module errorNon-fatal error (printed as B5 in the errorlog.)

Emulationmodule/Controller

400X CPU error Controller450X ASIC compression/decompression error Controller460X FCI error

Non fatal error (printed as B9)Controller


G024 Win 7-6 SM

7.3.3 CONTROLLER USER ERRORS

Display Description Location/action

85: Error Graphics environment initializationerror

Optional memory/Controller

86: Error Invalid control code parameter Incorrect printer driver orincorrect cable installed

91: Error Font/image environmentinitialization error

Install additional memory.

94: Error Download data error Incorrect ‘total memory size’setting in the driver

A3: ErrorReceive buffer overflow Increase the I/O buffer size

using the system menu (usermode)

A6: Error Overflow during compression Install additional memory.

A7: ErrorError during drawing processing Use a smaller font size or a

less complex font, or replacethe controller

A8: ErrorError during library drawing Switch the machine off/on. If

that does not work, replacethe controller.

AB: Error Print overrun Install additional memory.

B0: Error Optional memory error Reinstall/replace optionalmemory.

B1: Error Standard parallel interface error Interface cable/controller

B3: Error

Invalid initial set-up setting Reset the printer settingsusing ‘Menu reset’ in theMaintenance menu (usermode).

B4: Error Flash ROM card slot error Controller/Flash ROM card

B5: Error Optional emulation module error Reset/replace emulationmodule.

B6: Error Optional parallel interface boarderror

Reset/replace optionalparallel interface board

B7: Error Optional network interface boarderror

Reinstall/replace networkinterface board

B9: Error FCI read/write error Controller


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7.3.4 INTERNAL ERRORS

When an internal error occurs, the message “Power Off/On” is displayed on thefirst line of the operation panel LCD. The internal error code is on the second line inthe format “Error XXYY-ZZZZZZZZ” (“XX” denotes a classification code; “YY”denotes a process number, and “ZZZZZZZZ” indicates the program address wherethe 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) Description00 Error in the TLB user area.01 CPU TLB update exception02 CPU mismatch exception (load or fetch)03 CPU mismatch exception (store)04 CPU address error exception (load or fetch)

05 CPU address error exception (store)

06 CPU bus error exception (load or fetch)07 CPU bus error exception (store)08 CPU system call exception09 CPU break point exception10 CPU reserved instruction exception11 CPU coprocessor disabled exception12 CPU operation overflow exception13 CPU trap exception14 Coherency (instruction) error15 CPU floating-point operation exception16 CPU timer interrupt17 ROCKY level 4 interrupt (ART or Tim)18 ROCKY level 3 interrupt (CP)19 ROCKY level 2 interrupt (XINT1 or XINT0)20 ROCKY level 1 interrupt (CBE, DBE, Dtc0, Verr, Fin, Vdtc, Fout)21 ROCKY level 0 interrupt (Debug)22 Software interrupt23 Software interrupt24 Other CPU exceptions25 Memory allocation error26 Overflow error27 Frame allocation error28 Card eject error29 Printer engine error30 Option board error31 Session-to-network interface board communications error


G024 Win 7-8 SM

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.

NETWORK INTERFACE BOARD

TYPE 305

NOTE: This section describes elements specific to the Network Interface BoardType 305. For additional information, such as installation, firmwareupgrades, etc., please refer to the controller section of the servicemanual and to the user's documentation


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8. NETWORK INTERFACE BOARD

8.1 OVERVIEW

8.1.1 SPECIFICATIONS

Configuration: Embedded

LAN Interface: 10BASE-T/100BASE-TX

Frame Type: Ethernet II (*1), IEEE802.3, IEEE802.2, SNAP*1: Only Ethernet II for TCP/IP

Protocol: TCP/IP, EtherTalk (*2), IPX/SPX (NetBEUI is not supported)

*2: Only possible when equipped with RICOH-SCRIPT2.

Network Cable: STP (Shielded Twisted Pair)**, Category 5

SNMP Support: IP and IPX SNMP support of MIB-II

8.1.2 BLOCK DIAGRAM

**NOTE: If UTP (Unshielded Twisted Pair) cable is used too much EMI (Electro-magnetic Interference) is emitted exceeding the required emissionstandard. Also, the ferrite core must be properly installed to the STPcable. Refer to the Operating Instructions Manual for details.

C P UMC68340PV25.166MHz

BridgeAG1001V

M A CAm79C971

P H YICS1890

S R A MRJ-45

Control lerBoard

NetworkEnvi ronment

D R A M2 M B

ASICDISCII

F lashROM2 M B

E E P R O MOPTION

I/F

NETWORK INTERFACE BOARD 31 March, 1999

G024 Win 8-2 SM

8.2 COMPONENT LAYOUT

8.2.1 NETWORK INTERFACE BOARD DIAGRAM

8.2.2 DEVICES

Device DescriptionCPU MC68340PV25 (25.166MHz)

Memory Flash ROM MBM29F800B-90PFTN(1 MB x 2)

DRAM TC5118160AJ-60 (2 MB x 1)SRAM CY7C199 (256kbit x 2)

EEPROM ST93C46CB1 (1kbit x 1)ASIC Gate array MBCG24243 (DISCII)

Bridge AG1001VMAC Am79C971KC "PCnet-FAST"PHY ICS1890

Fla

ssh

RO

M

M A CAm79C971

RJ-45

Front

EEPROM

Fla

ssh

RO

M

DR

AM

PHYICS1890

SRAM SRAM

Rear

CPUMC68340PV

ASICDISCII

BridgeAG1001V

LED1S W 1

LED3(G)

LED4(G)

G024O006.WMF


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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 hasa 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 resetsignal. The controller board communicates with the network interface boardthrough 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: ReadyOff: Busy

This LED blinks while the firmware is downloading.

2. LED2: Not used.

3. LED3: Displays the LAN type.On: 100BASE-TXOff: 10BASE-T

4. LED4: Displays the link status.On: Link safeOff: Link failure or link disabled


G024 Win 8-4 SM

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 15seconds.

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 procedurefailed, the previous settings remain. Repeat the above procedure until the oldsettings have been cleared.


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8.3.4 NETWORK SETTING INFORMATION

Since the controller does not support the "Summary Printout" function for thenetwork interface board, check the network setting information by printing out auser mode configuration page.

NOTE: Even though NetBEUI parameters are displayed on the variousconfiguration pages, the NetBEUI protocol is not supported on this unit.

G024O007.BMP

G024O007.BMP


G024 Win 8-6 SM


NIB OPTION FIRMWARE MODIFICATION HISTORY


SERIALNUMBER

FIRMWAREVERSION

Initial Production Release G6785839B Initial Production 3.7.5

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.

G6785839C February ’99Production

3.7.7

Corrects the following:• The firmware was modified to support

A250/B001.

G6785839D March ’99Production

3.8.6

Corrects the following:• One banner data page of NetWare was

split into two pages when using NetWare3.12 pserver mode.

• In NetWare remote printer mode, the NIBconsumed a server connection license.To avoid this, the firmware has beenmodified to disconnect the NCPconnection immediately after the remoteprinter has connected to the server.

G6785839E April ’99Production

3.8.7

Corrects the following:• On the web status monitor, the wording

in German was incorrect.“FreierSpeicher” corrected to “FreierSpeicher”.

• The Web status monitor displays “NoTray/No Paper” error when a tray is notclosed completely. The message hasbeen changed to “Other Error”.

• Disabling (Down) or enabling (Up)AppleTalk protocol from the operationpanel sometimes did not take effect afterthe change. To avoid this, the firmwarehas been changed to save a new settingto the NVRAM immediately after achange.

G6785839F June ’99Production

3.8.8

Corrects the following:• When a printer error occurs, the printer

information cannot be accessed usingMacintosh printer utilities such as ApplePrinter Utility.

• IPP (Internet Print Protocol) function hasbeen added.

G6785839G July ’99Production

3.9.2

Rev. 05/2000


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SERIALNUMBER

FIRMWAREVERSION

Corrects the following:• The wording “Config Reference” has

been changed to “Riferim. Config” for theItalian 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 problemin browsing the NIB in an AppleTalknetwork. The cause of this was in theCisco router but the NIB firmware hasbeen modified to correct this.

G6785839H October ’99Production

3.9.8

Corrects the following:• PCL text filter support has been added.• “RICOH” brand name has been deleted

from several functions and reports.

G6785839J November ’99Production

4.0.0

Corrects the following:• HTTP access has been improved when

multiple protocols are used at the sametime (e.g. telnet, IPP and HTTP).

G6785839K April ’00Production

4.0.2

Corrects the following:• Bi-directional communication of "diprint"

(using 9100 port of TCP/IP printing) issupported (required for DAZEL system).

• The "diprint direct [On/Off]" commandusing telnet has been implemented forsupporting bi-directional communicationof diprint (required for DAZEL system).PortNavi and Multidirect Print are notsupported if bi-directionalcommunication has been selected.

• The spelling of the command "retern" inthe UNIX install shell has been correctedto "return".

• The DHCP of NetWare5 is supported.• The DHCP relay agent is supported.

(This has been confirmed only withWindows NT 4.0 relay agent at thistime.)

• There may be some minor (character)display errors on the LCD while the NIBfirmware is being upgraded. Thefirmware has been modified to preventthis.

G6785839L October ‘00Production

4.0.6

Corrects the following:• Classless InterDomain Routing (CIDR) is

supported.• DHCP of Solaris 2.6 is supported.

G6785839M February ‘01Production

4.0.7

Rev. 07/2001

⇒


G024 Win 8-8 SM


DESCRIPTION OF MODIFICATION FIRMWARE LEVEL

SERIAL NUMBER

FIRMWARE VERSION

Corrects the following: • Can not connect to NetWare Servers

when the servers use NCP Packet Signature Level 2.

G6785839N August ’01 Production

4.0.8

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-2002-03.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testing/c06/snmpv1/

G6785839P July ’02 Production

4.1.0

⇒

Rev. 12/2002

G024 with FIERY 500 CONTROLLER

SERVICE MANUAL

NOTE: This service manual is designed to be an addendum to the existing G024engine (with base controller and Network Interface Board Type 305)service manual.

As such, this service manual only details those areas that are unique to theG024 Fiery 500 version full-color laser printer. For any additionalinformation, 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.

SM i G024 PS

G024 with FIERY 500 CONTROLLER SERVICE MANUAL

TABLE OF CONTENTS

1. OVERALL MACHINE INFORMATION ........................................ 1-11.1 SPECIFICATIONS.....................................................................................1-11.2 LAYOUT....................................................................................................1-2

2. FUNCTIONAL OVERVIEW.......................................................... 2-12.1 BLOCK DIAGRAM AND FUNCTIONS ......................................................2-1

CPU ......................................................................................................2-1Memory.................................................................................................2-1DRAM ...................................................................................................2-2SRAM ...................................................................................................2-2NVRAM Functionality............................................................................2-2Fiery Rip Chips (EFI ASICs) .................................................................2-3Real Time Clock ...................................................................................2-3

2.2 PRINT DATA PROCESSING ....................................................................2-42.3 BUILT-IN COLOR MANAGEMENT ...........................................................2-52.4 PAPER FEED.............................................................................................2-6

2.4.1 PAPER SIZE DETECTION FOR TRAY 1..........................................2-62.4.2 PAPER SIZE DETECTION FOR THE BY-PASS TRAY ...................2-7

3. INSTALLATION........................................................................... 3-1

4. SERVICE TABLES AND PROCEDURES ................................... 4-14.1 DIAGNOSTICS MODE..............................................................................4-1

4.1.1 OVERVIEW ......................................................................................4-1Map of the Diagnostic Menu .................................................................4-1

4.1.2 RUNNING THE DIAGNOSTICS .......................................................4-2Basic Procedure ...................................................................................4-2Using the Custom Diagnostics Set .......................................................4-3Diagnostic Test Result Display .............................................................4-4Exit Custom Menu ................................................................................4-4

4.1.3 CONTENTS OF INDIVIDUAL DIAGNOSTIC TESTS .......................4-5IDE Diagnostic Test ..............................................................................4-5Ethernet Diagnostics.............................................................................4-6RAM Diagnostics ..................................................................................4-7Video Chip Diagnostics.........................................................................4-8Boot ROM Diagnostics .........................................................................4-8Firmware Diagnostics ...........................................................................4-8I2CEEPROM diagnostics......................................................................4-8

4.2 ENGINE SP MODE ...................................................................................4-94.2.1 ENTERING ENGINE SP MODE........................................................4-94.2.2 KEY OPERATION ............................................................................4-9

4.3 BOOT ROM MENU .................................................................................4-10

G024 PS ii SM

4.3.1 PURPOSE OF THE BOOT ROM MENU........................................4-10Entering the Boot ROM Menu.............................................................4-10Contents of the Boot ROM Menu........................................................4-10Exiting the Boot ROM Menu ...............................................................4-104.3.2 NAVIGATING THE MENU........................................................4-11Boot ROM menu map .........................................................................4-11Key Usage in the Main Menu..............................................................4-12Key Usage in each Menu Item............................................................4-12

4.3.3 DISPLAYING VERSION INFORMATION.......................................4-124.3.4 INSTALLING SOFTWARE UPGRADES ........................................4-13

Preparation .........................................................................................4-13Procedure ...........................................................................................4-13Recovery Mechanism .........................................................................4-13

4.3.5 FORMATTING THE HARD DISK ...................................................4-14Procedure ...........................................................................................4-14

4.3.6 CHANGING THE ETHERNET MAC ADDRESS.............................4-14Preparation .........................................................................................4-14Procedure ...........................................................................................4-14

4.3.7 BRAND NAME SELECTION ..........................................................4-15Preparation .........................................................................................4-15Procedure ...........................................................................................4-15

4.3.8 CLEARING THE NVRAM PARAMETERS......................................4-15Procedure ...........................................................................................4-15

4.4 SERVICE MODE.....................................................................................4-164.4.1 OVERVIEW ....................................................................................4-16

Password ............................................................................................4-16Service Menu Map..............................................................................4-16Entering the Service Menu..................................................................4-16

4.4.2 PRINT SERVICE INFORMATION LIST .........................................4-174.4.3 PRINT COLOR CHART..................................................................4-184.4.4 CLEAR FUSER CTR ......................................................................4-18

5. PERIODIC MAINTENANCE ........................................................ 5-1

6. REPLACEMENT AND ADJUSTMENT........................................ 6-16.1 CONTROLLER BOARD AND TEMPERATURE/HUMIDITY SENSOR REPLACEMENT .......................................................................................6-1

7. TROUBLESHOOTING................................................................. 7-17.1 TYPES OF PROBLEMS............................................................................7-17.2 TROUBLESHOOTING PROCEDURE.......................................................7-2

7.2.1 HARDWARE TESTS ........................................................................7-27.2.2 OPERATION-RELATED TESTS ......................................................7-27.2.3 SOFTWARE-RELATED TESTS .......................................................7-3

7.3 ERROR MESSAGES ................................................................................7-47.3.1 OVERVIEW ......................................................................................7-47.3.2 CONTROLLER DIAGNOSTICS ERRORS .......................................7-57.3.3 ENGINE USER ERRORS (CAUTIONARY)......................................7-77.3.4 ENGINE SERVICE CODES .............................................................7-7

SM iii G024 PS

7.4 FIRMWARE HISTORY……………………………………………………7-7

08/2001

�IMPORTANT SAFETY NOTICESPHYSICAL INJURY PREVENTION




4. If an adjustment or operation check must be made requiring the removal oropening of the exterior covers while the main switch is on, keep hands awayfrom electrified or mechanically driven components.

5. The printer drives some of its components when it completes the warm-upperiod. Keep hands away from mechanical and electrical components whenthe printer starts operation.





3. Toner is non-toxic, but if it gets in your eyes by accident, it may causetemporary eye discomfort. Remove it with eye drops or flush eyes withwater. If this is unsuccessful, get medical attention immediately.


1. Do NOT incinerate toner cartridges, development toner magazine (DTM) orused toner. Toner dust may ignite suddenly when exposed to an openflame.



Trademarks

Microsoft, Windows 95/98, and Windows NT 4.0 are registered trademarks ofMicrosoft 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 betrademarks of their respective companies. We disclaim any and all rights in thosemarks.

OVERALL INFORMATION

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SM 1-1 G024 PS


1.1 SPECIFICATIONS

Page Description Language: Adobe PostScript 3PCL 5e/5c compatible

Printer Driver Platform: Macintosh, Windows 95/98, Windows NT4.0

Resolution: 600 dpi

Gradation Mode: 2 bits/pixel

Interface: IEEE1284 Compatible, Nibble or ECP modeEthernet 10BaseT/100BaseTX, 10Base 5

Network Protocol: NetWare 3.10, 3.11, 4.X, IPX/SPXEtherTalk System 7 and laterTCP/IP, SNMP, ARP, UDP (Token Ring is optional)

Frame Types: 802.2, 802.3, SNMP, Ethernet-II, Ethernet SNMP

Printing Services: 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 bitmapline printer font for PCL5c

Memory: Standard 32MB

DIMM Slots: 2 (for optional memory)

EIDE Interface: 1 (for optional HDD)

Options: 32/64MB DIMM2.5-inch 1.6-GB hard disk drive

NOTE: The G024 Fiery 500 Version alone and when equipped with the typicaloptions (Paper Feed Units, Memory Units and Printer Hard Disk) meetsthe EMI requirements of the FCC rules part 15, class B.

When configured with the Token Ring option, the product meets theEMI requirements of the FCC rules part 15, Class A.

SPECIFICATIONS

G024 PS 1-2 SM

Paper Size Standard trayShort 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 theoperation panel by the user).

LEGEND

Product Code RICOH SAVIN GESTETNER

G024 AP505 SLP517cp C7005P

G908 Paper Feed UnitType 305



G503 Memory Unit Type505 (32MB&64MB)

Memory Unit Type505 (32MB&64MB)

Memory Unit Type505 (32MB&64MB)

G690 Printer Hard DiskType 505

Printer Hard DiskType 505

Printer Hard DiskType 505

N/A Fiery 500Token Ring Kit

Fiery 500Token Ring Kit

Fiery 500Token Ring Kit

N/A = Not Applicable

NOTE: For additional specification information, refer to the G024 engineservice manual.

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SM 1-3 G024 PS

1.2 LAYOUT

1. Controller (Fiery 500)

NOTE: For additional information refer to the G024 engine service manual andG024 engine component layout.

G024O011.WMF

1

FUNCTIONAL OVERVIEW


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FUNCTIONAL OVERVIEW

SM 2-1 G024 PS

2. FUNCTIONAL OVERVIEW

2.1 BLOCK DIAGRAM AND FUNCTIONS

CPU

This product utilizes a MIPS R4700 (133 MHz) CPU.

CPUMIPS R4700

PowerSupervisor

IDEControl ler

System I2CE E P R O M

I/F ControlASIC (IX)

Video ControlASIC (VX)

EthernetControl ler

MemoryControl lerASIC (DX)

PCIConnector

Engine I/FConnector

IDE HDDConnector

IEEE 1284Connector

Ethernet RJ45Connector

Ethernet AUIConnector

Token RingCard (Option)

SDRAMFlash ROM

4 DIMM Slots

On BoardFlash ROM

(Boot Code)

G024C503.WMF

BLOCK DIAGRAM AND FUNCTIONS

G024 PS 2-2 SM

Memory

There is a proprietary memory ASIC that supports up to 8 DIMMs, up to 32 MB ofboot PROM or flash memory. The ASIC can support burst accesses for 8 or 64 bitwide PROMs.

However, this controller only supports 4 DIMMs. Three of these are for optionalmemory, and one is for the flash/mask ROM that holds the internal fonts.

DRAM

The Memory ASIC supports industry standard synchronous DRAM DIMMs foroptional printer memory (see the previous page).

The R4700 bus is 64 bits wide. Architecturally, the system can support up to 256bytes of DRAM and 8 DIMM slots (64 MB DIMMs will be supported whencommercially available).

SRAM

The SRAM is used for processing print data.

NVRAM Functionality

The NVRAM holds printer parameters that must be maintained across powercycles. NVRAM space is in the order of 32KB.

The NVRAM consists of 1 MB of flash memory soldered to the motherboard.

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FUNCTIONAL OVERVIEW

SM 2-3 G024 PS

Fiery Rip Chips (EFI ASICs)

The three ASICs (designed by EFI) are responsible for the high-speed andperformance 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 Rev2.1 of the PCI specification.

Real Time Clock

This controller does not utilize a real time clock.

PRINT DATA PROCESSING

G024 PS 2-4 SM

2.2 PRINT DATA PROCESSING

The key roles to each section of the print system are outlined below.

• The drivers are responsible for generating the page description on the hostsystem and for transmitting data to the printer.

• The I/O manager mediates the connection between the parallel port ornetwork interface and establishes a device or print manager connection.

• The print manager is responsible for spooling the job (if appropriate) and forfeeding jobs to the correct PDL interpreter.

• The PDL interpreters are responsible for turning page descriptions intorendered 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 alsohandles certain print quality processing functions.

PostScr iptgenerat ion

P C Lgenerat ion

Ethernet

Parallel

Spool ing, PDLswitching

D S Cparsing

PostScr ipt

PJL pars ingPCL 5e/5c

PageCompress ion

PageCompress ion

Decomp,Video

Drivers Connectivity IO/Print/Device Mgr PDLs Compression Page Mgr Video

Mgr

Finishing,Engine loading

G024C504.WMF

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FUNCTIONAL OVERVIEW

SM 2-5 G024 PS

2.3 BUILT-IN COLOR MANAGEMENT

This controller has a full complement of built-in color management processes.

Component Description Location/PlatformsPostScript color

renderingdictionaries

(CRDs)

CRDs optimized for photos, graphics,presentation objects;plain paper/transparency media types

In controllerROM/Flash memory

Press simulationcontrol

Lookup tables to simulate densitycharacteristics of offset printing processes

Controller SRAM

Device profilesColorSync 2/ICM profiles compatible withMacintosh and Windows colormanagement systems

Macintosh/Windows95

PAPER FEED

G024 PS 2-6 SM

2.4 PAPER FEED

2.4.1 PAPER SIZE DETECTION FOR TRAY 1

Paper size detection is based on the three paper size switches [A] located on themain unit. These switches detect the setting of the paper size dial [B] on the papertray.

The paper size dial has grooves and ridges on the side facing the paper sizeswitches. A switch deactivates when it falls into a groove, and activates when aridge presses against it.

Paper size detection for tray 1

Sensor StatusDial No. Paper Size

XNOB2 XNOB1 XNOB01 12" x 18" SEF 0 0 02 Others 0 1 13 71/4" x 101/2" LEF 0 0 14 81/2" x 14" SEF 1 0 05 81/2" x 11” LEF 1 0 16 A4 LEF 0 1 07 11" x 17" SEF 1 1 08 No Cassette 1 1 1

SEF: Short edge feed LEF: Long edge feedOthers: SEF – A3, 8" x 13", 81/4" x 13", 81/2" x 13", 13" x 18"

LEF - 51/2" x 81/2"

[A]

[B]

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FUNCTIONAL OVERVIEW

SM 2-7 G024 PS

2.4.2 PAPER SIZE DETECTION FOR THE BY-PASS TRAY

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]. Paperwidth is detected based on how the various patterns (strips) are shorted by thecontacts on the side fences.

