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Gestetner G060 Service Manual

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G060/G570/G082
SERVICE MANUAL
001159MIU
RICOH GROUP COMPANIES

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Summary of Contents for Gestetner G060

  • Page 1 G060/G570/G082 SERVICE MANUAL 001159MIU RICOH GROUP COMPANIES...
  • Page 3 RICOH GROUP COMPANIES...
  • Page 5 G570 SERVICE MANUAL RICOH GROUP COMPANIES...
  • Page 7 RICOH GROUP COMPANIES...
  • Page 9 G060/G570/G082 SERVICE MANUAL 001159MIU...
  • Page 11 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 13 WARNING Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
  • Page 15 LEGEND COMPANY PRODUCT CODE GESTETNER LANIER RICOH SAVIN G060 DSc38 2138 AH AP3800C SLP38c G570 DSc38S 2138CMF AP3800CMF SLP38cS G082 DSc38F 2138E AP3850C SLP38c DE DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 9/2001 Original Printing 2/2002 G570 Addition 6/2002 G082 Addition...

  • Page 17: Table Of Contents

    1st side....................3-2 2nd side in duplex ................3-2 Adjustment Procedure................3-3 3.2.2 COLOR REGISTRATION ..............3-3 Line Position Adjustment..............3-3 Adjustment for Line Speed of Fusing Unit..........3-3 3.2.3 PRINTER GAMMA................3-4 Adjustment Overview ................3-4 Adjustment Procedure................3-4 G060...
  • Page 18 3.9.1 MOVING THE CONTROLLER BOX OUT OF THE WAY ....3-36 3.9.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C, B OUT OF THE WAY..............3-36 3.9.3 CONTROLLER AND BCU ............. 3-37 3.9.4 NVRAM REPLACEMENT PROCEDURE ........3-38 NVRAM for BCU ................3-38 NVRAM for Controller ................ 3-38 G060...
  • Page 19 Registration roller speed adjustment (For B&W mode).......4-50 4.5 ELECTRICAL COMPONENT DEFECTS ..........4-51 4.5.1 SENSORS ..................4-51 4.6 BLOWN FUSE CONDITIONS ..............4-52 4.7 LEDS (BCU) ....................4-52 SERVICE TABLES 5 SERVICE TABLES................ 5-1 5.1 SERVICE PROGRAM MODE..............5-1 5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...5-1 G060...
  • Page 20 6 DETAILED SECTION DESCRIPTIONS........6-1 6.1 OVERVIEW ....................6-1 6.1.1 COMPONENT LAYOUT ..............6-1 6.1.2 PAPER PATH .................. 6-2 6.1.3 DRIVE LAYOUT................6-3 6.1.4 BOARD STRUCTURE ..............6-4 Overview ....................6-4 Descriptions ..................6-5 6.1.5 PRINTING PROCESS ..............6-6 G060...
  • Page 21 6.4.1 OVERVIEW ................... 6-25 6.4.2 DRIVE.................... 6-26 6.4.3 DRUM CHARGE AND QUENCHING ..........6-27 6.4.4 DRUM CLEANING................. 6-28 6.4.5 WASTE TONER COLLECTION............. 6-29 6.4.6 WASTE TONER BOTTLE FULL DETECTION ......6-30 6.4.7 PCU DETECTION (DEVELOPMENT UNIT DETECTION) .... 6-31 6.5 DEVELOPMENT..................6-32 G060...
  • Page 22 Level 2 Energy Saver Mode ............... 6-60 6.9 PAPER EXIT................... 6-61 6.9.1 OVERVIEW ................... 6-61 6.9.2 PAPER OVERFLOW DETECTION..........6-62 6.10 CONTROLLER ..................6-63 6.10.1 OVERVIEW ................. 6-63 6.10.2 BOARD LAYOUT................. 6-65 6.10.3 PRINT DATA PROCESSING............6-66 RPCS Driver..................6-66 G060...
  • Page 23 1.1.4 DUPLEX INVERTER MOTOR 2 AND SWITCH....... 7-2 1.1.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR....7-3 1.1.6 EXIT SENSOR 1 AND 2 ..............7-3 1.2 DUPLEX FEED UNIT................7-4 1.2.1 DUPLEX DRIVE BOARD..............7-4 1.2.2 DUPLEX FEED MOTOR..............7-4 1.2.3 DUPLEX FEED SENSOR..............7-5 G060...
  • Page 24 1.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS ....9-2 1.3 PAPER FEED MOTOR AND MAIN BOARD..........9-3 1.4 TRAY LIFT MOTORS ................9-4 1.5 PAPER FEED CLUTCHES............... 9-4 1.6 PAPER FEED UNIT REPLACEMENT ............9-5 2 DETAILED DESCRIPTIONS ............9-6 2.1 OVERVIEW ....................9-6 G060 viii...
  • Page 25 1.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR ... 11-3 1.5 STAPLER TRAY..................11-3 1.6 UPPER STACK HEIGHT SENSORS/ TRAY 1 UPPER LIMIT SWITCH ............11-4 1.7 EXIT GUIDE PLATE MOTOR..............11-5 1.8 LIFT MOTORS..................11-5 1.9 LOWER EXIT SENSOR................11-7 1.10 LOWER STACK HEIGHT SENSORS........... 11-8 G060...
  • Page 26 4.7.1 STAPLER MOVEMENT ............... 11-26 Stapler Rotation ................11-26 Side-to-Side Movement..............11-26 4.7.2 STAPLER ..................11-27 4.7.3 FEED OUT AND TRANSPORT ........... 11-28 4.8 PUNCH UNIT (OPTIONAL) ..............11-29 4.8.1 PUNCH DRIVE MECHANISM ............. 11-29 4.8.2 PUNCH WASTE COLLECTION........... 11-30 G060...
  • Page 27 2.1 PRINTER DRIVERS ................13-5 2.2 UTILITY SOFTWARE ................13-5 3 MACHINE CONFIGURATION ..............13-6 4 OPTIONAL EQUIPMENT ................13-8 4.1 500-SHEET TRAY ................13-8 4.2 1000-SHEET TRAY ................13-8 4.3 2000-SHEET LARGE CAPACITY TRAY ...........13-8 4.4 TWO-TRAY FINISHER & PUNCH UNIT ...........13-9 4.5 FOUR-BIN MAILBOX ..............13-10 G060...
  • Page 28 2.1 USER MAINTENANCE................2-1 2.2 SERVICE MAINTENANCE ............... 2-3 3. REPLACEMENT AND ADJUSTMENT........3-1 3.1 SPECIAL TOOLS ..................3-1 3.2 LUBRICANTS ................... 3-1 3.3 IMAGE ADJUSTMENT ................3-2 3.3.1 PRINTING..................3-2 Leading edge registration..............3-2 Side-to-side registration ............... 3-2 G060...
  • Page 29 SP4-907-1 VPU Test Pattern: R ............4-7 SP4-907-2 VPU Test Pattern: G ............4-7 SP4-907-3 VPU Test Pattern: B ............4-7 4.2.2 IPU TEST MODE................4-8 SP4-904-1 Register Write/Read Check Result ........4-8 SP4-904-2 Image Path Check Result ...........4-8 4.3 SERVICE CALL CONDITIONS ..............4-9 xiii G060...
  • Page 30 Table 4: Original Size Detection ............5-68 5.4.3 OUTPUT CHECK TABLE ...............5-69 5.4.4 TEST PATTERN (SP5-997) ............5-73 5.5 SCANNER SP ..................5-74 5.5.1 SP MODES..................5-74 SP1-xxx (System and Others) ............5-74 SP2-XXX (Scanning-image quality) ............5-75 SP8-XXX (Delivery) ................5-82 5.6 REBOOT / SYSTEM SETTING RESET ..........5-84 G060...
  • Page 31 Black Level Correction ................. 6-8 Adjustments ..................6-8 VPU Test Mode..................6-8 6.2.3 IPU BLOCK DIAGRAM ..............6-9 Shading Correction ................6-9 Picture Element (Dot Position) Correction.......... 6-10 Scan Line Correction................6-10 Image Separation................6-10 Scanner Gamma Correction (RGB Gamma Correction) ....6-11 G060...
  • Page 32 1.2 ORIGINAL FEED UNIT................8-2 1.3 ORIGINAL PICK-UP ROLLER..............8-2 1.4 ORIGINAL FEED BELT ................8-3 1.5 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS ................... 8-4 1.6 ORIGINAL LENGTH SENSORS............... 8-5 1.7 SEPARATION ROLLER ................8-5 1.8 INVERTER /ORIGINAL SET SENSORS ..........8-6 G060...
  • Page 33 4.4.1 PICK-UP AND SEPARATION............8-19 4.4.2 ORIGINAL SKEW CORRECTION ..........8-20 4.4.3 REDUCING THE INTERVAL BETWEEN PAGES ......8-20 4.5 ORIGINAL TRANSPORT AND EXIT ............8-21 4.5.1 SINGLE-SIDED ORIGINALS ............8-21 4.5.2 DOUBLE-SIDED ORIGINALS............8-22 4.6 STAMP ....................8-23 xvii G060...
  • Page 34 SP Mode Button Summary..............3-2 Switching Between SP Mode and Copy Mode for Test Printing... 3-3 Selecting the Program Number ............3-3 3.1.2 SERVICE PROGRAM MODE TABLES ........... 3-4 3.2 BIT SWITCHES ..................3-9 3.2.1 SYSTEM SWITCHES ..............3-9 G060 xviii...
  • Page 35 4.4.3 DOCUMENT SERVER ..............4-16 4.4.4 LAN FAX DRIVER ................. 4-17 Regular transmission ................. 4-18 Print and transmission................ 4-18 Using Document Server ..............4-18 SPECIFICATIONS................5-1 1. GENERAL SPECIFICATIONS..............5-1 2. CAPABILITIES OF PROGRAMMABLE ITEMS .......... 5-3 3. MACHINE CONFIGURATION ..............5-4 G060...
  • Page 36 5.2 PRINTER CONTROLLER SERVICE MODE...........5-3 5.2.1 SERVICE MODE MENU ("1. SERVICE") ..........5-3 5.2.2 BIT SWITCH PROGRAMMING ...............5-3 5.3 PRINTER ENGINE SERVICE MODE...............5-4 5.4 FIRMWARE UPDATE PROCEDURE...............5-5 5.4.1 TYPE OF FIRMWARE................5-5 5.4.2 FIRMWARE UPGRADE OVERVIEW .............5-5 5.4.3 SUPPORTED OS AND TOOLS...............5-5 5.4.4 FIRMWARE UPGRADE................5-6 G060...
  • Page 37 1.1.2 PAPER EXIT ....................7-4 2. SOFTWARE ACCESSORIES................7-5 2.1 PRINTER DRIVERS..................7-5 2.2 UTILITY SOFTWARE ...................7-5 3. MACHINE CONFIGURATION................7-6 4. OPTIONAL EQUIPMENT..................7-7 4.1 500-SHEET TRAY..................7-7 4.2 1000-SHEET TRAY..................7-7 4.3 2000-SHEET LARGE CAPACITY TRAY...........7-7 4.4 TWO-TRAY FINISHER & PUNCH UNIT ...........7-8 4.5 FOUR-BIN MAILBOX ..................7-9 G060...

  • Page 39: Important Safety Notices

    IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the printer and peripherals, make sure that the printer power cord is unplugged. 2. The wall outlet should be near the printer and easily accessible. 3. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components.

  • Page 40: Laser Safety

    SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. 2. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.) 3.
  • Page 41 Trademarks ® ® ® Microsoft , Windows , and MS-DOS are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® PostScript is a registered trademark of Adobe Systems, Incorporated. ® is a registered trademark of Hewlett-Packard Company. ®...
  • Page 43 Rev. 09/2003 INSTALLATI0N G060 TWO-TRAY PAPER FEED UNIT G568 G082 PREVENTIVE MAINTENCE G060 LARGE CAPACITY TRAY G569 REPLACEMENT AND ADJUSTMENT G060 TWO-TRAY FINISHER G565 TROUBLESHOOTING G060 FOUR-BIN MAILBOX G566 SERVICE TABLES G060 SPECIFICATIONS G060 DETAILED DESCRIPTIONS G060 COPIER FEATURE EXPANDER G570...

