Ricoh G031 Service Manual

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G031/G032/G049/G054

SERVICE MANUAL

000832MIU

RICOH GROUP COMPANIES

Table of Contents

Troubleshooting

Summary of Contents for Ricoh G031

Page 1: Service Manual
® ® G031/G032/G049/G054 SERVICE MANUAL 000832MIU RICOH GROUP COMPANIES...
Page 3 ® ® RICOH GROUP COMPANIES...
Page 5 G031/G032/G049/G054 SERVICE MANUAL 000832MIU...
Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
Page 11 Rev. 7/2000 LEGEND PRODUCT CODE COMPANY GESTETNER RICOH SAVIN G031 P7020 AP2000 SLP20 G032 P7014 AP1400 SLP14 G049 P7021 AP2100 SLP21 G054 P7016 AP1600 SLP16 DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 5/99 Original Printing 4/2000 G049/G054 Addition...
Page 13: Table Of Contents
2.3.5 DRUM CLEANING................2-15 2.4 IMAGE TRANSFER AND PAPER SEPARATION ........2-16 2.4.1 OVERVIEW ..................2-16 2.4.2 TRANSFER ROLLER CLEANING..........2-17 2.5 PAPER FEED..................2-18 2.5.1 OVERVIEW ..................2-18 2.5.2 PAPER TRAY .................2-20 2.5.3 BY-PASS TRAY................2-25 2.5.4 PAPER REGISTRATION..............2-27 2.6 IMAGE FUSING ..................2-29 2.6.1 OVERVIEW ..................2-29 G031/G032/G049/G054...
Page 14 OPTIONAL HDD & PERIPHERALS ..........3-3 3.8.2 CONNECTION BETWEEN PRINTER CONTROL BOARD AND NETWORK INTERFACE BOARD ............3-6 3.8.3 PRINTING THE NETWORK INTERFACE BOARD CONFIGURATION SHEET...............3-6 SERVICE TABLES AND PROCEDURES 4. SERVICE PROCEDURES AND TABLES ........4-1 4.1 OVERVIEW ....................4-1 4.2 SERVICE PROGRAM MODE..............4-2 G031/G032/G049/G054...
Page 15 4.8.2 POWER-UP DIAGNOSTIC MODE ..........4-25 4.8.3 DETAILED DIAGNOSTIC MODE ...........4-26 4.8.4 DIAGNOSTIC TEST DETAILS ............4-27 4.9 FIRMWARE HISTORY ................4-29 4.9.1 CONTROLLER FIRMWARE HISTORY (G031)......4-29 4.9.2 CONTROLLER FIRMWARE HISTORY (G032)......4-30 PREVENTIVE MAINTENANCE 5. PREVENTIVE MAINTENANCE............ 5-1 5.1 PREVENTIVE MAINTENANCE SCHEDULE ..........5-1 REPLACEMENT AND ADJUSTMENT 6.
Page 16 7.4.3 FUSES....................7-17 ENVELOPE FEEDER G913 1. OVERALL INFORMATION............8-1 1.1 SPECIFICATIONS..................8-1 1.2 MECHANICAL COMPONENT LAYOUT............8-1 2. DETAILED SECTION DESCRIPTIONS ........8-2 2.1 PAPER LIFT ....................8-2 3. INSTALLATION ................8-3 4. REPLACEMENT AND ADJUSTMENT........8-4 4.1 FRICTION PAD REPLACEMENT .............8-4 G031/G032/G049/G054...
Page 17 1. OVERALL MACHINE INFORMATION ........10-1 1.1 SPECIFICATIONS...................10-1 2. INSTALLATION PROCEDURE..........10-2 2.1 HARDWARE INSTALLATION ..............10-2 2.1.1 SERIAL NUMBER AND MAC ADDRESS........10-2 2.1.2 STATUS SHEET................10-2 2.2 PROGRAMMING NETWORK/PROTOCOL PARAMETERS....10-3 2.2.1 IPX NETWORK................10-3 2.2.2 TCP/IP NETWORK.................10-4 2.2.3 ETHERTALK (APPLETALK) NETWORK ........10-5 G031/G032/G049/G054...
Page 18 2.10 PRINTER CONTROL BOARD........……………….11-3 2.10.2 DEVICES………………………………………………………………11-5 3. G049/G054 FIRMWARE HISTORY..........11-6 3.1 G049 ENGINE FIRMWARE MODIFICATION HISTORY ......11-6 3.2 G054 ENGINE FIRMWARE MODIFICATION HISTORY ......11-6 3.3 G049 CONTROLLER FIRMWARE MODIFICATION HISTORY ....11-7 3.4 G054 CONTROLLER FIRMWARE MODIFICATION HISTORY ....11-8 G031/G032/G049/G054...
Page 19 THE PRINTER..............APPENDIX-13 1.4 USING A DIMM ...............APPENDIX-14 1.4.1 PREPARING THE DIMM..........APPENDIX-14 1.4.2 DOWNLOADING FROM THE DIMM TO THE PRINTER..............APPENDIX-19 1.5 COPYING FROM A PC DIRECTLY ........APPENDIX-20 1.5.1 PREPARATION ..............APPENDIX-20 1.5.2 DOWNLOADING TO THE FLASH MEMORY....APPENDIX-22 1.6 SSU TROUBLESHOOTING ............APPENDIX-26 G031/G032/G049/G054...
Page 21: Important Safety Notices
1. Do not incinerate the toner cassettes. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of toner cassettes in accordance with local regulations. (This is a non-toxic unit.) 3. Dispose of replaced parts in accordance with local regulations. G031/G032...
Page 22: Laser Safety
WARNING FOR LASER UNIT WARNING: Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING: G031/G032...
Page 23 Rev. 04/2000 OVERALL INFORMATION G031/G032 PAPER FEED UNIT G914/G915 DETAILED DESCRIPTIONS G031/G032 NETWORK INTERFACE BOARD G919 INSTALLATION G031/G032 G049/G054 SERVICE MANUAL SERVICE PROCEDURES AND TABLES G031/G032 APPENDIX PREVENTIVE MAINTENANCE G031/G032 REPLACEMENT AND ADJUSTMENT G031/G032 TROUBLESHOOTING G031/G032 ENVELOPE FEEDER G913...
Page 25: Overall Information
OVERALL INFORMATION...
Page 27: Overall Machine Information
Desktop Print Process: Laser beam scanning & electrophotographic printing Monocomponent toner development Printing Speed G031: (600 dpi): Maximum 20 pages per minute (A4/LT LEF) G032: Maximum 14 pages per minute (A4/LT SEF) NOTE: LEF, long edge feed. SEF, short edge feed...
Page 28 SPECIFICATIONS Rev. 04/2000 Printing Paper Size: G031: Maximum A3/11" x 17" Minimum A5 LEF - Standard Tray B6 SEF - By-pass Tray A5 LEF - Optional PFU Custom paper size (PCL 6/PS): By-pass Tray 11.69" x 17" ~ 3.88" x 5.83"...
Page 29 Standard Tray: 250 sheets By-pass Tray: 100 sheets 10 envelopes (G031) 5 envelopes (G032) Optional Paper Feed Unit: 500 sheets x 2 (G031) 500 sheets x 1 (G032) Optional Envelope Feeder: 60 envelopes Standard 8 MB, up to 40 MB with optional SIMM.
Page 30 SPECIFICATIONS • Printer Drivers Utility Software • PS PPD files (Main frame CD-ROM): • Font Manager • Aficio Manager • Operating Instructions (G031/G032 -22, -27, -29) • IP-P2P Utility Software • IPXP2P (Optional Network Interface • MAP Board): • Bootpl •...
Page 31: Machine Configuration
Hard Disk Drive Type 2000 G690-17 Memory Unit Type 204 (16 MB) G688-04 Memory Unit Type 204 (32 MB) G688-05 *NOTE: The envelope feeder for the G031 can only be installed in place of the optional 2nd paper tray. G031/G032...
Page 32: Paper Path
PAPER PATH 1.3 PAPER PATH G031 Output Tray By-pass Tray Paper Tray G031V503.WMF G032 Output Tray By-pass Tray G031V504.WMF Paper Tray G031/G032...
Page 33: Mechanical Component Layout
11. Polygonal Mirror Motor 4. Transfer Roller 12. 1st Mirror (G031) F-theta Lens (G032) 5. By-pass Feed Roller 13. Barrel Toroidal Lens (G031) 6. By-pass Tray 14. F-theta Mirror (G031) 7. Registration Rollers (G031) Relay Roller (G032) 15. Shield Glass 8.
Page 34: Electrical Component Layout
ELECTRICAL COMPONENT LAYOUT 1.5 ELECTRICAL COMPONENT LAYOUT G031 G031V501.WMF 1. Laser Synchronization Detector 14. Tray Paper End Sensor 2. Engine Control Board 15. Fusing Thermistor 3. Exhaust Fan Motor 16. Tray Paper Near-end Sensor 4. High Voltage Supply Board 17. Control Panel Board 5.
Page 35 7. By-pass Feed Solenoid 18. LD Drive Board (with synchronization detector) 8. Toner Near-end Sensor 19. Main Switch 9. Registration Sensor 20. Polygonal Mirror Motor 10. By-pass Tray Paper Sensor 21. Printer Control Board 11. Tray Paper End Sensor G031/G032...
Page 36: Electrical Component Descriptions
Refer to the electrical component layout and the point-to-point diagram on the waterproof paper in the pocket for the locations of these components. Index No. Symbol Description Note G031 G032 Printed Circuit Boards High Voltage Supply Supplies high voltage to the drum PCB1 Board charge roller, development roller, and transfer roller.
Page 37 ELECTRICAL COMPONENT DESCRIPTIONS Index No. Symbol Description Note G031 G032 Magnetic Clutches Tray Paper Feed Starts paper feed from the paper tray. — (G031) Registration Drives the registration rollers. — (G031) Solenoids By-pass Feed Starts paper feed from the by-pass SOL1 tray.
Page 38: Printing Process
–100 V –400 V G031V507.WMF G031/4 use an all-in-one type of toner cartridge that includes the drum, toner, development roller, charge roller and other components. 1. DRUM CHARGE In the dark, the charge roller gives a negative charge of –600 volts to the organic photo-conductive (OPC) drum.
Page 39 The discharge plate helps separate the paper from the drum. 6. CLEANING The cleaning blade removes any toner remaining on the drum surface after the image is transferred to the paper. 7. QUENCHING There is no quenching mechanism. 1-13 G031/G032...
Page 40: Board Structure
+5 V/+24 V G031V508.WMF The engine control firmware controls the components connected to the engine control board (ECB). The printer control board controls the control panel board. The printer control board is also connected to the personal computer. G031/G032 1-14...
Page 41: Major Components
Supplies high voltage to the drum charge roller, development roller, and transfer roller. 6. Fusing Unit Fuses toner to the paper. The fusing lamp is controlled by the ECB. 7. Control Panel Board Controls the display panel, the LED, and the touch keypad. 1-15 G031/G032...
Page 42: Comparison
COMPARISON 1.9 COMPARISON G031 G032 Standard Paper Tray 250 sheets 250 sheets 250 sheets Standard Bypass Tray 100 sheets 100 sheets 100 sheets Optional Paper Tray 500 sheets x 2 500 sheets 500 sheets x 2 + 1,500 sheets Envelope Feeder...
Page 43: Detailed Descriptions
DETAILED DESCRIPTIONS...
Page 45: Detailed Section Descriptions
The printer control board receives the print data from the host computer (AT compatible Windows PC or Macintosh). • For the G031, the printer control board has two OBI (Optional Bus Interface) connectors to connect a network interface board (NIB), RS232C interface, or HDD unit.
Page 46: Printer Control Board
The control board controls the following to produce the print image data. 1) IEEE1284 parallel port interface 2) Control panel 3) Edge smoothing and toner saving 4) Engine control board 5) Interfacing with the HDD, NIB, and RS232C board. G031/G032...
Page 47: Image Data Processiing
8 x 8 matrix filter is used. As a result, less toner is used to create the latent image on the drum and black areas print as gray. The printer driver prevents edge smoothing and toner saving mode from being used at the same time. G031/G032...
Page 48: Host Interface
2.1.4 HOST INTERFACE Bi-directional Parallel Interface G031D505.WMF A 36-pin bi-directional parallel interface connector (female) is used. The bi-directional parallel interface on the controller works in three modes; Compatible, Nibble and ECP modes. These modes are standardized by IEEE 1284. G031/G032...
Page 49: Laser Exposure
Strength of the beam on the drum 0.636 mW 0.43 mW Printing Binary (2 bits/pixel) Binary (2 bits/pixel) There are two polygon motor speeds: - G031 - Resolution (dpi) Modes Motor Speed (rpm) Data Frequency (MHz) 300/600 dpi printing 22478.22 22.0926...
Page 50: Optical Path
LASER EXPOSURE 2.2.2 OPTICAL PATH G031 G031D506.WMF G032 G031D507.WMF [A]: Polygonal Mirror [G]: BTL (Barrel Toroidal Lens) [B]: Cylindrical Lenses [H]: 1st Mirror [C]: LD Drive Board [I]: F-theta Lens [D]: Drum [J]: Laser Synchronization Detector [E]: LD Shutter [K]: Shield Glass...