Paper size detection for the by-pass feed traySensor Status

Paper SizeXBIT0 XBIT1 XBIT2 XBIT3

A3 Wide LEF 1 1 1 0A4 LEF 1 1 0 0A3 SEF 1 1 0 081/2" x 11" LEF 1 1 0 011" x 17" SEF 1 1 0 071/4" x 101/2" LEF 1 1 0 1B5 JIS LEF 1 1 0 1B4 JIS SEF 1 1 0 181/2" x 14" SEF 1 0 0 151/2" x 81/2" SEF 1 0 0 1A5 LEF 1 0 0 18" x 13" SEF 1 0 0 181/4" x 13" SEF 1 0 0 181/2" x 13" SEF 1 0 0 1B6 JIS SEF 0 1 1 1A6 SEF 0 1 1 1

NOTE: For additional paper feed information refer to the G024 engine servicemanual.

G024D410 WMF

G024D411. WMF

A3 SEFA4 LEFDTL SEFLT LEF

B4 SEFB5 LEFEXE LEF

A5 LEFHLT LEFLG SEF

A6 SEFB6 SEF

A3 WIDE SEF

[A]

LEF: Long edge feed SEF: Short edge feed

[B]

INSTALLATION

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INSTALLATION

SM 3-1 G024 PS

3. INSTALLATION

Refer to the following operation manuals.

• For the printer: Quick Installation Guide, Operating Instructions PrinterReference, Operating Instructions Getting Started and the OperatingInstructions User’s Guide.

• For options: Operating Instructions Printer Reference

SERVICE TABLES

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12 May, 1999 SERVICE TABLES AND PROCEDURES

SM 4-1 G024 PS

4. SERVICE TABLES AND PROCEDURES

4.1 DIAGNOSTICS MODE

4.1.1 OVERVIEW

There are several sets of diagnostic tests. This section includes an outline of howto select, run, and stop a custom diagnostic test set and a brief description of themessages displayed on the front panel during and after the diagnostic test.

Map of the Diagnostic Menu

Using the diagnostics menu, you can use the printer’s operation panel to select oneof several different diagnostic sets (Custom, Start-up, Burn-in, Function) andvarious test options.

START SELF-TEST

DIAGNOSTIC SETSC U S T O M

DIAGNOSTIC SETSFUNCTION

DIAGNOSTIC SETSBURN- IN

DIAGNOSTIC SETSSTART-UP

RUN START-UPTESTS

DIAGNOSTIC TESTS<TEST/GROUP NAME>

RUN BOARD TESTS

RUN BURN- INTESTS

END

RUN UNTILDONE <OTHER>

RUN CUSTOM TESTS

EXIT CUSTOM?[NO]/ [YES]

[#ENTER] TOGGLES SELECTIONOF CURRENT TEST /GROUP

[VV]/[WW] S C R O L L S T H R O U G HTESTS & GROUPS

[VV]/[WW] S C R O L L S T H R O U G HTESTS & GROUPS

[#ENTER]

[#ENTER][MENU]/[#ENTER]

[VV]

[VV]

[MENU]

[CANCEL]

[CANCEL]

BEGIN

[MENU]

[MENU]

[MENU]

[#ENTER]

[#ENTER]

[WW]

[VV]/[WW] T O G G L E SSELECTION

[VV]

[VV]

[VV]

[VV]

[WW]

[WW]

[WW]

[#ENTER]

G024C505.WMF

DIAGNOSTICS MODE 12 May, 1999

G024 PS 4-2 SM

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 diskdrives) 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 whenSTART SELF-TEST appears on the front panel display. Release the [V] keywhen the DIAGNOSTIC SETS menu is displayed. From here a diagnostic setcan 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 thismenu.• 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 tospecify which tests should be run. It also allows you to specify the conditions forthe tests to stop (e.g., stop if an error is detected, or do all tests until the end). Ifany 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 isthe 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. Thesetest the functionality of all the components.

Burn-In: If this is selected, a set of tests is executed repeatedly to exercise allboard functions. External connections are unnecessary.

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SM 4-3 G024 PS

Using the Custom Diagnostics Set

1. If CUSTOM was selected, you may select the individual diagnostic tests. Youcan view all the available tests by pressing the [V] or [W] buttons to scroll upor 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 (forexample, +IDE), and this follows the group name. (The “+” symbol indicatesthat the test has been selected; see below.)

2. Initially, no group/test is selected. Select or deselect a group/test by pressingthe [#Enter] button when the group/test name is displayed.

NOTE: When a group is selected a “+” symbol may not be displayed. In thiscase after pressing [# Enter] , press the [Menu] key as detailed in step3 below. Be careful not to press [# Enter] twice or the group will bedeselected.

• 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 UNTILfollowed 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 selectedwill 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 stopthe test, press [CANCEL] .

• If you select INTERRUPTED, the tests will run until you interrupt the tests bypressing 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.


G024 PS 4-4 SM

Diagnostic Test Result Display

When executing each selected test, the message "TESTING:”, followed by thename of the test will be displayed on the front panel. The green LED will be lit forthe 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 ofany error(s). This error report consists of the message

TESTS FAILEDUP/DOWN/CANCEL

After this report appears, view the names of the failed tests and the correspondingerror code using the [V]/[W] buttons. Refer to section 4.1.3 of this manual fordescriptions of the individual tests and section 7 of this manual for descriptions ofthe 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 ispresented after the tests have ended, asking the user if he wants to exit the customtests. 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 theDiagnostic Menu, while selecting NO presents the Custom Diagnostic Tests menuagain.

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SM 4-5 G024 PS

4.1.3 CONTENTS OF INDIVIDUAL DIAGNOSTIC TESTS

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 IDEcontroller 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/Oaddress 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 messageand 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 4-

second buzzer sounding as the heads go back and forth, giving an audibleindication that they are working.


G024 PS 4-6 SM

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 addressrecognition and bus mastering. It has the base address set and is compared toensure 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 endssuccessfully.

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 befree of errors, as this test assumes that any kind of packet error will result in a testfailure.

ENET WRITE (Packet write test)

128 packets are transmitted. The packet type is set to 0xDEAD to ensure that othersystems 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 befree of errors, as this test assumes that any kind of packet error will result in a testfailure.

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SM 4-7 G024 PS

RAM Diagnostics

RAM diagnostics tests the DIMMs and the system paths to the DIMMs (I2 C andmemory bus).

These tests are running in memory without corrupting the diagnostics area. Beforethe 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 (serialpresence detect). It is presumed that the bus works; otherwise, diagnostics wouldnot be running in memory. However, transient conditions and any additional DIMMswill be tested.

MEM PATTERN

This test writes various patterns to the entire untested memory area, then confirmsthat they were written correctly.

MEM ADDRESS

This test writes the inverse of the address into the address. It then reads it backand verifies.

MEM GND BOUNCE

This diagnostic tests the ground bounce in the memory.

Ground bounce occurs when there is excessive inductance on leads from thememory chip. If ground bounce causes the ground level on the chip to float to thelogical 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 1’s from the chip (maximizing thecurrent flow through the leads), then read all 0’s.

This test writes alternating 64-bit words of all 1’s and all 0’s (i.e., 64-bits of 1, then64-bits of 0, etc.) When written from or read into the processor’s internal cache, thechip will be stressed as described in the above paragraph.

MEM RANDOM

This diagnostic tests the memory by writing random data, reading it, and verifying.


G024 PS 4-8 SM

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 theparameter blocks are writable.

BOOTROM WRITE (Boot ROM Write Diagnostics)

This test writes various patterns to the parameter blocks in the Boot ROM. If theseparameter 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 checksumon the system DIMM.

I2CEEPROM diagnosticsThis test reads the contents of the on-board I2C EEPROM at both sequential andrandom addresses to ensure that data is readable.

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SM 4-9 G024 PS

4.2 ENGINE SP MODE

4.2.1 ENTERING ENGINE SP MODE

To enter engine SP mode, hold down the [Online] [A] and [Menu] [B] keys on theoperation panel and turn on the power.

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 keykeeps the existing setting.

NOTE: Refer to section 4 “SP mode” in the G024 engine service manual foradditional information.

ErrorPower Data in

Menu Cancel

On Line

#Enter

G024C500.WMF

G024C501.WMF

[A][B]

[A] [B]

BOOT ROM MENU 12 May, 1999

G024 PS 4-10 SM

4.3 BOOT ROM MENU

4.3.1 PURPOSE OF THE BOOT ROM MENU

Entering the Boot ROM Menu

During power-on, hold down the [ONLINE] [A] and [ ] [B] keys on the front paneluntil 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.

ErrorPower Data in

Menu Cancel

On Line

#Enter

G024C500.WMF

G024C501.WMF

[A] [B]

[A] [B]

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SM 4-11 G024 PS

4.3.2 NAVIGATING THE MENU

Boot ROM menu map

VERSION INFO

[WW]

I N S T A L L U P G R A D E S

FORMAT D ISK

C H A N G E E N E T M A CA D D R E S S

C L E A R N V R A MP A R A M E T E R S

B O O T S T R A PV1.3.26 02/04/98

INSTALL:B O O T R O M

FORMAT D ISK:N O

E N E T M A C A D D R E S S1234:5678:90AB

C L E A R N V R A M :N O

S Y S T E M C O D EMAR 23 1999

INSTALL:S Y S T E M C O D E

C L E A R N V R A M :Y E S

INSTALL:F ILE SYSTEM

[MENU]/ [#ENTER]

[MENU] [MENU] [MENU]

[MENU][VV]

FORMAT D ISK:L O W L E V E L

[#Enter]Instal ls upgrade and returns

[#Enter]Instal ls upgrade and returns

[#Enter]Instal ls upgradeand returns

[#Enter]Formats hard disk dr ive and return

[MENU]

[#Enter]Saves the MAC address and re turns

[MENU]

[#ENTER]

[#ENTER]

[#ENTER]

[#ENTER]

[#ENTER][MENU]

[VV]

[WW]

[WW]

[VV]

[VV]/[WW]

[VV]/[WW]

[#Enter]Clears the NVRAM parameters andreturns

[MENU]

[MENU]

[MENU]

[MENU]

[MENU]

[VV]

[WW]

C H A N G E D E F A U L TO E M

DEFAULT OEM:RICOH *

DEFAULT OEM:XXXX

[#ENTER] [VV]/[WW]

[#ENTER]

Note2

Note 2

Note 1

B O O T C O D EV1.3.26 02/04/98

[WW]

[VV][MENU]/[#ENTER]

Note 1: J10 must be shor ted.Note 2: Shor t J8 to access these menus.

[WW]

[MENU]

FORMAT D ISK:H IGH LEVEL

[VV]

[WW]

[#ENTER]

G024C506.WMF


G024 PS 4-12 SM

Key Usage in the Main Menu

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

Key Usage in each Menu Item

Key Description[MENU] Return to the main menu.[CANCEL] Exit the Boot ROM menu and continue system startup.[#Enter] Select the current item in the menu or save the current value.[VV]/[WW] 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.

4.3.3 DISPLAYING VERSION INFORMATION

The version information for the bootstrap and the boot code can be displayed. Theversion number and the release date is shown. The version number can bedifferent for the bootstrap and the boot code.

For more information about bootstrap and boot code, refer to section 4.3.4“Installing Software Upgrades.”

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SM 4-13 G024 PS

4.3.4 INSTALLING SOFTWARE UPGRADES

The system software consists of three different elements: the Boot ROM, thesystem code and the file system. All of these elements can be upgraded throughthe parallel port.

The files used for upgrades are bootrom.sys , system.sys and filesys.sysfor the Boot ROM, system code and file system upgrades respectively. The file forrecovering from a bad boot code is bootrom.rcy . The file formats are notinterchangeable.

PreparationTo upgrade the Boot Rom first, power-off the printer then short the jumper pinstogether at J10 on the controller board. Next, power the printer back on and enterthe 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 notappear 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 downloadedfile is processed and stored.

• The front panel will display an error message if the upgrade fails. If an erroroccurred, 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 theflash ROM) and boot code (located in the DIMM).

The boot-strap is a small block of memory where essential initialization coderesides. The system will continue to function properly even if the bootstrap is notupgraded.

The boot code is the section where the diagnostics and ROM menu functionresides. This is not locked and can always be updated when necessary. Since it ispossible to accidentally erase the boot code, a “disaster recovery” mechanism isprovided. This recovery mechanism can reload the Boot ROM if the bootstrap is


G024 PS 4-14 SM

valid. This recovery mechanism should not be used as the procedure for upgradingthe 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) throughthe 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 willcontinue 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 ahard disk drive installed in the system.

Procedure

1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys toselect “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 customerwishes 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 thecontroller board to make this menu available.

Procedure

1. Once in the appropriate menu, refer to section 4.3.2, use the[ ]/[ ] keys toposition the cursor at the digit to change, and the [V]/[W] keys to change thedigit 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 forgetthe current MAC address during editing.

2. Press the [#Enter] key to save the Ethernet MAC address.

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SM 4-15 G024 PS

• To return to the main menu without saving the MAC address, press the[MENU] key.

4.3.7 BRAND NAME SELECTION

It is possible to change the machine’s brand name.

Preparation

Prior to entering the Boot ROM Menu, short the jumper pins together at J8 on thecontroller board to make this menu available.

Procedure

1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys toselect 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 bootROM. Use the following procedure to clear these parameters.

All data listed on the configuration sheet is erased, and these must be stored in theNVRAM again after clearing.

Procedure

1. Once in the appropriate menu, refer to section 4.3.2, use the [V]/[W] keys toselect “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] , orpress the [MENU] key.

• The front panel will report if the procedure was successful. If it isunsuccessful, press any key to continue.

SERVICE MODE 12 May, 1999

G024 PS 4-16 SM

4.4 SERVICE MODE

4.4.1 OVERVIEW

Password

A special key combination is required to enter this menu. This is to preventcustomers from accessing this menu.

Service Menu Map

Entering the Service Menu

Press the [Menu] key, then use the [▼] key until SERVICE MENU is displayedpress [Enter] key.

While the LCD displays “ENTER PASSWORD”, press the [ON LINE] and [ ] keysat the same time.

To exit this menu, turn off the machine.

SERVICE

ENTER PASSWORD

PRINT SERVICEINFORMATION LIST

PRINT COLOR CHART

CLEAR FUSE CTR

Exits menu andprints list

Incorrectpassword

Enter password

Exits menu andprints chart

Clears fusercounter and exits

menu

Correct password

[Enter]

[VV/WW] key

[Enter]

[Enter]

[Enter][VV/WW] key

G024C502.WMF

Rev. 7/99

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SM 4-17 G024 PS

4.4.2 PRINT SERVICE INFORMATION LIST

The table below explains the contents of the engine maintenance list printout. Thecontroller obtains the data from the engine (MCU).

Item DescriptionMCU Firmwareversion

The MCU board firmware version number.

Density Settings Customers can adjust the toner density via the maintenance menu.Adjusted values are stored in the NVRAM on the MCU.

Margin Settings Customers can adjust side-to-side registration from the optional traywith the Maintenance Menu. In addition, leading edge registration canbe done with engine SP mode (1. Margin). These values are stored inthe NVRAM on the MCU.

Total Indicates the total number of printouts. The counter is incrementedwhen the paper exit sensor detects paper exit completion (regardlessof paper size, type, and mono/color mode).

Color Print Counter value for printouts in color mode.B/W color Counter value for printouts in monochrome mode.PCU PCU replacement is indicated when this value reaches 60000. This

value increases by 4 in color mode printing and by 1 in black modeprinting. When printing in A3/DLT, double counting occurs.

Fusing unit Fusing unit replacement is indicated when this value reaches to 60000.This counter increases by 2 for A3/DLT size printing and by 1 forprinting in other sizes.

Fusing UnitReplacement

Number of fusing unit resets made with service mode.

A3/DLT, A4/LT,LG, B4 and etc.Size counter

Number of sheets of each size of paper that passed the exit sensor.

Feed Jam,Transfer Jamand Eject Jam


Cou

nter

s

SC Number of SCsSC Error History The most recent 3 SC codes.Jam History The most recent 10 jam codes and the total counter value at the time.

000: Paper cassette001: Paper feed path002: Paper exit

Process-control errorHistory

The most recent 3 errors during process control and the total countervalue at the time.Not all of the errors are indicated as SC errors.

ID sensor PWMsetting

The value set with engine SP mode, 9: ID Sensor PWM.

SERVICE MODE 12 May, 1999

G024 PS 4-18 SM

4.4.3 PRINT COLOR CHART

This prints a color test chart, so that the image quality can be tested for all colors atvarious 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 MCUboard). 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 FuserCtr) for details on how to clear the fusing unit counter after fusing unit replacement.

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12 May, 1999 REPLACEMENT AND ADJUSTMENT

SM 6-1 G024


6.1 CONTROLLER BOARD AND TEMPERATURE /HUMIDITY SENSOR REPLACEMENT

NOTE: Print the “Configuration Sheet” (refer to the Operating Instructions “GettingStarted” Manual) prior to replacing the controller board. This is required asthe NVRAMs cannot be exchanged after replacement. The user mustrestore 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], (1screw, 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 Centronicsparallel port).

6. Remove the controller board [F] (6 screws).

7. When installing the controller board make certain that the hard drive (ifequipped) is properly reconnected and that the parallel port connector “bailclips” are positioned properly.

After replacing the controller board, make sure that the brand name (and MACaddress if required by the user) stored in the machine is correct. (See Section 4“Service Tables and Procedures - Boot ROM Menu”.)

G024R551.WMF

G024R552.WMF

G024R553.WMF

[A] [B]

[C]

[D]

[E]

[F]

TROUBLESHOOTING

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TYPES OF PROBLEMS

SM 7-1 G024 PS

7. TROUBLESHOOTING

7.1 TYPES OF PROBLEMS

The problems can be classified as follows:

Operat ion

Hardware

Sof tware

Operat ingcondi t ions

• Printer-side Print Sett ings• Printer-side Init ial Sett ings• Host-s ide Appl icat ion Sett ings

• Faul ty Engine

• Faulty Control ler

• Hardware Limi tat ions

• Main Uni t

• Opt ion

• Consumab les

• Main Uni t

• Opt ion

• Bug in Contro l ler ROM

• Bug in Emulat ion Module Sof tware

• Control ler Limitat ions

• Bug in Host-s ide Appl icat ion

• Host-s ide Appl icat ion Limitat ions

• Environment (power, temperature and humidi ty , dust, noise, vibrat ion)• Consumab les

G024O014.WMF

TROUBLESHOOTING PROCEDURE

G024 PS 7-2 SM



1. Start-up diagnosticsTurn on the power and check whether the LCD displays an error code.

2. Custom diagnostic testSee “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 testMake a test print from a computer.• Check that the correct cable is used (and connected properly).• Check the cable wire’s 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 thecurrent settings match the settings on the configuration page that the customerkeeps.

If a “normal” configuration page is not available from the customer, ask thecustomer to print a configuration page at some time when the controller is workingproperly, and to always keep it for reference.

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TROUBLESHOOTING PROCEDURE

SM 7-3 G024 PS


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

ERROR MESSAGES

G024 PS 7-4 SM

7.3 ERROR MESSAGES

7.3.1 OVERVIEW


1. Controller Diagnostics ErrorsErrors detected while the unit performs start-up diagnostics/custom diagnosticson the controller hardware.

2. Engine User Errors (Cautionary)Errors that do not require user intervention to continue printing (the printer canstill communicate with the PC over the interface). However, for the best printingquality, the user should correct the problem as soon as possible.


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ERROR MESSAGES

SM 7-5 G024 PS

7.3.2 CONTROLLER DIAGNOSTICS ERRORS

When a controller diagnostics error occurs, the first line of the operation panel LCDdisplays the name of the test that detected the error.

The second line contains a 6-digit code following “TYPE ID” that gives error detailsfor designers to use when debugging.

IDE Test Error

Code Description Location0x1001 IDE controller problems IDE chip0x1002 Hard disk problems or cable connection

problemHDD or cable

0x1003 Unexpected return values of function calls Chip or HDD

Ethernet Test Error

Code Description Location0x400 Cannot find Ethernet chip0x401 Internal register test failed

0x2001 Internal error0x2002 Chip error0x2003 Receive error0x2004 Transmit error0x2005 No net activity0x2006 Fatal summary0x2007 Lost carrier0x2008 Transmit flow error0x2009 No chip0x2010 Interrupt error0x2011 Low receive

Replace the controller.

MEM Test Error

Code Description Location0x0300 Bad memory information0x0301 Bad memory0x0302 Ground bounce test failed


VX Test Error

Code Description Location0x1801 Bad VX chip; registers cannot be

programmed correctlyReplace the controller.

ERROR MESSAGES

G024 PS 7-6 SM

Boot ROM Test Error

Code Description Location0x1811 Internal error0x1812 Unknown boot flash type0x1813 Incorrect chip installed0x1814 Successive reads return different values0x1815 Checksum failed for boot ROM0x1816 Erasing boot ROM not completed

successfully.0x1817 Data written to the boot ROM cannot be

verified correctly.0x1818 Boot ROM write test not performed since

parameter blocks are not empty0x1819 Parameter blocks cannot be overwritten


EFIDIMM Test Error

Code Description Location0x1820 System DIMM not found0x1821 Cannot read from system DIMM properly,

or system DIMM located in an incorrectslot

0x1823 Checksum for system code failed.0x1824 Checksum for file system failed0x1825 Checksum for system code and file

system failed.


I2CEEPROM Test Error

Code Description Location0x1100 Read error at I2CEEPROM Replace the controller.

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FIRMWARE HISTORY

SM 7-7 G024 PS


Refer to the Troubleshooting section in the Operating Instructions PrinterReference Manual.


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




DESCRIPTION OF MODIFICATIONFIRMWARE

LEVELSERIAL

NUMBERFIRMWAREVERSION

Corrects the following:1. Wording change in RPS2 menu. Previous Changed to Bright Vivid Super Bright Super Vivid2. Improving BG/UCR.3. Cannot print out correctly from

AcrobatReader4.0 when selecting 2 Bytefont downloads.

G5035908 A April 2000Production

2.61

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

G5035908 B November 2000Production

3.10

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.

G5035908 C June 2001Production

3.55

08/2001

⇒

G047/G048

SERVICE MANUAL

NOTE: This service manual is designed to be an addendum to the existingG024 engine (with base controller and Network Interface BoardType305) service manual.

As such, this service manual only details those areas that are uniqueto the G047/G048 manual (simplex) and auto-duplex full-color laserprinters. For any additional information, please refer to the G024engine service manual.