  • Page 45: Installation

    INSTALLATION...

  • Page 47: Installation Requirements

    8. Install the machine on a strong, level base. (Inclination on any side must be no more than 5 mm.) 9. Avoid installing the machine in areas that may be subjected to strong vibration. 1.1.2 MACHINE LEVEL Front to back: Within 5 mm (0.2") Right to left: Within 5 mm (0.2") G060...

  • Page 48: Machine Space Requirement

    2. Avoid using an outlet extension plug or cord. 3. Ground the machine. 1. Input voltage level: 120 V, 60 Hz: More than 10 A 2. Permissible voltage fluctuation: ±10 % 3. Do not put or place anything on the power cord. G060...

  • Page 49: Optional Unit Combinations

    • Item 1, 2 or 3 3 types of punch kit Item 4 Four-bin mailbox Items 4, 5 Duplex unit 3 types of memory DIMM IEEE 1394 Item 8 NVRAM NOTE: Two memory DIMMs (up to 384 MB) can be installed. G060V112.JPG G060...

  • Page 50: Installation Flow Chart

    Install the two-tray finisher. Install the printer. G060I002.WMF Two-tray Finisher: Needs the duplex unit, HDD or at least 128 MB of memory, and a paper tray unit or LCT. Punch Unit: Needs the finisher. IEEE1394 Board: Needs the memory DIMM. G060...

  • Page 51: Machine Installation

    Fax No. setting SP5-812-2 Programs the service station fax number. The number is printed on the counter list when the meter charge mode is selected, so that the user can fax the counter data to the service station. G060...
  • Page 52 The negative counters used in meter charge mode will be reset to zero. NOTE: 1) The default setting for this machine is meter-charge mode off. 2) The meter-charge counter cannot be reset. G060...

  • Page 53: Optional Unit Installation

    2. Remove the front stand [A] ( x 2). 3. Remove the rear stand [B] ( x 2, 2 brackets). CAUTION: Reinstall the two stands in their original positions, or the machine might tip over when pulling out the paper trays and so on. G060...

  • Page 54: Punch Unit Installation

    1. Punch unit ................. 1 2. Sensor arm................1 3. Hopper ..................1 4. Step screw ................1 5. Spring..................1 6. Spacer (2 mm) ................1 7. Spacer (1 mm) ................1 8. Tapping screw................1 9. Tapping screw................2 G060...

  • Page 55: Installation Procedure

    1. Unpack the punch unit and remove all tape and shipping retainers. 2. Open the front door and remove the rear cover [A] ( x 4). 3. Remove the bracket [B] ( x 2) and paper guide [C] ( x 1). G060...
  • Page 56 4. Remove the hopper cover [A] ( x 2). 5. Install the sensor bracket [B] (stepped  x 1). 6. Install the spring [C]. 7. Install the 2 mm spacer [D]. 8. Install the punch unit [E] ( x 2, stepped  x 1). G060 1-10...
  • Page 57 11. Fasten the two 1 mm spacers [C] to the rear frame for future adjustment. NOTE: The spacers are used to adjust the horizontal positioning of the punch holes. 12. Reassemble the finisher and check the punch operation. 1-11 G060...

  • Page 59: Preventive Maintenance

    PREVENTIVE MAINTENANCE...

  • Page 61: User Maintenance

    The machine stops when the counters for parts in maintenance kits C, E and G reach the replacement value in the following table. NOTE: To have the machine display the alert only for maintenance kits C, E, and G, set SP5-930-3 to 0. G060...

  • Page 62: Main Unit

    Included in maintenance kit E Dust Filter Included in maintenance kit D Pick-up Roller Included in maintenance kit H Feed Roller Included in maintenance kit H Separation Roller Included in maintenance kit H Punch Kit Item Remarks Chads Discard chads. G060...

  • Page 63: Service Maintenance

    Two-tray Finisher Items 100K 150K 1,000K Remarks Rollers Damp cloth Discharge Brush Dry cloth Sensors Blower brush Jogger Fences Replace if required. Four-bin Mailbox Item 100K 150K 1,000K Remarks Rollers Damp cloth Tray Paper Sensors Blower blush or dry cloth G060...

  • Page 65: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 67: Special Tools

    NOTE: This manual uses the following symbols. : See or refer to  : Screw : Connector  : Clip ring  : E ring 3.1 SPECIAL TOOLS Part Number Part Name Q’ty A2309352 Flash Memory Card - 4MB G0219350 Loop-back connector - Parallel G060...

  • Page 68: Image Adjustment

    The registration in both main and sub-scan direction may fluctuate within the following tolerance. 1st side • Sub-scan direction: 0 ± 1.5 mm • Main-scan direction: 0 ± 2 mm 2nd side in duplex • Sub-scan direction: 0 ± 3 mm • Main-scan direction: 0 ± 4 mm G060...

  • Page 69: Adjustment Procedure

    Adjust the speed of development motor-K with the following user tool in the Maintenance menu. “Menu/Maintenance/Color Regist./Fuser Adjust/Custom Adjust” Refer to Maintenance Guide 1 of the Operating Instructions for how to adjust this. G060...

  • Page 70: Printer Gamma

    CMY gradation scale is gray. Repeat the adjustment if there is an anomaly. 9. If the adjustment results prove satisfactory, execute “Data Save”. G060...

  • Page 71: Sm G060

    1. Paper exit tray [A] ( x 2) G060R202.WMF 3.3.3 UPPER RIGHT COVER 1. Right cover [A] ( x 2) NOTE: To loosen the screws, close the upper right cover; to remove the right cover, open the upper right cover. 2. Upper right cover [B] G060R204.WMF G060...

  • Page 72: Front Cover

    3. Connector cover [A], if the optional duplex unit is not installed 4. Left cover [B] ( x 6) G060R714.WMF 5. Open the left door [C]. 6. Rear left cover [D] ( x 3) G060R717.WMF G060...

  • Page 73: Upper Left Cover And Operation Panel

    3.3.6 UPPER LEFT COVER AND OPERATION PANEL 1. Open the front cover. 2. Open the upper light cover 3. Operation panel [A] ( x 2, x 2, 2 hooks) 4. Upper left cover [B] ( x 2, 1 hook) G060R716.WMF G060...

  • Page 74: Laser Optics

    This printer uses a class IIIb laser beam with a wavelength of 655 nm and an output of 7 mW. The laser can cause serious eye injury. G060...

  • Page 75: Laser Optics Housing Unit

    7. Hold the toner supply unit [C] up  Then, lower the unit NOTE: The pin [D] for the front and rear shafts holds the toner supply unit. G060R206.WMF 8. Connector cover [E] ( x 1) 9. Four flat cables [F] 10. Connector [G] G060R207.WMF G060...
  • Page 76 After installing the laser optics housing unit, do forced line position adjustment (SP5-993-002 or 'Maintenance - Color Registration - Auto Adjust' in User Program mode). G060 3-10...

  • Page 77: Adjustments After Replacing The Laser Optics Housing Unit

    5. Adjust the laser beam pitch values in SP2-109-2 and -3 until the printout is correct, as shown below. Feed direction Adjustment not completed Adjustment completed G060R002.WMF 6. Execute SP5-993-2 or “Auto Adjust” with the Maintenance menu in the user tools. 3-11 G060...

  • Page 78: Polygon Mirror Motor

    3. Polygon mirror motor [B] ( x 4 and x 1) G060R210.WMF 3.4.4 LASER SYNCHRONIZING DETECTOR BOARDS 1. Laser optics housing unit ( 3.1.2 LASER OPTICS HOUSING UNIT) 2. Synchronizing detector boards [A] ( x 1, x 2) G060R211.WMF G060 3-12...

  • Page 79: Pcu And Development Unit

    G060R302.WMF 7. Release the lever and pull the PCU [E] out until the handle appears. 8. Grasp the handle [F] and pull the PCU out of the machine. G060R303.WMF 3-13 G060...

  • Page 80: Paper Feed

    2. By-pass tray cover [A] (1 hook,  x 1) 3. Raise the paper end sensor actuator. 4. Pick-up roller [B] (1 hook) G060R102.WMF 5. Feed roller [C] ( x 1) 6. Separation roller [D] ( x 1) G060R110.WMF G060 3-14...

  • Page 81: Paper Width Detection Board

    5. Paper width detection board [D] ( x 1, x 1) 3.6.3 VERTICAL TRANSPORT SENSOR G060R104.WMF 1. Open the right door. 2. Vertical transport cover [A] ( x 4) 3. Vertical transport sensor [B] ( x 1) 3-15 G060...

  • Page 82: Right Door Unit

    3. Upper right cover ( 3.3 EXTERIOR COVERS) 4. Right rear cover [A] ( x 4) 5. Open the right door. 6. Lift the vertical transport unit [B] to remove it from its hinges ( x 3,  x 1). G060 3-16...

  • Page 83: Registration Sensor And Relay Sensor

    4. Clutch holder [A] ( x 2, 1 bearing) 5. Paper feed clutch for tray 1 [B] ( x 1) 6. Clutch holder [C] ( x 2, 1 bearing) 7. Paper feed clutch for tray 2 [D] ( G060R713.WMF x 1) 3-17 G060...

  • Page 84: By-Pass Feed Clutch

    2. Swing out the high voltage supply unit. ( 3.6.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C, B OUT OF THE WAY) 3. Tray lift motors (tray 1 [A], tray 2 [B]) ( x 2, x 1) G060 3-18...

  • Page 85: Transfer And Paper Transport Unit

    • Execute SP3-920-5 (refresh mode), • Execute line position adjustment (SP5-993-002 or "Auto Adjust" in the user program mode) • Print the 1-dot grid pattern on A3/11"x17" paper and check the color shift level ( 4.4.3 Color Shift After Transfer Unit Replacement). 3-19 G060...
  • Page 86 • Perform forced line position adjustment (SP5-993-002 or ‘Maintenance menu – Color Registration - Auto Adjust’ in User Program mode), • Print the 1-dot grid pattern on A3/11"x17" paper and check the color shift level ( 4.4.3 Color Shift After Transfer Unit Replacement). G060 3-20...

  • Page 87: Transfer Belt Cleaning Unit

    TRANSFER UNIT) is installed and that the transfer unit release lever is put back to the original position ( 3.5 PCU AND DEVELOPMENT UNIT). After replacing the transfer belt cleaning unit, perform forced line position adjustment (SP5-993-002 or "Maintenance menu - Color registration - Auto Adjust' in User Program mode). 3-21 G060...

  • Page 88: Cleaning Blade And Cleaning Roller

    Front: a long, thin, silvery spring Rear: a short, thick, black spring 7. Cleaning blade [G] (1 bearing) After replacing the cleaning blade, perform forced line position adjustment (SP5- 993-002 or 'Maintenance menu - Color registration - Auto Adjust' in User Program mode). G060 3-22...

  • Page 89: Transfer Belt

    5. Transfer exit guide [C] ( x 1, 1 step screw) 6. Left bracket [D] ( x 2, x 1) NOTE: Make sure that the grounding plate [E] is in the correct position when reinstalling the left bracket. 3-23 G060...
  • Page 90 10. Grounding plate [I] ( x 1) 11. Right bracket [J] ( x 1) Reassembly  Set the transfer entrance guide in position.  Hold up the transfer entrance guide. ‘ Screw the transfer entrance guide into position. G060R813.WMF G060 3-24...
  • Page 91  Pull the transfer belt roller to the right. ‘ Set the right end of the spring. ’ Check that the spring is straight. “ Press the front end of the gear shaft to properly set the gear on the shaft. G060R814.WMF 3-25 G060...
  • Page 92 3) When reassembling, check that the connector [R] is outside the transfer belt. After replacing the transfer belt, perform forced line position adjustment (SP5-993- 002 or 'Maintenance menu - Color registration - Auto Adjust' in User Program mode). G060 3-26...