Page 51 The laser synchronization detector [J] synchronizes the start of the main scan. G032 The G032 has a shorter beam path than the G031. The beam which is reflected by the polygonal mirror goes to the F-theta lens [I]. The beam reaches the drum [D] through the shield glass [K]. The F-theta lens [I] does the functions of both the F-theta [F] mirror and the BTL [G].
Page 52: Auto Power Control (Apc)
The PD passes an electrical current to the LD driver IC and this IC adjusts its output level to keep the laser diode output constant. The laser diode power level is adjusted on the production line. Do not touch the variable resistors on the LD unit in the field. G031/G032...
Page 53: Ld Safety Switch
The switch is on the LD 24 V line. Mechanical Laser Shutter When the toner cartridge is removed, the laser shutter is released and this interrupts the laser beam. G031/G032...
Page 54: Toner Cartridge
[C]. Monocomponent toner is used. The cleaning blade [B] cleans the drum surface. The toner near end sensor is mounted within the print engine, under the toner cartridge. The toner near end sensor can be seen with the toner cartridge removed. G031/G032 2-10...
Page 55: Drive
[D] through a series of gears. The main motor speed is controlled by the engine control board (ECB). When a new cartridge is installed, the machine clears the near-end condition if the toner near-end sensor detects that there is sufficient toner. There is no counter for the toner cartridge. 2-11 G031/G032...
Page 56: Drum Charge
The drum charge roller is part of the toner cartridge, so when the toner runs out, the drum charge roller is changed at the same time. This happens before the drum charge roller gets dirty. G031/G032 2-12...
Page 57: Development
2.3.4 DEVELOPMENT Overview G031D509.WMF This machine uses monocomponent toner. The G031 has two agitators [F] in the toner cartridge(shown above). The G032 has one agitator. The agitator(s) [F] and the mixing blade [D] mix the toner in the toner cartridge and transport it to the development roller [C].
Page 58 The high voltage supply unit gives the development roller a charge of –400 V dc and an ac component of 1.8 kVp-p 1.8 kHz ac is also used. To prevent toner from transferring to non-image areas on the drum, the development bias is different for image areas and non-image areas. G031/G032 2-14...
Page 59: Drum Cleaning
The toner cartridge in the commercial toner cartridge has a toner collection coil [C] and scraper [D]. These improve the collection of waste toner. There is no toner recycling mechanism. 2-15 G031/G032...
Page 60: Image Transfer And Paper Separation
The transfer current depends on the paper size. For A3/11” x 17” paper in the G031, 7µA is supplied, and for A4/LT paper in the G032, 6µA is supplied (for 600 dpi resolution in both of these cases). The transfer roller attracts the toner from the drum onto the paper.
Page 61: Transfer Roller Cleaning
The machine goes through the cleaning mode in the following conditions: • After a printer jam has been cleared. • Just after the power is switched on. • After 10 sheets of paper have been printed and the print job has finished. 2-17 G031/G032...
Page 62: Paper Feed
PAPER FEED 2.5 PAPER FEED 2.5.1 OVERVIEW G031 G031D514.WMF There is a paper tray [A] and a by-pass tray [B]. The paper tray holds 250 sheets. The by-pass tray can hold 100 sheets of paper. The paper feed roller [C] drives the top sheet of paper from the paper tray to the registration rollers [D].
Page 63 This machine does not have a paper size switch. So, before printing, the user must register the paper size in the paper tray at the printer’s operation panel. The built-in tray can only hold A4 or letter size paper. 2-19 G031/G032...
Page 64: Paper Tray
PAPER FEED 2.5.2 PAPER TRAY G031 Tray Extension The tray can be extended manually to hold paper longer than A4/Letter size. The default setting of the tray length is for short paper. To use longer paper, release the catches [A] at both sides, then extend the tray and re-lock the catches.
Page 65 When the paper actuates the registration sensor [E], the tray paper feed clutch turns off. When the paper reaches a certain position, the registration clutch [F] turns on to transfer drive from the main motor to the registration rollers. Then the registration rollers feed the paper to the transfer area. 2-21 G031/G032...
Page 66 When almost 50 sheets are left on the tray, the tray bottom plate pushes up the feeler of the tray paper near end sensor [D]. However, there is no indication on the printer’s operation panel; the signal is only for use by the host computer. G031/G032 2-22...
Page 67 The tray bottom plate is connected to the cassette arm [A] by the spring [B]. When the cassette is put in the machine, the slope of the guide block [C] on the machine lifts the cassette arm up and the spring lifts up the bottom plate. 2-23 G031/G032...
Page 68 To fix this problem, remove all paper from the paper tray then turn on the machine. Paper End Detection This is the same as for the G031. There is no near-end detection. G031/G032 2-24...
Page 69: By-Pass Tray
PAPER FEED 2.5.3 BY-PASS TRAY G031 G031D522.WMF G031D523.WMF When paper is placed on the tray, the by-pass tray paper feeler [A] is pushed up and the actuator leaves the by-pass tray paper sensor [B]. After image processing in the printer control board, the CPU energizes the by-pass feed solenoid and the by-pass feed roller [C] starts to feed paper to the registration roller [D].
Page 70 This machine uses a feed roller and friction pad mechanism, with drive from the main motor transmitted when the by-pass feed clutch turns on. The friction pad only allows the top sheet to feed to the relay roller. G031/G032 2-26...
Page 71: Paper Registration
PAPER FEED 2.5.4 PAPER REGISTRATION G031 G031D518.WMF Main motor rotation is transmitted to the registration clutch gear [A]. The registration sensor [B] is just before the registration rollers [C]. When the paper leading edge activates the registration sensor, the registration clutch [D] turns off and the registration rollers stop turning.
Page 72 The registration sensor [A] is just after the relay roller [B]. However, this machine has no registration roller. A certain time after the paper leading edge activates the registration sensor, the CPU starts to write the latent image on the drum. The registration sensor is also used for paper misfeed detection. G031/G032 2-28...
Page 73: Image Fusing
1. Pressure Roller Release Lever 6. Hot Roller 2. Pressure Spring 7. Exit Roller 3. Fusing Lamp 8. Fusing Exit Sensor 4. Fusing Thermistor 9. Hot Roller Strippers 5. New Fusing Unit Detector (G031 10. Pressure Roller only) 2-29 G031/G032...
Page 74: Fusing
The thermofuse [D] protects the fusing unit from overheating. 2.6.3 FUSING UNIT DRIVE G031D529.WMF The main motor drives the hot roller [A] through a train of gears. The hot roller drives the exit roller [B] through a gear. G031/G032 2-30...
Page 75: Pressure Roller/Paper Exit
Then the exit roller feeds the paper to the paper tray. 2.6.5 FUSING UNIT DRIVE RELEASE G031D531.WMF When the pressure roller release levers [A] are pushed down, the pressure roller moves away so that jammed paper can be removed. 2-31 G031/G032...
Page 76: New Fusing Unit Detection (Stinger - P3 Only)
2.6.6 NEW FUSING UNIT DETECTION (G031 ONLY) G031D532.WMF The fusing unit in the G031 maintenance kit has this detection mechanism (the fusing unit obtained as a service part does not). When the fusing unit has been replaced, the CPU detects the new unit and automatically removes the “Replace Maintenance Kit”...
Page 77: Fusing Temperature Control
[A]. Then, the CPU maintains this temperature using on-off control. To start printing, the CPU raises the temperature to the printing temperature [B] and maintains it as shown on the next page. In energy saver mode, the fusing lamp is off. 2-33 G031/G032...
Page 78 IMAGE FUSING The CPU controls the temperature as shown in the following tables to keep the fusing lamp at the appropriate temperature for each condition. G031 Power on → After 2 minutes Condition Within 2 minutes Ready to print 170°C 170°C...
Page 79: Overheat Protection
Even if the thermistor overheat protection fails, there is a thermofuse in series with the common ground line of the fusing lamp. If the temperature of the thermofuse [B] reaches 169°C, the thermofuse opens, removing power from the fusing lamp. At this time, the printer stops operating. 2-35 G031/G032...
Page 80: Energy Saver Mode
The machine leaves energy saver mode when one of the following happens. • Print command received from the PC • Front cover opened and closed • Paper tray pulled out and replaced • Any operation panel keys pressed G031/G032 2-36...
Page 81: Cover Open Detection
[B] rotates as shown in the picture. Then the front cover safety switch [C] turns off. If the front cover safety switch turns off, the +24V line from PSU to ECB is cut. As a result, the power for the LD driver is cut. 2-37 G031/G032...
Page 82: Removing The Fusing Unit
[C]. Therefore, the front cover cannot be closed. When the fusing unit is installed properly [D], the projection on the fusing unit [E] lifts up the stopper. Therefore, the safety switch release lever can pass and the front cover can be closed. G031/G032 2-38...
Page 83: Engine Control Board
E E P R O M S R A M C P U H8/3002 C N 1 1 C N 1 2 C N 1 3 C N 1 4 C N 5 C N 1 5 C N 1 6 G031D540.WMF 2-39 G031/G032...
Page 84: Devices
LD driver sample hold function Pattern generation Fusing unit control timer I/O port EPROM 128 K engine firmware ROM EEPROM Service maintenance information (counters, registration, etc.) 1 kbit SRAM 32 KB The test pattern will be printed when TB1 is shorted. G031/G032 2-40...
Page 85: Structure
S e n s o r s Sync. + 5 V Detector P S U Laser D i o d e + 2 4 V LD Drive B o a r d + 5 V S Regulator G031D541.WMF 2-41 G031/G032...
Page 86: Connection To The Ecb
C N 8 C N 9 G031D542.WMF * The G032 does not use the following: 1) 1st paper size sensor 2) Paper near end sensor 3) Laser synchronization detector board (It is on the LD drive board.) 4) Registration clutch G031/G032 2-42...
Page 87 Turns the 1st tray paper feed clutch/solenoid on/off CN12 Turns the by-pass tray solenoid on/off CN13 Turns the registration clutch on/off (only used for G031) CN14 Turns the fan motor on/off and controls the fan motor speed. CN15 Controls the charge voltage, development bias, and transfer roller bias.
Page 88: Signal Table
1st tray paper near-end signal CN4-5 FPS0 1st tray paper size signal CN4-6 FPS1 1st tray paper size signal CN4-7 CN4-8 FPS2 1st tray paper size signal CN5-1 CN5-2 /TEND Toner near-end condition CN5-3 CN5-4 CN6-1 CN6-2 /FSET0 Fusing unit 100V/200V selection G031/G032 2-44...
Page 89 PFU paper near end condition CN9-10 OPNE1 PFU paper near end condition CN9-11 OPS0 PFU paper size detection CN9-12 OPS1 PFU paper size detection CN9-13 OPS2 PFU paper size detection CN9-14 OPEND PFU paper end detection CN9-15 XOTSET PFU paper detection 2-45 G031/G032...
Page 90 MCPWM Charge roller PWM signal CN15-12 BIPWM Development bias PWM signal CN15-13 CN15-14 +24V CN16-1 +24V CN16-2 CN16-3 CN16-4 CN16-5 /FURLY Fusing relay enable CN16-6 /HEAT Fusing lamp on CN17-1 +24V CN17-2 /FULRY Fusing relay on (Factory use) G031/G032 2-46...