SM i G047/G048

G047/G048 SERVICE MANUALTABLE OF CONTENTS


1. OVERALL MACHINE INFORMATION ........................................1-11.1 SPECIFICATIONS ....................................................................................1-11.2 MECHANICAL OVERVIEW ......................................................................1-31.3 MAIN UNIT LAYOUT.................................................................................1-31.4 SYSTEM BLOCK ......................................................................................1-5

1.4.1 BLOCK DIAGRAM............................................................................1-5


2. DETAILED SECTION DESCRIPTIONS.......................................2-12.1 KEY DIFFERENCES FROM BASE MODEL (G024) .................................2-1

2.1.1 OVERVIEW ......................................................................................2-12.1.2 FUSING UNIT ..................................................................................2-22.1.3 OPTICAL UNIT.................................................................................2-22.1.4 PAPER FEEDING AND REGISTRATION........................................2-32.1.5 PROCESS CONTROL .....................................................................2-32.1.6 ELECTRICAL COMPONENTS.........................................................2-3

2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY).............................2-42.2.1 OVERVIEW ......................................................................................2-4

Layout...................................................................................................2-4Electrical Components..........................................................................2-5

2.2.2 EXIT UNIT ........................................................................................2-7Driving Mechanism ...............................................................................2-7Junction Gate .......................................................................................2-7Exit Cover Open Detection ...................................................................2-8

2.2.3 VERTICAL TRANSPORT UNIT .......................................................2-9Driving Mechanism ...............................................................................2-9Paper Feed Detection...........................................................................2-9Vertical Transport Unit Cover Open Detection....................................2-10

2.2.4 DUPLEX UNIT................................................................................2-11Driving Mechanism .............................................................................2-11Reverse Mechanism...........................................................................2-11Jogging Mechanism............................................................................2-12Feed-out .............................................................................................2-12Reverse Tray Detection......................................................................2-12

G047/G048 ii SM

2.2.5 INTERLEAF....................................................................................2-13Paper Path for Duplex Printing ...........................................................2-13Print Order for Duplex Black & White Printing ....................................2-14Print Order for Duplex Color Printing ..................................................2-14

INSTALLATION

3. INSTALLATION PROCEDURE ...................................................3-1

SERVICE TABLES

4. SP MODE ....................................................................................4-14.1 OVERVIEW...............................................................................................4-14.2 ENGINE SP MODE...................................................................................4-1

4.2.1 OVERVIEW ......................................................................................4-1To enter and exit engine SP mode .......................................................4-1Outline of the engine SP mode functions..............................................4-1

4.2.2 MENU OPERATION/DISPLAY.........................................................4-24.2.3 MARGIN (REGISTRATION ADJUSTMENT)....................................4-24.2.4 PARAMETER ...................................................................................4-34.2.5 CLEAR MEMORY ............................................................................4-34.2.6 SENSOR CHECK.............................................................................4-44.2.7 NIP WIDTH.......................................................................................4-54.2.8 RESET SC .......................................................................................4-54.2.9 PROCESS CTRL .............................................................................4-64.2.10 TEST PRINT ..................................................................................4-64.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION) .....................4-64.2.12 IMAGE ADJUST.............................................................................4-64.2.13 OUTPUT CHECK ...........................................................................4-74.2.14 HIGHLIGHT ADJUSTMENT...........................................................4-84.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)........................4-84.2.16 PRIMARY BIAS ADJUSTMENT.....................................................4-9


5. PREVENTIVE MAINTENANCE ...................................................5-15.1 PM TASKS ................................................................................................5-1

5.1.1 REPLACEMENT ..............................................................................5-15.1.2 CLEANING .......................................................................................5-15.1.3 INSPECTION ...................................................................................5-1

5.2 PM TABLE ................................................................................................5-25.2.1 MAIN UNIT .......................................................................................5-25.2.2 OPTIONAL PAPER FEED UNIT ......................................................5-2

SM iii G047/G048


6. REPLACEMENT AND ADJUSTMENT (AUTO-DUPLEX MODEL) ...........................................................6-1

6.1 EXTERIOR................................................................................................6-16.1.1 TOP OVER.......................................................................................6-1

6.2 PAPER EXIT UNIT....................................................................................6-26.2.1 UPPER COVER ...............................................................................6-26.2.2 LOWER COVER ..............................................................................6-26.2.3 PAPER EXIT UNIT...........................................................................6-36.2.4 JUNCTION GATE SOLENOID .........................................................6-4

6.3 VERTICAL TRANSPORT UNIT ................................................................6-56.3.1 VERTICAL TRANSPORT UNIT COVER..........................................6-56.3.2 UPPER, LEFT AND RIGHT SIDE COVER.......................................6-56.3.3 VERTICAL UNIT SENSOR ..............................................................6-66.3.4 VERTICAL TRANSPORT MOTOR...................................................6-66.3.5 VERTICAL TRANSPORT UNIT .......................................................6-7

6.4 DUPLEX UNIT...........................................................................................6-86.4.1 DUPLEX TRAY ................................................................................6-86.4.2 REVERSE ROLLER.........................................................................6-96.4.3 DUPLEX FEED MOTOR/REVERSE MOTOR................................6-106.4.4 DUPLEX FEED SENSOR ..............................................................6-106.4.5 JOGER HOME POSITION SENSOR .............................................6-116.4.6 JOGGER MOTOR/REVERSE SOLENOID ....................................6-126.4.7 REVERSE SENSOR ......................................................................6-136.4.8 TEMPERATURE/HUMIDITY SENSOR..........................................6-136.4.9 RELAY MOTOR/RELAY ROLLER .................................................6-14

6.5 FUSING SECTION..................................................................................6-156.5.1 FUSING UNIT ................................................................................6-15

6.6 LASER SECTION....................................................................................6-166.6.1 CAUTION DECAL LOCATIONS.....................................................6-166.6.2 OPTICAL HAUSING UNIT .............................................................6-17

6.7 ELECTRICAL COMPONENTS................................................................6-186.7.1 CONTROLLER BOARD .................................................................6-186.7.2 DUPLEX DC SUPPLY UNIT ..........................................................6-196.7.3 POWER SUPPLY UNIT .................................................................6-206.7.4 HIGH VOLTAGE SUPPLY UNIT ....................................................6-216.7.5 MCU ...............................................................................................6-226.7.6 DUPLEX DRIVER BOARD.............................................................6-22

G047/G048 iv SM

TROUBLESHOOTING

7. TROUBLESHOOTING ................................................................ 7-17.1 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 ..............................................................................7-27.1.3 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

Rev. 08/2001

SM i G047/G048

G047/G048 CONTROLLERSERVICE MANUAL

TABLE OF CONTENTS


1. OVERALL MACHINE INFORMATION ........................................1-11.1 BASIC SPECIFICATIONS.........................................................................1-1


2. DETAILED DESCRIPTIONS........................................................2-12.1 DIFFERENT POINT FROM BASE MODEL (G024) ..................................2-1

2.1.1 SYSTEM SOFTWARE .....................................................................2-12.1.2 HARDWARE ....................................................................................2-1

2.2 FUNCTIONAL OVERVIEW .......................................................................2-22.2.1 SYSTEM LAYOUT ...........................................................................2-22.2.2 CONTROLLER BOARD LAYOUT....................................................2-32.2.3 FUNCTION OF EACH DEVICE........................................................2-4

2.3 PRINT DATA PROCESSING ....................................................................2-52.3.1 GRADATION & PRINTABLE DATA .................................................2-52.3.2 IMAGE DATA PROCESSING FLOW ...............................................2-6

IPDL-C (Intelligent Page Description Language for Color) ...................2-7CMS (Color Management System).......................................................2-8Color Correction by the Driver ..............................................................2-8BG/UCR (Black Generation/Under Color Removal) .............................2-8Gamma Correction ...............................................................................2-8Dither Processing .................................................................................2-9Maximum Amount Toner Control..........................................................2-94 Bit Expansion.....................................................................................2-9

INSTALLATION

3. INSTALLATION...........................................................................3-13.1 BRAND SETTING .....................................................................................3-1

SERVICE TABLES

4. SERVICE TABLES ......................................................................4-14.1 CONTROLLER SP MODE ........................................................................4-1

G047/G048 ii SM

4.1.1 ENTERING AND EXITING CONTROLLER SP MODE ....................4-14.1.2 MENUS AND DISPLAY....................................................................4-24.1.3 SP MODE MENU HIERARCHY .......................................................4-24.1.4 SP MODE DETAILS.........................................................................4-6

S1. Maintenance Sheet ........................................................................4-6S2. Color Chart.....................................................................................4-7S3. Maintenance Clear .........................................................................4-7S4. Clear All Memory............................................................................4-7S5. Gamma (γ) Calibration ...................................................................4-7S6. Printer ID ........................................................................................4-7S7. Toner Limiter ..................................................................................4-8S8. Brand (Default Setting: RICOH.EXP) .............................................4-8S9. Meter Click .....................................................................................4-8IPDL-C Menu........................................................................................4-9Media Menu ([Media] key) ....................................................................4-9

4.2 POWER-UP SELF-DIAGNOSTICS.........................................................4-104.3 POWER-UP SELF-DIAGNOSTICS FLOW CHART ................................4-104.4 DETAILED SELF-DIAGNOSTICS MODE ...............................................4-114.5 DETAILED SELF-DIAGNOSTICS FLOW CHART ..................................4-11


5. PERIODIC MAINTENANCE.........................................................5-1


6. REPLACEMENT AND ADJUSTMENT ........................................6-16.1 CONTROLLER BOARD REPLACEMENT ................................................6-16.2 IMAGE ADJUSTMENT..............................................................................6-16.3 SOFTWARE UPGRADE PROCEDURE ...................................................6-1

TROUBLESHOOTING

7. TROUBLESHOOTING.................................................................7-17.1 TYPES OF PROBLEMS............................................................................7-17.2 TROUBLESHOOTING PROCEDURE ......................................................7-2

7.2.1 HARDWARE TESTS........................................................................7-27.2.2 OPERATION-RELATED TESTS ......................................................7-27.2.3 SOFTWARE-RELATED TESTS.......................................................7-2

7.3 ERROR MESSAGES ................................................................................7-37.3.1 OVERVIEW ......................................................................................7-37.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS.............................7-47.3.3 CONTROLLER USER ERRORS......................................................7-57.3.4 INTERNAL ERRORS .......................................................................7-67.3.5 ENGINE USER ERRORS (CAUTIONARY)......................................7-7

SM iii G047/G048

7.3.6 ENGINE USER ERRORS.................................................................7-77.3.7 ENGINE SERVICE CODES .............................................................7-7


8. NETWORK INTERFACE BOARD (C4000 FERRET) .................. 8-18.1 OVERVIEW ...............................................................................................8-1



8.3 BASIC OPERATIONS ...............................................................................8-38.3.1 OVERVIEW ......................................................................................8-38.3.2 SWITCH FUNCTION........................................................................8-4

NVRAM Reset Procedure .....................................................................8-48.4 FIRMWARE HISTORY ...............................................................................8-5

8.4.1 NIB FIRMWARE MODIFICATION HISTORY ....................................8-5

Rev. 07/2001

!IMPORTANT SAFETY NOTICES

PHYSICAL INJURY PREVENTION




4. If an adjustment or operation check must be made requiring the removal oropening of the exterior covers while the main switch is on, keep hands awayfrom electrically supplied or mechanically driven components.

5. The printer energizes some of its components when it completes the warm-up period. Keep hands away from mechanical and electrical componentswhen the printer starts operation.





3. Toner is non-toxic, but if it gets in your eyes by accident, it may causetemporary eye discomfort. Cleanse the eyes using suitable eye drops orflush eyes with water. If this is unsuccessful, get medical attentionimmediately.


1. Do NOT incinerate toner cartridges, development toner magazine (DTM) orused toner. Toner dust may ignite suddenly when exposed to an open flame.



LASER SAFETYThe Center for Devices and Radiological Health (CDRH) prohibits the repair oflaser-based optical units in the field. The optical unit can only be repaired in afactory or at a location with the requisite equipment. The laser subsystem is onlyreplaceable in the field by a qualified Customer Engineer. The laser chassis is notfield repairable. Customer engineers are therefore directed to return all chassis andlaser subsystems to the factory or service depot when the optical subsystemrequires replacement.

!WARNINGUse of controls, or adjustment, or performance of procedures other thanthose specified in this manual may result in hazardous laser radiationexposure.

!WARNINGWARNING: Turn off the main switch before attempting any of the

procedures in the Laser Unit section. Laser beams canseriously damage your eyes.

CAUTION MARKING:

OVERALL INFORMATION

SPECIFICATIONS

SM 1-1 G047/G048

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1.1 SPECIFICATIONS

Configuration: Desk top

Print Process: Dry electrostatic transfer system

Resolution: 600 dpi (1800dpi x 600dpi equivalent print quality)

Paper Size: Standard trayShort 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 theoperation 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 labelsOHP 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)

Print Speed: Simplex printsColor: 6 ppm (A4/81/2" x 11" LEF)Monochrome: 24 ppm (A4/81/2" x 11" LEF)

Duplex printsColor: 5.5 ppm (A4/81/2" x 11" LEF)Monochrome: 21.7 ppm (A4/81/2" x 11" LEF)

Warm-up Time: Less than 380 seconds (at 23°C/73°F)

Paper Capacity: 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.)

SPECIFICATIONS

G047/G048 1-2 SM

Paper OutputCapacity:

250 sheets (A4/81/2" x 11" or less)100 sheets (More than A4/81/2" x 11")

Output Method: Face down

Power Supply: 120 V, 60 Hz, 10 A220 to 240 V, 50/60 Hz, 5.2 A

Power Consumption: Maximum: Less than 1,200 WAverage during printing: Less than 750 WStand-by mode: Less than 150 WEnergy saver mode: Less than 45 W

Noise Emission:(Sound PowerLevel)

Stand-by: Less than 43 dBOperating: Less than 65 dB

Dimensions: 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)

Weight: Simplex model (G047) Approximately 62 kg (136.7 lbs.)(including consumables)

Auto-Duplex model (G048)Approximately 82 kg (180.8 lbs.)(including consumables)

Option: Paper Feed Unit Type305 (G908) 500-Sheet Paper TrayUnit – 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: Type306 Black (G756), Type306 Cyan (G759), Type306Magenta (G758), Type306 Yellow (G757)

Fuser Oil: Type306 (G745)

Photo ConductorUnit:

Type306 (G744)

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).

MECHANICAL OVERVIEW

SM 1-3 G047/G048

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Same as base model (G024).Refer to the G024 Engine Service Manual for details.

1.3 MAIN UNIT LAYOUT

1. Paper Transfer Unit2. Photoconductor Unit (PCU)3. Paper Tray/Paper Feed Mechanism4. Development Unit (DTM)5. Duplex Unit6. Optical Housing Unit7. Main Control Unit (MCU)

8. Vertical Transport Unit9. High Voltage Supply Unit10. DC Supply Unit11. Controller Board12. Power Supply Unit13. Fusing Unit

G048V101.WMF

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MAIN UNIT LAYOUT

G047/G048 1-4 SM

(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) PCUA 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

SYSTEM BLOCK

SM 1-5 G047/G048

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(11) Tray/Transport• Standard tray: Universal tray, friction pad separation

By-pass tray: FRR method

(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

MCU

ASIC

CPU

ROM NVRAM DRAM

I/O

FIFO

AMDG MotorControl

Video I/FGAVD/PLLC

ADC

SolenoidsClutches

LDModulation

Control

PrinterController

RevolverMain MotorPCU Motor

OperationPanel

Selector

D/A

PSU

High VoltageSupply Board

Fusing Unit

ID Sensor

IC Card

Thermistor

HumiditySensor

SensorsVertical

TransportSensor

PWM

FusingControl

PatternGeneration Expander

InterchangeSolenoids

Sensor

Motor SolenoidsDDB

DC Supply Unit

: Additional components on duplex model (G048)

G048V554.WMF

KEY DIFFERENCES FROM BASE MODEL (G024)

SM 2-1 G047/G048

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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 Located after fusing, switches the paper path to direct thesheet to exit or to the vertical transport unit.

Vertical TransportUnit

Used when duplex printing. Transports the sheet to duplexunit after fusing. This unit is located behind the main-body ofthe printer.

Duplex Unit This unit is located at the bottom of the main-body. In thisunit, a sheet is turned, jogged and then fed to the main-bodyagain. Sheets are fed into this unit one–by–one.

“Interleaf control” is used for this model to increase the printing speed.

2. Printing Speed:

Printing Speed G047/G048 Base Model (G024)Black & White mode 24 ppm 17 ppmColor mode 6 ppm 5 ppm

First Print G047/G048 Base Model (G024)Black & White mode 13 sec. 14 sec.Color mode 26 sec. 30 sec.

3. Image Quality Improvement:Increasing the line frequency in photograph and text mode improves the qualityof the image. A new laser optical unit is used to increase the line frequency.

Line Frequency G047/G048 Base Model (G024)Photograph 180 lpi 106 lpiGraphics 106 lpi 106 lpiText 268 lpi 211 lpi


G047/G048 2-2 SM

2.1.2 FUSING UNIT

The following points differ from the base model’s (G024) fusing unit.

1. Pressure Roller:For duplex printing, the material used to make the pressure roller has beenchanged from Teflon to Silicon rubber to help improve duplex printingperformance.

2. Heat Isolation:To maintain the fusing roller temperature, heat isolation bushings are mountedbetween 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 unitto the main-body of the machine.

2.1.3 OPTICAL UNIT

The following points differ from the base model’s (G024) optical unit.

1. Polygonal Mirror Motor:The speed of the polygonal mirror motor has been increased to allow for anincrease in print speed.

G047/G048 Base Model (G024)Paper feed speed 121.54 mm/sec 101.27 mm/sec.Mirror motor revolutionspeed 28,706 rpm 23,922 rpm

2. LD Unit:To improve the image quality, the diameter of the laser beam has beendecreased and the power of the beam was increased.

G047/G048 Base Model (G024)Diameter of Beam 69 µm x 76 µm 76 µm x 76 µmLD Power 1.91 mW 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 thepolygon mirror motor and the other is on the side of the housing unit.


SM 2-3 G047/G048

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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 topermit duplex printing from the bypass tray.

2.1.5 PROCESS CONTROL

The following points differ from the G024’s process control method.

1. K-DTM Initialization:The image density target level has been lowered.

G047/G048 Base Model (G024)ID on sheet 1.6 1.7Volume of toner 0.56 mg/cm2 0.60 mg/cm2

2. Color-DTMs Initialization:The image density target level has been changed.

G047/G048 Base Model (G024)ID on sheet 1.4 1.5Volume of toner (C) 0.56 mg/cm2 0.55 mg/cm2

Volume of toner (Y) 0.54 mg/cm2 0.55 mg/cm2

Volume of toner (M) 0.62 mg/cm2 0.60 mg/cm2

3. Charge Grid Bias Compensation:Compensation control was changed because the number of lines in photomode 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 signal’s clock rate waschanged.

2. MCU:The MCU has been changed to improve the efficiency of duplex printing bysupporting 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.

DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

G047/G048 2-4 SM

2.2 DUPLEX PRINTING (AUTO-DUPLEX MODEL ONLY)

2.2.1 OVERVIEW

Layout

1. Junction Gate2. Relay Roller3. Reverse Rollers4. Duplex Pick-up Roller5. Jogger Fence

6. Duplex Feed Rollers7. Duplex Unit8. Vertical Transport Rollers9. Vertical Transport Unit10. Exit Unit

G048D101.WMF

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Electrical Components

1. Vertical Transport Entrance Sensor2. Vertical Transport Cover Switch3. Duplex DC Supply Unit4. Vertical Transport Unit Switch5. Vertical Transport Motor6. Temp./Hum. Sensor7. Duplex Driver Board8. Relay Motor9. Duplex Feed Sensor

10. Jogger HP Sensor11. Jogger Motor12. Reverse Solenoid13. Reverse Sensor14. Duplex Reverse Motor15. Duplex Feed Motor16. Vertical Transport Exit Sensor17. Junction Gate Solenoid18. 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.

G048D103.WMF

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G047/G048 2-6 SM

Auto-duplexing was not available in the base unit (G024). As a result the followingcomponents 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 printer’s 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.


SM 2-7 G047/G048

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2.2.2 EXIT UNIT

Driving Mechanism

The fusing unit [A] and drive gears [B], powered by the main motor [C], drive thefeed and exit rollers [D and E].

Junction Gate

The junction gate [A] is located at the entrance of the exit unit. Paper is directed tothe exit tray or to the vertical transport unit by this gate. This gate is positioned bysolenoid [B]. When this solenoid activates, the paper is directed into the verticaltransport unit.

G048D002.WMF

G048D001.WMF

[C]

[E]

[D]

[A]

[B]

[A]

[B]


G047/G048 2-8 SM

Exit Cover Open Detection

The exit unit cover switch [A] is on the right side of the unit and is responsible fordetecting if the exit unit cover is open. This switch interrupts a 24VDC line to theMain Control Board (PCB2).

G048D003.WMF

[A]


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2.2.3 VERTICAL TRANSPORT UNIT

Driving Mechanism

The vertical transport motor [A] drives the vertical transport rollers [B] via gears [C]and timing-belts [D].

Paper Feed Detection

Two sensors (photo-interrupters) detect paper presence in the vertical transportunit. The first is referred to as the vertical transport entrance sensor [A] and thesecond is referred to as the vertical transport exit sensor [B].

G048D501.WMF

G048D010.WMF

[B]

[A]

[B]

[A]

[C]

[D]

[D]


G047/G048 2-10 SM

Vertical Transport Unit Cover Open Detection

Two vertical transport safety switches are used to determine if the vertical transportunit 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 coveris open.

These switches are placed in series to one another on the same 24VDC line.

G048D008.WMF

G048D007.WMF

[A]

[B]


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2.2.4 DUPLEX UNIT

Driving Mechanism

OverviewThe duplex feed motor [A] transports the paper arriving from the vertical transportunit 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. Theduplex feed motor [B] continues to move the paper, via the reverse rollers, until ithas been placed in the reverse tray.Next, the paper is driven out of the reverse tray by the action of the duplex reversemotor, reverse transport idler roller (referred to as the duplex pick-up roller) andreverse rollers, where it is driven up to the relay roller.

Reverse Mechanism

First, paper is fed by the duplex feedrollers [A] (which function as transportrollers) and then by the reverse rollers[B]. When the reverse sensor [C] detectsthe leading edge of paper, the reversesolenoid [D] activates, lowering theduplex pick-up roller [F], and paper is fedinto the reverse tray [E].When the reverse sensor [C] detects thetrailing edge of paper, the reversesolenoid deactivates and the duplexpick-up roller lifts slightly, pressing thesheet against the second reverse roller.

G048D015.WMF

[D]

[B][A]

[E]

[B]

[C]

[A]

[F]

[C]


G047/G048 2-12 SM

Jogging Mechanism

When printing, the jogger fences [A]are moved to their standby position(10mm wider than the printedpaper’s width).After the reverse rollers stop, thejogger motor [B] positions the joggerfences to their feed-out position(1mm narrower than the printedpapers width). If, after completing theprint job, no other sheets are to beduplexed, the fences return to theirhome position (determined when thetab on the front jogger fence entersthe home position sensor [C]).

Feed-out

After jogging the paper, the reverserollers turns counter-clockwise and thereverse solenoid activates. This feedspaper to the relay roller [A], which isdriven by the relay motor [B].

Reverse Tray Detection

The reverse tray is connected to theduplex driver board [A] through drawerconnectors [B]. When the tray is slidinto the machine, these drawerconnectors complete a loop backsignal that helps to ensure that thetray is positioned properly into themachine.