  • Page 93: Others

    [D] and the left drive roller mark [E] are positioned at the top when reassembling. If the gear and roller are not positioned as shown, this may cause the transfer belt speed to fluctuate slightly, resulting in color shifts. 3-27 G060...

  • Page 94: Fusing

    Maintenance menu in the user tools “Menu/Maintenance/Color Regist./Fuser Adjust/At Unit Replace”. This mode is automatically required after the machine detects a new fusing unit is installed. Refer to Maintenance Guide 1 of the Operating Instructions for how to adjust this. G060 3-28...

  • Page 95: Oil Supply Unit

    4. Oil supply Unit [A] 3.8.3 UPPER COVER G060R501.WMF 1. Oil supply unit [A] 2. Knob [B] ( x 1) 3. Oil unit separation lever [C] ( x 1) 4. Upper cover [D] (Step screw x 1,  x 3) 3-29 G060...

  • Page 96: Fusing Belt Unit

    NOTE: When reassembling, insert the hook [C] into the lower cover groove [D]. Otherwise, the plate bends slightly and the pick-off pawls may damage the pressure roller. After reinstalling the plate, push the central portion [E] down to make sure that the plate is in position. G060 3-30...
  • Page 97 3. Pressure springs [E] 4. Belt tension springs [F][G] 5.  x 4 [H] G060R507.WMF 6. Pressure brackets [I] NOTE: If you have difficulty removing the brackets, press down one of the places indicated by the arrows [J][K]. 3-31 G060...
  • Page 98 [M]. The unit that comes with the machine does not have this. G060R821.WMF 8. Fuse terminal [N] ( x 1) 9. Thermistor connector [O] ( x 1) 10. Pull the fusing belt unit [P] up and remove it. G060 3-32...

  • Page 99: Pressure Roller

    NOTE: When reassembling, check that the protruding part of the gear faces the inside. 5. Fuse stay [D] ( x 1) 6. Thermistor bracket [E] ( x 1) US: 350W EU/AA 325W G060R803.WMF 7. Pressure roller fusing lamp [F] ( x 1) 3-33 G060...
  • Page 100 FUSING G060R805.WMF 8. Pressure roller unit [G] ( x 4) G060R806.WMF 9. Pressure roller stoppers [H][I] ( x 1 each) 10. C rings [J][K] 11. Bearings [L][M] 12. Pressure roller [N] G060 3-34...

  • Page 101: Paper Exit

    FUSING 3.8.6 PAPER EXIT G060R601.WMF 1. Paper exit cover ( 3.3 EXTERIOR COVERS) 2. Exit upper limit sensor cover [A] ( x 2) 3. Exit upper limit sensor [B] 4. Paper exit sensor [C] 3-35 G060...

  • Page 102: Electrical Components

    However, because the LD cables are disconnected, no output appears. 3.9.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT - C, B OUT OF THE WAY 1. Rear cover ( 3.3 EXTERIOR COVERS) 2. Swing out the high voltage supply unit [A] ( x 2). G060R711.WMF G060 3-36...

  • Page 103: Controller And Bcu

    NVRAM board. If the old NVRAM is not installed on the new controller board, the total counter information will be inaccurate. If the NVRAM on the old board is defective, replace the NVRAM ( 3.6.4 NVRAM REPLACEMENT PROCEDURE). G060R703.WMF 3-37 G060...

  • Page 104: Nvram Replacement Procedure

    6. Reset the settings for meter charge with SP5-930-1 to -5. 7. Reset the total counter to 0 (SP 7-825-1) if meter charge mode (SP 5-930-1) is enabled. 8. Enter the SP mode changes at the factory and the field. G060 3-38...

  • Page 105: Removing The High Voltage Supply Board - C, B

    3.9.6 PSU G060R715.WMF 1. Left cover ( 3.3 EXTERIOR COVERS) 2. PSU [A] ( x 5, x 12) NOTE: Check that the interlock switches on the PSU work normally after reinstalling the PSU (open/close the left and front doors). 3-39 G060...

  • Page 106: Drive Unit

    The nuts will drop in the rear side of the machine if they are not secured properly. G060R706.WMF 4. Lower gear guide ( 3.10.3 DEVELOPMENT DRIVE MOTOR - CMY) 5. Registration clutch [I] ( x1, x 1) G060 3-40...

  • Page 107: Development Clutches

    4. Y drum gear ( x 1) ( 3.10.1 REGISTRATION CLUTCH) 5. Lower gear guide ( 3.10.3 DEVELOPMENT DRIVE MOTOR - CMY) NOTE: To remove the B, Y, and C development clutches, you do not have to remove the lower gear guide. 3-41 G060...
  • Page 108 (no black or yellow). If the cables are routed as shown in Case 2, the power lines for the clutches are connected incorrectly, causing damage to the BCU board. G060 3-42...

  • Page 109: Development Drive Motor - Cmy

    4. Development clutches ( 3.7.2 DEVELOPMENT CLUTCHES) 5. Three gears [C]∼[E] 6. Timing belt [F] G060R818.WMF 7. Four gear drive holders [G]∼[J] ( x 1 for each) 8. Development clutch securing plate [K] ( x 8, x 2) 3-43 G060...

  • Page 110: Drum Drive Motor - Cmy And Drum Drive Motor - K

    1. Rear cover ( 3.3 EXTERIOR COVERS) 2. Development clutch securing plate ( 3.10.3 DEVELOPMENT DRIVE MOTOR - CMY) 3. Drum drive motor - CMY [A] ( x 2) 4. Drum drive motor - K [B] ( x 2) G060 3-44...

  • Page 111: Development Drive Motor - K

    NOTE: If you have difficulty removing the duct, remove the right duct [C]. G060R721.WMF 5. Development clutch securing plate ( 3.10.3 DEVELOPMENT DRIVE MOTOR - CMY) 6. Development drive motor – K [C] ( x 4, x 1) 3-45 G060...

  • Page 113: Troubleshooting

    TROUBLESHOOTING...

  • Page 115: Process Control Error Conditions

    Check if the development unit is properly set. development unit” If the problem is still the same, check the following: is displayed. • Poor connection of connectors • TD sensor defective • Harness damage • BCU board failure • Firmware problem (engine main or MUSIC) G060...
  • Page 116 NOTE: When the machine detects new development units, it automatically starts developer initialization. If an error other than Error 8 occurs, developer initialization is automatically resumed by opening and closing the front door or turning the main switch off and on. G060...

  • Page 117: Process Control Self-Check Result

    (if SP3- correction 125-002 is set to “2”). Forced Process control self- A cover was opened or the Do the process control termination check was forcibly main switch was turned off self-check again. terminated. during the self-check. G060...

  • Page 118: Line Position Adjustment Result

    Note 1: Concerning the error codes (05, 06, 07 or 10) which stop sampling data when either the front or rear ID sensor detect an error, the machine may display the error code for both ID sensors in some cases. G060...
  • Page 119 In addition, the green LED on the BICU stays on or off under the following condition. The MUSIC CPU resets due to Fix the bias leak and/or replace electrical noise generated by a high voltage leak on a damaged OPC drum. G060...
  • Page 120 Poor connection between the Check the connection between toner cartridge detection board the detection board and memory and the memory chip on the toner chip. cartridge The memory chip on the toner Replace the toner cartridge. cartridge fails. G060...

  • Page 121: Service Call Conditions

    Image development 2 400 - Image transfer 420 - Paper separation 430 - Cleaning 440 - Around drum 460 - Unit 480 - Others Paper feed / Fusing 500 - Paper feed 515 - Duplex 520 - Paper transport G060...
  • Page 122 780 - Unique for a specific model Controller 800 - Error after ready condition 820 - Diagnostics error 860 - Hard disk 880 - Unique for a specific model Others 900 - Counter 920 - Memory 990 - Others G060...

  • Page 123: Sc Table

    4. Replace the front (for K&Y) or rear (C&M) synchronizing (for C&M) synchronizing detector detector board (the board. beam does not target 5. Replace the LD unit. the photo detector.) • Defective LD unit 6. Replace the BCU. • Defective BCU G060...
  • Page 124 5. Replace the LD unit. or rear (K&Y) 6. Replace the BCU. synchronizing If a synch. detector board cannot be detector board • Defective LD unit replaced, do the following as a temporary measure: • Disable main scan length detection (SP 2-919-001) G060 4-10...
  • Page 125 • When the feedback signal stays Low 7 seconds after completing the laser exposure, or • When the feedback signal stays Low until the laser exposure timing for the next page in multi-page print mode. 4-11 G060...
  • Page 126 LD positioning motor. to switch off. 3. Replace the LD positioning motor. when switching the 4. Replace the LD home position actuator • Brown fuse (FU81) on sensor. 5. Check and/or replace the PSU. the Power supply unit G060 4-12...
  • Page 127 2. Reset the related color development SC 375 Vt error [Y] than 0.5V. unit. than 0.5V.) SC 376 Vt error [C] • Defective TD sensor 3. Replace the related color SC 377 Vt error [M] development unit. 4-13 G060...
  • Page 128 OK. If the problem SC 389 Development image quality is not OK, fix the following range: gamma error -150V ≤ Vk ≥ 150V problem. Then, enable the SC detection again. • Development gamma calculation error G060 4-14...
  • Page 129 4. Replace the power pack B/C. input terminal • Incorrect power pack not within the control target 30 5. Replace the cable. consecutive times, this SC 6. Replace the BCU. B/C output code is generated. • Damaged cable • Defective BCU 4-15 G060...
  • Page 130 3. Replace the thermistor. feed section) side of the laser 4. Replace the BCU. error • BCU defect optics unit, is less than -30°C for 10 seconds consecutively, the BCU determines that the circuit is opened and displays this SC code. G060 4-16...
  • Page 131 BCT and high voltage every 2 ms and generates this between the BCU and supply board. SC code when the error high voltage supply 6. Replace the BCU. condition occurs 250 board consecutive times. • Defective BCU 4-17 G060...
  • Page 132 3. Check and/or replace the paper lift error motor • Defective bottom user to reset the tray. If this sensor. condition occurs three 4. Check and/or replace the tray lift plate lift mechanism consecutive times, the SC is motor. generated. G060 4-18...
  • Page 133 • If the end fence home motor or connector disconnection position sensor stays ON for a specific number of pulses after the tray motor and stack transport clutch turn on to transport the paper stack. 4-19 G060...
  • Page 134 18 3. Check and/or replace the defective disconnection • Defective lift sensor seconds, the machine asks the component. user to reset the tray. If this or connector condition occurs three disconnection consecutive times, the SC is generated. G060 4-20...
  • Page 135 • Defective PSU SC 543 Heating roller The detected fusing 1. Replace the PSU. • Defective BCU fusing lamp temperature stays at 200 °C or 2. Replace the BCU. overheat more for five seconds. 4-21 G060...
  • Page 136 • Defective PSU SC 553 Pressure roller The detected pressure roller 1. Replace the fusing unit. • Defective BCU fusing lamp temperature stays at 200 °C or 2. Replace the PSU. overheat more for five seconds. 3. Replace the BCU. G060 4-22...
  • Page 137 500 ms. If the number of zero-cross signal generated is either more than 66 or less than 45 and when this condition is detected 10 consecutive times, this code is displayed. 4-23 G060...
  • Page 138 BCU NVRAM A read/write diagnostics error 1. Turn the main switch OFF/ON. read/write is detected when the main SW 2. Replace the NVRAM. NVRAM (BCU) diagnostics is turned ON. error Note: This only occurs with the 8kB NVRAM. G060 4-24...
  • Page 139 • Loose connection error hammer motor turns on. connector is properly connected. • Overload caused by 3. Check if the staple jam occurs. stapling too many 4. Replace the staple hammer motor. pages • Defective staple hammer motor 4-25 G060...
  • Page 140 • Defective stapler 2. Check if the stapler rotation motor motor error specified time after the stapler connector is properly connected. rotation motor rotation motor starts rotating. 3. Replace the stapler rotation motor. • Motor overload G060 4-26...
  • Page 141 4. Replace the tray 2 lift motor. • Motor overload • The lower stack height sensor 1 is deactivated consecutively (not detecting paper) for 15 seconds after the shift tray starts moving down. 4-27 G060...
  • Page 142 2. Check and/or replace the RAM DIMM. [766D] Memory error Unexpected system memory 3. Check and/or replace the ROM • Defective controller size DIMM. • Software error 4. Replace the controller. 5. See NOTE at the end of the SC table. G060 4-28...
  • Page 143 [0D05] problem with the CPU timer. If the ASIC firmware. • Defective RAM-DIMM timer does not function in the 3. Replace the RAM-DIMM. • Defective controller specified range, this SC code 4. Replace the controller board. is displayed. 4-29 G060...
  • Page 144 Verification Error detected during a 1. Turn the main switch off and on. error write/verify check for the 2. Replace the SRAM DIMM. • Defective SRAM standard RAM (SRAM DIMM). 3. Replace the controller. DIMM • Defective controller G060 4-30...
  • Page 145 1. Turn the main switch off and on. error: I/F error BCU is not properly • Defective controller 2. Check the connection between the [0F21] connected. BCU and controller. • Defective BCU 3. Replace the controller. 4. Replace the BCU 4-31 G060...
  • Page 146 • Defective cables 2. Check the connection between the the power is supplied to the HDD and controller. • Defective HDD HDD. 3. Check and replace the cables. • Defective controller 4. Replace the HDD. 5. Replace the controller. G060 4-32...
  • Page 147 RAM-DIMM, ROM- turned on. DIMM are properly connected. DIMM • Defective controller 3. Reinstall the controller system firmware. • Software problem 4. Replace the controller. SC 999 Firmware error See G570 SM page 4-43 for description of SC 999 4-33 G060...
  • Page 148 • Logging (SP5-990-004) • Printer driver settings used when the problem occurs • All data displayed on the screen (SC code, error code, and program address where the problem is logged.) • Image file which causes the problem, if possible G060 4-34...