Page 91: Printer Control Board
PRINTER CONTROL BOARD 2.10 PRINTER CONTROL BOARD 2.10.1 PCB LAYOUT G031 Option Bus (CN3) Option Bus (CN2) Flash Flash E E P R O M R O M R O M D I M M S L O T C P U...
Page 92: Devices
8 MB (16 Mbit DRAM x 4) EEPROM 2 KB (NVRAM) Centronics I/F Bi-directional parallel interface (standardized by IEEE1284) OPTION I/F G031: 2 slots RS232C Ethernet (100 Base-Tx, 10 Base-T) Hard disk drive IC Card adapter for up-dating controller firmware (CN3) G032: 1 slot...
Page 93: Installation
INSTALLATION...
Page 95: Installation Requirements
120 V, 60 Hz: More than 6.0 A (for North America) 220 V ~ 240 V, 50/60 Hz: More than 5.0 A (for Europe) 2. Permissible voltage fluctuation : 5% 3. Do not set anything on the power cord. G031/G032...
Page 96: Printer Installation
See the “Hard Disk Installation” sheet that comes with the option. 3.6 MEMORY UNIT INSTALLATION See the “Installing the Memory Unit” section in the Operating Instructions. 3.7 NETWORK INTERFACE BOARD INSTALLATION See the “Installing the Network Interface Board” section in the Operating Instructions. G031/G032...
Page 97 BOARD (AND RELATED OPTIONS: HDD, RAM SIMM, NIC) AND OPTIONAL HDD & PERIPHERALS G031/032-17 G031I501.WMF G031/032-22, -27, -29 G031I502.WMF Please refer to the key names and locations in the above illustration. 1. Plug in the power cord and turn on the main switch. Then “Ready” is displayed.
Page 98: Checking The Connections
F o n t N u m b e r Font Height 1 2 . 0 0 Font Pitch 1 0 . 0 0 S y m b o l S e t R o m a n 8 G031I500.WMF G031/G032...
Page 99 • For the software version of the engine control board, check “Engine Version” [B]. If there are any problems with the above check items, reinstall the printer controller and other options. Then set up the machine again and test it again. G031/G032...
Page 100: Connection Between Main Printer Control Board
NIB setup menu in the Host Interface menu (user program mode). If this menu is not displayed, the NIB is not connected properly. If any problem occurs during the above steps, reinstall the NIB and other options, then set the machine up again and test it again. G031/G032...
Page 101: Service Tables And Procedures
SERVICE TABLES AND PROCEDURES...
Page 103: Service Procedures And Tables
• Service Tool Menu: This is also covered in the Appendix. Operation panel Please refer to the illustration for the key names and their locations. G031M501.WMF G031M506.WMF G031/G032...
Page 104: Service Program Mode
2) Wait for a few seconds and then turn it on again. The user mode menu will appear. 2. “Form Feed” key and “Escape” key 1) Press the “Form Feed” key and “Escape” key together. 2) Wait a few seconds. The machine exits service mode automatically. 3) The printer starts to initialize. G031/G032...
Page 105: Service Program Mode Menu Tree
SERVICE PROGRAM MODE 4.2.2 SERVICE PROGRAM MODE MENU TREE The following diagram shows the service mode menu tree. G031M500.WMF G031/G032...
Page 106 NOTE: The setting appearing initially on the display is the current setting. 2. Select the required setting using the “Up/Down arrow” keys, then press the “Enter” key. NOTE: The previous value remains if the “Enter” key is not pressed. 3. Exit service mode. G031/G032...
Page 107: Service Mode Menu Table
Adjustments” for details. Sub Scan Normal Feed Leading Edge Adjusts the printing leading edge –0.3 ~ +0.3 mm Registration registration using the frame on the for G031 (Normal Print Log. –0.2 ~ +0.2 mm Printing) for G032 Use the “...
Page 108 Engine ROM Version Displays the Engine Control Board Version Display (ECB) ROM version. Controller F/W Version Displays the main printer control Display (Main board firmware version. Control Board) Network NIB Firmware Displays the NIB firmware version. version Display G031/G032...
Page 109 Development an electrical component on for a Bias ON long time. 1,200 dpi Charger: Charge roller Development Bias ON Registration Clutch ON (G031) By-pass Solenoid ON Feed Clutch (G031) Feed Solenoid ON (G032) 2nd Feed Clutch ON 2nd Feed...
Page 110 4. The product number of the controller board is used as the printer ID and stored in the factory. See the “Printer ID” section how to store the serial number. Diag. Diagnostic Error Clear the diagnostic error log. Clear Log Clear To clear the log, press the “Enter” key. G031/G032...
Page 111: Print Log
: 0 X 1010 2. OPTION NIC : 0 X 1301 3. ASIC P1284 : 0 X 0902 4. OPTION NIC : 0 X 1301 5. ASIC P1284 : 0 X 0902 6. ASIC P1284 : 0 X 0902 G031M508.WMF G031/G032...
Page 112 Refer to the “IC Card Boot Service Menu” section for how to reset the NVRAM. [B]: Engine ROM version The engine control board firmware version. This firmware can only be updated by replacing the EPROM on the engine control board. G031/G032 4-10...
Page 113 Counter” on the configuration page. The paper feed roller counter, transfer roller counter and fuser counter are automatically reset when new fusing unit in the Maintenance KIT is installed (G031). When the PM clear is performed by user menu, these counters are reset. 4-11...
Page 114 This frame is drawn a sixth of an inch (4.2 mm) from the paper edges. The registration is adjusted in the factory. If the registration has drifted, adjust the sub scan or the main scan (see “Replacement and Adjustment - Print Registration Adjustment”). G031/G032 4-12...
Page 115: Printer Id
Serial Number: 80900082 G031M511.WMF An 8-digit numeral appears. 2. Press the “Online” key, “Form feed”, “Menu” key, and Serial Number: “Up arrow” key at the same time 8 0900082 A cursor will appear under the 1st digit. G031M512.WMF 4-13 G031/G032...
Page 116 7. Use the “arrow” keys to select “PRINT LOG”. Service Mode: 3. PRINT LOG G031M515.WMF 8. Print the log sheet and check that the printer ID at the top of the page (serial number and model name) is correct. G031/G032 4-14...
Page 117: Ic Card Boot Service Mode
3. Plug the IC card into the IC card adapter, then connect it to the option bus connector. NOTE: The G031 has two option bus connectors. The left connector can only be used for this function. 4. Turn the printer on. The IC card boot service menu will be displayed.
Page 118: Ic Card Boot Service Mode Tree
1. Scroll through the 1st level programs using the “Up/Down arrow” keys. Then press the “Enter” key. 2. Scroll through the items in the next lowest level using the “Up/Down arrow” keys. 3. To go back to a higher level, press the “Escape” key. G031/G032 4-16...
Page 119: Service Menu Table
Note: This resets all the settings stored in the NVRAM to their default settings. This procedure is required only after replacing the NVRAM chip. TEST Print Print controller generated test pattern (Factory use) See the appendix for details. 4-17 G031/G032...
Page 120: Eeprom And Nvram Reset Procedures
Error logging NOTE: When the EEPROM or NVRAM is cleared, all the data in the memory shown above is cleared. Memory clear procedures • Service Program Mode - EEPROM Clear • IC Card Boot Service Mode – NVRAM Clear G031/G032 4-18...
Page 121: Downloading New Controller Software
If power is interrupted during downloading, the printer can boot again with the previous firmware except if it happens while downloading the boot area. In this case, the printer must be booted with an IC card. NOTE: For additional details see Appendix, “Downloading Controller Firmware for G031/G032 4-19 G031/G032...
Page 122: Downloading New Firmware From An Ic Card
DOWNLOADING NEW CONTROLLER SOFTWARE 4.5.2 DOWNLOADING NEW FIRMWARE FROM AN IC CARD Preparation • IC card containing new firmware • IC card adapter Connecting the IC Card G031 Option Bus (CN3) Option Bus (CN2) D I P S W Flash Flash...
Page 123 3. Attach the IC card to the IC card adapter, then plug the adapter into the option bus connector. NOTE: G031 has two option bus connectors. Only the connector on the left side can be used for downloading. 4. Turn on the printer. The printer will boot from the firmware in the IC card.
Page 124 1) Press the “Form Feed” key and the “Escape” key together. Then initialization will start. 2) Turn the printer off and on. 3) If an error occurs, after initializing the printer for the first time after a firmware update, it may be necessary to perform the update again. G031/G032 4-22...
Page 125: User Menu
L I S T P R I N T C O N F I G . P A G E P C L F O N T L I S T P S F O N T L I S T G031M507.WMF 4-23 G031/G032...
Page 126: Ecb Test Pattern
E C B E n g i n e R O M E E P R O M G031M527.WMF Procedure 1. Turn the printer on. 2. Short the TB1 pins. 3. The test pattern is automatically printed out. G031/G032 4-24...
Page 127: Diagnostic Test Modes
If the error is for an optional device (if one of the following SCs is displayed), switch off the power, disconnect the defective optional device, then turn the power back on. The machine will restart. SC Code Optional Device SC2600 SC2700 SC2800 DIMM SC2900 RS232C SC3100 SIMM SC3200 Unknown Option SC3201 Unknown Option 4-25 G031/G032...
Page 128: Detailed Diagnostic Mode
If the Centronics or RS232C loopback connector is not plugged in, an error will occur for the device with the missing connector Print Log Output The print log is printed automatically after the detailed diagnostic test has finished. G031/G032 4-26...
Page 129: Diagnostic Test Details
The option tests are executed only if these devices are detected. The parallel and the RS232C loopback tests require the loopback connectors to be connected. If these connectors are not attached, the tests for these components will result in an error. 4-27 G031/G032...
Page 130 / F A U L T / S E L E C I N G031M504.WMF Loopback Connector for the RS232C Interface T X D R T S D T R R X D C T S D S R G031M505.WMF G031/G032 4-28...
Page 131: Firmware History
FIRMWARE HISTORY Rev. 01/2003 4.9 FIRMWARE HISTORY 4.9.1 G031 CONTROLLER FIRMWARE MODIFICATION HISTORY G031 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION Initial Production G0315915 E 1st Mass 1.05 Production • HDD and Serial Port functions have been...
Page 132 Windows PS file Unix file. • G0325915 P Prod. 2.08 Printing stalls when using PS driver Discontinued under Windows XP. • G0325915 Q Prod. 2.09 Printer option now supports Mac OS X Discontinued version 10.1 (Native) and newer. G031/G032 4-30...
Page 133: Preventive Maintenance
PREVENTIVE MAINTENANCE...
Page 135: Preventive Maintenance Schedule
The maintenance kit contains the following items. • Fusing Unit • Transfer Roller • Paper Feed Roller (3 pcs for the G031, 1 pc for the G032) • Friction Pad When the maintenance counter reaches 80 for the G031 and 60 for the G032, "REPLACE MAINTENANCE KIT"...
Page 137: Replacement And Adjustment
REPLACEMENT AND ADJUSTMENT...
Page 139: Covers
6.1 COVERS 6.1.1 EXTERIOR COVER REMOVAL G031R507.WMF G031 1. Remove the fusing unit. (Refer to Fusing Unit Replacement, section 6.2.1.) 2. Remove the top cover [A] (two screws). 3. Pull the hook [B] towards the outside, then remove the left cover [C] (1 screw).
Page 140: Front Cover Removal