G048D006.WMF

G048D009.WMF

G048D153.WMF

[A]

[B]

[A]

[B]

[B]

[C][A]


SM 2-13 G047/G048

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2.2.5 INTERLEAF

An interleaf mechanism was added to increase duplex printing performance inblack & white print mode. Also, this model only prints face down.

Paper Path for Duplex PrintingA: Paper feed for back-side print ( -1: Standard tray -2: Optional tray)B: Secondary transfer for back-side printC: Fusing back-side printD: JunctionE: Vertical transportF: ReverseG: Paper feed for front-side printH: Secondary transfer for front-side printI: Fusing for front-side printJ: JunctionK: Paper exit

G048D211.WMF

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D/J


G047/G048 2-14 SM

Print Order for Duplex Black & White Printing

The following example shows what happens when printing 8 sheets of A4/LTR sizepaper in duplex black & white mode. 4 sheets of A4/LTR size paper can be keptinside the machine during this print process.

Print Order for Duplex Color Printing

The following example shows what happens when printing 8 sheets of A4/LTR sizein duplex color mode.

2

12 14 1610

4 6 8

1 3 5

1513119

➀ ➁ ➂ ➃

➀ ➄ ➁ ➅ ➂ ➆7➃ ➇

➇➆➅➄

G048D212.WMF

2 4 6 81 3 5 7➁ ➂ ➃➀ ➃➂➁➀

2 sheets print 2 sheets print 2 sheets print

G048D214.WMF

INSTALLATION

INSTALLATION PROCEDURE

SM 3-1 G047/G048

3. INSTALLATION PROCEDURE


• For the printer: Quick Installation Guide• For options: Setup Guide (one of the Operator’s Manuals)

If the customer has a service contract with a meter click system, set up the counteras follows:

1. Enter Controller SP mode (refer to 4.1.1 ENTERING AND EXITINGCONTROLLER SP MODE in the controller’s section of this service manual fordetails).

2. Set “Meter Click” from the maintenance menu to the proper mode depending onthe contract type (refer to 4.1.4 SP MODE DETAILS in the controller’s sectionof this service manual for details).

3. Exit SP mode, and then confirm that display of both “Color” and “Black” is 0 byexecuting “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 correctmodel name on the LCD panel and in the configuration page header.NOTE: This must be done before delivering the printer to the customer’s site.

To modify the unit’s 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] keysin sequence. Do not let more than a second or two pass between buttonselections.

3. Select the appropriate brand name and press the [#Enter] key.In

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SERVICE TABLES

OVERVIEW

SM 4-1 G047/G048

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4. SP MODE

4.1 OVERVIEW

This printer has two SP modes:1) Engine SP mode2) Controller SP mode

The controller SP modes are described in the controller’s section of this servicemanual.

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.


The following table highlights the differences from the base model (G024).

Menu Item Difference from the base model (G024)1: Margin Duplex printing menu and two adjustable items were added.2: Parameter The secondary transfer bias can be adjusted individually for

printing on the front side and for the other side of paper.3: Clear Memory Same as the base model (G024)4: Sensor Check Eight more sensors were added to the vertical transport and

duplex units.5: Nip Width Same as the base model (G024)6: Reset SC Same as the base model (G024)7: Process Ctrl Same as the base model (G024)8: Test Print Three menus were added for auto-duplex printing.9: ID Sensor PWM Same as the base model (G024)10: Image Adjust Same as the base model (G024)11: Output Check 10 more components were added to the vertical transport and

duplex units.12: Hi-light Same as the base model (G024)13: Lub_Interval Same as the base model (G024)14: BLT-TR BIAS Additional function to adjust the primary transfer bias.

ENGINE SP MODE

G047/G048 4-2 SM


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 Layer 2 Layer 3 Layer 4Print: StdTray 1Tray 2Tray 3(D) Tray 1(D) Tray 2(D) Tray 3By-pass Tray

Margin: PrintStd. Paper

(D) shows duplexprinting.

Margin: PrintThick Paper

Print: ThickBy-pass Tray

MarginPattern Print

Margin: PrintTransparency

Print: TransBy-pass Tray

Margin: AdjustTray1: Left

Tray1: LeftX.XTray1: Top: 1stX.X

Margin: AdjustTray1: Top: 1st

It can be adjustedfor tray 2, tray 3,and the by-passtray in the sameway as for tray1.

Margin: AdjustTrans: Top: 1st(For OHPs)

Trans: Top: 1stX.X

Margin: AdjustBack: Left

Back: LeftX. X

Maintenance1: Margin

MarginAdjust

Margin: AdjustBack: Top

Back: TopX. X

ENGINE SP MODE

SM 4-3 G047/G048

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4.2.4 PARAMETER

NOTE: Items indicated in bold italic are additional ones for this model.

Layer 1 Layer 2 Layer 3 Layer 4Std. PaperTransfer Bias

BiasXXX%

Std. Paper(D) Transfer Bias

(D) BiasXXX%Temp.LowTemp.Normal

ParameterStd. Paper

Std. PaperFusing Temp.

Temp.High

ParameterThick Paper


Maintenance2: Parameter

ParameterTransparency

Same as Std. Paper(D) not available

Same as Std. Paper(D) not available

4.2.5 CLEAR MEMORY


NOTE: Counter values used for meter clicks are not cleared.

ENGINE SP MODE

G047/G048 4-4 SM

4.2.6 SENSOR CHECK

NOTE: Items indicated in bold-italic are additions to this model.



P End-1st Paper detected Paper not detected

Paper End Sensor(By-pass Tray)

P End-By-pass Paper detected Paper not detected


P End-2nd Paper detected Paper not detected


P End-3rd Paper detected Paper not detected

Registration Sensor Registration Paper not detected Paper detectedExit Sensor Exit Paper detected Paper not detectedPaper Size Switch(Tray 1)

P Size-1st *1 *1


P Size-2nd *1 *1


P Size-3rd *1 *1

By-pass Paper WidthDetection Board

P Size-By-pass *2 *2

PCU Set Switch PCU Set Detected Not detectedDTM Set Sensor CTC Set Detected Not detectedToner End Sensor CTC Toner End Not end EndDoor Safety Switch Cvr Opn-F Closed OpenExit Cover Switch Cvr Opn-EX Closed OpenOil End Sensor Oil End End Not end(Fusing Unit) Fusing Set Detected Not detectedUsed Toner Sensor Used Toner Not full Full(Tray 2) Tray Set-2nd Not detected Detected(Tray 3) Tray Set-3rd Not detected DetectedPCU Reset Sensor PCU Reset Old NewRevolver H.P. Sensor Revolver H.P. Home position Not home positionTransfer RollerPosition Sensor

Tfr Position Release Touch


P Feed-2nd Paper not detected Paper detected


P Feed-3rd Paper not detected Paper detected

ID Sensor ID *3 *3Humidity *4 *4Temperature/Humidity

Sensor Temp *5 *5DTM Cover Switch Cvr Opn-S Open ClosedPull-out Sensor (MainBody)

Pick-up Paper detected Paper not detected

Charger Corona SetSwitch

Main Charger Detected Not detected

Vertical transportunit/cover switch

Cvr Open-Duplex Open*6

Closed*6

Reverse sensor Reverse Sensor Paper detected Paper not detected

ENGINE SP MODE

SM 4-5 G047/G048

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Duplex Feed sensor P Feed-Duplex Paper not detected Paper detectedJogger HP sensor Jogger H. P Home position Not home positionDuplex unitconnection signal

Duplex-Unit Set Not detected*7

Detected*7

Duplex trayconnection signal

Duplex Tray Set Not detected*8

Detected*8

Vertical transportentrance sensor

V feed P1 Paper detected Paper not detected

Vertical transportexit sensor

V Feed P2 Paper detected Paper not detected

*1: “Paper size detection” in Section 2 explains the status of the paper sizeswitches for paper size detection. (0: Pressed, 1: Not pressed)

*2: The indicated value is always “1f” as there is no paper size detectionmechanism on this model.

*3: The displayed value indicates the K sensor output when the LED in the IDsensor is turned on. The specified output value (reference for normaloperation) is 2.7 ± 0.8 V.

*4: The detection results are shown in the XXX YYY format. XXX indicatesabsolute humidity, and YYY indicates relative humidity. (Reference for normaloperation: YYY should be between 5 and 95.)

*5: The displayed value indicates the detected temperature. (Reference for normaloperation: 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 ischecked. (10th pin of the CN254 on the MCU)

*8: Loop back signal for the duplex driver board is checked. (13th pin of theCN896 on the Duplex driver board)

4.2.7 NIP WIDTH


4.2.8 RESET SC


ENGINE SP MODE

G047/G048 4-6 SM

4.2.9 PROCESS CTRL


4.2.10 TEST PRINT


Layer 1 Layer 2 Layer 3 Layer 4Test PrintPattern 1

Pattern 1Tray X

PrintingTray X

Test PrintPattern 2


Test PrintPattern 3


Test PrintPattern 1(D)




Maintenance8: Test Print



4.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)


4.2.12 IMAGE ADJUST


ENGINE SP MODE

SM 4-7 G047/G048

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4.2.13 OUTPUT CHECK


Name Display OperationBy-pass Feed Clutch Bypass Feed Cl. Continues for a certain timePull-out Clutch Pick-up Cl. Continues until instructed to

turn OFFPaper Feed Clutch Feed Cl. Continues for a certain timeRelay Roller Clutch Transport Cl. Continues until instructed to

turn OFFRegistration Clutch Regist. Cl. Continues until instructed to

turn OFFTransfer Roller Clutch Tr. Roller Cl. Continues for a certain timeDevelopment Drive Solenoid Development Sol. Continues until instructed to

turn OFFBy-pass Feed Solenoid Bypass Sol. Continues for a certain timeTransfer Belt Cleaning Solenoid Cleaning Sol. Continues until instructed to

turn OFFQuenching Lamp Quenching LED Continues until instructed to

turn OFFPCU Motor-slow Continues until instructed to

turn OFFPCU Motor-normal Continues until instructed to

turn OFFPCU Motor-fast Continues until instructed to

turn OFF

PCU Motor

PCU Motor-reverse Continues until instructed toturn OFF

Main Mtr-normal Continues until instructed toturn OFF

Main Motor

Main Mtr-slow Continues until instructed toturn OFF

Polygon Mirror Motor Scanner Motor Continues until instructed toturn OFF

Revolver Motor Revolver Motor Continues until instructed toturn OFF

Tray Main Motor (for tray 2) OT1 Motor Continues until instructed toturn OFF

Paper Feed Clutch (for tray 2) OT1 Feed Clutch Continues for a certain timeTray Main Motor (for tray 3) OT2 Motor Continues until instructed to

turn OFFPaper Feed Clutch (for tray 3) OT2 Feed Clutch Continues for a certain timeVertical Transport Motor V Feed motor Continues until instructed

to turn OFFDuplex Feed Motor Duplex Tray Mtr Continues until instructed

to turn OFFDuplex Reverse Motor Rvrs Mtr Continues until instructed

to turn OFF

ENGINE SP MODE

G047/G048 4-8 SM

Name Display OperationDuplex Reverse Motor Rvrs Mtr-rvrs Continues until instructed

to turn OFFReverse Solenoid Press Roller Sol Continues until instructed

to turn OFFJogger(for H.P.)

Jogger HP Continues for a certaintime

Jogger(jogger fences out)

Jogger Continues for a certaintime

Jogger(jogger fences in)

Jogger reverse Continues for a certaintime

Relay Motor Pull Out Motor Continues until instructedto turn OFF

Junction Gate Solenoid Divergence Sol. Continues until instructedto turn OFF

4.2.14 HIGHLIGHT ADJUSTMENT


4.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL ADJUSTMENT)


ENGINE SP MODE

SM 4-9 G047/G048

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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 Layer 2 Layer 3BLT-TR BIASCyan

CyanXXX

BLT-TR BIASMagenta

MagentaXXX

BLT-TR BIASYellow

YellowXXX


BLT-TR BIASBlack

BlackXXX

PREVENTIVE MAINTANENCE

PM TASKS

SM 5-1 G047/G048

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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 nextpage.

The fusing unit replacement interval is not determined in the same manner as thebase machine. For details, see the note after the PM table.

• For the replacement procedures, refer to Chapter 6 “Replacement andAdjustment” in this manual and Chapter 3, “Replacement and Adjustment” in thePaper Feed Unit Type305 (G908) manual for the optional 500-sheet paper tray.

!CAUTIONWhen 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 customer’s site.

• Visually inspect the components, and replace them if there is any damage.

!CAUTIONA high voltage is applied to bias electrodes. When inspecting any biaselectrodes, ensure that the power switch is turned off.

PM TABLE

G047/G048 5-2 SM

5.2 PM TABLE

5.2.1 MAIN UNIT


Item EM 60K 100K NotePaper Feed Roller C R Alcohol or waterRegistration Roller C Alcohol or waterFriction Pad C R WaterBottom Plate Pad C WaterBy-pass Feed Roller C Alcohol or waterBy-pass Pick up Roller C Alcohol or waterBy-pass Separation Roller C Alcohol or waterCharge Corona Unit C*1 Cleaner in the PCUQuenching Lamp I Blower brush (if dirty)ID Sensor C Dry clothDust Shield Glass C*1 Cleaner brush (P/N: G0241533)Fusing Unit R*2

Exit roller-Exit Unit C Auto-duplex model onlyFeed roller-Exit Unit C Auto-duplex model onlyFeed rollers-Duplex Unit C Auto-duplex model onlyVertical Transport Rollers C Auto-duplex model onlyDuplex Rollers C Auto-duplex model onlyRelay Roller C Auto-duplex model only

*1: This item is also a user maintenance item.

*2: Regardless of the meter-click setting, the number of pages that the countercounts 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 stillcontinue.

NOTE: The following indication will NOT be shown on the display when one ofthe meter-click modes are selected even if the counter reaches the PMinterval.“Change Fusing Unit”“Change PCU”“Need Charger Unit”The Charger unit and Fusing unit counter need to be manually clearedby “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) servicemanual.

EXTERIOR

SM 6-1 G047/G048

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6. REPLACEMENT AND ADJUSTMENT(AUTO-DUPLEX MODEL)

6.1 EXTERIOR

6.1.1 TOP OVER

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).

2. Open the vertical transport unit [C] (2 screws).

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 topcover off, carefully push the top cover slightly towards the back of theprinter and then lift the cover off.

G048R810.WMF

[D]

[C]

[B]

[A]

PAPER EXIT UNIT

G047/G048 6-2 SM

6.2 PAPER EXIT UNIT

6.2.1 UPPER COVER

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 theback of the cover then lift the cover up and off.

6.2.2 LOWER COVER

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).

G048R829.WMF

G048R830.WMF

[B][A]

[A]

[B]

PAPER EXIT UNIT

SM 6-3 G047/G048

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6.2.3 PAPER EXIT UNIT

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].

G048R824.WMF

[A]

[C][D]

[B]

PAPER EXIT UNIT

G047/G048 6-4 SM

6.2.4 JUNCTION GATE SOLENOID

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.

G048R827.WMF

G048R840.WMF

G048R825.WMF

[A]

[C]

[E]

[B]

[D]

VERTICAL TRANSPORT UNIT

SM 6-5 G047/G048

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6.3 VERTICAL TRANSPORT UNIT

6.3.1 VERTICAL TRANSPORT UNIT COVER

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

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).

G048R802.WMF

G048R803.WMF

[B]

[A]

[B]

[C]

[A]

[C]


G047/G048 6-6 SM

6.3.3 VERTICAL UNIT SENSORS

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

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).

G048R801.WMF

G048R804.WMF

[A]

[B]

[A]


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6.3.5 VERTICAL TRANSPORT UNIT

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 clampand 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 screweach).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.

G048R823.WMF

[A]

[C]

[B]

DUPLEX UNIT

G047/G048 6-8 SM

6.4 DUPLEX UNIT

6.4.1 DUPLEX TRAY

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.

G048R828.WMF

[A]

[B]

DUPLEX UNIT

SM 6-9 G047/G048

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6.4.2 REVERSE ROLLER

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 Mylarstrips properly when re-installing the lower reverse plate. Do not set theplate down on the Mylar strips. Also note that the lower reverse plate issecured in the front by a small tab [H].

6. Remove the reverse roller gears [F] by carefully “prying” up the gear’s lockingtab, then remove the rollers [G] (4 clips and 4 bushings).

G048R811.WMF

G048R813.WMF

G048R819.WMF

[B]

[C]

[D]

[G]

[A]

[E]

[F]

[H]

DUPLEX UNIT

G047/G048 6-10 SM

6.4.3 DUPLEX FEED MOTOR/REVERSE MOTOR


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 withthe brackets (2 screws each).NOTE: Be careful not to damage the motor’s harness when removing. Also

note that the idle gear is not secured to the motor’s bracket.

4. Remove the motors from their brackets (2 screws and 1 connector each).

6.4.4 DUPLEX FEED SENSOR



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 sensorbracket’s guide plate properly.

G048R815.WMF

G048R817.WMF

[B]

[A]

[B][A]

DUPLEX UNIT

SM 6-11 G047/G048

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6.4.5 DUPLEX UPPER UNIT AND JOGER HOME POSITIONSENSOR



3. Remove the center plate and duplex feed sensor connector [A]. (Refer tosection 6.4.4.) Pass the sensor’s connector through the side frame’s cableguide (grommet).

4. Disconnect the feed [B] and reverse motor [C] connectors.NOTE: Be certain that all the wires of the motor’s harness are clear from the

cable clamps.

5. Open the front set upper and lower guide plates and slowly slide the joggerfences [D] to the inside. When completed, close the upper and lower guideplates.

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 and6 above. Once completed, carefully “push” the sensor from its bracketusing your fingers. When removing the sensor from its bracket, notethe locking tabs on the sensor. Using this method, it is not necessary toremove the duplex upper unit.

G048R812.WMF

[A]

[D]

[B][C]

[E]

[F]

DUPLEX UNIT

G047/G048 6-12 SM

6.4.6 JOGGER MOTOR/REVERSE SOLENOID


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 guideplates “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).

G048R814.WMF

G048R816.WMF

[A]

[C]

[B]

[D]

*

DUPLEX UNIT

SM 6-13 G047/G048

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6.4.7 REVERSE SENSOR


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

1. Open the vertical transport unit.

2. Remove the temperature/humidity sensor [A] (1 screw and 1 connector).

G048R818.WMF

G048R808.WMF

[A]

[A]

DUPLEX UNIT

G047/G048 6-14 SM

6.4.9 RELAY MOTOR/RELAY ROLLER

1. Remove the left and right side mainframe covers.

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, thenseparate them.


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).

G048R836.WMF G048R835.WMF

G048R834.WMF

G048R839.WMF

[A]

[D]

[I][H]

[B]

[E]

[F]

[G]

[J]

[C]

[C]

FUSING SECTION

SM 6-15 G047/G048

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6.5 FUSING SECTION

6.5.1 FUSING UNIT

!CAUTION1. 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.

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).

G048R831.WMF

G048R832.WMF

[C]

[B]

[D]

[E]

[A]

LASER SECTION

G047/G048 6-16 SM

6.6 LASER SECTION

!WARNINGTurn off the main switch and unplug the machine before attempting any ofthe procedures in this section. Laser light (radiation) can seriously damageyour 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

LASER SECTION

SM 6-17 G047/G048

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6.6.2 OPTICAL HOUSING UNIT/POLYGON MIRROR MOTOR

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 G024’s Service Documentation prior to and while performing thisremoval procedure.The steps below detail the procedure to use when removing the 2 screws securingthe 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.

G048R827.WMF

G048R826.WMF

[A]

[B]

[D][C]

ELECTRICAL COMPONENTS

G047/G048 6-18 SM

6.7 ELECTRICAL COMPONENTS

6.7.1 CONTROLLER BOARD

NOTE: Before replacing the controller, when possible, first print a list of the currentsettings. In the event of NV-RAM damage, it will be necessary to re-configure all settings according to this list.

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 and1 board connector).

NOTE: 1) If the customer has added optional expansion memory or a NIC, removeit before replacing the controller. Remember to install the memory orNIC on the new controller board.

2) To replace the controller boards, remove the NVRAM chip (IC23) on theold board, install it on the new board, then install the new board. TheNVRAM chip stores user settings and service records. These settingswill be lost if the NVRAM chip is not transferred.

G048R805.WMF

G048R806.WMF

[A]

[D]

[B]

[C]


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6.7.2 DUPLEX DC SUPPLY UNIT

!WARNINGTo avoid the possibility of an electrical shock, unplug the power cablebefore replacing the power supply unit.

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 screwsand 2 connectors).

3. Remove the dc supply unit from the bracket (4 screws).

G048R807.WMF

[A]

[B]


G047/G048 6-20 SM

6.7.3 POWER SUPPLY UNIT

!WARNINGTo avoid the possibility of an electrical shock, unplug the power cablebefore replacing the power supply unit.

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 ➀ to swing it out part way ➁.

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 2hooks).

G048R820.WMF

G048R821.WMF

[B]

[A]

[C]


SM 6-21 G047/G048

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6.7.4 HIGH VOLTAGE SUPPLY UNIT

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).

!WARNINGCarefully connect the high-voltage wires as shown in the diagram below.

NOTE: This symbol points to the back of the main-body. When viewing thissupply unit installed in the printer, the arrow points to the backside ofthe printer main-body (towards rear of unit).

G048R255.WMF

CN190

G048R512.WMF

[A]

[B]

White connector:Belt transfer bias roller

Yellow connector:Development blade

White connector:Development roller

Blue connector:Supply roller

Yellow connector:Charge corona unit wire

Blue connector:Charge corona unit grid

White connector:Transfer roller


G047/G048 6-22 SM

6.7.5 MCU

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 oldboard, install it on the new board, and then install the new board.In the event of NVRAM damage, install a new NVRAM chip, and contactyour supervisor for additional steps. A forced process control will also benecessary (Engine SP mode 7: Process Control – Initialize).

6.7.6 DUPLEX DRIVER BOARD

1. Remove the duplex backside cover [A] (4 screws).

2. Remove connectors on the board.

3. Remove the duplex driver board [B] (6 screws).

G048R822.WMF

G048R833.WMF

[A]

[A]

[B]

TROUBLESHOOTING

SC TABLES

SM 7-1 G047/G048

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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 intothree types:

Service Call Type ResultsTYPE 1:Safety warning and immediateshutdown (Fusing unit errors)


TYPE 2:Immediate shutdown


TYPE 3:Log only (Process control errors)

The printer does not stop. No SC error message isdisplayed. 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 SCitem in the engine SP mode menu. They cannot be released by turning the mainpower switch off and on.

SC TABLES

G047/G048 7-2 SM

7.1.2 SC ERROR LIST

NOTE: The errors marked with an asterisk “*” are additional or changed codes forthis model.

SCNo. Type Name Occurrence conditions Detection conditions Probable Cause


unit errorThe detection signal forthe 500-sheet paper trayunit is abnormal.


21




Pressure rollerthermistor, MCU

22



No detection in theevent of SC or lack offusing unit.