  • Page 149: Troubleshooting Guide

    When paper touches the If 4C thin lines become smeared: appear in solid image areas. spurs and the spurs do not rotate, the spurs scratch the mage. G060T501.WMF If white lines appear in solid image areas: G060T502.WMF 4-35 G060...
  • Page 150 Making prints with a low image area ratio causes the toner-carrier attraction to increase, resulting in low image density. Activating the Auto TD Adjustment corrects toner density within the target range; however, it takes up to 6 minutes to complete the self-check and Auto TD Adjustment. G060 4-36...
  • Page 151 ID proper development potential gap during machine operation. without adjusting the toner concentration. Over the course of the print operation, the ID will then get closer and closer to the target level. 4-37 G060...
  • Page 152 (i.e. not processed as text/line data), decrease the setting for Photo from 260% to 170 - 190%. NOTE: If the toner limit is lowered too much, it may cause the density of shadow areas to be not smooth. G060 4-38...

  • Page 153: Color Shift

    G060T503.WMF • Paper skew directly affects the color shift between the front and rear sides. There are several factors. One of them is the position of the side fences. 4-39 G060...
  • Page 154 Color shifts between the front and rear sides • Side fences are not properly set. Reposition the paper attraction roller unit. • Pressure between the paper attraction roller and transfer belt is not even at the front and rear sides. G060 4-40...

  • Page 155: Adjustment Standard: Max. 200 Μm

    5. Take the required action explained in each section depending on the type of color shift. 6. Do the ‘Auto Adjust’ in the User Program mode after the adjustment is done in step 5, and check the result. 7. Repeat steps 3 to 6 until the color shift is acceptable. 4-41 G060...
  • Page 156 Then, repeat this step until the shift between magenta (by-pass feed) and black is minimized. NOTE: Fusing roller speed can be adjusted with ‘’Custom Adjust’ in Fuser Adjust in the User Program Mode, instead of with SP mode. G060 4-42...
  • Page 157 Correction [dots] = +(40/42.4) = Approx. +1 • If the magenta line has shifted down in relation to black by 70µm in 600dpi mode, subtract 2 from the current setting of SP5-993-17. Correction [dots] = -(70/42.4) = Approx. –2 4-43 G060...
  • Page 158 Correction [%] = (0.1/287) x 10000 = Approx. +4 • If the magenta line is reduced by 0.05 mm in relation to the black line, subtract “2” from the current setting of SP5-993-014. Correction [%] = -(0.05/287) x 10000 = Approx. -2 G060 4-44...
  • Page 159 • Check if the transfer belt is in correct position, if the toward the trailing tension springs are properly set, or if the paper edge. attraction roller is properly installed.. 3.7.4 Transfer Belt) 4-45 G060...

  • Page 160: How To Measure The Gap Between Color Lines

    (percentage) of SP1- 004-001, 002, or 007 depending on the mode selected. • SP1-004-001 Normal paper, Color mode, 1200 dpi (62.5 mm/s) G060T505.WMF • SP1-004-002 Normal Paper, Color mode, 600 dpi (125 mm/s) • SP1-004-007 Thick Paper (62.5 mm/s) G060 4-46...
  • Page 161 Pattern 4 Color shift (registration) in the main- scan direction Colored line shifts in the main-scan direction and the amount of shift is the same at left, center, and right. This is caused by incorrect color registration. G060T508.WMF 4-47 G060...

  • Page 162: Color Shift After Transfer Unit Replacement

    4. Perform the line position adjustment (SP5-993-002 or ‘Auto Adjust’ in User Program mode). 5. Print a 1-dot grid pattern using A3/11”x17” paper in 600 dpi mode. 6. If the color shift in the main-scan direction is not within the adjustment standard, follow the troubleshooting guide. G060 4-48...

  • Page 163: Fusing Roller Speed Adjustment

    2. Check if there is any color which has shifted from the black line by the same amount all the way down the page from leading to trailing edge. If there is, follow the troubleshooting procedure (Sub-scan/Whole image). 4-49 G060...

  • Page 164: Registration Roller Speed Adjustment (For B&W Mode)

    3. Depending on the paper used, a horizontal band may appear at 60 mm (2.76") from the leading edge on A3 (11"x17") paper. If the horizontal band is observed on the 2-dot pattern, decrease the setting of SP1-004-006 in 0.1% steps until the problem is solved. G060 4-50...

  • Page 165: Electrical Component Defects

    The paper overflow message is not Open displayed even when a paper overflow Exit upper limit 210-A6 condition exists, causing paper jam. sensor The paper overflow message is Shorted displayed. The CN numbers are the connector numbers on the BCU. 4-51 G060...

  • Page 166: Blown Fuse Conditions

    (This fuse is directly soldered on the PSU.) 4.7 LEDS (BCU) Status Blinking Stays OFF or ON LED1 (RED) Main functions The Main CPU does not function correctly. properly. The MUSIC CPU functions The MUSIC CPU does not function LED (Green) correctly. properly. G060 4-52...

  • Page 167: Service Tables

    SERVICE TABLES...

  • Page 169: Service Program Mode

    Method 2: Press the “Up/Down arrow” keys together for about 5 seconds, then press the “Enter” key. The above message shown in the illustration appears on the display. NOTE: The machine automatically goes off line when you enter the service mode. G060...

  • Page 170: Accessing The Required Program

    SP Modes Related to the Controller SP2-208-009 SP5-009-001 SP2-213-001 SP5-961-001 SP2-224-001 to 004 SP5-930-001 to 005 SP5-994-001 and 002 SP7-905-007 and 009 NOTE: If the settings of SP modes 5-993-013 to 015 are changed, these changes will affect the next line position adjustment. G060...

  • Page 171: Printer Controller Service Mode

    [FC, K], [FC, Y], [FC, M], or [FC, C]: Black, Yellow, Magenta, or Cyan in full color mode Paper Feed Station P: Paper tray B: By-pass table Fusing Section H: Heating roller P: Pressure roller Print Mode S: Simplex D: Duplex Process Speed 62.5, 125, 185 G060...

  • Page 172: Others

    NOTE: If “Alphanumeric” is written to the right of the bracket as shown above, the setting of the SP mode is displayed on the screen using alphanumeric characters instead of only numbers. However, the settings in the bracket in the SP mode table are explained by using only the numbers. G060...

  • Page 173: Service Mode Menu ("1. Service")

    Stores the print gamma adjusted with the “Gamma Adj.” menu item as the current setting. Before the machine stores the new ‘current setting’, it moves the data currently stored as the ‘current setting’ to the ‘previous setting’ memory storage location. G060...
  • Page 174 • [ ] [ ]: Move to the next bit. bit0 • [Escape]: Exit without saving changes. • [Enter]: Exit and save changes. NOTE: The left digit on the display is bit 7 and the right digit is bit 0. 4. Press [Enter] to save changes and exit. G060...

  • Page 175: Printer Engine Service Mode

    [ 96.0 to 104.0 / 100.0 / 0.1 %/step ] NOTE: • SP1-004-002 and 005 is for color mode. Fine adjustment for B&W mode can be done with SP1-005-001 and 002. • SP1-004-004 is for normal paper. Fine adjustment for thick paper can be done with SP1-005-003. G060...
  • Page 176 PRINTER SP MODE Rev. 10/2003 Mode No. Function / [ Setting ] (Class 1 and 2) [Data Save] Data Save Stores the print gamma adjusted with the “Gamma Adj.” menu item as the current setting. Before the machine stores the new ‘current setting’, it moves the data currently stored as the ‘current setting’...
  • Page 177 [ 100 to 190 / 175 / 5°C/step] H:N[FC] S 62.5 [ 100 to 190 / 150 / 5°C/step] H:N[FC] S 125 [ 100 to 190 / NA: 175 EU: 180 / 5°C/step] 10 H:N[FC] D 62.5 [ 100 to 190 / 145 / 5°C/step] G060...
  • Page 178 [Paper Size] Tray Paper Size Tray 1 A4/LT Specifies the paper size for tray 1. [ 0 or 1 / 0 / - ] Alphanumeric 0: A4 sideways, 1: LT sideways Tray 1 can only use these two sizes. US: 1 FA G060 5-10...
  • Page 179 [ 0 to 15 / 0 / 1°C/step] H:Low Temp Sets the fusing temperature increase for the low temperature condition. [ 0 to 15 / 5 / 1°C/step] P:Low Temp [ 0 to 15 / 5 / 1°C/step] 5-11 G060...
  • Page 180 (Target temperature specified by SP1-105-12, -13, -23, -24) - (Temperature specified by this SP mode (default: 5°C for heating roller, 10°C for pressure roller)) H:Print Temp [ 0 to 20 / 5 / 1°C /step ] P:Print Temp [ 0 to 20 / 10 / 1°C /step ] G060 5-12...