5. Remove the cable cover [C] (1 screw). 6. Release the shutter arm [D] as shown. 7. Remove the clamp (G031, 1 screw) or cable cover [E] (G032, 1 screw). 8. Remove the two screws [F] securing the cables. 9. Remove the front cover [G].
Page 141: Control Board Cover Removal
6.1.3 CONTROL BOARD COVER REMOVAL G031R510.WMF 1. Remove the top, left and right covers. (Refer to Exterior Cover Removal, section 6.1.1.) 2. Remove the shielding plate [A] (5 screws, G031 only). 3. Remove the control board cover [B] (11 screws). G031/G032...
Page 142: Fusing Unit
2. Open the front cover. 3. Release the levers [A] as shown. 4. Replace the fusing unit [B]. 5. Perform the PM clear (except after installing the fusing unit in the G031 maintenance kit). • User Menu – Maintenance – PM Clear...
Page 143: Hot Roller And Fusing Lamp Replacement
2. Remove the fusing cover [A] (2 screws). 3. Remove the fusing exit sensor [B]. 4. Remove the bracket [C] and the spring [D]. (G031 has two brackets [C] and two springs [D], G032 has one of each.) 5. Separate the fusing unit (2 screws [E]).
Page 144 NOTE: 1) Be careful not to scratch the hot roller with the stripper pawls. 2) Do not touch the hot roller with your bare hands. 3) When re-installing the hot roller, make sure that the bushing [F] is in the correct place, as shown. G031/G032...
Page 145: Pressure Roller Replacement
1. Perform steps 1 to 5 of Hot Roller and Fusing Lamp Replacement, section 6.2.2. 2. G031 only: Remove the exit guide plate [A] (2 screws). 3. G031 only: Remove the entrance guide [B] (3 screws). 4. Remove the pressure arms [C].
Page 146: Fusing Thermofuse Replacement
6.2.4 FUSING THERMOFUSE REPLACEMENT G031R544.WMF 1. Remove the hot roller. (Refer to Hot Roller and Fusing Lamp Replacement, section 6.2.2.) 2. Remove the two screw covers [A] (230 V machine only, 1 screw each). 3. Replace the fusing thermofuse [B] (2 screws). G031/G032...
Page 147: Fusing Drawer Connector Replacement
4. Remove the two cable covers [C] (1 screw each). NOTE: When re-installing the cable covers, secure the cable under the cover correctly. 5. Remove the three screws [D] securing the cable. 6. Replace the fusing drawer connector [E] (1 screw). G031/G032...
Page 148: Transfer Roller
TRANSFER ROLLER 6.3 TRANSFER ROLLER 6.3.1 TRANSFER ROLLER REPLACEMENT G031R513.WMF 1. Open the front cover. 2. Open the transfer roller cover [A]. 3. Replace the transfer roller [B]. NOTE: Do not touch the transfer roller with your bare hands. G031/G032 6-10...
Page 149: Paper Feed
12 March 1999 PAPER FEED 6.4 PAPER FEED 6.4.1 BY-PASS TRAY REMOVAL - G031 - G032 - G031R514.WMF G031R541.WMF G031 1. Open the by-pass tray [A]. 2. While lifting the hooks [B], lower the by-pass tray and remove it as shown [C].
Page 150: By-Pass Feed Roller Replacement
PAPER FEED 6.4.2 BY-PASS FEED ROLLER REPLACEMENT G031 G031R515.WMF 1. Remove the right cover. (Refer to Exterior Cover Removal, section 6.1.1.) 2. While releasing the hook [A], remove the by-pass feed roller cover [B], as shown. NOTE: Remove the by-pass feed roller cover carefully (it is attached tightly).
Page 151 [B] on the by-pass feed clutch [C] touches the underside of the bracket [D]. 5. While unhooking the hook [E] from the by-pass feed clutch, remove the by-pass feed roller [F], as shown. NOTE: Do not touch the by-pass feed roller with your bare hands. 6-13 G031/G032...
Page 152 3. While unhooking the hooks [E], remove the by-pass feed roller [F], as shown. NOTE: 1) Do not touch the by-pass feed roller with your bare hands. 2) While pushing the gear [G] towards the inside of the mahcine, re- install the by-pass feed roller. G031/G032 6-14...
Page 153: Paper Feed Roller Replacement
12 March 1999 PAPER FEED 6.4.3 PAPER FEED ROLLER REPLACEMENT G031 G031R520.WMF 1. Draw out the paper cassette. 2. While releasing the spring mechanism [A], remove the paper feed roller [B]. NOTE: Do not touch the paper feed roller with your bare hands.
Page 154 PAPER FEED G032 G031R521.WMF 1. Draw out the paper cassette. 2. While releasing the hook [A], remove the paper feed roller [B]. NOTE: Do not touch the paper feed roller with your bare hands. G031/G032 6-16...
Page 155: Relay Roller Replacement (Stinger - P4 Only)
1. Remove the by-pass feed roller cover. (Refer to By-pass Feed Roller Replacement, section 6.4.2.) 2. While unhooking the hooks [A], pull the shaft [B] out to the right. 3. Replace the relay rollers [C]. NOTE: Do not touch the relay rollers with your bare hands. 6-17 G031/G032...
Page 156: Friction Pad Replacement
2. Remove the paper from the paper tray. Turn the tray upside down and place it on a flat surface. 3. While unhooking the hooks [A], remove the friction pad [B], as shown. NOTE: Be sure to unhook the hooks. Otherwise, they may be broken. G031/G032 6-18...
Page 157: Tray Paper Feed Clutch Replacement
2. Remove the paper feed roller. (Refer to Paper Feed Roller Replacement, section 6.4.3.) 3. While unhooking the hook [A], pull the shaft [B] out to the left. 4. Replace the tray paper feed clutch [C] (1 connector on the engine control board). 6-19 G031/G032...
Page 158: Laser Unit
Turn off the main switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes. 6.5.1 CAUTION DECAL LOCATIONS Caution decals are located in the laser section as shown below. - G031 - G031R501.WMF - G032 - G031R500.WMF G031/G032...
Page 159 Laser Unit 1. Remove the top cover. (Refer to Exterior Cover Removal, section 6.1.1.) 2. Remove the laser unit [A] (4 screws and 3 connectors [G031] or 2 connector [G032]). NOTE: 1) Disconnect connectors [B] and [C] first. When connector [D] is accessible, disconnect it.
Page 160: Ld Unit/Laser Synchronization Detector Replacement
LASER UNIT 6.5.3 LD UNIT/LASER SYNCHRONIZATION DETECTOR REPLACEMENT G031 G031R503.WMF LD Unit 1. Remove the laser unit. (Refer to Laser Unit/Shield Glass Replacement, section 6.5.1.) 2. Replace the LD unit [A] by removing the screws [B] as shown. NOTE: Do not touch VR101 [C] and VR102 [D], because they are adjusted in the factory before shipment.
Page 161: Polygonal Mirror Motor Replacement
12 March 1999 LASER UNIT 6.5.4 POLYGONAL MIRROR MOTOR REPLACEMENT G031 G031R504.WMF NOTE: When doing the following steps, take care not to damage the mirror surface with the tip of the screwdriver. 1. Remove the top cover. (Refer to Exterior Cover Removal, section 6.1.1.) 2.
Page 162: Ld Unit/Polygonal Mirror Motor Replacement
1. Remove the top cover. (Refer to Exterior Cover Removal, section 6.1.1.) 2. Remove the laser unit top cover [A] (2 screws and 1 grounding plate [B]). 3. Replace the polygonal mirror motor [D] (4 screws and 1 connector). G031/G032 6-24...
Page 163: Others
6.6.1 TONER NEAR-END SENSOR REPLACEMENT G031R535.WMF 1. Remove the control board cover. (Refer to Control Board Cover Removal, section 6.1.3.) 2. Remove the toner cassette. 3. Replace the toner near-end sensor [A], as shown (1 connector on the engine control board). 6-25 G031/G032...
Page 164: Main Motor/Gear Box Removal
2. Remove the by-pass feed clutch [B]. (Refer to By-pass Feed Roller Replacement, section 6.4.2.) 3. Remove the main motor. (Refer to Main Motor Removal.) 4. Remove the registration clutch [C] (1 snap ring). 5. Remove the gear box [D] (5 screws). G031/G032 6-26...
Page 165: Engine Control Board Replacement
1. Remove the control board cover. (Refer to Control Board Cover Removal, section 6.1.3.) 2. Replace the engine control board [A]. (4 screws and all connectors). 3. Take the EEPROM (IC5) [B] off the old board, and put it on the new board. 6-27 G031/G032...
Page 166: Printer Control Board Replacement
1. Remove the control board cover. (Refer to Control Board Cover Removal, section 6.1.3.) 2. Replace the printer control board [A] (6 screws and all connectors). 3. Take the NVRAM off the old board, and put it in the socket on the new board. G031/G032 6-28...
Page 167: High Voltage Supply Board
1. Remove the control board cover. (Refer to Control Board Cover Removal, section 6.1.3.) 2. Remove the LD unit. (Refer to LD Unit/Laser Synchronization Detector Replacement section 6.5.3 for G031, or LD Unit/Polygonal Mirror Motor Replacement section 6.5.5. for G032.) 3. Remove the engine control board. (Refer to Engine Control Board Replacement, section 6.6.3.)
Page 168: Power Supply Unit Replacement
6.1.3.) 2. Remove the LD unit. (Refer to LD Unit/Laser Synchronization Detector Replacement section 6.5.3 for G031, or LD Unit/Polygonal Mirror Motor Replacement section 6.5.5. for G032.) 3. Remove the printer control board. (Refer to Printer Control Board Replacement, section 6.6.4.)
Page 169: Print Registration Adjustment
Main Scan in the service program mode. This will adjust the laser start timing, and is individually adjusted for each paper feed tray. If the setting is moved in the plus direction, the right margin will be bigger. 6-31 G031/G032...
Page 171: Troubleshooting
TROUBLESHOOTING...
Page 173: Operator Errors
The paper size setting of the tray differs from the actual paper size in the tray. Reset Method: • Pull out the paper tray and check the paper size setting then put the tray back. • Press “Enter” and load the correct size of paper into the tray. G031/G032...
Page 174 Replace Maintenance Kit Definition: It is time to replace the parts in the maintenance kit. Reset Method: • G031: Replace the maintenance kit. • G032: Replace the maintenance kit, then do the User Tools – Maintenance – PM Clear procedure. G031/G032...
Page 175 (Auto Continue does not work if this error exists.) If that happens, you cannot continue printing if there is a paper size error. You should take one of the following actions to clear this error. • Press “Enter”. • Open and close any of the trays. G031/G032...
Page 176 Network Interface Board Error Message: Error SC_2700 Definition: Error in the optional network interface board. Reset Method: Remove the network interface board from the printer and turn the printer’s main switch off and on. Then try to do the print job again. G031/G032...
Page 177 Left Optional Board Error Message: Error SC_3201 Definition: Error in the left optional board. Reset Method: Remove the left optional board from the printer and turn the printer’s main switch off and on. Then try to do the print job again. G031/G032...
Page 178: Printer Engine Sc Codes
10 seconds continuously during operation. Possible Causes: • Polygon mirror motor defective • Poor connection between the polygon mirror motor driver and the engine control board • Engine control board defective G031/G032...
Page 179 • Poor fusing unit connection • Engine control board defective SC543: Fusing High Temperature Error Definition: A fusing temperature of over 230°C is detected for 1 second by the fusing thermistor. Possible Causes • Fusing thermistor defective • Power supply unit defective G031/G032...
Page 180 The fusing unit for a different area is installed in the machine. Possible causes • Wrong fusing unit SC999: Communication Error Definition: Communication error between engine and control board. Possible causes • Command error or parity error between engine and control board. G031/G032...