Pressure rollerthermistor, MCU

23


Reheating has been doneand the motor is notrunning, or 60 secondshave passed after themain motor halted. Then,the roller temperature hasbeen below 130°C for 60seconds


Pressure rollerthermistor, MCU,pressure roller lampconnector

24




Hot roller thermistor,MCU

25Type 1 High hot

rollertemperature


No detection in theevent of SC or fusingunit absence

Hot roller thermistor,MCU

26


Reheat has been doneand the motor is notrunning, or 60 secondshave passed after mainmotor halt. Then, theroller temperature hasbeen below 130°C for 60seconds


Hot roller thermistor,MCU, hot rollerlamp connector

* 27

Type 2 Zero-crosscycledetectionerror

50 Hz ACThe number of zero-crossis detected less than 89times or more than 111times in one second forcontinuous 5 seconds.60 Hz ACThe number of zero-crossis detected less than 109times or more than 131times in one second forcontinuous 5 seconds.


Frequency of thecommercial ACpower

SC TABLES

SM 7-3 G047/G048

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28




There is adisconnection in thepaper transfer biassupply circuit.(Deformation ofterminals or springs,dirty bearings.)When thecontact/separationlever is normal: Badtransfer rollerposition sensor,harness, or MCU.When thecontact/separationlever is faulty: Badtransfer roller clutchor MCU.

29




There is adisconnection in theprimary transfer biassupply circuit. (Dirtyor deformedelectrodes)

31




There is a shortcircuit in the supplybias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter).

32





33




There isdisconnection in thecharge corona unitbias supply circuit.(Dirty or deformedelectrodes)

34






Continuous unlock fortwo seconds

Main motor, MCU


Continuous unlock fortwo seconds

PCU motor, MCU

SC TABLES

G047/G048 7-4 SM


38



Revolver motor,MCU, or incorrectinstallation of colordevelopment unit

39Type 2 Polygon

mirror motorerror


Polygon mirrormotor, MCU

40



ID sensor calibration ID sensor

41



Transfer belt H.P.sensor, MCU


LD error (abnormal laserpower output).

LD, LD controlboard


ion detectionerror

Synchronization detectionerror of the optical unit.

During polygon mirrormotor revolution.


45




There is a shortcircuit in the chargebias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter).

46




There is a shortcircuit in the papertransfer bias supplycircuit (due todeformed terminalsor electrodes orconductive foreignmatter).

47





48




There is a shortcircuit in the papertransfer bias supplycircuit (due todeformed terminalsor electrodes orconductive foreignmatter).

49


When reheating, theroller temperature doesnot reach the reheat starttemperature (targettemperature –20°C)within five minutes.

During re-heating. Pressure rollerthermistor, pressureroller lampconnector, MCU

SC TABLES

SM 7-5 G047/G048

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50


When reheating, theroller temperature doesnot reach the reheat starttemperature (targettemperature –10°C)within five minutes.

During reheating. Hot roller thermistor,hot roller lampconnector, MCU

51





52





57Type 2 Print

commanderror


59




Temperature sensor

60




Humidity sensor

*61

Type 2 PaperTransferroller error

Paper transfer positionsensor does not detectthe movement of roller.

When the contact andseparation of theroller need to bedetected.

Transfer rollerposition sensorMCUHarnessTransfer roller clutch

*62Type 2 Auto-Duplex

unit detectionerror.

Auto-duplex unit isdetected on the manual-duplex model.

When the power ison.

MCU

*63

Type 2 Joggermovementerror

Jogger home positionsensor does not turn on.

During duplexprinting.

Jogger motorJogger HP sensorMCUDDB

SC TABLES

G047/G048 7-6 SM

7.1.3 PROCESS CONTROL ERROR LIST

PENo. Type Name Occurrence conditions Detection conditions Probable Cause

103 Type 3

K ID sensorerror

While the LED is off, theID sensor output does notmeet the standardvoltage (between 0.05 Vand 1.5 V).


When the outputmeets the standardvoltage: MCU,harnessWhen the outputdoes not meet thestandard: K IDsensor

104 Type 3

ID sensoroutput error(roughadjustment)

The difference in IDsensor outputs when thetransfer belt is read andwhen the LED is off doesnot meet the standardvoltage (Vbkcal ± 0.4 V).


K ID sensor, MCU,transfer belt error,transfer belt surfaceunevenness,incorrect ID sensorinstallation

105 Type 3

ID sensoroutput error(fineadjustment)

The difference in IDsensor outputs when thetransfer belt is read andwhen the LED is off doesnot meet the standardvoltage (Vbkcal ± 0.1 V).


K ID sensor, MCU,transfer belt error,transfer belt surfaceunevenness

110 Type 3

ID sensorpattern error(Cyan)

The slope γM of the linerepresenting therelationship between theC development bias andattached toner amount isnot between –0.01 and –0.0005.


Incorrect color DTMinstallation, incorrectPCU installation,development biaserror, MCU, LDcontrol malfunction,loss ofsynchronization

111 Type 3

ID sensorpattern error(Magenta)

The slope γM of the linerepresenting therelationship between theM development bias andattached toner amount isnot between –0.01 and –0.0005.



112 Type 3

ID sensorpattern error(Yellow)

The slope γM of the linerepresenting therelationship between theY development bias andattached toner amount isnot between –0.01 and –0.0005.



116 Type 3

ID sensorpattern error(K)

The slope γM of the linerepresenting therelationship between theK development bias andattached toner amount isnot between –0.01 and –0.001.


Incorrect K DTMinstallation, incorrectPCU installation,development biaserror, MCU, LDcontrol malfunction,loss ofsynchronization

SC TABLES

SM 7-7 G047/G048

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PENo. Type Name Occurrence conditions Detection conditions Probable Cause

118 Type 3

ID sensorpattern readerror (K)

The difference in IDsensor outputs when theID sensor pattern is readand when thebackground surface ofthe transfer belt is read is0.8 V or less.

K-DTM biasinitialization

Incorrect DTMinstallation, incorrectPCU installation,development biaserror, MCU, LDcontrol malfunction,loss ofsynchronization

123 Type 3

ID sensorpattern error(K)

The slope γM of the linerepresenting therelationship between theDTM bias and attachedtoner amount is notbetween –0.01 and –0.001.

K-DTM bias control Incorrect DTMinstallation, incorrectPCU installation,development biaserror, MCU, LDcontrol malfunction,loss ofsynchronization

USER ERROR LIST

G047/G048 7-8 SM

7.2 USER ERROR LIST

This table only details those items that have been added to, and that are differentfrom, the base model (G024).

Error Operationafter error


Add Toner: xx Printing stops. The PCU counter isincreased to 100after toner near-endis detected.

Replace theDTM.

This error is shownwhen “Stop” isselected in the TonerEmpty menu.

Low on : x,x,x Printing can bedone.

Toner near-enddetection is enabledtwo seconds afterthe developmentdrive solenoid turnson until it turns off.The toner near-endmessage isdisplayed whentoner end is detectedfive times.

Replace theDTM.

When near-end isdetected, closing thefront cover initiatesrecovery. If the tonernear-end status iscleared, it is notdetected duringrecovery. In single-color (black-and-white)continuous output,toner near-end isdetected duringprocess control.

Change PCU Printing can bedone.

The CPU counterreaches 72,000.

Replace the PCUto reset thecounter.

Counting (upon exit)A3/DLT or smallerK single-color: Plus 1Full color: Plus 4

For sizes larger thanA3/DLT, countingdoubles.This is not shown ifmeter-click mode isselected.

ChangeFusing Unit

Printing can bedone.

The fusing unitcounter reaches60,000.

Manually releasethe messageusing‘MaintenanceClear’ incontroller SPmode.

A3 or larger:Number of sheets thathave passed x 2

Smaller than A3:Number of sheets thathave passed

This is not shown ifmeter-click mode isselected.

Need Charger Printing can bedone.

Charger counterreaches 24 K.

Replace chargerunit and reset thecharger counter.

This is not shown ifmeter-click mode isselected.

VerticalTransport UnitCover Open

Printing is disabled. Always monitored. Close the cover.

USER ERROR LIST

SM 7-9 G047/G048

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Error Operationafter error


Duplex-trayJam

Printing is disabled. <Case 1>The duplex feedsensor does notdetect paper 3.2seconds after thevertical transport exitsensor detectspaper.

<Case 2>The reverse sensordoes not detectpaper 3.2 secondsafter the duplex feedsensor detectspaper.

<Case 3>The reverse sensordoes not detectpaper 0.5 secondsafter the duplexreverse motor turnson.

Remove thejammed paper.

VerticalTransport UnitJam

Printing is disabled. The verticaltransport entrancesensor does notdetect paper 3.2seconds after thepaper exit sensor infusing unit detectspaper.

Or

The verticaltransport exit sensordoes not detectpaper 2.8 secondsafter the verticalentrance sensordetects paper.

Remove thejammed paper byopening thevertical transportunit.

Duplex UnitExit Jam

Printing is disabled. The pull-out sensorfor the main framedoes not detectpaper 0.9 secondsafter the relay motorturns on.

FIRMWARE HISTORY

G047/G048 7-10 SM





LEVELSERIAL






3.10



3.55

Rev.08/2001

⇒

G047/G048

CONTROLLER ANDNETWORK INTERFACE BOARD

TYPE306SERVICE MANUAL

NOTE: The first section of this part of the Service Manualrefers to the Controller. The second section details theNetwork Interface Board Type 306.

OVERALL INFORMATION


SM 1-1 G047/G048

Ove

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1.1 BASIC SPECIFICATIONS

Page DescriptionLanguage:

• IPDL-C (Intelligent Page Description Language for Color)• RICOH-SCRIPT2

Printer Driver: • IPDL-C: Windows 95/98/2000/NT 4.0• RICOH-SCRIPT2: Windows 95/98/2000/NT 4.0,

Macintosh (PPD for LaserWriter 8)Resolution: 600 dpi (1800dpi x 600dpi equivalent print quality)

Color Mode: Color, B&W

Gradation Mode 1 or 2 bits/pixel

Toner Saving: On/Off (printer driver setting) Default Setting: Disabled

Color Correction: On/Off (printer driver setting) Default setting: Enabled

Interface: • Standard: Parallel port (IEEE1284: Compatible/Nibble/ECP mode supported)

• Option: Parallel port (IEEE1284: only Compatible modesupported), Ethernet (100 BASE-TX, 10 BASE-T)

Fonts RICOH-SCRIPT2: 39 Roman fonts

Memory Standard: 32 MB (simplex model), 64 MB (duplex model)Up to 256 MB can be installed (2 SDRAMS).

SDRAM DIMM Slot 2

Option Bus Interface 2 (for optional network I/F board and optional parallel I/F)

Options • 32 MB Memory• 64 MB Memory• 128 MB Memory• Network Interface Board Type306• IEEE1284 Parallel Interface Type204• Paper Feed Unit Type305


SM 2-1 G047/G048

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s2. 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 simplexmodel.

3. The appropriate electric counter can be selected depending on the type ofmaintenance contract for meter click charge. A new User mode, “ShowCounter”, 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 numberof 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 currentstatus 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 papersize selected by the printer driver takes priority over the size selected on theoperation panel.

7. The printer can be set so that it will either stop or continue printing when tonerhas 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. CPUNEC VR4310-177

2. ASICRocky-R, which is compatible with SDRAM. FCI2.5C was removed because300-dpi mode is not supported. Therefore, toner saving mode is controlled byfirmware.

3. SDRAMThe type of SDRAM used has been changed from SIMM to DIMM.

4. NVRAMThe capacity of the NVRAM has been expanded to 8 KB to store the Job andPrint Logs.

5. DIP SwitchesDip switches do not require resetting when upgrading firmware.


G047/G048 2-2 SM

2.2 FUNCTIONAL OVERVIEW

2.2.1 SYSTEM LAYOUT

Control ler Board

IC Card

Pro

gram

RO

M I

/F

RP

S2

IC C

ard

I/F

V ideo I/F

IEE

E12

84 I

/F

Opt

ion

Bus

I/F

SDRAM I /F

S D R A M

SDRAM I /F

S D R A M

Network I /FBoard

Host

Host

G048O701.WMF


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s2.2.2 CONTROLLER BOARD LAYOUT

DIP SW

NVRAM

Fon

tR

OM

ASICROCKY R

CPUR4310

Fla

shR

OM

Fla

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OM

Pro

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RO

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F

Opt

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Bus

I/F

Opt

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Bus

I/F

IEE

E12

84 I/

F

Video I/F

Option RAM I/F

Standard/Option RAM I/F

IC C

ard

I/F

G048O702.WMF


G047/G048 2-4 SM

2.2.3 FUNCTION OF EACH DEVICE

Device FunctionCPU VR4310-177 (177 MHz)ASIC ROCKY R 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 Stores program (2 MB) The flash ROM is programmable via anIC card.

NVRAM Stores the initial settings and printer parameters.(8 KB EEPROM)

FONT ROM Stores internal printer fonts.(One 64-Mbit mask ROM)

Program ROM RICOH-SCRIPT2 Emulation ModuleThe emulation module is programmable by IC card.

DIP SW

O F F

1 2 3 4 5 6 7 8

Video I/F Interface the controller with the printer engine.IEEE1284 I/F Provides an interface that connects to a local host (IEEE1284

compliant).Option Bus I/F Two slots; each can hold either an optional network interface or

a parallel interface board. You cannot install two boards of thesame type.

Option RAM I/F A slot for accommodating the memory.IC Card Accommodates an IC card to upgrade firmware.

SW No. Setting Content1 OFF2 ON

3-8 OFF

Do not touch these switches in the field.

G048O708.WMF


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s2.3 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 pagecannot be printed and the job is automatically canceled if the memory for imageprocessing overflows while converting the image data to bitmap format. This mayhappen depending on the mode selected or the image’s data size.

If the memory overflows, try changing the gradation settings in the driver byselecting a different print mode, or using a “Custom” setting (“Print Quality” tab indriver’s interface).


G047/G048 2-6 SM

2.3.2 IMAGE DATA PROCESSING FLOW

Control ler

IPDL-C Driver

C M S

PS Driver

Manua l GammaCorrect ion

Printer Engine

Operat ion PanelM C U

Max imumAmount Value

(for service)

G a m m aCorrect ion

Max imumAmount

Toner Control

RPS2 Module( including CMS)


Table

1/2bitText/Photo

Dither

BG/UCR

BG/UCR

Dithering

4bit Expansion

RGB 8bi t CMYK 8bi tRGB 8bi t

CMYK 8bi t

CMYK 8bi t

CMYK 8bi t

CMYK 1/2bi t

CMYK 4bi t

G048O706.WMF


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sIPDL-C (Intelligent Page Description Language for Color)

First, the image data received froman application is separated intothree elements: text, graphics, andimages. Then, the data for eachelement is converted to IPDL-C.The data converted is not done forthe whole page at once. Eachband (area specified) isindependently processed (bandingprocessing) for the dataconversion as shown in the figure.

The IPDL-C conversion from eachelement is stored in free memoryand converted to bitmap data.Bitmap data is compressed andstored in the band pool memory,DRAM.

After data processing is complete,the controller sends thedecompressed data to the printerengine and the engine startsprinting.

CONTROLLER

DRIVER

What is IPDL-C... .

��

What is IPDL-C.. . .

TEXT

IMAGE

IPDL-CBanding processing

(Converted to IPDL-C)

��Free Memory

Converted f romIPDL-C to bi tmapformat

APPLICATION

Band pool memory

Compressed bi tmap data

��

��

��

Compression

�� GDI

��

��

��

GRAPHICS

��

IPDL-C

IPDL-C

G048O707.WMF


G047/G048 2-8 SM

CMS (Color Management System)

CMS works to optimize the color print quality using a color profile which is basedon the characteristics of the printer.

In RICOH-SCRIPT2, CMS functions similar to IPDL-C; but the RGB conversion isdone in the controller.

CMS is used whenever the color profile setting in the printer driver is set to anyvalue other than “Off.”

Color Correction by the Driver

The driver adjusts the following parameters in accordance with the driver settingsmade 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 CMYKconversion, 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 theadjustment procedure, see “Section 6: Replacement and Adjustments” in thecontroller 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 anddithering.

8bit1/2bit → 4bi t Expansion

Control ler

PrinterDriver


ManualG a m m a

Correct ion

Pr inter Engine

Process Contro lBG /UCR Dither ing

Image Densi tyAdjustment in

Sol id Areas

Image Densi tyAdjustment inHighl ight Area

G048O709.WMF


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sDither Processing

The dither pattern is prepared for the photo, text, graphic and thin linesindependently for 1- and 2-bit modes. These dither patterns help to create theillusion 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 beingscattered around text or printed lines.

The maximum amount values are prepared independently for text and photo. Theycan 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 thedata to 4 bits to meet the image-processing algorithm of the printer engine. Whenexpanding 1/2 bit to 4 bit, add some of the same data to the original data as shownin the figure. Even when the data is expanded, dithering remains the same.

b0 b0 b0 b0'

b01bit

4bitExpans ion b1 b0 b1' b0'

2bit

4bitExpans ion

b1 b0

G048O710.WMF

INSTALLATION

INSTALLATION

SM 3-1 G047/G048

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3. INSTALLATION


• For the printer: Quick Installation Guide• For options: Setup Guide

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 correctmodel name on the LCD panel and in the configuration page header.NOTE: This must be done before delivering the printer to the customer’s site.

To modify the unit’s 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] keysin sequence. Do not let more than a second or two pass between buttonselections.

3. Select the appropriate brand name and press the [#Enter] key.

SERVICE TABLES

SERVICE TABLES

SM 4-1 G047/G048

Ser

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4. SERVICE TABLES

4.1 CONTROLLER SP MODE

When accessing controller SP mode, the SP mode menu is added to the “JobTimeout,” “Maintenance” and “Media” menus.

4.1.1 ENTERING AND EXITING CONTROLLER SP MODE

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 onthe operation panel. Hold the keys down until all of the LEDs and the LCD turnoff. 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 (don’t 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. Donot forget to exit SP mode after servicing. If inadvertently left in controllerSP mode, users could change settings or clear all settings by accident.

G048O015.WMF

G048O016.WMF

[B][A]

[B][A]

[C]

[C]

SERVICE TABLES

G047/G048 4-2 SM

4.1.2 MENUS AND DISPLAY

Same as the base model (G024).Refer to the G024 controller and network interface board section of the G024engine service manual for details.

4.1.3 SP MODE MENU HIERARCHY

The table below shows the controller SP mode menu hierarchy. The individuallayers in the table below can be accessed while in controller SP mode by pressingthe [#Enter] key. When in SP mode, S1 to S9 are added to the Maintenancemenu.

Layer 1 Layer 2 Layer 3 Layer 4Show Counter Color: xxxxxxx

Black: xxxxxxxIt can be accessed if themeter click mode isselected.

1. Job Timeout Off0 – 999 seconds

2. I/O Timeout 0 – 999 seconds3. MinLineWidth 1 – 4 dots It can also be accessed

in SP mode.

IPDL-C Menu(displayed if IPDL-Cis selected.)

4. Toner Usage OffOn

Same as above

1. Color Level 1 bit2 bit

2. Color Mode ColorBlack & White

3. Color Set OffVividSuper VividFineSuper Fine

4. ColorProfile PhotographPresentationSolid Color

5. TonerSaving OffOn

6. Dithering AutoPhotographicText

7. Paper Type Plain PaperOHPThick PaperPlain (Duplex Backside)Thick (Duplex Backside)

8. Auto Tray SW OnOff

9. Duplex Print OffOn

A: Duplex Bind Long EdgeShort Edge

B: Job Timeout Off0 – 999 seconds

RPS2 Menu(displayed if RPS2 isselected.)

C. I/O Timeout 0 – 999 seconds

SERVICE TABLES

SM 4-3 G047/G048

Ser

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Tab

les

Layer 1 Layer 2 Layer 3 Layer 4D: Feed Timeout 60 seconds

0 – 999 secondsE: Print Errors Off

OnF: Ktalk Mode Not availableG: Parallel IF1 System Default

ACK InsideACK Outside

RPS2 Menu(displayed if RPS2 isselected.)

H: Parallel IF2 System DefaultACK InsideACK Outside

Displayed if an optionalparallel interface boardis installed.

1. Paper Tray Tray 1By-passTray 2Tray 3

“Tray 2 and 3” aredisplayed if an optionalpaper feed unit isinstalled.

2. Tray Size [*] 8.5 x 13A5B4 JISB5 JIS8.5 x 5.58 x 138.25 x 15

3. Bypass Use ManualAuto Tray

4. I/O Buffer 16 KB32 KB64 KB128 KB256 KB512 KB

5. Energy Saver Off5 minutes15 minutes30 minutes45 minutes60 minutes

6. Energy Level Level 1Level 2

7. PDL Sensing AutoManual

8. Transfer Hi-speedNormal

9. Parallel 1 ACK insideACK outsideSTB down

10. Parallel 2 ACK insideACK outsideSTB down

11. Bi-direction Original ModeStandard

12. OHP Slip OnOff

System Menu

13. Printer Language IPDL-CRPS

SERVICE TABLES

G047/G048 4-4 SM

Layer 1 Layer 2 Layer 3 Layer 414. Language English

FrenchGermanItalianDutchSpanishJapanese

System Menu

32. IP ADDRESS to39. Active PTL.

Displayed if an optionalnetwork interface boardis installed.

1. Reinstall Charger2. Toner Select Cyan

MagentaYellowBlack

3. Toner level4. Registration Byps.: Vert.

Bypass/Thick: VTray: Vert.Dup.: Vert.Tray1: Horiz.Tray2: Horiz.Tray3: Horiz.

“Tray 2 and 3” aredisplayed if an optionalpaper feed unit isinstalled.

5. Toner Empty ContinueStop

6. Menu Reset7. Menu Protect Off

OnIt can also be accessedif the [Enter], [Escape],and [Menu] keys arepressed in sequencewhen the printer is online. It is alwaysdisplayed in SP mode.

8. Log Protect OffOn

Same as above

9. Log Clear If “Menu Protect” isselected, it is notdisplayed.

10. Ethernet Auto 10 Mbps100 Mbps

It can also be accessedif the [Enter], [Escape],and [Menu] keys arepressed in sequence ifthe printer is on line andan optional networkinterface board isinstalled. It is alwaysdisplayed in SP mode.

S1. Maint. PageS2. Color ChartS3. Maint. Clear Fusing Unit

Maintenance

S4. Clear All Mem.

SERVICE TABLES

SM 4-5 G047/G048

Ser

vice

Tab

les

Layer 1 Layer 2 Layer 3 Layer 4Load Setting Default

Setting-OldSetting-Current

Mode Select 1 bit/photo, 2 bit/photo1 bit/Text, 2 bit/text

Print Sheet

S5. Gamma Calib.

Gamma Select BlackCyanMagentaYellowSave Settings

S6. Printer ID Not usedS7. Toner Limiter Text

Photo

Maintenance

S8. Meter Click OffPrint/JapanDevelop. CountPrint CountPrint/Japan: DDev.Count: DPrint Count: D

1. Config. Page2. Color Sample3. Job Log

List Print

4. StatisticsIPDL-CSelect PDLOPTION#1 RPS2

SERVICE TABLES

G047/G048 4-6 SM

4.1.4 SP MODE DETAILS

S1. Maintenance Sheet

The table below explains the contents of the engine’s maintenance list printout.The controller obtains the data from the printer engine (MCU).