  • Page 181: Sp2-Xxx (Drum)

    [0 to 255 / 71 / 1/step ] DFU AC:[M] 62.5 [0 to 255 / 71 / 1/step ] DFU AC:[M] 125 AC:[C] 62.5 [0 to 255 / 71 / 1/step ] DFU AC:[C] 125 [0 to 255 / 71 / 1/step ] DFU 5-13 G060...
  • Page 182 [ 0 to 255 / 50 / 50 pulse/step ] FA [ 0 to 255 / 42 / 50 pulse/step ] FA Pitch 600 Display 1200 [ 0 to 255 / - / 1 pulse/step ] Display 600 [ 0 to 255 / - / 1 pulse/step ] G060 5-14...
  • Page 183 Sets the toner supply rate used when the toner supply method (SP2-208-1 to 4) is set to ‘0’ (fixed Fixed Rate [Y] supply mode). Fixed Rate [M] [ 0 to 100 / 5 / 1%/step ] Fixed Rate [C] 5-15 G060...
  • Page 184 The machine detects toner end when the following End [YMC] happens 10 times consecutively. Then, the machine stops printing, even during a print job. Vt > Vref + Threshold [ 0 to 5.0 / 0.8 / 0.1 V/step ] G060 5-16...
  • Page 185 Humidity Auto Correction and adjust the Vcnt value in SP2-224-1 to 4 (by trial and error). [ 0 or 1 / 1 / - ] Alphanumeric 0: Disabled 1: Enabled 5-17 G060...
  • Page 186 [ 0 to 50 / 16 / 1 µA/step ] [FC,K]P D 125 [ 0 to 50 / 6 / 1 µA/step ] [FC,Y]P D 62.5 [ 0 to 50 / 11 / 1 µA/step ] [FC,Y]P D 125 G060 5-18...
  • Page 187 [FC,K]SP D125 [ 0 to 50 / 13 / 1 µA/step ] [FC,Y]SP D125 [ 0 to 50 / 11 / 1 µA/step ] [FC,M]SP D125 [ 0 to 50 / 12 / 1 µA/step ] [FC,C]SP D125 5-19 G060...
  • Page 188 [FC] SP S 125 [ 10 to 30 / 10 / 0.1/step ] [FC] SP D 62.5 [ 10 to 30 / 2 / 0.1/step ] [FC] SP D 125 [ 10 to 30 / 5 / 0.1/step ] G060 5-20...
  • Page 189 [FC,M] 1200 [ 0 to 20000 / 1136 / 1 dot ] DFU [FC,C] 1200 [ 0 to 20000 / 5762 / 1 dot ] DFU [K] 600 [ 0 to 20000 / 3755 / 1 dot ] DFU 5-21 G060...
  • Page 190 When the line position adjustment fails, it is one of possible causes when the mirror position motor locks. Performing this SP mode can move the mirrors back to the original position if it locks. Then, do the forced line position adjustment (SP5- 993-002). G060 5-22...

  • Page 191: Sp3-Xxx (Process)

    If Vsg is out of the adjustment range and this is detected 3 times consecutively, it leads to SC385. LED Current R Displays the ID sensor LED current adjusted during Vsg adjustment. [ 0 to 1023 / - / 1 ] 5-23 G060...
  • Page 192 [ 0 to 3 / 0 / 1/step ] Alphanumeric 0: Disable 1: Initial & Non-use self-check 2: Job end & Non-use self-check 3: Initial & Job end & Non-use self-check Do not adjust unless advised by senior technical staff. G060 5-24...
  • Page 193 [ 0 to 1.00 / 0.12 / 0.01 mg/cm2 /step] DFU Printer [M] Printer [C] [ 0 to 1.00 / 0.13 / 0.01 mg/cm2 /step] DFU CF [K] CF [Y] [ 0 to 100 / 0.14 / 0.01 mg/cm2 /step] DFU CF [M] CF [C] 5-25 G060...
  • Page 194 Sets the coefficient to calculate the counter value for black-and-white prints. [ 0 to 1.00 / 1.00 / 0.01/step ] DFU With the default setting (100), counters used for process control count up by 1 when 1 black-and- white print has been made. G060 5-26...
  • Page 195 When the total number of prints since the last refresh mode exceeds the number specified in this SP mode, refresh mode is done before the job end process control self-check. [ 10 to 2550 / 200 / 10 prints/step ] 5-27 G060...
  • Page 196 NOTE: If toner is drastically consumed for a short time, this may cause carrier to flow out. To prevent this, toner is consumed over a long period of time. (It takes about 20 minutes to complete this toner refresh mode). All Color G060 5-28...
  • Page 197 [ 0 to 9999 / - / 1/step ] All colors are displayed. The results are displayed in the order “K Y C M” e.g., 1 1 9 1: The self-check for Cyan failed but the others were successful See the troubleshooting section for details. 5-29 G060...

  • Page 198: Sp5-Xxx (Mode)

    [ 0 or 1 / 0 / - ] 0: Normal count 1: Double count [ES Level 2 Set] ES Level 2 Set Enables or disables Energy Saver Level 2 (Auto Off mode). [ 0 or 1 / 0 / - ] 0: Enabled 1: Disabled G060 5-30...
  • Page 199 SP5-930-1. This can be up to 13 characters (both numbers and alphabetic characters can be input). [HDD Init.] HDD Initialization HDD Init. Initializes the hard disk. Use this SP mode only in there is a hard disk error. 5-31 G060...
  • Page 200 [Meter Charge] Meter Charge Mode ON/OFF Enables or disables the Meter Charge mode. When enabling the Meter Charge mode, the “Counter” menu is added to the user menu. [ 0 or 1 / 0 / - ] Alphanumeric 0: OFF 1: ON G060 5-32...
  • Page 201 500 sheets and the lower tray for 1,500 sheets. [ 0 or 1 / 1 / - ] 0: Disabled 1: Enabled NOTE: The main switch must be turned off and on to effect the setting change. 5-33 G060...
  • Page 202 Enables or disables the line position adjustment during a print job when the temperature differs by the amount specified in SP5-993-003 from the temperature at the last adjustment. [ 0 or 1 / 1 / - ] Alphanumeric 0: Disabled 1: Enabled G060 5-34...
  • Page 203 [ -128 to 127 / 0 / 1 dot/step ] FA 18 S Reg. 600[C] 600dpi: 1 dot = 40µ 19 S Reg. 1200[Y] 1200 dpi: 1 dot = 20µ 20 S Reg. 1200[M] 21 S Reg. 1200[C] 5-35 G060...
  • Page 204 [ 0 to 4 / 1 / 1/step ] 0: By-pass Table 1: Tray 1 2: Tray 2 3: Tray 3 4: Tray 4 NOTE: The machine makes a test pattern on the paper size loaded in the selected paper tray. G060 5-36...
  • Page 205 Prints the test pattern with the settings specified with SP5-997-001 to 006. NOTE: When exiting the SP mode, the test print mode is automatically canceled. [Memory Clear 2] ENG Setting Clears the engine settings except for counters. ENG Counter Clears all counters. 5-37 G060...

  • Page 206: Sp6-Xxx (Peripherals)

    [ -3.5 to 3.5 / 0 / 0.5 mm/step ] NOTE: Although the adjustable range is ±3.5 mm, the stapling position can be changed only by 1.0 mm when stapling one position at the front or rear side even when the input value is more than 1.0. G060 5-38...

  • Page 207: Sp7-Xxx (Data Log)

    Displays the number of times hole punching has been done. [ 0 to 9999999 / 0 / 1/step ] [SC Counter] SC Counter Displays the number of SC codes detected. [ 0 to 9999 / 0 / 1/step ] 5-39 G060...
  • Page 208 D Exit 2:OFF D Exit 3:OFF D Feed:OFF F Entrance F Shift Tray 1 F Shift Tray 2 F Staple F Exit F Drive F Tray Up/Down F Jogger F Staple F Exit F Punch F Jam Clear G060 5-40...
  • Page 209 (SP7-906-1 to 9) and is reset to “0”. PF Tray 3/LCT The total number of sheets printed with the last PF Tray 4 unit replaced can be checked with SP7-906-1 to 9. S:Fusing NOTE: The LCT is counted as the 3rd feed S:Transfer station. 5-41 G060...
  • Page 210 Transfer [SC/Jam Clear] SC/Jam Counter Clear SC/Jam Clear Clears the counters related to SC codes and paper jams. [Counter Clear] Counter Clear Clears all counters. See NOTE 1 after the SP table for a list of settings cleared. G060 5-42...
  • Page 211 2.5K prints before detecting the end condition. The unit life is 1860 revolutions. Increment: Delays the alert display timing. Decrement: Hastens the alert display timing. 1.0K prints = 93 [ 0 to 10000 / 1628 / 1 K revolutions/step ] 5-43 G060...
  • Page 212 [ 0 to 100.00 / - / 0.01 %/step ] Last [M] Last [Y] [Firmware PN] Firmware Part Number Controller Displays the part number of the firmware. Engine Displays the part number of the firmware. Finisher Mail Box Duplex MUSIC Factory Printer Test G060 5-44...
  • Page 213 PRINTER ENGINE SERVICE MODE Rev. 03/2003 Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Firmware Ver.] Controller Displays the firmware version. Engine Finisher Mail Box Duplex MUSIC Factory Printer Test 5-45 G060...
  • Page 214 • Serial number information • SP modes related to meter charge • Counters and logging data ENG Counter All counters and logging data related to engine [Counter Clear] Counter Clear SP7-101, 204, 209, 502, 504, 506, and 507 G060 5-46...

  • Page 215: Input Check Table

    Upper Relay Sensor (PFU) Paper not detected Paper detected Lower Relay Sensor (PFU) Paper not detected Paper detected Registration Sensor Paper not detected Paper detected Duplex Inverter Sensor Paper not detected Paper detected Duplex Feed Sensor Paper not detected Paper detected 5-47 G060...
  • Page 216 Paper not detected Paper detected Tray 3 Paper Overflow Sensor Not full Full Tray 3 Paper Sensor Paper not detected Paper detected Tray 4 Paper Overflow Sensor Not full Full Tray 4 Paper Sensor Paper not detected Paper detected G060 5-48...
  • Page 217 11” x 17” SEF 11” x 17” SEF A3 SEF A3 SEF B4 SEF ” x 11” SEF A4 SEF 8” x 13” SEF F SEF A5 SEF ” x 18 ” SEF B6 SEF Post Card Post Card 5-49 G060...

  • Page 218: Output Check Table

    DevAC [YMC] Development AC Bias for Color DevAC [K] Development AC Bias for Black Transfer [Y] Transfer Current for Yellow Transfer [M] Transfer Current for Magenta Transfer [C] Transfer Current for Cyan Transfer [K] Transfer Current for Black G060 5-50...
  • Page 219 Air Pump Motor DevAC TRG[YMC] Development AC Trigger for Color DevAC TRG[K] Development AC Trigger for Black DevPWM TRG[K] Development PWM Trigger for Black DevPWM TRG[C] Development PWM Trigger for Cyan DevPWM TRG[M] Development PWM Trigger for Magenta 5-51 G060...
  • Page 220 DI M12 450CW Duplex Inverter Motor 1&2 / 450 / Clockwise Duplex M125CCW Duplex Feed Motor / 125 / Counterclockwise Duplex M230CCW Duplex Feed Motor / 230 / Counterclockwise Duplex M370CCW Duplex Feed Motor / 370 / Counterclockwise G060 5-52...
  • Page 221 LD2 Power for Black / 125 LD2 [K] 185 LD2 Power for Black / 185 LD [K]62.5 LD Power for Black / 62.5 LD [K]125 LD Power for Black / 125 LD [K]185 LD Power for Black / 185 5-53 G060...

  • Page 222: Test Pattern (Sp5-997)

    24. Blank Selects the desired paper size. "Y PASS Tray or By-pass S P 5 - 9 9 7 - 0 0 6 4RAY Prints the test pattern. S P 5 - 9 9 7 - 0 0 7 G060 5-54...

  • Page 223: Firmware Update Procedure

    Controller System Firmware: If a download attempt fails, you must boot up the machine from the IC card. To do this, DIP SW 1 on the controller board needs to be ON. The machine will automatically start upgrading the firmware. 5-55 G060...

  • Page 224: Controller/Engine Firmware Upgrade

    R em ove the IC card D isplays "U pdated P ow er off on" after com pleting update G058R713.WMF T urn M ain SW off R em ove the IC card Attach the cover C lose the front door G060 5-56...

  • Page 225: Controller Self-Diagnostics

    Detailed Check Real Time Clock Check S C 8 2 6 Font ROM Sum Check Network Check Error Logged Error Logged E N D Engine I/F Check Error Logged Interrupt Check Error Logged Memory Chip Check Error Logged 5-57 G060...

  • Page 226: Detailed Self-Diagnostics

    • Refer to the diagnostics report for the detected errors. The errors detected during self-diagnostics can be checked with SP7-832-001 (Diag. Result). • Refer to section 4.2 for details about the error codes. G060 5-58...