Page 181: Diagnostic Error Codes
• Optional device in the Option0 Unidentified or unsupported SC3200 device in the right option slot right option slot defective • Optional device in the Option1 Unidentified or unsupported (Only G031) SC3201 device in the left option slot left option slot defective G031/G032...
Page 182 Interrupt 5 exception The above “∗∗” means the device code for which the diagnostic program error occurred during its device test. For details of the device codes, refer to the ‘Device Code” column of the “Power-up Diagnostic Mode” table. G031/G032 7-10...
Page 183 Instruction cache write back error 0504 Instruction cache clear error 0511 Data cache size error 0512 Data cache hit error 0513 Data cache write back error 0514 Data cache write back clear error 0515 Data cache clear error 7-11 G031/G032...
Page 184 STROBE signal goes high Interrupt start error of the VR4300 when 0908 the STROBE signal goes high Interrupt masking error when the STROBE 0909 signal goes high Interrupt request error of the ASIC when 090A the INIT signal goes low G031/G032 7-12...
Page 185 0921 signal goes high 0922 Loopback data error Interrupt request error of the ASIC in DMA 0923 mode Interrupt request error of the VR4300 in 0924 DMA mode Interrupt start error of the VR4300 in DMA 0925 mode 7-13 G031/G032...
Page 186 PVDMA mode timeout 0D06 PVDMA read bus error 0D07 PVDMA write bus error 0D08 FILL operation error 0D09 MOVE operation error 0D0A HALF operation error 0D0B QUART operation error 0D0C K3 operation error 0D0D K3 double operation error G031/G032 7-14...
Page 187 Command reception interrupt request error 1304 of the VR4300 in NIB mode Command reception interrupt start error in 1305 NIB mode Command reception interrupt masking 1306 error in NIB mode 1307 NIB command error 1308 NIB buffer full error 7-15 G031/G032...
Page 188 1501 Unidentified or unsupported device in the Optional device in the right option slot right option slot defective 1502 Unidentified or unsupported device in the Optional device in the left option slot (only G031) left option slot defective G031/G032 7-16...
Page 189: Electrical Component Defects
220 ~ 240 V Power Supply Board 5 A/125 V 3.15 A/250 V No response. 15 A/250 V 6.3 A/250 V After turning on the main switch, SC542 is displayed. 5 A/125 V 5 A/250 V No response. 7-17 G031/G032...
Page 191: Envelope Feeder G913
ENVELOPE FEEDER G913...
Page 193: Overall Information
G032: 360 mm x 421 mm x 119 mm (14.2" x 16.6" x 4.7") Weight: G031: 2.5 kg G032: 1.6 kg 1.2 MECHANICAL COMPONENT LAYOUT This optional unit is a tray that slides into the optional paper feed unit, replacing the paper tray.
Page 194: Detailed Section Descriptions
PAPER LIFT 2. DETAILED SECTION DESCRIPTIONS 2.1 PAPER LIFT Refer to the paper feed section in the service manual for the main body. G031/G032...
Page 195: Installation
PAPER LIFT 3. INSTALLATION See the “Installing the Envelope Feeder” in section 2 (Installing Options) of the operating instructions. G031/G032...
Page 196: Replacement And Adjustment
4. REPLACEMENT AND ADJUSTMENT 4.1 FRICTION PAD REPLACEMENT G913R500.WMF 1. Draw out the envelope feeder. 2. While unhooking hooks [A], replace the friction pad [B], as shown. NOTE: Make sure to unhook the hooks, or the hooks may be damaged. G031/G032...
Page 197 PAPER FEED UNIT G914/G915...
Page 199: Overall Machine Information
SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS 1.1.1 G031 (PAPER FEED UNIT G915-17, G914-17) Copy Paper Size: Maximum A3/11" x 17" Minimum A5 (lengthwise) Copy Paper Weight: 60 ~ 90 g/m , 16 ~ 24 lb Dimensions (W x D x H): 450 mm x 528.8 mm x 125 mm...
Page 200: Mechanical Component Layout
MECHANICAL COMPONENT LAYOUT 1.2 MECHANICAL COMPONENT LAYOUT G031 G914V500.WMF G032 G914V501.WMF 1. Paper Feed Roller 2. Friction Pad G031/G032...
Page 201: Electrical Component Layout
ELECTRICAL COMPONENT LAYOUT 1.3 ELECTRICAL COMPONENT LAYOUT G031 G914V502.WMF G032 G914V503.WMF 1. Paper Feed Unit Board 6. PFU Paper End Sensor 2. Paper Feed Motor 7. PFU Paper Near-end Sensor 3. PFU Paper Feed Clutch 8. PFU Paper Near-end Sensor 4.
Page 202: Electrical Component Description
Detects whether the main cassette (G032 only) is installed Switch PFU Paper Size Switch Detects the paper size selected by the dial Clutch PFU Paper Feed Clutch Starts paper feed PFU Paper Feed Unit Board Interfaces the sensor signals with PCB1 the printer G031/G032...
Page 203: Detailed Section Descriptions
PAPER SIZE DETECTION 2. DETAILED SECTION DESCRIPTIONS 2.1 PAPER SIZE DETECTION Refer to Paper Size Detection for G031 (section 2 of the manual for the main body). 2.2 PAPER LIFT Refer to Paper Lift, (section 2 of the manual for the main body).
Page 204: Paper Feed
PAPER FEED 2.5 PAPER FEED G031 G032 G914D502.WMF G914D503.WMF The paper feed motor drives the PFU paper feed clutch gear [A] and the drive roller gear [B] through several gears. The paper feed unit uses a feed roller and friction pad mechanism. The friction pad only allows the top sheet to be fed.
Page 205 PAPER FEED G031 G032 G914D504.WMF G914D505.WMF The PFU paper feed clutch turns on at the same time as the paper feed motor starts. The paper actuates the PFU paper feed sensor [A], and the drive roller feeds the paper to the registration rollers.
Page 206: Installation
PAPER FEED 3. INSTALLATION See the “Paper Feed Unit Installation” sheet that comes with the Operating Instructions. G031/G032...
Page 207 PAPER FEED UNIT (OPTION FOR G031) 4. REPLACEMENT AND ADJUSTMENT 4.1 PAPER FEED UNIT (OPTION FOR G031) 4.1.1 PAPER FEED ASSEMBLY REMOVAL G914R500.WMF 1. Remove the top cover [A] (7 screws). 2. Remove the paper feed assembly [B] (3 screws and 5 connectors).
Page 208: Drive Roller Replacement
PAPER FEED UNIT (OPTION FOR G031) 4.1.2 DRIVE ROLLER REPLACEMENT G914R501.WMF 1. Remove the paper feed assembly. (Refer to Paper Feed Assembly Removal.) 2. Replace the drive roller [A] (2 snap rings). Do not touch the drive roller with your bare hands.
Page 209: Paper Feed Motor Replacement
PAPER FEED UNIT (OPTION FOR G031) 4.1.3 PAPER FEED MOTOR REPLACEMENT G914R502.WMF 1. Remove the paper feed assembly. (Refer to Paper Feed Assembly Removal.) 2. Replace the paper feed motor [A] (2 screws). 9-11 G031/G032...
Page 210: Paper Feed Clutch Removal
PAPER FEED UNIT (OPTION FOR G031) 4.1.4 PAPER FEED CLUTCH REMOVAL G914R503.WMF 1. Remove the paper feed assembly. (Refer to Paper Feed Assembly Removal.) 2. Remove the paper feed roller. (Refer to Paper Feed Roller Replacement in the service manual for the main body.) 3.
Page 211: Paper Feed Unit Board/Paper Size Switch Replacement
PAPER FEED UNIT (OPTION FOR G031) 4.1.5 PAPER FEED UNIT BOARD/PAPER SIZE SWITCH REPLACEMENT G914R504.WMF Paper Feed Unit Board 1. Remove the top cover. (Refer to Paper Feed Assembly Removal.) 2. Replace the paper feed unit board [A] (1 screw and 8 connectors).
Page 212: Paper Feed Roller/Paper Feed Clutch Replacement
2. Remove the snap ring [A]. 3. Release the lever [B] as shown. 4. Lower the shaft [C], then remove the paper feed clutch [D]. 5. Replace the paper feed roller [E]. Do not touch the paper feed roller with your bare hands. G031/G032 9-14...
Page 213: Paper Drive Roller Replacement
2. Remove the snap ring [A]. 3. While releasing the lever [B], remove the paper drive roller assembly [C]. 4. Replace the paper drive roller (bushing [D], gear [E], and lever [B]). Do not touch the paper drive roller with your bare hands. 9-15 G031/G032...
Page 214: Drive Roller Idler/Friction Pad Replacement
3. Remove the two springs [B] and two bushings [C]. 4. Replace the relay roller [D]. Friction Pad 1. Draw out the paper cassette. 2. Replace the friction pad [E] (2 hooks and 1 spring). Be sure to unhook the hooks. Otherwise, the hooks may be broken. G031/G032 9-16...
Page 215: Paper Feed Motor/Paper Feed Unit Board Replacement
6. Replace the paper feed motor (2 screws) [D]. Paper Feed Unit Board 1. Remove the paper feed motor assembly [C]. (Refer to Paper Feed Motor Replacement.) 2. Replace the paper feed unit board [E] (2 screws and all connectors). 9-17 G031/G032...
Page 217 NETWORK INTERFACE BOARD G919 TYPE 2000...
Page 219: Overall Machine Information
• MAP (Management Access Protocol) Utility Software • IPX peer-to-peer printing • IP peer-to-peer printing • BOOTP (16-bit and 32-bit) • NetWare setup utility • Built-in web server Other • Built-in Telnet server • Firmware update over an IPX or IP network 10-1 G031/G032...
Page 220: Installation Procedure
Keep the status sheet with the machine, because it has the following information. • Unit serial number • Firmware version • Network (MAC) address • Network/Protocol information G031/G032 10-2...
Page 221: Programming Network/Protocol Parameters
(Default = Auto-Sense) Disable Bindery Optional (Default = No) (Uncheck the box) NOTE: The preferred NDS context must be typed in without a starting dot ( . ). • OU=Development.O=Corp [OK] • .OU=Development.O=Corp [NG] • Development.Corp [OK] • .Development.Corp [NG] 10-3 G031/G032...
Page 222: Tcp/Ip Network
NIB is reset. The assigned IP address may not be the same every time. LPD Parameters Enable LPD Enables or disables the LPD Banner banner (Default = No) Available PDLs Available printer languages are for NIC Port automatically selected. G031/G032 10-4...
Page 223: Ethertalk (Appletalk) Network
The Apple Printer Utility can change the printer name only. 2) Even if the printer name and zone name are changed with a utility, the changed names will be reset to the defaults at the next power-on, due to NIB-to-Controller interface limitations. 10-5 G031/G032...
Page 224: Setup For Various Network Types
• Name or address of the server providing lpd: IP Address of the NIB • Name of the printer or print queue on that server: PORT1 (uppercase) After installing a printer connected to the LPR port, share the printer for other workgroup members. G031/G032 10-6...
Page 225: Novell Netware Network
2.3.3 TCP/IP NETWORK LPR/LPD Printing The NIB supports standard lpd. If a Windows or UNIX workstation has an lpr spooler, it can send print jobs to the NIB directly. FTP Printing This printer does not support FTP printing. 10-7 G031/G032...
Page 226: Service Tables And Procedures
3. The green LED flashes 3 times, then the amber and green LEDs light alternately (once per second). 4. Turn off the machine and remove the network interface board. 5. Reset the jumper setting to the default, and reassemble the machine. 6. Turn on the machine. G031/G032 10-8...
Page 227: Flash Rom Update
Not possible NetWare 2.x server Use FlashUP NetWare 3.x server Use FlashUP NetWare 4.x server Bindery Enabled Use FlashUP Bindery Disabled Not possible TCP/IP Network U s e F T P D L NetBEUI Network Not possible G919M501.WMF 10-9 G031/G032...
Page 228: Flashup Utility (For Novell Ipx Networks)
5. In the “Destination Location” dialog box, choose a folder (directory) to install the software, then click “Next >”. 6. Confirm the program folder (group) name, then click “Next >”. 7. After the software has been installed, click “Finish” in the “Setup Complete” dialog box. G031/G032 10-10...