Item DescriptionMCU version The MCU board firmware version number.Toner density Toner density can be adjusted via the Maintenance. Menu by customers.

Adjusted values are stored in NVRAM on the MCU.Registration 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.

Total counter Indicates the total number of printouts. The counter is incremented when thepaper exit sensor detects paper exit completion (regardless of paper size,type, and mono/color mode).

Color Counter value printed in color mode.Mono color Counter value printed in black mode.

PCU counter PCU replacement is indicated when this value reaches 72000. This value isincremented by 4 in color mode printing and by 1 in Black mode printingexcept A3/DLT. When printing with A3/DLT, double counting occurs.

Fusing unit Fusing unit replacement is indicated when this value reaches to 60000. Thiscounter is incremented by 2 for A3/DLT size printing and by 1 for other sizeprinting.

Fusingunit/Counterreset time

Number of Fusing unit resets with controller SP mode (S3).

ChargerCounter

Charger replacement is indicated when this value reaches to 24000.

Charger ResetCounter

Number of Charger resets with controller UP mode.

A3/DLT, A4/LT,LG, B4 andOther Sizecounter

Number of each size paper that passed the exit sensor.

Feed Jam,Transfer Jamand Exit Jamcounter


Feed Jam,Transfer Jamand Exit Jamcounter (Duplex)

Number of paper jams in each section for duplex printing.

SC counter Number of SCsMeter Click Type of counting method for meter click modeCount bydevelopments

Number of developments. This counter increases by 1 when a print of anysize is made.

Count by prints Number of prints. This counter increases by 1 for any size printing.Count bydevelopments(A3/DLT double)

Number of developments. This counter increases by 2 for A3/DLT sizeprinting and by 1 for all other sizes.

Count by prints(A3/DTL double)

Number of prints. This counter increases by 2 for A3/DLT size printing and by1 for all other sizes.

SERVICE TABLES

SM 4-7 G047/G048

Ser

vice

Tab

les

Item DescriptionCount by prints(Japan)

Not used.

Count by prints(Japan:A3/DTLdouble)

Not used.

SC Logging The most recent 3 SC codes.Jam Logging The most recent 10 jamming codes and the total counter value at the time.

000: At paper cassette001: At paper pass002: At paper exit

Process-ControlError Logging

The most recent 3 errors while process control and the total counter value atthe time.Not all of the errors are indicated as SC errors.

ID sensor PWM The value set with engine SP mode, 9: ID Sensor PWM.

S2. Color Chart


S3. Maintenance Clear


S4. Clear All Memory

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

S5. Gamma (γγγγ) ) ) ) Calibration


S6. Printer ID

Not used with this model.NOTE: This is used for controller identification when installing fonts for RICOH-

SCRIPT2 onto the hard disk. However, since it is not possible to install thehard disk in this model, it is not necessary to set the printer ID.

SERVICE TABLES

G047/G048 4-8 SM

S7. Toner Limiter

The maximum toner values can be adjusted from 100 to 400% for both Text andPhoto 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 toneraround lines and text areas. If the value is set low, the color balance of low-densityareas 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 ServiceContract.

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 inMeter Click mode, not the total counter value. Both counter values are includedin the engine maintenance sheet.

4. After selecting meter clock mode, the counter value for the selected countingmethod is automatically set to 0. However, it cannot be reset to 0 after themachine begins counting.

5. All developments/prints are counted at paper exit.

SERVICE TABLES

SM 4-9 G047/G048

Ser

vice

Tab

les

6. Counting method:

1) By development-

Black 1C 2C 3C Full colorFull color +1 +2 +3 +3

Black and white +1 +1

NOTE: If the meter click mode is set to “Dev. Count: D”, it is incremented by 2for A3/DLT size.

2) By print-

Black 1C 2C 3C Full colorFull color +1 +1 +1 +1

Black and white +1

If the meter click mode is set to “Print Count: D”, it is incremented by 2 forA3/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 Description3. MinLineWidth Adjusts the minimum line width within 1 to 4 dots.4. Toner Usage 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 thedisplay) menu.

Menu Item Function/Use

3. SummaryDisplays the currently installed versions of the controller system,emulation modules, and engine (MCU) firmware, and the amount ofmemory installed in the controller.

SERVICE TABLES

G047/G048 4-10 SM

4.2 POWER-UP SELF-DIAGNOSTICS


4.3 POWER-UP SELF-DIAGNOSTICS FLOW CHART

Test Font ROM

Test FPU

Test T imer

Test CPU

Test Standard RAM

Test Code ROM

Turn on power

Tes t D IMM

Star t System

Standby Condi t ion

Non-fatal Error(user error)

Display Error on LCD

Code ROM sum check






Print List of Sett ings(Black/white)

Read/wri te test

Frequency check

Test of t imer funct ionsof Rocky R

Operat ion Test

Font ROM sum check

DIMM (RPS2) sum check

Diagnostic

Yes

No


G048O711.WMF

SERVICE TABLES

SM 4-11 G047/G048

Ser

vice

Tab

les

4.4 DETAILED SELF-DIAGNOSTICS MODE


4.5 DETAILED SELF-DIAGNOSTICS FLOW CHART

Test Font ROM

Test NVRAM

Test Paral lel Interface

Test FPU

Test Opt ional RAM

Test Timer

Test CPU

Test Standard RAM

Test Code ROM

Turn on power

Test DIMM

Start System

Standby Condit ion

Non-fatal Error

Print List of Settings(Color)

Display Error on LCD

Code ROM sum check









Print List of Settings(Black/white)

Read/write test

Frequency check

Test of t imer functionsof Rocky R

Read/write test

Operation test

Loop back test on thestandard paral lel interface

Read/write test

Font ROM sum check

DIMM (RPS2) sum check

Diagnostic

Yes

No


G048O712.WMF


SM 5-1 G047/G048

Per

iod

icM

ain

ten

ance


Refer to Section 5 - Periodic Maintenance in the base model (G024) engine servicemanual.


SM 6-1 G047/G048

Rep

lace

men

tan

dA

dju

stm

ent


6.1 CONTROLLER BOARD REPLACEMENT

Refer to section 6.7.1 Controller Board of the G047/G048 engine service manualfor the replacement procedure.

6.2 IMAGE ADJUSTMENT


6.3 SOFTWARE UPGRADE PROCEDURE

The controller, RICOH-SCRIPT 2 and network interface boards have a flash ROMfor storing control software. This allows version upgrades using an IC card.NOTE: The G024’s controller manual refers to this card as a “Flash ROM Card. ”

The term IC card and flash ROM card are synonymous.The engine’s firmware cannot be upgraded using this procedure. Refer to the baseengine’s (G024) service manual for details on how to upgrade the MCU firmware.

NOTE: Before starting an upgrade procedure, make sure that the software in theIC card is newer than the software in the controller, RICOH-SCRIPT2 ornetwork 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 interfaceboards 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 thecard “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 theIC card to the appropriate IC (located on the controller, RICOH-SCRIPT2 ornetwork interface board).

CAUTION: Do NOT turn off the machine while the software is being updated.Otherwise, the controller, NIB, or RICOH-SCRIPT2 module may bedamaged.


G047/G048 6-2 SM

For the controller or RICOH-SCRIPT2:The LCD display on the operation panel changes as shown below as therewrite procedure proceeds. (‘MELT’ is displayed during the software upgradefor 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 hasreceived the data from the IC card. However, note that it takes about 30seconds to rewrite the data in the controller or Ricoh-Script 2 after this messageis displayed.The message NG!!NG!!” is displayed if an error occurs during the rewriteprocess. If this condition occurs, reinstall the IC card and turn the power off andon again.

For the network interface board:The appearance of the message “DOWNLOAD OK.” indicates that thecontroller has received the data from the IC card. However, note that it takesabout 30 seconds to rewrite the data in the network interface board after thismessage is displayed.

DOWNLOAD -> ############ -> DOWNLOAD OK.

The message “DOWNLOAD NG.” is displayed if an error occurs during therewrite process. If this condition occurs, reinstall the IC card and turn the poweroff 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 andmake sure that it matches the version on the IC card.

TROUBLESHOOTING

TROUBLESHOOTING

SM 7-1 G047/G048

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7. TROUBLESHOOTING

7.1 TYPES OF PROBLEMSThe problems can be classified as follows:

Operation

Hardware

Software

Operatingconditions

• Printer-side Print Settings• Printer-side Initial Settings• Host-side Application Settings

• Faulty Engine

• Faulty Controller

• Hardware Limitations

• Main Unit

• Option

• Consumables

• Main Unit

• Option

• Software Fault in Controller ROM

• Software Fault in Emulation Module Software

• Controller Limitations

• Software Fault in Host-side Application

• Host-side Application Limitations

• Environment (power, temperature and humidity, dust, noise, vibration)• Consumables

G048O014.WMF

TROUBLESHOOTING

G047/G048 7-2 SM








TROUBLESHOOTING

SM 7-3 G047/G048

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7.3 ERROR MESSAGES

7.3.1 OVERVIEW


1. Controller Self-diagnostic ErrorsErrors detected while the unit performs power-up self-diagnostics/detailed self-diagnostics on the controller hardware.

2. Controller User ErrorsErrors caused because the controller software cannot process the job becauseof, for example, insufficient memory.

3. Internal ErrorsErrors caused because the controller’s control function fails to functionnormally.

4. Engine User Errors (Cautionary)Errors that do not require user intervention to continue printing (the printer canstill communicate with the PC over the interface). However, for the best printquality, the user should correct the problem as soon as possible.

5. Engine User ErrorsSevere errors that cause the unit to stop printing, requiring the user to fix theproblem before printing again.


Only one error message can be displayed at a time. There is an order of priority fordisplaying errors. This is as follows, starting with the highest priority: InternalErrors, Controller Self-diagnostics Errors, Engine Service Codes (SCs), EngineUser Errors, Engine User Errors (Cautionary), and Controller User Errors.

TROUBLESHOOTING

G047/G048 7-4 SM

7.3.2 CONTROLLER SELF-DIAGNOSTICS ERRORS

When a controller self-diagnostics error occurs, the error code is displayed on thefirst line of the operation panel LCD.

The second line contains an 8-digit code that gives details of the error fordesigners to debug. For a memory error, the second line of the LCD indicates theaddress where the error occurred. For errors other than memory errors, the secondline always reads “FFFFFFFF”.

Code Description Location00XX Exception processing error Controller0101 Code ROM sum check error Controller0201 Standard memory read/write error Controller

0301/0401Optional memory read/write errorNon-fatal error (printed as B0 in the error log.)

Optional memory

060X CPU exception self-diagnostics error Controller0D0X ASIC timer error Controller0EXX AISIC operation panel interface error Controller

110XASIC Centronics interface errorNon-fatal error (printed as B1 in the error log.)

Controller

1401 NVRAM error (Read/Write) Controller160X Font ROM error (Sum) Controller1B0X Optional Interface 1 Error Controller1C0X Optional Interface 2 Error Controller

1D0XOptional parallel interface board errorNon-fatal error (printed as B6 in the error log.)

Optional parallelinterface board

250XDIMM (emulation module) errorNon-fatal error (printed as B5 in the error log.)

Emulationmodule/Controller

400X FPU error Controller

TROUBLESHOOTING

SM 7-5 G047/G048

Tro

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7.3.3 CONTROLLER USER ERRORS

Display Description Location/action

85: Error Graphics environment initializationerror

Optional memory/Controller

86: Error Invalid control code parameter Incorrect printer driver or incorrectcable installed

91: Error Font/image environmentinitialization error

Install additional memory.

94: Error Download data error Incorrect ‘total memory size’ settingin the driver

A3: Error Receive buffer overflow Increase the I/O buffer size usingthe system menu (user mode)

A6: Error Overflow during compression Install additional memory.

A7: ErrorError during drawing processing Use a smaller font size or a less

complex font, or replace thecontroller

A8: ErrorError during library drawing Switch the machine off/on. If that

does not work, replace thecontroller.

AB: Error Print overrun Install additional memory.B0: Error Optional memory error Reinstall/replace optional memory.B1: Error Standard parallel interface error Interface cable/controller

B3: ErrorInvalid initial set-up setting Reset the printer settings using

‘Menu reset’ in the Maintenancemenu (user mode).

B4: Error IC card slot error Controller/IC cardB5: Error Optional emulation module error Reset/replace emulation module.

B6: Error Optional parallel interface boarderror

Reset/replace optional parallelinterface board

B7: Error Optional network interface boarderror

Reinstall/replace network interfaceboard

TROUBLESHOOTING

G047/G048 7-6 SM

7.3.4 INTERNAL ERRORS

When an internal error occurs, the message “Power Off/On” is displayed on thefirst line of the operation panel LCD. The internal error code is on the second line inthe format “Error XXYY-ZZZZZZZZ” (“XX” denotes a classification code; “YY”denotes a process number, and “ZZZZZZZZ” indicates the program address wherethe 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) Description00 Error in the TLB user area.01 CPU TLB update exception02 CPU mismatch exception (load or fetch)03 CPU mismatch exception (store)04 CPU address error exception (load or fetch)

05 CPU address error exception (store)

06 CPU bus error exception (load or fetch)07 CPU bus error exception (store)08 CPU system call exception09 CPU break point exception10 CPU reserved instruction exception11 CPU coprocessor disabled exception12 CPU operation overflow exception13 CPU trap exception14 Coherency (instruction) error15 CPU floating-point operation exception16 CPU timer interrupt17 ROCKY level 4 interrupt (ART or Tim)18 ROCKY level 3 interrupt (CP)19 ROCKY level 2 interrupt (XINT1 or XINT0)20 ROCKY level 1 interrupt (CBE, DBE, Dtc0, Verr, Fin, Vdtc, Fout)21 ROCKY level 0 interrupt (Debug)22 Software interrupt23 Software interrupt24 Other CPU exceptions25 Memory allocation error26 Overflow error27 Frame allocation error28 Card eject error29 Printer engine error30 Option board error31 Session-to-network interface board communications error

TROUBLESHOOTING

SM 7-7 G047/G048

Tro

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The unit can continue printing even when one of the messages listed below isencountered.

Display Description Number of sheets untilwarning state

Change Fuser Fusing unit replacement timearrived.

Information only

Change PCU Photoconductor unitreplacement time arrived

Information only

Need Charger Charger replacement timearrived.

Information only

Low on: XXX Toner near endXXX denotes the color name(CMYK or their combination).

100

Add Fusing Oil Fusing oil near end 100Waste T Full Waste toner bottle is nearly full. 20

NOTE: “Change Fuser,” “Change PCU” and “Need Charger” are not displayed ifmeter 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 operator’s manual).


Refer to the Troubleshooting section in the base model (G024) engine servicemanual.


Type306

(C4000 FERRET)

NOTE: This section describes elements specific to the Network Interface BoardType306. For additional information, such as installation, firmwareupgrades, etc., please refer to the controller section of the servicemanual and to the user's documentation.

OVERVIEW

SM 8-1 G047/G048

Net

wo

rkIn

terf

ace

Bo

ard

8. NETWORK INTERFACE BOARD TYPE306(C4000 FERRET)

8.1 OVERVIEW

8.1.1 SPECIFICATIONS

Configuration: Embedded

LAN Interface: 100BASE-TX/10BASE-T

Frame Type: Ethernet II, IEEE802.3, IEEE802.2, SNAP

Protocol: TCP/IP, AppleTalk, NetWare, NetBEUI

SNAP: MIB-II, PrinterMIB, HostResourceMIB, RicohPrivateMIB

8.1.2 BLOCK DIAGRAM

Opt

ion

Bus

I/F

F i l ter Module

LAN I/F

EthernetControl ler

E E P R O M1Kb

ASIC

C P U Flash ROM1MB

S D R A M8MB (64Mb)Control ler

Board

NetworkEnvironment

G048O713.WMF

COMPONENT LAYOUT

G047/G048 8-2 SM

8.2 COMPONENT LAYOUT

8.2.1 NETWORK INTERFACE BOARD DIAGRAM

8.2.2 DEVICES

Device DescriptionCPU HD6417612RFASIC MB87L1231Flash ROM MBM29LV800BA-70PFTN (8 Mbit)SDRAM 64Mbit: 100MHzEEPROM M93C46-WMN6 (1kbit)Ethernet Controller AM79C973KC/W

RJ-

45

E E P R O M

C P UHD6417612

EthernetControl ler

AM79C973

SD

RA

M

ASICMB87L1231

FlashR O M

LED4(G)

LED3(G)

LED1(Y)

S W 2

G048O705.WMF

BASIC OPERATIONS

SM 8-3 G047/G048

Net

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ard

8.3 BASIC OPERATIONS

8.3.1 OVERVIEW

This network board can manage both 100BASE-TX and 10BASE-T. It has amaximum 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 resetsignal. The controller board communicates with the network interface boardthrough the option I/F connector.

The function of LED and SW is as follows;

Functions

LED1Displays the operating status.ON: Ready, OFF: Busy

LED2 Not used

LED3Displays the LAN Type.ON: 100 BASE-TX, OFF: 10 BASE-T

LED4Displays the link status.ON: Link safe, OFF: Link failure or Link disable

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 functionon this printer due to the controller’s specifications.

BASIC OPERATIONS

G047/G048 8-4 SM

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 thisprinter due to controller’s 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 15seconds.

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 procedurefailed, the previous settings remain. Repeat the above procedure until the oldsettings have been cleared.

FIRMWARE HISTORY

SM 8-5 G047/G048

Net

wor

k In

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Boa

rd

8.4 FIRMWARE HISTORY 8.4.1 NIB FIRMWARE MODIFICATION HISTORY

NIB FIRMWARE MODIFICATION HISTORY


SERIAL NUMBER

FIRMWARE VERSION

Initial Production G6785847 D First Production

4.8.2

First release for G062 and B017/B018 Corrects the following: • Classless InterDomain Routing (CIDR) is

supported.

G6785847 E Sept. ’00 Production

5.0.2

Corrects the following: • The spelling of the command “retern” in the

UNIX install shell has been corrected to “return”.

G6785847 F Oct. ’00 Production

5.0.4

Corrects the following: • DHCP of Solaris 2.6 is supported.

G6785847 G Feb. ’01 Production

5.0.7

Corrects the following: • SNMP Trap IP address is set to 11.22.33.44

incorrectly before the NIB is assigned the IP address from the DHCP server

• Disconnects from NetWare Servers that uses relatively old CPU’s (i486)

• Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2.

G6785847 H Aug. ’01 Production

5.1.0

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-2002-03.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testing/c06/snmpv1/

G6785847 J July ’02 Production

5.1.2

⇒

Rev. 12/2002

TECHNICAL SERVICE BULLETINS

R

B

A

S

G

Tpf

U

G

I

Note: This copy is intended as a m

aster original for reproduction of additional bulletins.

ICOH GROUP COMPANIES CONTROL NO. 054

TECHNICAL SERVICE BULLETIN

ULLETIN NUMBER: G024 - 001 10/04/99

PPLICABLE MODEL: GESTETNER – C7005W/700SP RICOH – AP305/505 SAVIN – SLP517C/517CP

UBJECT: HARNESSES

ENERAL:

he following Harnesses are being changed to reduce Electro-Magnetic Interference (EMI). The followingarts updates are being issued for all G024 Parts Catalogs. Please update your Parts Catalogs with the

ollowing information.

REFERENCEOLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

G0245114 G0245121 Fusing Harness 1 1 39 10G0245118 G0245106 Toner Sensor Harness 1 1 43 6G0245130 G0245105 Right Main Harness 1 1 37 13G0245132 G0245104 Main Input Harness 1 1 37 12

NITS AFFECTED:

024 Serial Number cut-in not available at time of publication.

NTERCHANGEABILITY CHART:\

0 OLD and NEW parts can be used in both OLD andNEW machines. 2 NEW parts CAN NOT be used in OLD machines.

OLD parts can be used in OLD and NEW machines.

1 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.

3/S 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 orpreviously modified, use the new part numbers individually.

! PAR

TS

Note: T

his copy is intended as a master original

for reproduction of additional bulletins.


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SUBJECT: GRADATION IMAGE PRINTING WITH PCL DRIVER

SYMPTOM:

When documents containing gradation images are printed with the PCL driver, the gradation may not besmooth. Patchy red or green dots may appear depending on the colors contained in the image and thedensity of the gradation.

CAUSE:

In Toner Reduction Mode, a Dither Pattern control error will occur when the total index value of the CMYKcolor 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.

� C

OP

Y Q

UA

LITY

CONTROL NO. 389

Note: T




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

GENERAL:

The “Recovery Mechanism” for failure of upgrading Boot ROM by using Boot ROM.rcy is explained in theField Service Manual (4.3.4 Installing Software Upgrades). This recovery mechanism is NOT available onabove listed PS models.

If any failure occurs during upgrading Boot ROM, please try to recover the system by retrying to downloadthe 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 “=” barson the LCD of the unit.Do not switch off the unit until the status returns to “INSTALL: ####” on the LCD display.

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BULLETIN NUMBER: G024 – 004 1/11/2000

APPLICABLE MODEL:GESTETNER – C7005WRICOH – AP305SAVIN – SLP517C

SUBJECT: SERVICE MANUAL - CORRECTION

GENERAL: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 theIC card.

PAGE:

• 6-40 Updated Information

An arrow has highlighted the revised areas ⇒.

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R Vxxx C VxxxEnter On Line KEY

CurrentFirmware version


G024R514.WMF

CONTROL NO 011ABW

ELECTRICAL WIRING

G024 6-40 SM

6.5.5 UPGRADING THE MCU FIRMWARE

NOTE: Turn off the printer before inserting or removing the IC card. (Otherwise theIC card may be damaged.)


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 theMCU. The side with ‘A’ on it must be facing upwards.

4. Turn on the printer. (Check that the following is displayed on the operationpanel.)

5. Check that the firmware versions are correct. (Make sure that the firmware inthe 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 followingsequence:

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 fromthe beginning.)


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, whichis displayed immediately after power-on. (If the firmware version differs from theIC card firmware version displayed in step 3, repeat from step 1.)

R Vxxx C VxxxEnter On L ine KEY

G024R514.WMF

FLASH DWLOADINGERASE! !

FLASH DWLOADINGWRIT ING

FLASH DWLOADINGOK!! OK! !

G024R513.WMF

Current Firmwareversion


⇒

Rev. 12/99

RICOH GROUP COMPANIES CONTROL NO. 007CLR


BULLETIN NUMBER: G024 - 005 12/23/99

APPLICABLE MODEL: GESTETNER – C7005P RICOH – AP505 SAVIN – SLP517CP

SUBJECT: UPDATING THE PRINTER DRIVER

GENERAL:

! New PS and PCL printer drivers are released with the new drivers addressing the following issues:

Title1/Title2 Problem Name Description OS

Print Image/PCL driver

Patterned areas incertain colors are notcorrectly reproduced

Patterned areas in pink are printed with plainred.