  • Page 227: User Program Mode

    P aper S ize D uplex O utput T ray Job S eparation E nergy S aver 1 E nergy S aver 2 B & W P age D etect U nit of M eas ure R esolution USER PROGRAM MODE.WMF 5-59 G060...

  • Page 228: Dip Switches

    Fusing clutch is installed installed NOTE: A DIP switch has been added to the BCU board (P/N G0775069 or later). This setting is very important. If the switch is not set correctly, a paper jam or fusing problem will occur. G060 5-60...
  • Page 229 DETAILED DESCRIPTIONS...

  • Page 231: Detailed Section Descriptions

    3. Development Unit 11. Duplex Feed Unit 4. Laser Optics Housing Unit 12. Transfer Unit 5. Polygon Mirror Motor 13. Transfer Belt Cleaning Unit 6. Toner Cartridge 14. ID Sensor 7. By-pass Feed Table 15. Duplex Inverter Unit 8. Tray 2 G060...

  • Page 232: Paper Path

    The duplex unit has two exits for the two-tray finisher. When the one-tray paper feed unit is installed, paper feeds out to the two-tray finisher from the upper exit. When the two-tray paper feed unit or LCT is installed, paper feeds out to the two- tray finisher from the lower exit. G060...

  • Page 233: Drive Layout

    This drives the paper feed mechanisms for tray 1 and 2. 6. Transfer belt contact motor This moves the transfer belt into contact and away from the color PCUs. A flywheel on the drum drive gears (K, M, and C) stabilizes the gear rotation. G060...

  • Page 234: Board Structure

    Lamps Duplex 4-bin Finisher Unit Mailbox G060D551.WMF The BCU controls all the mechanical components. The IEEE1394 interface board, memory DIMM, and the HDD can be installed on the controller. The controller connects to the BCU through a PCI bus. G060...

  • Page 235: Descriptions

    6. Memory DIMM (Standard: 32MB DRAM, Option: 64/128/256MB DRAM) This is for additional printer processing memory, used for collation and for soft fonts. 7. Operation Panel Board Controls the display panel, the LED, and the keypad. 8. IEEE1284 Interface This is a parallel printer port. G060...

  • Page 236: Printing Process

    From the left, the PCU stations are black, yellow, cyan, and magenta. A transfer belt feeds paper past the PCUs, and the toner image on each drum is transferred to the paper. The paper path is inclined about 38 degrees to make the machine as compact as possible. G060...
  • Page 237 The ID sensor detects the density of the ID sensor pattern on the transfer belt. The ID sensor output is used for process control and for automatic line position, skew, and color registration adjustments for the latent image. G060...

  • Page 238: Process Control

    If SP3-125-1 is set to 0 (Off), the machine does not do the potential control, but uses the development bias adjusted with SP2-201-1 to -9, the charge roller voltage adjusted with SP2-001-1 to -9, and the laser power selected with SP2-103-1 to -27. However, these SPs should normally not be adjusted in the field. G060...
  • Page 239 M is adjusted with SP3-906-4 and N is adjusted with SP3-906-3. 6. After Toner End Recovery This starts after recovery from a toner end condition. 7. After Developer Initialization This starts after a developer initialization is done. Developer initialization occurs automatically after a new development unit has been installed. G060...

  • Page 240: Process Control Self Check Procedure

    ID sensor until its output (known as V ) is as follows. • V = 4.0 ± 0.5 Volts This calibration compensates for the transfer belt’s condition and the ID sensor condition, such as dirt on the surface of the belt or ID sensor. G060 6-10...
  • Page 241 M/A for each color by referring to a table in memory. The way that the laser power (V ) is selected depends on the setting of SP3-125-2. 6-11 G060...
  • Page 242 2. Each grade of the pattern is made using the bias and charge roller voltages selected above, and the various grades are made by changing the LD power. Step 7: Sensor Pattern Density Detection The ID sensor detects the densities of the 10 patterns for each color. This data goes to memory. G060 6-12...
  • Page 243 After that, the machine cleans the transfer belt by applying a positive dc charge to the cleaning roller for three rotations of the belt. It does not use the cleaning blade. L D P o w e r G060D003.WMF 6-13 G060...

  • Page 244: Toner Supply Control

    SP2-224-5 to -8. 3. Fixed supply mode This mode is used when the TD sensor becomes faulty. The amount of toner supply can be adjusted with SP2-208-5 to -8 if the image density is incorrect (the default setting is 5%). G060 6-14...
  • Page 245 After supplying toner, the machine clears the toner end condition if the following conditions are detected. • Vt [0] – Vt [3] > 0.5V • Vt – Vref > 0.3V 6-15 G060...

  • Page 246: Developer Initialization

    SP2-224-1 to -4 (adjust by trial and error). During developer initialization, the machine forcibly supplies toner because there is no toner inside the toner transport tube at installation. Then the machine does the process control self check. G060 6-16...

  • Page 247: Laser Exposure

    Laser exposure for magenta and cyan starts from the rear side of the drum, but for yellow and black it starts from the front side of the drum. This is because the units for magenta and cyan are on the other side of the polygon mirror from the units for yellow and black. 6-17 G060...

  • Page 248: Optical Path

    1,200 x 600 Dual beam OHP/Thick writing 1,200 x 1,200 29,528 paper) Color 600 x 600 29,528 (except 1,200 x 600 OHP/Thick 1,200 x 1,200 29,528 62.5 paper) OHP/Thick 600 x 600 1,200 x 600 29,528 62.5 1,200 x 1,200 G060 6-18...
  • Page 249 If the count for one particular beam varies from normal, the LD clock frequency for that beam is adjusted. If the board at the end position is defective, this cannot be detected. Switch the detection feature off with SP2-919-1. 6-19 G060...

  • Page 250: Dual Beam Writing

    LD positioning motor moves the LD unit to the home position, and then to the proper position. After the laser optics housing unit has been replaced, the beam pitch for 600 dpi and 1200 dpi must be adjusted (SP2-109-2, -3). G060 6-20...

  • Page 251: Ld Safety Switch

    [B] when LDB (K) C N 2 2 4 - 3 CN401-48 (K) closing or opening the front and left doors as shown. C N 2 2 4 - 2 CN401-49 (K) E - M A C G060D802.WMF 6-21 G060...
  • Page 252 1. Sub scan line position for YCM based on the line position for K (color registration) 2. Main scan line position for KYCM 3. Magnification ratio for KYCM 4. Skew for YCM based on the line position for K G060 6-22...
  • Page 253 If the machine detects that the image is out of position in the main scan direction, it changes the laser write start timing for each scan line. Magnification Adjustment If the machine detects that magnification adjustment is necessary, it changes the LD clock frequency for the required color. 6-23 G060...
  • Page 254 Main Scan Skew Adjustment G060D254.WMF The 3rd mirror positioning motors [A] for magenta, cyan, and yellow each adjust the angle of the 3rd mirror [B], based on the 3rd mirror position for black. This corrects main scan skew. G060 6-24...

  • Page 255: Photoconductor Unit

    The photoconductor gap between PCU and development roller is determined by the drum positioning plate and the rear shaft, and is not adjustable in the field. The push switches in the drum positioning plate detect when a new PCU has been installed. 6-25 G060...
  • Page 256 The drum drive motor-K [A] drives the PCU for black. It also drives the transfer unit. The drum drive motor-CMY [B] drives the PCUs for magenta, cyan, and yellow. Using one motor to drive these three drums reduces CMY color misalignment. G060 6-26...
  • Page 257 SP3-920-1 to -4 determine when this procedure (known as ‘refresh mode’) is done. It can also be executed at any time if the prints are smeared (using SP3-920-5). Quenching is done by illuminating the whole area of the drum with the laser at the end of every job. 6-27 G060...

  • Page 258: Drum Cleaning

    6.4.4 DRUM CLEANING G060D305.WMF The cleaning brush [A] spreads out the waste toner remaining on the drum. The cleaning blade [B] then scrapes it off. The toner collection auger [C] transports the toner towards the waste toner collection bottle. G060 6-28...
  • Page 259 There are two holes in the waste toner collection duct. If the toner is unable to drop through the hole [K] at the centre of the bottle, it is transported to the end of the duct and drops into the bottle through the hole [L] at the end. 6-29 G060...
  • Page 260 ”Waste Toner is Almost Full”. After that, the machine can print 1,000 more sheets. After printing 1,000 sheets, it displays ”Replace Waste Toner”, and after the end of the job, the printer cannot be used until the bottle is replaced or emptied. G060 6-30...
  • Page 261 The machine goes to standby development unit is present. mode. NOTE: If some PCUs or development units are not installed, the machine displays error messages in the following order. (M dev→M PCU→C dev→C PCU→Y dev→Y PCU→K dev→K PCU) 6-31 G060...
  • Page 262 The TD sensor and front ID sensor control toner density. Each development unit has a TD sensor. The diameter of the development roller is 18 mm (circumference about 56.5 mm). G060 6-32...
  • Page 263 The gear trains are indicated in the diagram by dotted lines. The development drive motor-CMY [B] drives the development unit for magenta, cyan, and yellow through gears and clutches. This motor also drives the registration roller and by-pass feed table. 6-33 G060...

  • Page 264: Developer Agitation

    DEVELOPMENT 6.5.3 DEVELOPER AGITATION G060D308.WMF Two mixing augers [A and B] circulate the developer forward and backward to agitate the developer. This happens during the process control self check, during toner supply, and during development. G060 6-34...
  • Page 265 (i.e., if SP3-125-1 is set to 1), the dc bias is the value stored in SP2-201-1 to -9 (do not adjust in the field unless advised to do so). The ac bias cannot be adjusted. 6.5.5 DEVELOPMENT UNIT DETECTION This is the same as PCU detection. See “Photoconductor Unit – PCU Detection’. 6-35 G060...

  • Page 266: Toner Supply Mechanism

    The toner mixed with air becomes a fluid, and passes part of the way along the transport tube towards the toner attraction pump. This pump draws the toner the rest of the way (see the next page). G060 6-36...
  • Page 267 0.7 s and off for 1.3 s. The number of times that the clutch turns on depends on the amount of toner to be supplied, which depends on the results of toner supply control. Motor drive comes from the development drive motors. 6-37 G060...

  • Page 268: Toner Cartridge Detection

    This is used to calculate the amount of toner remaining in the toner cartridge. The chip also detects whether the cartridge is installed (if the cartridge is not installed, the machine does not detect a signal from the memory chip). G060 6-38...
  • Page 269 There are two paper trays (500 sheets each), and a by-pass feed table (100 sheets). The paper feed mechanism uses an FRR system. Tray 1 can only hold A4 or letter paper. Tray 2 can hold a range of sizes. 6-39 G060...
  • Page 270 When the paper feed clutch [E] turns on, the pick-up, feed [F], and separation [G] rollers start rotating to feed the paper. The paper feed clutch stays on until shortly after the registration sensor activates. G060 6-40...
  • Page 271 [F] on the lift arm shaft [G]. Then the tray lift arm [H] lifts the tray bottom plate [I] until the paper lift sensor for the tray detects that the top of the stack is at the paper feed position. 6-41 G060...
  • Page 272 *3: The machine detects either 11” x 8½” LEF or B5 SEF, depending on the setting of SP 1-902-4 The machine disables paper feed from a tray if the paper size cannot be detected (if the paper size actuator is broken or no tray is installed). G060 6-42...
  • Page 273 If there is some paper in the paper tray, the paper stack raises the paper end feeler and the paper end sensor deactivates. When the paper tray runs out of paper, the paper end feeler drops into the cutout in the tray bottom plate, and this activates the paper end sensor. 6-43 G060...
  • Page 274 (the location of the gear train is indicated by dotted lines in the above diagram). The machine makes a paper buckle at the registration roller to correct paper skew. The paper buckle can be adjusted with SP1-003-1 to - 8. G060 6-44...
  • Page 275 Line speed (mm/s) Paper feed from tray to registration roller Fusing, paper exit to standard tray, and mailbox A bit slower than “Process line speed” Duplex invert and feed Finisher 6-45 G060...
  • Page 276 To feed paper, the by-pass pick-up solenoid (not shown in the diagram) moves the pick-up roller into contact with the top of the stack. Paper size and end detection are done in the usual manner. G060 6-46...