Page 229 5. If you do not see the desired unit in the list, click “Show All” to display all network interface cards that are currently logged in to the server. If you still cannot see the unit, click “Cancel”, restart the machine (printer), and try again. 10-11 G031/G032...
Page 230 Even if the firmware download has failed, a firmware download is still possible. The NIB while in a “down” status appears as DWN_xxx_xxxxxx in the dialog box in step 4 above. Download the firmware again to the NIB in the “down” status using the FlashUp utility. G031/G032 10-12...
Page 231: Ftpdl Utility (For Tcp/Ip Networks)
4. In the “Destination Location” dialog box, choose a folder (directory) to install the software, then click “Next >”. 5. Confirm the program folder (group) name, then click “Next >”. 6. After the software has been installed, click “Finish” in the “Setup Complete” dialog box. 10-13 G031/G032...
Page 232 1. Start the FTPDL utility. 2. Choose [FIle] - [Download]. 3. Choose a new firmware file and click “OK”. 4. Enter the IP address of the network interface card in which you wish to update the firmware, then click “OK”. G031/G032 10-14...
Page 233 CAUTION: Do not turn off the machine until after it prints a status sheet. Recovery from Failed Download If the firmware download using FTPDL has failed, use the FlashUP utility to recover the NIB. This is because the NIB may no longer contain the IP parameters after a failed download. 10-15 G031/G032...
Page 234: Troubleshooting
Blinks rapidly Error • Check the cable connection and the NetWare server status. • The NIB has reset its NVRAM to the Blink alternately NVRAM reset factory defaults. (Refer to section 3.1 for how to reset the NVRAM.) G031/G032 10-16...
Page 235: Nib Firmware Modification History
4. Ghost server problem: Multicast hash table used for Ethernet driver. This allows only specific AppleTalk multicasts instead of all multicasts, preventing the NIC from crashing during multicast storms. Other changes: Software modified to support WINS. 10-17 G031/G032...
Page 236 Note 1: IPP printing Only G049 and G054 support this feature. (not supported by G031/G032) Windows 2000 or Windows 98/ME allow IPP printing. IPP client program must be installed in Windows 98/ME before using the feature. The IPP client program, WPNPINS.exe, is on the Microsoft Web site.
Page 237 G049/G054 SERVICE MANUAL...
Page 239: Overall Machine Information
1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS NOTE: The new information for the G049/G054 is underlined in bold face. Printing Speed: G049: (600 dpi) Maximum 21 pages per minute (A4/LT LEF) G054: Maximum 16 pages per minute (A4/LT SEF) Printer Language: PCL6/PCL5e Compatible with Laser Jet 4000/5000 driver and printer.
Page 240: Machine Configuration
Utility Software 1. Printer Drivers 2. PS PPD Files 3. Font manager 4. Aficio Manager 5. Operating Instructions (G049/G054 – 22, 27) 6. Port Navi 1.2 MACHINE CONFIGURATION Internal Options Item Machine Code Printer Feature Expander Type 185 32MB G688 - 10 Printer Feature Expander Type 185 64MB G688 - 11 G049/G054...
Page 241: Detailed Section Descriptions
The built-in tray for the G032 can only hold A4/letter size. However, the G054 tray can handle A4/letter or shorter. The paper feed speed for the G049/G054 is the same as that of the G031/G032. However, the feeding interval has been decreased in the G049/G054, allowing a higher PPM.
Page 242 G054 Option Bus (CN 2) Flash DIMM Slot ASIC EEPROM Control Panel Centronics I/F G049/G054 11-4...
Page 243: Devices
Rev. 01/2003 2.10.2 DEVICES Devices Description 133 MHz VR4310 ASIC: ROCKY Z Memory map control Reset signal DRAM control DMA control FCI control (edge smoothing, toner saving) Interrupt control Engine serial communication control Interval control Centronics I/F I/O port Code ROM Flash ROM (2 MB) 32 bit 16 MB (16 bit DRAM ×...
Page 244: G049/G054 Firmware History
Rev. 01/2003 3. G049/G054 FIRMWARE HISTORY ⇒ 3.1 G049 ENGINE FIRMWARE MODIFICATION HISTORY G049 ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION First Mass Production G0295172 1st mass 0.04 Production ⇒ 3.2 G054 ENGINE FIRMWARE MODIFICATION HISTORY G054 ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL...
Page 245: G049 Controller Firmware Modification History
Rev. 01/2003 3.3 G049 CONTROLLER FIRMWARE MODIFICATION HISTORY ⇒ G049 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • 1st Mass 1.11 Initial Production G0495910 A Production • Jan. 2001 1.29 G0495910 B When using PCL5e, the right side line of Production a table is not printed.
Page 246: G054 Controller Firmware Modification History
Rev. 01/2003 3.4 G054 CONTROLLER FIRMWARE MODIFICATION HISTORY ⇒ G054 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • 1st Mass 1.11 Initial Production G0545910 A Production • Nov.2000 1.29 When using PCL5e, the right side line of G0545910 B Production a table is not printed.
Page 247 Downloading Controller Firmware for G031/G032 NOTE: In the following section the G031/G032 printer is occasionally referred to as the “Stinger”. This reference will be seen in computer screen captures and in various documentation throughout this section. The Stinger P3 = G031 and the Stinger P4 = G032.
Page 249: Downloading Controller Firmware
G031X549.WMF • Using a flash card writer and SwapBox • Copying to an IC card plugged into a G031 or G032 printer via a parallel cable, using either the DOS copy /b command or the Stinger downloading utility. Then, the IC card is taken to the customer’s premises, and downloaded using a service mode.
Page 250: Pc, Via Parallel Port
DOS copy /b command or the Stinger downloading utility. DIMM Slot Printer AT THE DIMM CUSTOMER'S PREMISES G031X553.WMF Then, the IC card is taken to the customer’s premises, and downloaded using a service mode. The DIMM card is available as a service tool. G031/G032...
Page 251: Releasing New Controller Firmware
Use the byte-swapped file (*carddwn.rom - created by SSU byte swap) • To copy directly to the printer’s firmware flash ROM (from a PC through a parallel cable): Use the byte-swapped file (*carddwn.rom - created by SSU byte swap) G031/G032...
Page 252: Service Tools
SERVICE TOOLS 1.2 SERVICE TOOLS 1.2.1 OPERATION PANEL The locations of the keys on the operation panel are shown below. G031X504.WMF G031X506.WMF G031/G032...
Page 253: Service Tool Menus
3. Plug the IC card into the IC card adapter, then connect it to the option bus connector on the printer control board. NOTE: The G031 has two option bus connectors. The left connector can only be used for this function.
Page 254 2. Remove the IC card and IC card adapter. 3. Turn DIP SW 1 to off. 4. Turn on the printer again. 5. Then, the user menu will appear. NOTE: Don’t forget to return DIP SW1 to the off position. Otherwise the printer will not boot. G031/G032...
Page 255: Stinger Service Utility (Ssu)
Makes a byte-swapped file for downloading from PC to printer via a parallel cable. SSU will be provided as an SSU.ZIP file. The SSU.ZIP includes seven files, as follows: • download.hed • gzip.exe • Paiview.exe • Pindump.exe • stinger.exe • stinger.ico • Xpaipal.smp G031/G032...
Page 256: Using An Ic Card
1. Make a byte-swapped file of the firmware file on a PC. • Use the Byte Swap button in the Stinger Service Utility. 2. Copy this file from the PC to an IC card plugged into a G031 or G032 printer, via a parallel cable.
Page 257 NOTE: Any destination file name can be used. However, the recommended file name is XXXdwm.rom. Using a standard naming system such as this will prevent confusion later. 5. Click Enter then click Exit. In the source file directory, XXXdwn.rom is created as the byte-swapped file. G031/G032...
Page 258 2. Connect the IC card to the IC card adapter, then connect the adapter to the option bus connector on the printer control board. NOTE: G031 has two option bus connectors. The left side connector is used for the downloading.
Page 259 USING AN IC CARD Second, prepare the PC 6. Start the utility (click stinger.exe or the SSU icon). The downloading utility window is opened. G031X523.PCX 7. Click the Download button in the Stinger utility window. The download window is displayed. G031X524.PCX A-11 G031/G032...
Page 260 NOTE: There are two ways to go back to user mode from the service tool mode. 1) Press the “ / ” keys together. Then press the “Form Feed” key and the “Escape” key together. Then the initialization will start. 2) Turn the printer off and then on. G031/G032 A-12...
Page 261: Downloading From The Ic Card To The Printer
Rev. 04/2000 USING AN IC CARD 1.3.2 DOWNLOADING FROM THE IC CARD TO THE PRINTER This is explained in ‘Downloading New Controller Software’ in section 4 of the service manual. A-13 G031/G032...
Page 262: Using A Dimm
1. Make a byte-swapped file of the firmware file on a PC. • Use the Byte Swap button in the Stinger Service Utility. 2. Copy this file from the PC to a DIMM card plugged into a G031 or G032 printer, via a parallel cable.
Page 263 3. Connect the IC card to the IC card adapter, then connect the adapter to the option bus connector on the printer control board. NOTE: G031 has two option bus connectors. The left side connector is used for the downloading.
Page 264 7. Press the “Enter” key then the “Form Feed” key. Please Download Wating G031X519.WMF Second, prepare the PC 8. Start the utility (click stinger.exe or the SSU icon). The downloading utility window is opened. G031X523.PCX 9. Click the Download button in the Stinger utility window. G031/G032 A-16...
Page 265 USING A DIMM 10. The download window is displayed. G031X524.PCX 11. Click the “Reference” key and select the firmware file that you wish to download (eg. P3carddwn.rom). G031X525.PCX NOTE: Only a byte-swapped file can be used for the download. A-17 G031/G032...
Page 266 14. Print the log print and check the controller firmware version. 15. Turn the printer off and then on to return to the user mode. The DIMM card now contains new firmware. The following procedure explains how to install the new firmware into the printer’s flash memory. G031/G032 A-18...
Page 267: Downloading From The Dimm To The Printer
12. Return to user mode. NOTE: There are two ways to go back to user mode from the service mode. 1) Press the “Form Feed” key and the “Escape” key together. Then initialization will start. 2) Turn the printer off then on. A-19 G031/G032...
Page 268: Copying From A Pc Directly
• Use the Byte Swap button in the Stinger Service Utility. 2. Copy this file from the PC to the G031 or G032 printer, via a parallel cable. • The computer must be connected to the printer with a parallel cable.
Page 269 NOTE: Any destination file name can be used. However, the recommended file name is XXXdwn.rom. Using a standard naming system such as this will prevent confusion later. 4. Click Enter then click Exit. In the source file directory, XXXdwn.rom is created as the byte-swapped file. A-21 G031/G032...
Page 270: Downloading To The Flash Memory