Win95/98

Driver setup/PCL driver

Editing the FontSubstitution Table

No substitution font appears in the pull downmenu of editing fonts in other languageversions of Windows than English.

WinNT4.0

! The CRD names on the ColorWise tab of the printer properties for both PS and PCL are renamed asfollows:Old New CRDPhotos ImagesText TextIllustrations Graphics

Continued…

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Tech Service Bulletin No. G024 – 005Page 2 of 2

! The updated files for each driver.

OS Old File Name (Version No.) New File Name (Version No.)Windows95/98 PSDriver

EFER5010.DLL (1.71.30) EFER5010.DLL (1.71.60)

EFGNPCLG.DRV (2.0.0065) EFGNPCLm.DRV (2.0.0069)Windows95/98 PCLDriver EFGNDLGG.DLL (1.60.80) EFGNDLGm.DLL (1.61.50)

EFGNPCL9.DLL (2.0.0048) EFGNPCLm.DLL (2.0.0069)Windows NT PCLDriver EFGNRES9.DLL (1.59.10) EFGNRESm.DLL (1.61.30)

NOTE: How to print the Test Page:

1. Select the Setting menu from the Windows Start menu.2. Select Printers and open the icon for the printer, which you have updated.3. Select Properties from file menu.4. 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 functionproperly.

If the currently installed printer settings are special, it is necessary to write down each setting of the printerproperties before deleting the printer icon.

1. Delete the printer icon for the currently installed printer version and confirm removal of old files beforeinstalling 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 anysettings were special, use the settings that were recorded prior to deleting the original printer driver andreenter them.

UNITS AFFECTED:

The new driver CD-ROM is applied to the production from October 1999 starting with S/N P07910#####.




APPLICABLE MODEL: GESTETNER – C7005W/C7005P RICOH – AP305/AP505 SAVIN – SLP517c/SLP517cp

SUBJECT: SERVICE MANUAL - INSERT

GENERAL:

The Service Manual page listed below must be replaced with the page supplied. Each bulletin packagecontains 1 set of replacement pages.

PAGES:

The revised area has been highlighted by an arrow ⇒.

• Legend Updated Information (Legend)

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LEGENDPRODUCT CODE COMPANY

GESTETNER RICOH SAVING024(WIN) C7005W AP305 SLP517cG024 (PS) C7005P AP505 SLP517cp

DOCUMENTATION HISTORYREV. NO. DATE COMMENTS

* 6/99 Original printing

1 7/99 G024 Fiery 500 Controller ServiceManual Addition

⇒

Rev. 01/2000






GENERAL:


PAGES:

The revised areas have been highlighted by an arrow ⇒.

• 7-2 Updated Information (SC 27)

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SC TABLES

G024 7-2 SM

7.1.2 SC ERROR LIST





21





22





23





24





25Type 1 High hot

rollertemperature




26





27




AC powerconditions.

28





⇒

Rev. 02/2000



BULLETIN NUMBER: G024 – 008 REISSUE ! 02/25/2000


SUBJECT: BANDING

SYMPTOM:

42 mm Pitch Horizontal Banding occurs on printed pages.

CAUSE:

Lines on the Development Roller have been caused by prolonged contact with the Development Bladeduring storage.

SOLUTION:

The lines will fade as pages are printed. This symptom will disappear after approximately 300 pages areprinted. Switching the Energy Saver Mode to “level 2” will automatically run the Development Roller every70-minutes. This will help to reduce the reoccurrence of this symptom.

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2000 RICOH Corporation. All rights reserved. CONTROL NO. 021CLR




SUBJECT: JAPANESE FONTS USING MICROSOFT INTERNET EXPLORER 5.x

SYMPTOM:

When you browse the G024 printer with Microsoft Internet Explorer 5.x (IE 5.x), IE 5.x requires installing aJapanese 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;

The message maybe different because of minor variations in the IE version or Windows OS. The abovemessage appears when using IE 5.00.2920.0000 on Windows 2000. In this case, IE requires the Japanesefont every time.

IE 5.00.2314.10003 on Windows NT 4.0 is shown the below. In this case, IE requires the Japanese fontafter browsing the NIB (Network Interface Board).

NOTE: The NIB works properly by canceling messages stating that the Japanese font is required.

Continued…

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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 theNIB.

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:

NetworkVersion 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.




APPLICABLE MODEL: GESTETNER – C5007W/C5007P RICOH – AP305/AP505 SAVIN – SLP517C/SLP517CP

SUBJECT: 98-MILLIMETER PITCH HORIZONTAL BANDING

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.

CAUSE:

An unstable rotation of the OPC Idle Roller in PCU Unit, causing misalignment of the colored toners in whicha 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 thePCU 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 dotnext 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 thecarton box, it has new type PCU UNIT installed.

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CONTROL NO. 024CLR

2000 RICOH Corporation. All rights reserved. CONTROL NO. 036ABW

TECHNICAL SERVICE BULLETINTECHNICAL SERVICE BULLETINTECHNICAL SERVICE BULLETINTECHNICAL SERVICE BULLETIN

BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024 - G024 - G024 - G024 - 011011011011 05/19/200005/19/200005/19/200005/19/2000

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER - C7005W GESTETNER - C7005W GESTETNER - C7005W GESTETNER - C7005W RICOH - AP305 RICOH - AP305 RICOH - AP305 RICOH - AP305 SAVIN - SLP517c SAVIN - SLP517c SAVIN - SLP517c SAVIN - SLP517c


GENERAL:

The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin packagecontains 1 set of replacement pages.

PAGES:


• Controller TOC III Updated Information (Controller Table of Contents)• 8-6,7 Updated Information (Firmware History)

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reproductionofadditionalbulletins.

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SM III G024

8.3 BASIC OPERATIONS ...............................................................................8-38.3.1 OVERVIEW ......................................................................................8-38.3.2 LED FUNCTIONS.............................................................................8-38.3.3 SWITCH FUNCTIONS......................................................................8-48.3.4 NETWORK SETTING FUNCTION ...................................................8-5

8.4 FIRMWARE HISTORY ..............................................................................8-6

Rev. 05/2000


G024 Win 8-6 SM




SERIALNUMBER

FIRMWAREVERSION

Initial Production Release G6785839B Initial Production 3.7.5

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.

G6785839C February ’99Production

3.7.7

Corrects the following:• The firmware was modified to support

A250/B001.

G6785839D March ’99Production

3.8.6

Corrects the following:• One banner data page of NetWare was

split into two pages when using NetWare3.12 pserver mode.

• In NetWare remote printer mode, the NIBconsumed a server connection license.To avoid this, the firmware has beenmodified to disconnect the NCPconnection immediately after the remoteprinter has connected to the server.

G6785839E April ’99Production

3.8.7

Corrects the following:• On the web status monitor, the wording

in German was incorrect.“FreierSpeicher” corrected to “FreierSpeicher”.

• The Web status monitor displays “NoTray/No Paper” error when a tray is notclosed completely. The message hasbeen changed to “Other Error”.

• Disabling (Down) or enabling (Up)AppleTalk protocol from the operationpanel sometimes did not take effect afterthe change. To avoid this, the firmwarehas been changed to save a new settingto the NVRAM immediately after achange.

G6785839F June ’99Production

3.8.8

Corrects the following:• When a printer error occurs, the printer

information cannot be accessed usingMacintosh printer utilities such as ApplePrinter Utility.

• IPP (Internet Print Protocol) function hasbeen added.

G6785839G July ’99Production

3.9.2

Rev. 05/2000


SM 8-7 G024 Win

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Typ

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5



SERIALNUMBER

FIRMWAREVERSION






3.9.8




4.0.0




4.0.2

Rev. 05/2000




APPLICABLE MODEL: GESTETNER – C7005W/C7005P RICOH – AP305/AP505 SAVIN – SLP517C/SLP517CP

SUBJECT: G024(WIN) PARTS CATALOG UPDATE / G024(PS) UPDATE

GENERAL:

The following Parts corrections and additions are being issued for all G024 Parts Catalog. Please correctyour Parts Catalog as follows.

REFERENCEOLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM

G0241550 G0241501 Front Cover 1 3 15G0241548 G0241551 Decal - Paper 1 3 18G0245313 G0241330 Main Control Board 1 35 10G0241548 G0241551 Decal - Paper 1 63 4

G0241554 Brand Name Seal – Win RIC 1 63 14*G0296845 Decal – Aficio 1 63 15*G0241552 Decal - OHP 1 63 16*

* Denotes New Item

Continued...

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RICOH COLOR LASER AP305

14-Brand Name Seal-Win RIC

15-Decal-Aficio 16-Decal-OHP

CONTROL NO. 037ABW

Publications Bulletin No. G024 - 012Page 2 of 3

The following table lists the differences between the G024WIN and the G024PS.

REFERENCEG024WIN G024PS DESCRIPTION QTY PAGE ITEMG0243282 G0243382 By-pass Feed Table Assy- PS 1 3 1G0243292 G0243392 Decal – Paper Size - PS 1 3 6G0245613 G0245611 Operation Panel Assy – PS NA 1 3 17G0245614 G0245612 Operation Panel Assy – PS EU 1 3 17G0241524 G0241514 Left Cover – PS 1 5 4G9083186 G0243093 Decal – Paper Size Dail – PS NA 1 13 1G9083186 G0243096 Decal – Paper Size Dail – PS EU 1 13 1G9083184 G0243091 Paper Size Dial Assy – PS NA 1 13 17G9083184 G0243094 Paper Size Dial Assy – PS EU 1 13 17G0243292 G0243392 Decal – Paper Size – PS 1 63 9G9083186 G0243093 Decal – Paper Size Dial – PS NA 1 63 12G9083186 G0243096 Decal – Paper Size Dial – PS EU 1 63 12G0248607 G0248637 Printer Reference – PS NA 1 63 13G0248650 G0248651 Printer Reference – PS SVN 1 63 13G0248697 G0248652 Printer Reference – PS GES 1 63 13G0241554 G0241556 Brand Name Seal – PS RIC 1 63 14G5336600 G5446600 Brand Name Seal – PS SVN 1 63 14G5336610 G5446610 Brand Name Seal – PS GES 1 63 14

Continued...

18-Decal-Fiery Driven

17-Decal-ControllerManual

Publications Bulletin No. G024 - 012Page 3 of 3

The following table lists the items exclusive to the G024PS.REFERENCE

G024WIN G024PS DESCRIPTION QTY PAGE ITEMG0245321 Controller-PS w/o ROM RAM 1 35B 51G0245323 FLASH DIMM-PS 1 35B 51G0245324 SDRAM-PS 1 35B 51G0241485 Connector Cover – PS 1 35B 52G0241495 Controller Board Bracket - -PS 1 35B 53G0241496 Controller Board Angle – PS 1 35B 54G0241487 Board Cover – PS 1 35B 55G0241499 Control Board Cover – PS 1 35B 56

03530060W Philips Pan Head Screw – M3x6 35B 15104513006B Tapping Screw – M3x6 35B 152G0248667 Users Guide – PS 1 63 13G0248647 Getting Started – PS 1 63 13G0241453 Ground Plate Stay Rear Lower 1 35B 57G0241455 Gasket 337 2 35B 58G0241456 Gasket 186 2 35B 59G0241457 Retainer-PS 1 35B 60G0241463 Gasket 20 2 35B 62G0241464 Gasket 30 1 35B 63G0241467 Tape GND 1 35B 64G5448637 Decal – Controller Manual – RIC 1 63 17G5448651 Decal – Controller Manual – SVN 1 63 17G5448652 Decal – Controller Manual – GES 1 63 17G0246830 Decal – Fiery Driven 1 63 18



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024 - 013G024 - 013G024 - 013G024 - 013 08/22/200008/22/200008/22/200008/22/2000

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER - C7005W/C7005P GESTETNER - C7005W/C7005P GESTETNER - C7005W/C7005P GESTETNER - C7005W/C7005P RICOH - AP305/AP505 RICOH - AP305/AP505 RICOH - AP305/AP505 RICOH - AP305/AP505 SAVIN - SLP517c/SLP517cp SAVIN - SLP517c/SLP517cp SAVIN - SLP517c/SLP517cp SAVIN - SLP517c/SLP517cp


GENERAL:


PAGES:


• IV, VI Updated Information (Table of Contents)• 4-2 Updated Information (Engine SP Mode Functions)• 4-15 Updated Information (Primary Transfer Bias Adjustment)• 7-13 Updated Information (Firmware History)

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G024 IV SM

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

INSTALLATION

3. INSTALLATION PROCEDURE.................................................... 3-13.1 ENVIRONMENT ........................................................................................3-13.2 MACHINE LEVEL......................................................................................3-23.3 MINIMUM SPACE REQUIREMENTS........................................................3-23.4 POWER REQUIREMENTS .......................................................................3-33.5 UNPACKING .............................................................................................3-33.6 MOVING....................................................................................................3-4


4. SP MODE ..................................................................................... 4-14.1 OVERVIEW ...............................................................................................4-14.2 ENGINE SP MODE ...................................................................................4-1

4.2.1 OVERVIEW ......................................................................................4-1Entering engine SP mode .....................................................................4-1To exit engine SP mode........................................................................4-1Outline of the engine SP mode functions..............................................4-2

4.2.2 MENU OPERATION/DISPLAY.........................................................4-2Key operation........................................................................................4-2

4.2.3 MARGIN (REGISTRATION ADJUSTMENT) ....................................4-44.2.4 PARAMETER ...................................................................................4-64.2.5 CLEAR MEMORY.............................................................................4-64.2.6 SENSOR CHECK.............................................................................4-74.2.7 NIP WIDTH.......................................................................................4-94.2.8 RESET SC........................................................................................4-94.2.9 PROCESS CTRL............................................................................4-104.2.10 TEST PRINT.................................................................................4-114.2.11 ID SENSOR PWM (PULSE WIDTH MODULATION)....................4-114.2.12 IMAGE ADJUST ...........................................................................4-124.2.13 OUTPUT CHECK .........................................................................4-124.2.14 HIGHLIGHT ADJUSTMENT .........................................................4-144.2.15 LUB_INTERVAL (BELT LUBRICATION INTERVAL

ADJUSTMENT).............................................................................4-144.2.16 BELT TRANSFER BIAS ADJUSTMENT ......................................4-15


5. PREVENTIVE MAINTENANCE.................................................... 5-15.1 PM TASKS ................................................................................................5-1

5.1.1 REPLACEMENT...............................................................................5-15.1.2 CLEANING .......................................................................................5-15.1.3 INSPECTION....................................................................................5-1

Rev. 08/2000

G024 VI SM

Troubleshooting ..................................................................................6-346.5 ELECTRICAL WIRING ............................................................................6-35

6.5.1 CONTROLLER BOARD, TEMPERATURE/HUMIDITY SENSOR ..6-356.5.2 POWER SUPPLY UNIT..................................................................6-366.5.3 HIGH VOLTAGE SUPPLY UNIT ....................................................6-386.5.4 MCU ...............................................................................................6-396.5.5 UPGRADING THE MCU FIRMWARE ............................................6-40

6.6 PAPER FEED SECTION.........................................................................6-416.6.1 BY-PASS PAPER END SENSOR, REGISTRATION SENSOR......6-416.6.2 PAPER WIDTH DETECTION BOARD ...........................................6-426.6.3 BY-PASS PAPER FEED ROLLER .................................................6-436.6.4 PAPER FEED ROLLER..................................................................6-446.6.5 PCU HOLDER ................................................................................6-456.6.6 TRANSFER ROLLER POSITION SENSOR, BY-PASS

PAPER FEED CLUTCH, REGISTRATION CLUTCH, ANDTRANSFER ROLLER CLUTCH ....................................................6-46

Transfer roller position sensor.............................................................6-47By-pass paper feed clutch ..................................................................6-47Registration clutch ..............................................................................6-47Transfer roller clutch ...........................................................................6-47

6.6.7 TRANSFER ROLLER .....................................................................6-486.6.8 REGISTRATION ROLLER IDLER..................................................6-486.6.9 REGISTRATION CLUTCH AND REGISTRATION DRIVE

ROLLER ..........................................................................................6-496.6.10 TRAY PAPER FEED CLUTCH, PAPER SIZE SWITCH,

AND PULL-OUT/RELAY ROLLER CLUTCH ................................6-50Paper size switch ................................................................................6-50Paper feed clutch ................................................................................6-50Pull-out clutch .....................................................................................6-51Relay roller clutch ...............................................................................6-51

TROUBLESHOOTING

7. TROUBLESHOOTING ................................................................. 7-17.1 SC TABLES...............................................................................................7-1

7.1.1 TYPES OF SERVICE CALL .............................................................7-17.1.2 SC ERROR LIST ..............................................................................7-27.1.3 PROCESS CONTROL ERROR LIST ...............................................7-6

7.2 USER ERROR LIST ..................................................................................7-87.3 FIRMWARE HISTORY ............................................................................7-13

500-SHEET PAPER TRAY UNIT (G908)

1. OVERALL MACHINE INFORMATION.......................................... 8-11.1 SPECIFICATIONS.....................................................................................8-11.2 PARTS LAYOUT .......................................................................................8-2

Rev. 08/2000

ENGINE SP MODE

G024 4-2 SM


The engine SP mode has the following menu items:

Menu Item Function and application1: Margin Independent vertical/horizontal registration adjustment for each

tray, and for OHP mode2: Parameter Independent adjustment of transfer bias and fusing temperature

for normal paper, thick paper, and OHPs3: Clear Memory Resets the counters and other values stored in NVRAM4: Sensor Check Sensor output check5: Nip Width Nip width measurement for fusing pressure adjustment6: Reset SC Resets fusing unit SC codes7: Process Ctrl Implementation of forced, normal, and color bias setting process

control and setting of execution intervals for periodic processcontrol

8: Test Print Prints internally generated patterns (4C overlay grids, 4x4 colorbelts, and solid-area color belts) for the print engine

9: ID Sensor PWM ID sensor output calibration10: Image Adjust Adjustment of image reproduction ratio in the main scan and sub-

scan directions11: Output Check Tests for motors, clutches, and solenoids12: Hi-light Fine adjustment of density for highlight (low-ID) areas.13: Lub_Interval Adjustment of lubricant application interval14: Soft Version Default “0”. Do not change.15: Belt-Tr Bias Adjustment of the Primary (Belt) Transfer Bias.


In the engine SP mode menu, you can move between menu levels, specifyparameters, 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 inEnglish only.

Key operation

[!] and ["] keys: Scroll through the menus. When either of these keys is pressedin a number setting menu, the displayed value changes by theminimum value.

[# Enter] key: When the selected item has a lower level menu, pressing thiskey moves you to the next lower level. At the lowest level, thiskey is used to determine the specified setting or execute theselected item.

[Escape] key: Pressing this key moves you to a higher level in the currentmenu. Before the specified value is confirmed by the [# Enter]key, pressing this key keeps the existing setting.

⇒⇒

Rev. 08/2000

ENGINE SP MODE

SM 4-15 G024

Ser

vice

Tab

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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. Thedefault setting is 800V.

Increasing this parameter can print vertical lines more sharply but white dots mayappear on solid image areas. Therefore, this mode should only be used whenblurry vertical lines appear.

Layer 1 Layer 2 Layer 3 Layer 4BLT-BIAS adjCyan

Cyan /#XXXX

BLT-BIAS adjMagenta

Magenta /#XXXX

BLT-BIAS adjYellow

Yellow /#XXXX


BLT-BIAS adjBack

Back /#XXXX

NOTE: This mode is available starting from ROM version 2.23 (applied toNovember 1999 production.)

⇒

Rev. 08/2000

FIRMWARE HISTORY

SM 7-13 G024

Tro

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SERIALNUMBER

FIRMWAREVERSION

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.

G0245500 H June ’99Production

2.16

Corrects the following:• Change the Transfer Current value on OHP

mode.

G0245500 J July ’99Production

2.17

Corrects the following:• Change the Transfer Current value on OHP mode

to optomize with FOLEX.• Set Setup status flag when detecting DTM cover

sheet.

G0245500 K September ’99Production

2.18

Corrects the following:• SC98 may occur while continuous B/W printing

depending upon the timing.• SC28 may occur while continuous color printing

depending upon the timing.• SC41 may occur if paper end is detected and

paper is added on the tray during half print speed.(Thick paper or OPC Transparency mediaprinting)

G0245500 L October ’99Production

2.20

Corrects the following:• Condition for SC105 detection.• Additional SP mode menu for Primary Transfer

Bias “15-BLT-TR BIAS”.• Secondary Bias Control error may occur during

initialization.

G0245500 N November ’99Production

2.23

Corrects the following:• Auto pattern printing after PCU replacement.

G0245500 Q February ‘00Production

2.26

Corrects the following:• Change timing for turning on the Revolver Motor

when detecting paper end as the countermeasurefor SC38 detection error.

• Skip the K-DTM process control procedure oncolor DTM replacement to thin vertical lines.

• The development roller is rotated twice on DTMreplacement to prevent thin vertical lines.

• Change the timing for turning off the charge biaswhen printing images wider than letter size inB/W mode.

G0245500 S April ‘00Production

2.30

⇒

Rev. 08/2000




APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P RICOH � AP305/AP505 RICOH � AP305/AP505 RICOH � AP305/AP505 RICOH � AP305/AP505 SAVIN � SLP517c/SLP517cp SAVIN � SLP517c/SLP517cp SAVIN � SLP517c/SLP517cp SAVIN � SLP517c/SLP517cp


GENERAL:


PAGES:


• 7-2 through 5 Updated Information (SC Error List)

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SC TABLES

G024 7-2 SM

7.1.2 SC ERROR LIST





21





22





23





24





25Type 1 High hot

rollertemperature




26





27



NOTE: From main enginefirmware ver. 2.21 orlater, this SC can bereleased by turning theunit OFF then ON.


60HZ ACThe number of zero-cross cycles isdetected less than109 times or morethan 131 times for 5continuous seconds.

⇒

Rev. 09/2000

SC TABLES

SM 7-3 G024

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28





29




There is adisconnection in theprimary transfer biassupply circuit. (Dirtyor deformedelectrodes.)

31




There is a shortcircuit in the supplybias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter.)

32





33




There isdisconnection in thecharge corona unitbias supply circuit.(Dirty or deformedelectrodes.)

34







Main motor, MCU.



PCU motor, MCU.

Rev. 09/2000

⇒

SC TABLES

G024 7-4 SM


38



Incorrect installationof colordevelopment unit,revolver motor,MCU defective.

39Type 2 Polygon

mirror motorerror


Polygon mirrormotor, MCU.

40



ID sensor calibration. ID sensor.

41



Transfer belt H.P.sensor, MCU.


LD error (abnormal laserpower output)

LD, LD controlboard


ion detectionerror

Synchronization detectionerror of the optical unit

During polygon mirrormotor revolution


45




There is a shortcircuit in the chargebias supply circuit(due to deformedterminals orelectrodes orconductive foreignmatter)

46





47





48





49



During reheating Pressure rollerthermistor, pressureroller lampconnector, MCU

Rev. 09/2000

⇒

SC TABLES

SM 7-5 G024

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50



During reheating Hot roller thermistor,hot roller lampconnector, MCU

51





52





57Type 2 Print

commanderror


59




Temperature sensor

60




Humidity sensor

Rev. 09/2000

⇒




APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W RICOH � AP305 RICOH � AP305 RICOH � AP305 RICOH � AP305 SAVIN � SLP517C SAVIN � SLP517C SAVIN � SLP517C SAVIN � SLP517C

SUBJECT: PARTS CATALOG UPDATES

GENERAL:

The following parts updates are being issued for all G024 Parts Catalogs.