  • Page 277: Image Transfer And Paper Separation

    There are two ID sensors. Only the front one detects the image density of the patterns generated on the transfer belt for process control. The other function of the ID sensors is for automatic line position adjustment. Both sensors are used for this. 6-47 G060...

  • Page 278: Transfer Belt Drive

    IMAGE TRANSFER AND PAPER SEPARATION 6.7.2 TRANSFER BELT DRIVE G060D402.WMF The drum drive motor-K [A] drives the transfer belt [B] and the cleaning unit via some gears. The speed of transfer belt drive depends on the process line speed. G060 6-48...
  • Page 279 • The current for cleaning cannot be adjusted. The back-up rollers [F] before the transfer charge brushes for each color make a wider contact area between the drum [G] and the belt. The other rollers are grounded to neutralize the belt surface. 6-49 G060...

  • Page 280: Transfer Belt Cleaning

    (the cleaning roller is electrically charged). The blade [D] in the cleaning unit scrapes the toner off the cleaning roller. The toner collection auger [E] transports the toner towards the waste toner collection bottle. G060 6-50...
  • Page 281 To pull out the transfer belt, the user moves the release lever and the belt moves down and away from all four drums. Then the unit can be pulled out. 6-51 G060...
  • Page 282 If ACS is off and color mode is selected, all data is printed with the transfer belt positioned against all four drums. The belt does not move even if a K only page appears, even if it is at the start of the job. G060 6-52...
  • Page 283 • Temperature is normally controlled by turning the fusing lamps on and off. To change between on/off control and phase control: SP1-104-1. • The oil supply pad supplies oil to the fusing belt through the oil supply roller. The oil supply sub-roller spreads the oil on the oil supply roller evenly. 6-53 G060...

  • Page 284: Fusing Unit Drive

    • The development drive motor-K drives the pressure roller [A], hot roller [B], oil supply roller [C], oil supply sub-roller [D] and belt cleaning roller [E] through a gear train. • The heating roller [F] is driven by the pressure with the fusing belt [G]. G060 6-54...

  • Page 285: Fusing Temperature Control

    The heating and pressure roller temperatures for fusing are stored in SP1-105-3 to -28. When the machine is switched on, the fusing lamp temperatures increase to the those specified by SP1-104-25. The print ready temperature is slightly less than the fusing temperature. The difference is specified by SP1-105-1 and -2. 6-55 G060...
  • Page 286 • If the thermostat temperature becomes greater than 210°C, the thermostat opens, removing power from the fusing lamp. • If the thermofuse temperature becomes greater than 169°C, the thermofuse opens, removing power from the fusing lamp. • At this time, the machine stops operation. G060 6-56...

  • Page 287: Oil Supply And Cleaning

    Then, for the remaining pages of the job, it stays in contact with the roller. At other times, the unit stays away to reduce oil consumption. 6-57 G060...
  • Page 288 Oil near-end is detected by counting the number of prints made. The machine indicates oil near-end 2,500 sheets before the life of the oil supply unit runs out. This timing can be changed with SP7-905-9. G060 6-58...
  • Page 289 The fusing unit’s life is detected by counting the number of prints made. The machine indicates near-end 2,500 sheets before the life of the unit runs out. This timing can be changed with SP7-905-7. 6-59 G060...

  • Page 290: Energy Saver Mode

    • Print command received from the PC • Any operation panel keys pressed NOTE: The machine does not leave level 2 energy saver mode when covers are opened and closed, because the CPU on the BCU is not active. G060 6-60...
  • Page 291 • To feed paper to the standard paper tray: The junction gate solenoid is off (default). • To feed paper to the external paper tray: The junction gate solenoid is on. • The development drive roller-K drives the exit rollers. 6-61 G060...
  • Page 292 PAPER EXIT 6.9.2 PAPER OVERFLOW DETECTION G060D601.WMF [A]: Paper overflow sensor • When the paper overflow sensor [A] is activated, the machine detects that the paper stack height has exceeded a certain limit and stops printing. G060 6-62...
  • Page 293 This DIMM also includes 8 kB of Mask ROM for storing internal printer fonts. Currently the remaining two DIMM slots are not being used. 6. NVRAM: 8 kB NVRAM for storing the printer parameters, total counter, and logged data 7. IEEE1284 Interface: Supports compatible, nibble, and ECP modes 6-63 G060...
  • Page 294 Controller IC Card. • Controller (Flash ROM and flash ROM DIMM) • BCU (Main CPU and MUSIC CPU) • NIB For details about downloading software from an IC card, see Service Tables – Firmware Update Procedure. G060 6-64...
  • Page 295 NOTE: The NVRAM board contains the total counter information for the machine it is currently installed in. If the controller board is replaced, you must reinstall the original NVRAM board on the new controller. Failure to do so will cause the total counter to be inaccurate. 6-65 G060...
  • Page 296 8 bit Matching ICM Engine/ ICM profile C M Y 8bit C M Y Dithering £ £ 8bit & Correction C M Y 1bit C M Y K • BG/UCR, 1 bit • Gray Correction • Toner Limitation G060D563.WMF G060 6-66...
  • Page 297 CMY data is replaced with K data by the BG/UCR algorithm. Gamma Correction The printer gamma can be adjusted with controller SP mode (Gamma Adj.). For CMYK, there are15 points between 0 and 100%. The corrected gamma data is stored in NVRAM. 6-67 G060...
  • Page 298 8-bit data to 1-bit data. However, these dither patterns create the illusion of 256 gradations for high quality prints. The optimum dither pattern is selected depending on the selected resolution. RIP: Raster Image Processing ROP: Raster Operation G060 6-68...
  • Page 299 • The partition can hold a log containing up to 20 errors, excluding logs stored using locked print. • The maximum number of pages is 2,000, including jobs using sample print and collation. • Locked print uses the same hard disk partition as sample print and collation, which is 5.8 GB. 6-69 G060...
  • Page 300 NOTE: The by-pass feed table cannot be unlocked (Tray Lock is always enabled). Manual Tray Select If the selected tray does not have the paper size and type specified by the driver, the controller stops printing until the user loads the correct paper. G060 6-70...
  • Page 301 The machine prints from the selected tray even if the paper size and type do not match the setting specified from the driver. If “Auto Continue” is disabled, the machine waits until the user loads the correct paper in the tray. 6-71 G060...
  • Page 302 G060D556.WMF printing to the next tray. • If all trays become full (overflow detected in all trays), the machine displays an error and stops printing. This time, all paper in all trays must be removed. G060 6-72...
  • Page 303 • There is only one punch position available, so the relationship between the punching position and the printed image depends on the paper feed orientation and image rotation. 2 Tray Finisher Punching Position Paper Feed Direction (Printed side) G060D558.WMF 6-73 G060...

  • Page 304: Ieee1394 Interface

    IEEE1394 network. IEEE1394 cables can be either 4-pin (data only) or 6-pin (data and power). IEEE1394 allows either 6-pin or 4-pin connectors. However, this machine only uses the 6-pin connectors. The machine has two 6-pin ports. G060 6-74...

  • Page 305: Block Diagram

    • EEPROM: 256-byte ROM 6.11.4 PIN ASSIGNMENT Pin assignment Pin 1 Pin 1 Pin 4 Pin 2 Pin 3 Pin 5 Pin 6 Pin 6 G060D561.WMF Signal Description Cable Power Receive strobe Transmit data Receive data Transmit strobe 6-75 G060...

  • Page 306: Remarks About This Interface Kit

    • Try to find out where in the chain the problem is occurring. Test the machine one-to-one with the computer to determine if the printer is defective (when the printer’s interface cable is plugged in, the computer should see ‘Printer Ready’; when the cable is disconnected, the computer should see ‘Offline’). G060 6-76...
  • Page 307 DUPLEX UNIT G571...
  • Page 309 DUPLEX INVERTER UNIT 1. REPLACEMENT AND ADJUSTMENT 1.1 DUPLEX INVERTER UNIT 1.1.1 TOP COVER 1. External tray [A] 2. Open the duplex left cover [B] 3. Top cover [C] ( x 4) G571R102.WMF 1.1.2 DUPLEX CONTROL BOARD G571R104.WMF G571R105.WMF 1. Top cover ( 1.1.1 TOP COVER) 2.

  • Page 310: Duplex Inverter Motor

    DUPLEX INVERTER UNIT 1.1.3 DUPLEX INVERTER MOTOR 1 G571R105.WMF G571R106.WMF 1. Top cover ( 1.1.1 TOP COVER) 2. Duplex unit ( 1.1.2 DUPLEX CONTROL BOARD) 3. Duplex control board bracket [A] ( x 2, x 8) 4. Duplex inverter motor 1 [B] ( x 2, x 1, 1 timing belt) 1.1.4 DUPLEX INVERTER MOTOR 2 AND SWITCH G571R107.WMF 1.
  • Page 311 DUPLEX INVERTER UNIT 1.1.5 EXIT SENSOR 3 AND DUPLEX INVERTER SENSOR 1. Open the duplex inverter unit [A] 2. Exit sensor 3 [B] ( x 1) 3. Duplex inverter sensor [C] ( x 1, x 1) G571R101.WMF 1.1.6 EXIT SENSOR 1 AND 2 1.
  • Page 312 DUPLEX FEED UNIT 1.2 DUPLEX FEED UNIT 1.2.1 DUPLEX DRIVE BOARD G571R108.WMF G571R111.WMF 1. Open the front cover 2. Duplex feed unit [A] ( x 1) 3. Inner cover [B] ( x 1) 1. Duplex drive board [C] ( x 2, x 3) 1.2.2 DUPLEX FEED MOTOR 1.
  • Page 313 DUPLEX FEED UNIT 1.2.3 DUPLEX FEED SENSOR G571R109.WMF 1. Duplex feed unit ( 1.2.1 DUPLEX DRIVE BOARD) 2. [A] Duplex feed sensor ( x 1) G571...
  • Page 314 OVERVIEW 2. DETAILED DESCRIPTIONS 2.1 OVERVIEW G571D101.WMF 1. Exit sensor 1 6. Junction mylar 2 2. Junction gate 7. Exit sensor 3 3. Duplex feed sensor 8. Junction mylar 1 4. Duplex inverter sensor 9. Exit sensor 2 5. Junction mylar 3 •...