NOTE: There are two ways to go back to user mode from the service tool mode. 1) Press the “ / ” keys together. Then press the “Form Feed” key and the “Escape” key together. Then initialization will start. 2) Turn the printer off and on. G031/G032 A-22...
Page 271 2. Download G031X533.WMF 4. Press the “Enter” key then press the “Form Feed” key. Please Download Waiting G031X519.WMF Second, prepare the PC 5. Start the utility (click stinger.exe or the SSU icon). The downloading utility window is opened. G031X523.PCX A-23 G031/G032...
Page 272 6. Click the Download button in the Stinger utility window. 7. The download window is displayed. G031X524.PCX 8. Click the “Reference” key and select the firmware file that you wish to download (eg. P3carddwn.rom). G031X525.PCX NOTE: Only a byte-swapped file can be used for the download. G031/G032 A-24...
Page 273 NOTE: There are two ways to go back to user mode from the service tool mode. 1) Press the “ / ” keys together. Then press the “Form Feed” key and the “Escape” key together. Then initialization will start. 2) Turn the printer off and then on. A-25 G031/G032...
Page 274: Ssu Troubleshooting
CD-ROM for example, SSU cannot create a temporary file. Also, if the rom file is in a network directory that is not shared, SSU cannot create a temporary file. Countermeasure: The rom file must be in a local directory. G031/G032 A-26...
Page 275 TECHNICAL SERVICE BULLETINS...
Page 276 You will be notified when it is available. The new version of Aficio Manager will be 1.06. Version 1.06 will not automatically poll networked printers unless specifically configured to do so. This can be accomplished in the Aficio Manager Options window, by highlighting the printer and then checking the “To Be Monitored” checkbox. RICOH GROUP COMPANIES CONTROL NO. 049...
Page 277 %440-'%&0)#13()0U ####+)78)82)6#h#4KNFNfKNEH ####6-'3,#h#%4FNNNfEHNN ####7%:-2#h#704FNfEH SUBJECT: CONTROL PANEL GENERAL: The following parts description corrections are being issued for all G031/G032 Parts Catalogs . Please update your Parts Catalogs with the following information. G031 REFERENCE PART NUMBER OLD DESCRIPTION NEW DESCRIPTION PAGE...
Page 278 NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. RICOH GROUP COMPANIES CONTROL NO. 051...
Page 279 2. To prevent the cleaning blade from slipping out of position, the amount of setting powder applied to the Cleaning Blade has been increased from June 1999 mainframe and commercial toner cartridge production runs. NOTE: The countermeasures described above apply to both G031 and G032 machines. RICOH GROUP COMPANIES CONTROL NO. 056...
Page 280 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G031/G032 – 005 03/01/2000 APPLICABLE MODEL: GESTETNER – P7020/P7014 RICOH – AP2000/AP1400 SAVIN – SLP20/SLP14 SUBJECT: SERVICE MANUAL - INSERT GENERAL: The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages.
Page 281 4.8.2 POWER-UP DIAGNOSTIC MODE ..........4-25 4.8.3 DETAILED DIAGNOSTIC MODE ..........4-26 4.8.4 DIAGNOSTIC TEST DETAILS............4-27 4.9 ROM HISTORY..................4-29 4.9.1 ROM HISTORY (G031)..............4-29 4.9.2 ROM HISTORY (G032)..............4-29 PREVENTIVE MAINTENANCE 5. PREVENTIVE MAINTENANCE ............ 5-1 5.1 PREVENTIVE MAINTENANCE SCHEDULE..........5-1 REPLACEMENT AND ADJUSTMENT 6.
Page 282 ENVELOPE FEEDER G913 1. OVERALL INFORMATION............8-1 1.1 SPECIFICATIONS ..................8-1 1.2 MECHANICAL COMPONENT LAYOUT........... 8-1 2. DETAILED SECTION DESCRIPTIONS ........8-2 2.1 PAPER LIFT ..................... 8-2 3. INSTALLATION ................8-3 4. REPLACEMENT AND ADJUSTMENT......... 8-4 4.1 FRICTION PAD REPLACEMENT............. 8-4 G031/G032...
Page 283: Rom History
Rev. 03/2000 ROM HISTORY ⇒ 4.9 ROM HISTORY 4.9.1 ROM HISTORY (G031) Description (P/N G0315915) Version Production Items Corrected: 2.03 K Oct. 99 Prod. • Wrinkling at 1200 dpi. • When the print job starts, while displaying “Tray x add paper”, Aficio Manager displays “Paper out”.
Page 284 G031 G032 G0291118 G0291119 Gear – C3 UNITS AFFECTED: All G031 and G032 printers manufactured after the Serial Numbers listed below will have the new style Gear –C3 installed during production. MODEL NAME SERIAL NUMBER Gestetner P7020 P0190700001 Gestetner P7014...
Page 285 G0292568 Right Turn Guide 32 * * Denotes new item number. UNITS AFFECTED: All G031 printers manufactured after the Serial Numbers listed below will have the new style Right Turn Guide installed during production. MODEL NAME SERIAL NUMBER Gestetner P7020...
Page 286 Fusing Entrance Guide 1→0 G0294116 Grounding Plate 1→0 UNITS AFFECTED: All G031 printers manufactured after the Serial Numbers listed below will have the Fusing Entrance Guide and Grounding Plate removed during production. MODEL NAME SERIAL NUMBER Gestetner P7020 P0190700001 Ricoh AP200...
Page 287 G031/G032 Service Documentation. The Service Manual pages listed below must be added to the G031/G032 Service Manual or replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages.
Page 288 1. OVERALL MACHINE INFORMATION ........11-1 1.1 SPECIFICATIONS .................. 11-1 1.2 MACHINE CONFIGURATION ..............11-2 DETAILED DESCRIPTIONS 2. DETAILED SECTION DESCRIPTIONS........11-3 2.5 PAPER FEED ..................11-3 2.5.1 OVERVIEW GO54 ................. 11-3 2.10 PRINTER CONTROL BOARD .............. 11-3 2.10.2 DEVICES ..................11-5 G031/G032...
Page 289 SPECIFICATIONS Rev. 04/2000 Printing Paper Size: G031: Maximum A3/11" x 17" Minimum A5 LEF - Standard Tray B6 SEF - By-pass Tray A5 LEF - Optional PFU Custom paper size (PCL 6/PS): By-pass Tray 11.69" x 17" ~ 3.88" x 5.83"...
Page 290 G049/G054 SERVICE MANUAL...
Page 291: Specifications
1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS NOTE: The new information for the G049/G054 is underlined in bold face. Printing Speed: G049: (600 dpi) Maximum 21 pages per minute (A4/LT LEF) G054: Maximum 16 pages per minute (A4/LT SEF) Printer Language: PCL6/PCL5e Compatible with Laser Jet 4000/5000 driver and printer.
Page 292 Utility Software 1. Printer Drivers 2. PS PPD Files 3. Font manager 4. Aficio Manager 5. Operating Instructions (G049/G054 – 22, 27) 6. Port Navi 1.2 MACHINE CONFIGURATION Internal Options Item Machine Code Printer Feature Expander Type 185 32MB G688 - 10 Printer Feature Expander Type 185 64MB G688 - 11 G049/G054...
Page 293 The built-in tray for the G032 can only hold A4/letter size. However, the G054 tray can handle A4/letter or shorter. The paper feed speed for the G049/G054 is the same as that of the G031/G032. However, the feeding interval has been decreased in the G049/G054, allowing a higher PPM.
Page 294 G054 Option Bus (CN 2) Flash DIMM Slot ASIC EEPROM Control Panel Centronics I/F G049/G054 11-4...
Page 295 2.10.2 DEVICES Devices Description 133 MHz VR4310 ASIC: ROCKY Z Memory map control Reset signal DRAM control DMA control FCI control (edge smoothing, toner saving) Interrupt control Engine serial communication control Interval control Centronics I/F I/O port Code ROM Flash ROM (2 MB) 32 bit 16 MB (16 bit DRAM ×...
Page 296 Use the byte-swapped file (*carddwn.rom - created by SSU byte swap) • To copy directly to the printer’s firmware flash ROM (from a PC through a parallel cable): Use the byte-swapped file (*carddwn.rom - created by SSU byte swap) G031/G032...
Page 297 Rev. 04/2000 USING AN IC CARD 1.3.2 DOWNLOADING FROM THE IC CARD TO THE PRINTER This is explained in ‘Downloading New Controller Software’ in section 4 of the service manual. A-13 G031/G032...
Page 298 14. Print the log print and check the controller firmware version. 15. Turn the printer off and then on to return to the user mode. The DIMM card now contains new firmware. The following procedure explains how to install the new firmware into the printer’s flash memory. G031/G032 A-18...
Page 299 Discharge Brush have been changed. Also, the Discharge Brush was incorrectly indexed as item 23. Please correct this to item 24. The following parts updates are being issued for all G031 Parts Catalogs. Please update your Parts Catalogs with the following information.
Page 300 UPDATE 3: DIMM ROM – The part number for the DIMM ROM has been added as a service part. The following part update is being issued for all G031 and G032 Parts Catalogs. Please update your Parts Catalogs with the following information.
Page 301 Exit Sensor Holder 51 * 04503008B Tapping Screw – M3x8 n!n+1 UNITS AFFECTED: All G031 printers manufactured after the Serial Numbers listed below will have the new style Exit Sensor Holder installed during production. MODEL NAME SERIAL NUMBER Gestetner P7020 P0190700001...
Page 302 UPDATE 2: Drive Housing and Gear –C6 – To minimize jitter, along with the modification to Gear – C3 (See TSB G031/G032 – 006), Gear – C6 has been modified. The hollow areas of the gear have been eliminated and are now solid.
Page 303 UPDATE 3: Stripper Pawls – To standardize with other models, the Stripper Pawls have been changed. The following parts updates are being issued for all G031/G032 Parts Catalogs. Please update your Parts Catalog with the following information. G031 only REFERENCE OLD PART NO.
Page 304 1 set of replacement pages. PAGES: The revised areas have been highlighted by an arrow ⇒. • Updated Information (Table of Contents) • 4-29 Updated Information (ROM History)     CONTROL NO. 037ABW 2000 RICOH Corporation. All rights reserved.
Page 306 Rev. 05/2000 FIRMWARE HISTORY ⇒ 4.9 FIRMWARE HISTORY 4.9.1 G031 FIRMWARE MODIFICATION HISTORY G031 PRINTER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • Initial Production G0315915 E 1st Mass 1.05 Production • HDD and Serial Port functions have been...
Page 307 The following information is to supply the technician with the new part numbers for the G049 and G054 printers. Since nearly all of the components of the G049 and G054 are the same as the G031 and G032, only those parts that are different will be described in this bulletin. The G049 information is placed into the G031 portion of the Parts Catalog and the G054 information is placed into the G032 portion of the Parts Catalog.
Page 308 Tech Service Bulletin No. G031/G032/G049/G054 – 011 Page 2 of 3 G049 only Page 29 REFERENCE PART NUMBER DESCRIPTION PAGE ITEM G0498607 Operating Instructions – LT English – (G049) • UPDATE 2: G054 Newly Added Parts – The following G054 parts updates are being added to the G032 section of the Parts Catalog.
Page 309 Tech Service Bulletin No. G031/G032/G049/G054 – 011 Page 3 of 3 G054 only Page 19 REFERENCE PART NUMBER DESCRIPTION PAGE ITEM ❇ G0545700 Main Control Board – (G054) G0415904 IC – ASIC ROCKY_Z – (G054) G0545900 Oscillator – Video – (G054)
Page 310 The following information is to supply the technician with the new part numbers for the G049 and G054 printers. Since nearly all of the components of the G049 and G054 are the same as the G031 and G032, only those parts that are different will be described in this bulletin. The G049 information is placed into the G031 portion of the Parts Catalog and the G054 information is placed into the G032 portion of the Parts Catalog.