• UPDATE 1:


11060459 G0241473 Bushing – 20.2 1 0 7 107

• UPDATE 2:


G0243084 - Spring Plate Seal 1!0 - 13 16Continued…

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Spring Plate Seal – The Spring Plate is no longer required.. Thefollowing part update is being issued for all G024 Parts Catalogs.


• UPDATE 3:


G0243724 - Seal – 7x15x15 1!0 43 5

UNITS AFFECTED:

All G024 printers manufactured after December 1999 will have the Seal – 7x15x15 removed duringproduction.

• UPDATE 4:


G8003140 G0302575 Friction Pad 1 1 13 7

UNITS AFFECTED:

All G024 printers manufactured after January 2000 will have the new style Friction Pad installed duringproduction.

Continued…

Seal – 7x15x15 – The Seal – 7x15x15 is being removed to preventhorizontal white lines. This modification has been in production sinceDecember 1999. The following part update is being issued for all G024Parts Catalogs.

Friction Pad – To prevent noise during paper feed, a new style FrictionPad is being installed during production. This modification has been inproduction since January 2000. The following part update is beingissued for all G024 Parts Catalogs.


• UPDATE 5:


G0243672 - Pressure Spring 2!1 9 10G0473672 Pressure Spring – Left 1 9 28 *

* Denotes new item number.

UNITS AFFECTED:

All G024 printers manufactured after March 2000 will have the new style Pressure Spring - Left installedduring production.

INTERCHANGEABILITY CHART:






Pressure Spring – To improve secondary transfer, a new stylePressure Spring for the left side is being installed during production.This modification has been in production since March 2000. Thefollowing part update is being issued for all G024 Parts Catalogs.



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024 � 016G024 � 016G024 � 016G024 � 016 09/15/200009/15/200009/15/200009/15/2000


SUBJECT: FRONT LOWER COVER ASSEMBLY

GENERAL:

The Front Lower Cover Assembly (P/N G0243336) will no longer be available. The Front Lower CoverAssembly 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 CoverAssembly.


G0243336 - Front Lower Cover Ass’y 1→0 3 20G0243337 Front Lower Cover 1 3 14H5164095 Decal – Energy Saver 1 3 19G0243344 Spring – 4mm 1 3 21

G0246830 Decal – Fiery Driven 1 3 22G0296845 Decal – Aficio 1 3 23

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SUBJECT: FUSING UNIT RIGHT SIDE PLATE

GENERAL:

The diameter of the base of the Driving Gear Shaft was changed from 10 mm to 20 mm to prevent the Shaftfrom being bent when removing paper jams from the Fusing Unit. The following part update is being issuedfor all G024 Parts Catalogs.


G0244614 G0244616 Right Side Plate 1 1 27 23

UNITS AFFECTED:

All G024 printers manufactured starting in September 1999 will have the new style Right Side Plate installedduring production.







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This diameter was changed to 20 mm from 10 mm.



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024 - G024 - G024 - G024 - 018018018018 12/13/200012/13/200012/13/200012/13/2000

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P GESTETNER � C7005W/C7005P RICOH � AP305/AP505 RICOH � AP305/AP505 RICOH � AP305/AP505 RICOH � AP305/AP505 SAVIN � SLP517C/SLP517CP SAVIN � SLP517C/SLP517CP SAVIN � SLP517C/SLP517CP SAVIN � SLP517C/SLP517CP

SUBJECT: FUSING UNIT GEAR

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).

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.

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Spacer – Fusing Stay(P/N: G0249001)

Line up the right side edge

VIEW FROM TOP

CONTROL NO. 043CLR


PRODUCTION COUNTERMEASURE:

GENERAL:

The following part addition is being issued for all G024 Parts Catalogs.

REFERENCENEW PART NO. DESCRIPTION QTY PAGE ITEM

G0249001 Spacer – Fusing Stay 0-1 47 16*

*DENOTES NEW ITEM NUMBER

UNITS AFFECTED:

All G024 printers manufactured after the Serial Numbers listed below will have the new style Tightener GearAssembly Bracket installed during production.

MODEL NAME SERIAL NUMBERGestetner C7005W / C7005P

Ricoh AP305 / AP505Savin SLP517C / SLP517CP

January 2000, Production

Modified Shape of Bracket

The shape of Tightener Gear AssemblyBracket that contains theContact/Separation Gear was changed,to prevent too much threadengagement between the gears.



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024WIN G024WIN G024WIN G024WIN � 019� 019� 019� 019 01/31/200101/31/200101/31/200101/31/2001

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER �NETWORK INTERFACE BOARD FOR C7005w GESTETNER �NETWORK INTERFACE BOARD FOR C7005w GESTETNER �NETWORK INTERFACE BOARD FOR C7005w GESTETNER �NETWORK INTERFACE BOARD FOR C7005w RICOH � NETWORK INTERFACE BOARD FOR AP305 RICOH � NETWORK INTERFACE BOARD FOR AP305 RICOH � NETWORK INTERFACE BOARD FOR AP305 RICOH � NETWORK INTERFACE BOARD FOR AP305 SAVIN NETWORK INTERFACE BOARD FOR SLP517cSAVIN NETWORK INTERFACE BOARD FOR SLP517cSAVIN NETWORK INTERFACE BOARD FOR SLP517cSAVIN NETWORK INTERFACE BOARD FOR SLP517c


GENERAL:The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin packagecontains 1 set of replacement pages.

PAGES:

• 8 - 7 Updated Information (G024 NIB OPTION FIRMWARE HISTORY)

An arrow has highlighted the revised areas ⇒.

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SERIALNUMBER

FIRMWAREVERSION

Corrects the following:• The wording “Config Reference” has been

changed to “Riferim. Config” for the Italianversion of Web status.

• The wording “Default Gateway Address” hasbeen changed to “Direcci. Gateway” for theSpanish version of Web status.

• A type of Cisco router caused a problem inbrowsing the NIB in an AppleTalk network.The cause of this was in the Cisco router butthe NIB firmware has been modified tocorrect this.


3.9.8

Corrects the following:• PCL text filter support has been added.• “RICOH” brand name has been deleted from

several functions and reports.


4.0.0


multiple protocols are used at the same time(e.g. telnet, IPP and HTTP).


4.0.2








G6785839L October 00Production

4.06

Rev. 01/2001

⇒



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024/G047/G048 � 020 G024/G047/G048 � 020 G024/G047/G048 � 020 G024/G047/G048 � 020 07/25/200107/25/200107/25/200107/25/2001

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7006W/7006DW GESTETNER � C7006W/7006DW GESTETNER � C7006W/7006DW GESTETNER � C7006W/7006DW RICOH � AP306/306D RICOH � AP306/306D RICOH � AP306/306D RICOH � AP306/306D SAVIN � SLP624s/624d SAVIN � SLP624s/624d SAVIN � SLP624s/624d SAVIN � SLP624s/624d

SUBJECT: VERTICAL STREAKS ON PRINTS

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 beenmodified. The new versions include a display message reminding customers to perform a periodic chargercleaning. The message is displayed every 5K developments.

Controller firmware version: 3.20 or laterEngine firmware version: 2.00 or later

For this feature, a “Charger Clean Counter” and “Charger Clean Reset Counter” have been added. Thesecounter values are shown on the Engine Maintenance Sheet.

NOTE: Errors and Limitations

Controller Firmware:Engine Firmware:

Ver. 3.20 or newer Older than ver. 3.20

Ver. 2.00 or newer No errors of any kind. SC error indicated after the first5K developments. The only wayto clear this condition is toupdate the controller firmware tover 1.09 or newer.

Older than ver. 2.00 No functional errors, but noperiodic alert is indicated.

No functional error, but noperiodical alert is indicated.

NOTE: When updating the engine firmware to version 2.00 or newer, the controller firmware also needs tobe updated to version 3.20 or newer.

The firmware revision can be downloaded through the Technology Solution Center FTP Sitehttp://tsc.ricohcorp.com.

NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about theFTP Internet Web Site and EPROM/Flash Card Exchange program.

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Tech Service Bulletin No. G024/G047/G048 – 020Page 2 of 2

GENERAL:

To distinguish between service parts containing the different firmware versions, the printer control board andMCU board were changed as follows. The following parts updates are being issued for all G047/G048 PartsCatalogs.


G0475768 G0475769 Printer Control Board 1 - 84A *G0475303 G0475306 Main Control Board (MCU) 1 - 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. Press [Menu].2. Press the ["] or [#] to display “Maintenance” and then press [Enter].3. Press the ["] or [#] to display “8. Disp.Cl.Chgr.” and then press {Enter].4. Press the ["] or [#] to display “”Off”, and then press [Enter].5. 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”.




APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W RICOH � AP305 RICOH � AP305 RICOH � AP305 RICOH � AP305 SAVIN � SLP517c SAVIN � SLP517c SAVIN � SLP517c SAVIN � SLP517c

SUBJECT: VERTICAL STREAKS ON PRINTS

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 beenmodified. The new versions include a display message reminding customers to perform a periodic chargercleaning. The message is displayed every 5K developments.

Controller firmware version: 1.09 or laterEngine firmware version: 3.01 or later

For this feature, a “Charger Clean Counter” and “Charger Clean Reset Counter” have been added. Thesecounter 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 thisfunction. The service manual page for the new Maintenance Table is supplied. Please update your G024Service Manual with the new page 4-3.

1.Toner Select CyanMagentaYellowBlack

2. Toner level3. Menu Reset4. Registration (Onlywhen optional tray isinstalled.)5. Menu Protect Off

OnIt can also beaccessed if the[Enter], [Escape], and[Menu] keys arepressed in sequencewhile the printer is online.

6. Reinstall Clean Charger Press # key

Maintenance

7. Disp.Cl.Chgr OnOff

Default : On

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Tech Service Bulletin No. G024/G047/G048 – 021Page 2 of 2

NOTE: Errors and Limitations

Controller Firmware:Engine Firmware:

Ver. 1.09 or newer Older than ver. 1.09

Ver. 3.01 or newer No errors of any kind. SC error indicated after the first5K developments. The only wayto clear this condition is toupdate the controller firmware tover 1.09 or newer.

Older than ver. 3.01 No functional errors, but noperiodic alert is indicated.

No functional error, but noperiodical alert is indicated.

" When updating the engine firmware to version 3.01 or newer, the controller firmware needs to beupdated to version 1.09 or newer.

" Do not use this Engine Firmware version on the G024-17/27 (PostScript version), otherwise an SC erroroccurs.

The latest firmware can be downloaded through the Technology Solution Center FTP Sitehttp://tsc.ricohcorp.com.





APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7006w/7006dw GESTETNER � C7006w/7006dw GESTETNER � C7006w/7006dw GESTETNER � C7006w/7006dw RICOH � AP306/306D RICOH � AP306/306D RICOH � AP306/306D RICOH � AP306/306D SAVIN � SLP624s/624d SAVIN � SLP624s/624d SAVIN � SLP624s/624d SAVIN � SLP624s/624d

SUBJECT: INCOMPLETE TONER FUSING

SYMPTOM:

Incomplete toner fusing or reduced glossiness may occur with the first print made after the machine recoversfrom Energy Saver Mode. This tends to occur more often with plain or standard paper that is relatively thick.

CAUSE:

When the machine starts printing after coming out of Energy Saver Mode, the hot roller temperature is nothigh 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 rollertemperature for the “first print” coming out of Energy Saver Mode is increased by 10°C over the originaltemperature.

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 Sitehttp://tsc.ricohcorp.com.


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Copyright 2001 RICOH Corporation. All rights reserved. CONTROL NO. 055CLR



APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � NETWORK INTERFACE BOARD for C7005W GESTETNER � NETWORK INTERFACE BOARD for C7005W GESTETNER � NETWORK INTERFACE BOARD for C7005W GESTETNER � NETWORK INTERFACE BOARD for C7005W RICOH - NETWORK INTERFACE BOARD for AP305 RICOH - NETWORK INTERFACE BOARD for AP305 RICOH - NETWORK INTERFACE BOARD for AP305 RICOH - NETWORK INTERFACE BOARD for AP305 SAVIN - NETWORK INTERFACE BOARD for SLP517C SAVIN - NETWORK INTERFACE BOARD for SLP517C SAVIN - NETWORK INTERFACE BOARD for SLP517C SAVIN - NETWORK INTERFACE BOARD for SLP517C


GENERAL:


PAGES:


• 8-7 Updated Information (NIB Firmware Modification History)

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3.9.8




4.0.0




4.0.2








G6785839L October ‘00Production

4.0.6

Corrects the following:• Classless InterDomain Routing (CIDR) is

supported.• DHCP of Solaris 2.6 is supported.

G6785839M February ‘01Production

4.0.7

Rev. 07/2001

⇒

Copyright 2001 RICOH Corporation. All rights reserved. CONTROL NO. 057CLR



APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � NETWORK INTERFACE BOARD for C7006W/7006dw GESTETNER � NETWORK INTERFACE BOARD for C7006W/7006dw GESTETNER � NETWORK INTERFACE BOARD for C7006W/7006dw GESTETNER � NETWORK INTERFACE BOARD for C7006W/7006dw RICOH - NETWORK INTERFACE BOARD for AP306/306D RICOH - NETWORK INTERFACE BOARD for AP306/306D RICOH - NETWORK INTERFACE BOARD for AP306/306D RICOH - NETWORK INTERFACE BOARD for AP306/306D SAVIN - NETWORK INTERFACE BOARD for SLP624s/624d SAVIN - NETWORK INTERFACE BOARD for SLP624s/624d SAVIN - NETWORK INTERFACE BOARD for SLP624s/624d SAVIN - NETWORK INTERFACE BOARD for SLP624s/624d


GENERAL:


PAGES:


• iii Updated Information (Table of Contents - NIB)• 8-5 Updated Information (NIB Firmware Modification History)

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SM iii G047/G048

7.3.6 ENGINE USER ERRORS.................................................................7-77.3.7 ENGINE SERVICE CODES .............................................................7-7


8. NETWORK INTERFACE BOARD (C4000 FERRET) .................. 8-18.1 OVERVIEW ...............................................................................................8-1



8.3 BASIC OPERATIONS ...............................................................................8-38.3.1 OVERVIEW ......................................................................................8-38.3.2 SWITCH FUNCTION........................................................................8-4

NVRAM Reset Procedure .....................................................................8-48.4 FIRMWARE HISTORY ...............................................................................8-5

8.4.1 NIB FIRMWARE MODIFICATION HISTORY ....................................8-5

Rev. 07/2001

FIRMWARE HISTORY

SM 8-5 G047/G048

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SERIALNUMBER

FIRMWAREVERSION

Initial Production G6785847 D FirstProduction

4.8.2

First release for G062 and B017/B018Corrects the following:• Classless InterDomain Routing (CIDR) is

supported.

G6785847 E Sept. ’00Production

5.0.2

Corrects the following:• The spelling of the command “retern” in the


G6785847 F Oct. ’00Production

5.0.4

Corrects the following:• DHCP of Solaris 2.6 is supported.

G6785847 G Feb. ’01Production

5.0.7

⇒

Rev. 07/2001

Copyright 2001 RICOH Corporation. All rights reserved.


BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024/G047/G048 � 025G024/G047/G048 � 025G024/G047/G048 � 025G024/G047/G048 � 025 09/24/200109/14/200109/14/200109/14/2001

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W GESTETNER � C7005W RICOH � COLOR PRINTER AP305 RICOH � COLOR PRINTER AP305 RICOH � COLOR PRINTER AP305 RICOH � COLOR PRINTER AP305 SAVIN � SLP517CSAVIN � SLP517CSAVIN � SLP517CSAVIN � SLP517C


GENERAL:


An arrow has highlighted the revised areas ⇒ .

PAGES:

• iii Updated Information Table Of Contents• 7 – 7 Updated Information Firmware Modification History

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SM iii G024 PS

7.4 FIRMWARE HISTORY……………………………………………………7-7

08/2001

G02

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FIRMWARE HISTORY

SM 7-7 G024 PS


Refer to the Troubleshooting section in the Operating Instructions PrinterReference Manual.


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





LEVELSERIAL


Corrects the following:1. Wording change in RPS2 menu. Previous Changed to Bright Vivid Super Bright Super Vivid2. Improving BG/UCR.3. Cannot print out correctly from

AcrobatReader4.0 when selecting 2 Bytefont downloads.

G5035908 A April 2000Production

2.61




2. No "Job Resetting..." display


3.10



3.55

08/2001

⇒



BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER:BULLETIN NUMBER: G024/G047/G048 G024/G047/G048 G024/G047/G048 G024/G047/G048 - 026- 026- 026- 026 09/24/200109/14/200109/14/200109/14/2001

APPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODELAPPLICABLE MODEL:::: GESTETNER � C7006W GESTETNER � C7006W GESTETNER � C7006W GESTETNER � C7006W RICOH � RICOH � RICOH � RICOH � AFICIO COLOR AP306AFICIO COLOR AP306AFICIO COLOR AP306AFICIO COLOR AP306 SAVIN � SLP624SSAVIN � SLP624SSAVIN � SLP624SSAVIN � SLP624S


GENERAL:


An arrow has highlighted the revised areas ⇒ .

PAGES:

• TOC IV Updated Information (table of contents)• 7-10 Updated Information (Firmware Modification History)

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G047/G048 iv SM

TROUBLESHOOTING

7. TROUBLESHOOTING ................................................................ 7-17.1 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 ..............................................................................7-27.1.3 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

Rev. 08/2001

FIRMWARE HISTORY

G047/G048 7-10 SM





LEVELSERIAL






3.10



3.55

Rev.08/2001

⇒


TECHNICAL SERVICE BULLETINTECHNICAL SERVICE BULLETIN

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.

REFERENCEPAGENEW PART

NUMBERDESCRIPTION QTY

G024 G047/ G048ITEM

G0473580 Charge corona Assembly 1 5 11 21*

*DENOTES NEW ITEM NUMBER

Note: T



n P

AR

TS

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.

REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM

G6785714 Network Interface Board 1 35 13 *

* DENOTES NEW ITEM NUMBER



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BULLETIN NUMBER: G024/G047/G048 � 029 12/04/2002

APPLICABLE MODEL: GESTETNER � C7005W RICOH � AP305 SAVIN � SLP517C SUBJECT: SERVICE MANUAL � INSERT N

ote: This copy is intended as a master original


! SER

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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 ⇒. • 8-8 Updated Information (NIB Firmware History)



G024 Win 8-8 SM



SERIAL NUMBER

FIRMWARE VERSION

Corrects the following: • Can not connect to NetWare Servers

when the servers use NCP Packet Signature Level 2.

G6785839N August ’01 Production

4.0.8

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-2002-03.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testing/c06/snmpv1/

G6785839P July ’02 Production

4.1.0

⇒

Rev. 12/2002


BULLETIN NUMBER: G024/G047/G048 � 030 12/06/2002

APPLICABLE MODEL: GESTETNER �C7006W/C7006DW RICOH �AP306/AP306D SAVIN �CLP624S/SLP624D SUBJECT: SERVICE MANUAL � INSERT N

ote: This copy is intended as a master original


! SER

VICE

MA

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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 ⇒. • 8-5 Updated Information (NIB Firmware History)


FIRMWARE HISTORY

SM 8-5 G047/G048

Net

wor

k In

terf

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Boa

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8.4 FIRMWARE HISTORY 8.4.1 NIB FIRMWARE MODIFICATION HISTORY



SERIAL NUMBER

FIRMWARE VERSION

Initial Production G6785847 D First Production

4.8.2

First release for G062 and B017/B018 Corrects the following: • Classless InterDomain Routing (CIDR) is

supported.

G6785847 E Sept. ’00 Production

5.0.2

Corrects the following: • The spelling of the command “retern” in the


G6785847 F Oct. ’00 Production

5.0.4

Corrects the following: • DHCP of Solaris 2.6 is supported.

G6785847 G Feb. ’01 Production

5.0.7

Corrects the following: • SNMP Trap IP address is set to 11.22.33.44

incorrectly before the NIB is assigned the IP address from the DHCP server

• Disconnects from NetWare Servers that uses relatively old CPU’s (i486)

• Can not connect to NetWare Servers when the servers use NCP Packet Signature Level 2.

G6785847 H Aug. ’01 Production

5.1.0

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-2002-03.html -PROTOS c06-snmpv1 test Suite :http://www.ee.oulu.fi/research/ouspg/protos/testing/c06/snmpv1/

G6785847 J July ’02 Production

5.1.2

⇒

Rev. 12/2002



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 GENERAL: The following parts updates are being issued for all G047 Parts Catalogs.

• UPDATE 1:

REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

G0474504 G0474507 Fusing Unit - 120V (G047) 1 1 29 14 G0474505 G0474508 Fusing Unit - 230V (G047) 1 1 29 14 G0484504 G0484507 Fusing Unit - 120V (G048) 1 1 29 14 G0484505 G0484508 Fusing Unit - 230V (G048) 1 1 29 14 G0474600 G0474608 Hot Roller 1 1 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 SERIAL NUMBER Gestetner C7006w P33204xxxxx Gestetner C7006dw P34204xxxxx Ricoh Color Laser AP306 P33204xxxxx Ricoh Color Laser AP306D P34204xxxxx Savin SLP624s P33204xxxxx Savin SLP624d P34204xxxxx

Continued…



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Fusing Unit – To increase the durability of the hot roller, the material of the roller surface (silicone rubber) has been changed.

Tech Service Bulletin No.G024/G047/G048– 031 Page 2 of 3

• UPDATE 2:


G0241770 G0481770 Bias Terminal Assembly 1-1 1 63 9 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 SERIAL NUMBER Gestetner C7006w P33201xxxxx Gestetner C7006dw P34201xxxxx Ricoh Color Laser AP306 P33201xxxxx Ricoh Color Laser AP306D P34201xxxxx Savin SLP624s P33201xxxxx

• UPDATE 3:


AE030024 08053380 Ball Bearing - 25X37X7MM 1 1 35 14 UNITS AFFECTED: All G024/G047/G048 printers manufactured after the serial numbers listed below will have the new style Ball Bearing installed during production.


Continued…

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.

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.

Tech Service Bulletin No.G024/G047/G048– 031 Page 3 of 3

• UPDATE 4: NOTE: In addition to this new motor, Inlet Fan Motor #AX640071 can also be used on this machine since

these two parts are identical.


AX640099 Fan Motor - DC24V 1.92W AX640140 Fan Motor - DC24V 4.08W 1 1 63 8

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.



0 OLD and NEW parts can be used in both OLD and NEW machines. 2 NEW parts CAN NOT be used in OLD machines.


1 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.


3/S 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.

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.

g024_sm

Documents

library drawing

classless

conductive

ohp modeto

g024g047g048

barrel torroidal

conductive

temporary