Page 311 ! ! ! ! Tech Service Bulletin No. G031/G032/G049/G054 – 011 REISSUE Page 2 of 3 G049 only Page 29 REFERENCE PART NUMBER DESCRIPTION PAGE ITEM G0498607 Operating Instructions – LT English – (G049) • UPDATE 2: G054 Newly Added Parts – The following G054 parts updates are being added to the G032 section of the Parts Catalog.
Page 312 ! ! ! ! Tech Service Bulletin No. G031/G032/G049/G054 – 011 REISSUE Page 3 of 3 G054 only Page 19 REFERENCE PART NUMBER DESCRIPTION PAGE ITEM ❇ G0545700 Main Control Board – (G054) G0415904 IC – ASIC ROCKY_Z – (G054) G0545900 Oscillator –...
Page 313 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 • 4-29 Updated Information (Firmware History)     CONTROL NO. 064ABW 2000 RICOH Corporation. All rights reserved.
Page 314 Rev. 10/2000 FIRMWARE HISTORY 4.9 FIRMWARE HISTORY 4.9.1 G031 FIRMWARE MODIFICATION HISTORY G031 PRINTER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • Initial Production G0315915 E 1st Mass 1.05 Production • HDD and Serial Port functions have been...
Page 315 h .Nf.E h .Nf.E h .Nf.E SUBJECT: SPRING CLUTCH GENERAL: The following part correction is being issued for all G031/G049 Parts Catalogs. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE...
Page 316 Tech Service Bulletin No. G031/G032/G049/G054 – 013 Page 2 of 2 UNITS AFFECTED: All G031/G049 printers manufactured after the Serial Numbers listed below will have the new spring clutch installed during production. MODEL NAME SERIAL NUMBER Gestetner P7020 P0190600001 Gestetner P7021...
Page 317 Updated Information (TOC). • 10-17 Updated Information (NIB Firmware History G919) • 11-6 Updated Information (Engine Firmware History G049/G054). • 11-7 Updated Information (Controller Firmware History G049/G054).     CONTROL NO 117ABW Copyright 2002 RICOH Corporation. All rights reserved.
Page 318: Overview Go54
1.1 SPECIFICATIONS...................11-1 1.2 MACHINE CONFIGURATION ..............11-2 DETAILED DESCRIPTIONS 2. DETAILED SECTION DESCRIPTIONS ........11-3 2.5 PAPER FEED …………………………………………………………………11-3 2.5.1 OVERVIEW GO5................11-3 2.10 PRINTER CONTROL BOARD........………………..11-3 2.10.2 DEVICES …………………………………………………………….11-5 3.0 ENGINE FIRMWARE MODIFICATION HISTORY…………………..…….11-6 3.1 CONTROLLER FIRMWARE MODIFICATION HISTORY……..……….…11-7 G031/G032/G049/G054...
Page 319 100M or 10M bps. Note 1: IPP printing Only G049 and G054 support this feature. (not supported by G031/G032) Windows 2000 or Windows 98/ME allow IPP printing. IPP client program must be installed in Windows 98/ME before using the feature. The IPP client program, WPNPINS.exe, is on the Microsoft Web site.
Page 320 Rev.12/2001 3.0 FIRMWARE MODIFICATION HISTORY ⇒ G049/G054 ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION G049 G054 1 mass 1.00 G0305157 B Production G0295172 1 mass 0.04 Production To meet EMI standard, the fusing temperature control July 2000 1.01 G0305157 C...
Page 321 Rev.01/2002 CONTROLLER FIRMWARE MODIFICATION HISTORY ⇒ G049/G054 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION G049 G054 • G0545910 A 1st Mass 1.11 Initial Production Production G0495910 A 1st Mass 1.11 Production 1. When using PCL5e, the right side line of G0545910 B Nov.2000 1.29...
Page 322 RICOH – AP2000/AP1400/AP2100/AP1600 SAVIN – SLP20/SLP14/SLP21/SLP16 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following parts updates are being issued for all G031/G032/G049/G054 Parts Catalogs. • UPDATE 1: Transfer Roller – The parts for the Transfer Roller and the Positioning Roller were incorrectly listed in the parts catalog. Please update your G031/G032/G049/G054 Parts Catalog with the following information.
Page 323 Tech Service Bulletin No G031/G032/G049/G054 – 015 Page 2 of 2 • UPDATE 2: Paper Cassette & Stopper Base Plate – The Stopper Base Plate has been changed to increase the durability of the fulcrum. To facilitate this, the shape of the attachment opening in the Paper Cassette has also been changed.
Page 324 The revised areas have been highlighted by an arrow • iii & vi Updated Information (Table of Contents) • 4-29 & 30 Updated Information (Firmware History) • 11-5 Updated Information (Devices) • 11-6 through 11-8 Updated Information (G049/G054 Firmware History)  Copyright 2003 RICOH Corporation. All rights reserved.
Page 325 4.8.2 POWER-UP DIAGNOSTIC MODE ..........4-25 4.8.3 DETAILED DIAGNOSTIC MODE ...........4-26 4.8.4 DIAGNOSTIC TEST DETAILS ............4-27 4.9 FIRMWARE HISTORY ................4-29 4.9.1 CONTROLLER FIRMWARE HISTORY (G031)......4-29 4.9.2 CONTROLLER FIRMWARE HISTORY (G032)......4-30 PREVENTIVE MAINTENANCE 5. PREVENTIVE MAINTENANCE............ 5-1 5.1 PREVENTIVE MAINTENANCE SCHEDULE ..........5-1 REPLACEMENT AND ADJUSTMENT 6.
Page 326 2.10 PRINTER CONTROL BOARD........……………….11-3 2.10.2 DEVICES………………………………………………………………11-5 3. G049/G054 FIRMWARE HISTORY..........11-6 3.1 G049 ENGINE FIRMWARE MODIFICATION HISTORY ......11-6 3.2 G054 ENGINE FIRMWARE MODIFICATION HISTORY ......11-6 3.3 G049 CONTROLLER FIRMWARE MODIFICATION HISTORY ....11-7 3.4 G054 CONTROLLER FIRMWARE MODIFICATION HISTORY ....11-8 G031/G032/G049/G054...
Page 327 FIRMWARE HISTORY Rev. 01/2003 4.9 FIRMWARE HISTORY 4.9.1 G031 CONTROLLER FIRMWARE MODIFICATION HISTORY G031 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION Initial Production G0315915 E 1st Mass 1.05 Production • HDD and Serial Port functions have been...
Page 328 Windows PS file Unix file. • G0325915 P Prod. 2.08 Printing stalls when using PS driver Discontinued under Windows XP. • G0325915 Q Prod. 2.09 Printer option now supports Mac OS X Discontinued version 10.1 (Native) and newer. G031/G032 4-30...
Page 329 Rev. 01/2003 2.10.2 DEVICES Devices Description 133 MHz VR4310 ASIC: ROCKY Z Memory map control Reset signal DRAM control DMA control FCI control (edge smoothing, toner saving) Interrupt control Engine serial communication control Interval control Centronics I/F I/O port Code ROM Flash ROM (2 MB) 32 bit 16 MB (16 bit DRAM ×...
Page 330 Rev. 01/2003 3. G049/G054 FIRMWARE HISTORY ⇒ 3.1 G049 ENGINE FIRMWARE MODIFICATION HISTORY G049 ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION First Mass Production G0295172 1st mass 0.04 Production ⇒ 3.2 G054 ENGINE FIRMWARE MODIFICATION HISTORY G054 ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL...
Page 331 Rev. 01/2003 3.3 G049 CONTROLLER FIRMWARE MODIFICATION HISTORY ⇒ G049 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • 1st Mass 1.11 Initial Production G0495910 A Production • Jan. 2001 1.29 G0495910 B When using PCL5e, the right side line of Production a table is not printed.
Page 332 Rev. 01/2003 3.4 G054 CONTROLLER FIRMWARE MODIFICATION HISTORY ⇒ G054 CONTROLLER FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION • 1st Mass 1.11 Initial Production G0545910 A Production • Nov.2000 1.29 When using PCL5e, the right side line of G0545910 B Production a table is not printed.
Page 333 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 • 10-17 and 18 Updated Information (G919 Firmware History)  Copyright 2003 RICOH Corporation. All rights reserved.
Page 334 4. Ghost server problem: Multicast hash table used for Ethernet driver. This allows only specific AppleTalk multicasts instead of all multicasts, preventing the NIC from crashing during multicast storms. Other changes: Software modified to support WINS. 10-17 G031/G032...
Page 335 Note 1: IPP printing Only G049 and G054 support this feature. (not supported by G031/G032) Windows 2000 or Windows 98/ME allow IPP printing. IPP client program must be installed in Windows 98/ME before using the feature. The IPP client program, WPNPINS.exe, is on the Microsoft Web site.
Page 336 GENERAL: The following parts have been changed to increase the durability of the paper cassette assembly. The following part update is being issued for all G031/G032/G049/G054 Parts Catalogs. Copyright  2004 RICOH Corporation. All rights reserved. Page 1 of 2...
Page 337 Tech Service Bulletin No. G031/G032/G049/G054 – 018 G032 only REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM G0302551 G0302541 Paper Cassette Ass’y G054 only REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM G0302553 G0302543 Paper Cassette Ass’y (G054)
Page 338 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G919 – 001 03/18/2003 APPLICABLE MODEL: GESTETNER – NIB TYPE 2000 for P7020/P7014/P7021/P7016 RICOH – NIB TYPE 2000 for AP2000/AP1400/AP2100/AP1600 SAVIN – NIB TYPE 2000 for SLP20/SLP14/SLP21/SLP16 SUBJECT: FTP DOWNLOAD 1.50a GENERAL: System Requirements Windows 95/98/Me/2000/NT/XP...
Page 339 Tech Service Bulletin No. G919 – 001 Page 2 of 4 5. Turn ON the main power and wait until it has booted up completely. If the NIB status sheet printing has been activated, please wait until this sheet is printed out. Be sure to print a NIB status sheet before and after upgrading the NIB.
Page 340 Tech Service Bulletin No. G919 – 001 Page 3 of 4 Input the target IP address 10. Input the target password (“sysadm”). IMPORTANT: For Steps 11-13, please Do not turn OFF the machine main power Do not send any print data to the machine Do not access an http:// internet page.
Page 341 Tech Service Bulletin No. G919 – 001 Page 4 of 4 Recovery Method IMPORTANT: Make sure the printer main power is off before beginning. 1. Remove the NIB, then move the jumper pin OP2 to the ON position (“BYPASS”). 2. Reattach the NIB and turn on the printer main power. 3.
Page 342 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G919 – 002 03/18/2003 APPLICABLE MODEL: GESTETNER – NIB TYPE 2000 for 9980 RICOH – NIB TYPE 2000 for AFICIO FAX5000L SAVIN – NIB TYPE 2000 for FAX3699 SUBJECT: FTP DOWNLOAD 1.50a GENERAL: System Requirements Windows 95/98/Me/2000/NT/XP...
Page 343 Tech Service Bulletin No. G919 – 002 Page 2 of 4 5. Turn ON the main power and wait until it has booted up completely. If the NIB status sheet printing has been activated, please wait until this sheet is printed out. Be sure to print a NIB status sheet before and after upgrading the NIB.
Page 344 Tech Service Bulletin No. G919 – 002 Page 3 of 4 Input the target IP address 10. Input the target password (“sysadm”). IMPORTANT: For Steps 11-13, please Do not turn OFF the machine main power Do not send any print data to the machine Do not access an http:// internet page.
Page 345 Tech Service Bulletin No. G919 – 002 Page 4 of 4 Recovery Method IMPORTANT: Make sure the printer main power is off before beginning. 1. Remove the NIB, then move the jumper pin OP2 to the ON position (“BYPASS”). 2. Reattach the NIB and turn on the printer main power. 3.

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G049 G054 G032

Ricoh G031 Service Manual

Overall Information

Detailed Descriptions

Installation

Preventive Maintenance

Replacement and Adjustment

Troubleshooting

Envelope Feeder G913

Network Interface Board G919 (Type2000)

Service Tables and Procedures

Appendix Downloading Controller Firmware

Quick Links

SERVICE MANUAL

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