  • Page 315: Duplex Operation

    DUPLEX OPERATION 2.2 DUPLEX OPERATION 2.2.1 UP TO A4/LT(8 " X 11") LEF There are three sheets of paper in the paper feed path at the same time, using the interleave method. Example: 8 pages. The number [A] in the illustration shows the order of pages. The number [B] in the illustration shows the order of sheets of paper (if shaded, this indicates the second side).
  • Page 316 DUPLEX INVERTER UNIT 2.3 DUPLEX INVERTER UNIT 2.3.1 DRIVE G571D104.WMF The duplex inverter motor 1 [A] drives the paper exit roller 1 [B], paper transport roller [C], paper exit roller 2 [D], and upper inverter roller [E]. The duplex inverter motor 2 [F] drives the exit roller 3 [G], paper exit roller 4 [H], and lower inverter roller [I].
  • Page 317 DUPLEX INVERTER UNIT 2.3.2 FEED TO EXTERNAL EXIT TRAY (NON-DUPLEX MODE) G571D106.WMF This shows how the machine feeds paper through the duplex unit to the external tray [A], when duplex mode has not been selected. NOTE: The paper cannot be fed out to the external tray if duplex printing is selected.
  • Page 318 DUPLEX INVERTER UNIT 2.3.3 FEED TO DUPLEX FEED UNIT G571D107.WMF G571D111.WMF This shows how the machine feeds paper back into the machine after side 1 has been printed. The junction gate [A] diverts the paper from the fusing unit to the lower part of the inverter unit.
  • Page 319 DUPLEX INVERTER UNIT 2.3.4 FEED TO TWO-TRAY FINISHER With Optional One-Tray Paper Feed Unit G571D107.WMF G571D108.WMF The paper is fed out to the finisher from the upper exit [A]. The junction gate [B] diverts the paper from the fusing unit to the lower part of the inverter unit.
  • Page 320 DUPLEX FEED UNIT 2.4 DUPLEX FEED UNIT 2.4.1 DRIVE G571D105.WMF The duplex feed motor [A] drives all paper transport rollers. 2.4.2 FEED-IN AND FEED-OUT G571D112.WMF The duplex feed unit feeds the paper from the duplex inverter unit to the relay roller [A].
  • Page 321 ONE-TRAY PAPER FEED UNIT G567...
  • Page 323 COVER REPLACEMENT 1. REPLACEMENT AND ADJUSTMENT 1.1 COVER REPLACEMENT G567R102.WMF 1. Rear cover [A] ( x 2) G567...
  • Page 324 ROLLER REPLACEMENT 23 February, 2001 1.2 ROLLER REPLACEMENT 1.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS G567R101.WMF 1. Paper tray 2. Pick-up roller [A] (1 hook) 3. Paper Feed Roller [B] ( x 1) 4. Separation Roller [C] ( x 1) G567...
  • Page 325 PAPER FEED MOTOR AND MAIN BOARD 1.3 PAPER FEED MOTOR AND MAIN BOARD G567R103.WMF 1. Rear cover ( 1.1 COVER REPLACEMENT) 2. Paper feed motor [A] ( x 1,  x 3) 3. Main board [B] ( x 2) G567...
  • Page 326 TRAY LIFT MOTOR 23 February, 2001 1.4 TRAY LIFT MOTOR 1. Rear cover ( 1.1 COVER REPLACEMENT) 2. Tray lift motor [A] ( x 1,  x 2) G567R104.WMF 1.5 PAPER FEED CLUTCH 1. Rear cover ( 1.1 COVER REPLACEMENT) 2.
  • Page 327 PAPER FEED UNIT REPLACEMENT 1.6 PAPER FEED UNIT REPLACEMENT G567R106.WMF 1. Right cover [A] 2. Paper feed unit [B] ( x 2, x 1) G567...
  • Page 328 OVERVIEW 23 February, 2001 2. DETAILED DESCRIPTIONS 2.1 OVERVIEW 2.1.1 MECHANICAL COMPONENT LAYOUT G567D001.WMF 1. Pick-up Roller 2. Paper Feed Roller 3. Relay Roller 4. Separation Roller 5. Tray G567...
  • Page 329 OVERVIEW 2.1.2 ELECTRICAL COMPONENT LAYOUT G567D101.WMF 1. Paper Size Switch 1 8. Lift Sensor 2. Paper Size Switch 2 9. Paper Feed Clutch 3. Paper Size Switch 3 10. Vertical Guide Switch 4. Paper Size Switch 4 11. Tray Lift Motor 5.
  • Page 330 OVERVIEW 23 February, 2001 2.1.3 DRIVE LAYOUT G567D102.WMF 1. Paper Feed Motor 2. Paper Feed Clutch 3. Paper Feed Roller 4. Separation Roller 5. Pick-up Roller G567...
  • Page 331 TWO-TRAY PAPER FEED UNIT G568...
  • Page 333 COVER REPLACEMENT 1. REPLACEMENT AND ADJUSTMENT 1.1 COVER REPLACEMENT G568R102.WMF 1. Rear cover [A] ( x 2) G568...
  • Page 334 ROLLER REPLACEMENT 1.2 ROLLER REPLACEMENT 1.2.1 PAPER FEED, SEPARATION, AND PICK-UP ROLLERS G568R101.WMF 1. Paper tray 2. Pick-up roller [A] (1 hook) 3. Paper Feed Roller [B] ( x 1) 4. Separation Roller [C] ( x 1) G568...
  • Page 335 PAPER FEED MOTOR AND MAIN BOARD 1.3 PAPER FEED MOTOR AND MAIN BOARD G568R103.WMF 1. Rear cover ( 1.1 COVER REPLACEMENT) 2. Paper feed motor [A] ( x 1,  x 3) 3. Main board [B] ( x 2) G568...
  • Page 336 TRAY LIFT MOTORS 1.4 TRAY LIFT MOTORS 1. Rear cover ( 1.1 COVER REPLACEMENT) 2. Tray lift motor [A] ( x 1,  x 2) G568R104.WMF 1.5 PAPER FEED CLUTCHES 1. Rear cover ( 1.1 COVER REPLACEMENT) 2. Paper feed clutches [A] ( x 1, 1 bracket, 1 bushing) G568R105.WMF G568...
  • Page 337 PAPER FEED UNIT REPLACEMENT 1.6 PAPER FEED UNIT REPLACEMENT G568R107.WMF G568R108.WMF 1. Vertical transport cover [A] (1 hook) 2. Paper feed unit [B] ( x 2, x 1) G568...
  • Page 338 OVERVIEW 2. DETAILED DESCRIPTIONS 2.1 OVERVIEW 2.1.1 MECHANICAL COMPONENT LAYOUT G568D001.WMF 1. Upper Pick-up Roller 6. Lower Paper Feed Roller 2. Upper Paper Feed Roller 7. Lower Separation Roller 3. Upper Relay Roller 8. Lower Pick-up Roller 4. Upper Separation Roller 9.
  • Page 339 OVERVIEW 2.1.2 ELECTRICAL COMPONENT LAYOUT G568D101.WMF 1. Paper Size Switch 1 14. Vertical Guide Switch 2. Paper Size Switch 2 15. Lower Lift Sensor 3. Paper Size Switch 3 16. Lower Tray Lift Motor 4. Paper Size Switch 4 17. Lower Paper End Sensor 5.
  • Page 340 OVERVIEW 2.1.3 DRIVE LAYOUT G568D102.WMF 1. Tray Motor 7. Lower Pick-up Roller 2. Upper Paper Feed Clutch 8. Upper Separation Roller 3. Lower Paper Feed Clutch 9. Upper Relay Roller 4. Lower Relay Roller 10. Upper Paper Feed Roller 5. Lower Separation Roller 11.
  • Page 341 LARGE CAPACITY TRAY G569...

  • Page 343: Detaching The Tray From The Mainframe

    DETACHING THE TRAY FROM THE MAINFRAME 1. REPLACEMENT AND ADJUSTMENT 1.1 DETACHING THE TRAY FROM THE MAINFRAME 1. To draw the tray out, press the stopper [A] on the guide rail. 2. To install the tray, set the tray on the guide rails, keep the tray level, and push the tray in.

  • Page 344: Changing The Tray Paper Size

    CHANGING THE TRAY PAPER SIZE 1.3 CHANGING THE TRAY PAPER SIZE G569R103.WMF 1. Screws [A] [B] 2. Change the position of the side fences. 3. Change the position of the rear fence HP sensor ( 1.2 REAR FENCE HP SENSOR). 4.

  • Page 345: Left Tray Paper End Sensor

    LEFT TRAY PAPER END SENSOR 1.4 LEFT TRAY PAPER END SENSOR G569R104.WMF 1. Pull out the large capacity tray. 2. Left tray side fence [A] ( x 2) 3. Rear fence bracket [B] ( x1) 4. Left tray paper end sensor [C] ( x 1) 10-3 G569...
  • Page 346 TRAY LIFT MOTOR 1.5 TRAY LIFT MOTOR G569R105.WMF G569R106.WMF 1. Rear cover [A] ( x 2) 2. Tray lift motor [B] ( x 3, x 1) G569 10-4...
  • Page 347 TRAY MOTOR AND STACK TRANSPORT CLUTCH 1.6 TRAY MOTOR AND STACK TRANSPORT CLUTCH G569R107.WMF 1. Rear cover ( 1.5 TRAY LIFT MOTOR) 2. Tray motor [A] ( x 6, x 1) 3. Bracket [B] ( x 1) 4. Stack transport clutch [C] ( x 2, 2 bushings, 1 gear) 10-5 G569...

  • Page 348: Paper Feed Clutch

    PAPER FEED CLUTCH 1.7 PAPER FEED CLUTCH G569R108.WMF 1. Rear cover ( 1.5 TRAY LIFT MOTOR) 2. Bracket [A] ( x 1) 3. Bushing 4. Paper feed clutch [B] G569 10-6...

  • Page 349: Paper Feed Unit

    PAPER FEED UNIT 1.8 PAPER FEED UNIT G569R109.WMF 1. Stack transport clutch ( 1.6 TRAY MOTOR AND STACK TRANSPORT CLUTCH) 2. Paper feed clutch ( 1.7 REPLACEMENT AND ADJUSTMENT) 3. Paper feed unit cable [A] 4. Open the vertical transport guide plate [B]. 5.

  • Page 350: Relay Sensors

    UPPER LIMIT, RIGHT TRAY PAPER END, AND RELAY SENSORS 1.9 UPPER LIMIT, RIGHT TRAY PAPER END, AND RELAY SENSORS G569R111.WMF Paper feed unit ( 1.8 PAPER FEED UNIT) 2. Sensors • Upper limit [A] • Relay [B] ( x 1, 1 bracket) •...
  • Page 351 PICK-UP/PAPER FEED/SEPARATION ROLLER 1.10 PICK-UP/PAPER FEED/SEPARATION ROLLER G569R110.WMF 1. Paper tray unit 2. Pick-up roller [A] (1 hook) 3. Separation roller [B] ( x 1) 4. Feed roller [C] ( x 1) NOTE: If the rollers are incorrectly installed, the one-way clutch does not work. 10-9 G569...
  • Page 352 OVERVIEW 2. DETAILED SECTION DESCRIPTIONS 2.1 OVERVIEW 2.1.1 MECHANICAL COMPONENT LAYOUT G569D001.WMF 1. Paper Height Sensors 5 8. Relay Roller 2. Paper Height Sensors 4 9. Separation Roller 3. Paper Height Sensors 1 10. Paper Height Sensors 2 4. Pick-up Roller 11.
  • Page 353 OVERVIEW 2.1.2 ELECTRICAL COMPONENT LAYOUT G569D101.WMF 1. End Fence Home Position Sensor 11. Upper Limit Sensor 2. Left Tray Paper End Sensor 12. Paper Feed Clutch 3. Paper Height Sensor 4 13. Paper Height Sensor 2 4. Paper Height Sensor 5 14.
  • Page 354 PAPER FEED 2.2 PAPER FEED G569D102.WMF • This product uses an FRR type paper feed mechanism. • The paper feed unit consists of the pick-up roller [A], paper feed roller [B], separation roller [C], and relay roller. • There is a torque limiter (ferrite powder type) in the back of the separation roller. G569 10-12...
  • Page 355 SEPARATION ROLLER AND PICK-UP ROLLER RELEASE 2.3 SEPARATION ROLLER AND PICK-UP ROLLER RELEASE G569D107.WMF G569D108.WMF To prevent the paper from being torn when pulling out the paper feed tray, the separation and pickup rollers are set so that they release automatically. When the paper tray [A] is not inside the machine, the separation roller [B] is away from the paper feed roller [C] and the pick-up roller [D] stays in the upper position.

  • Page 356: Tray Lift

    TRAY LIFT 2.4 TRAY LIFT G569D103.WMF When the paper feed tray is put in the machine, the tray sensor on the back face turns on and the tray lift motor [A] starts. The base plate lift shaft [B] is coupled to the lift motor at shaft [C], so the base plate of the tray is lifted.
  • Page 357 NEAR END/END DETECTION 2.5 NEAR END/END DETECTION This tray holds two stacks of paper, so the machine needs to monitor the status of both these stacks. There are seven sensors to do this. In the right tray (paper feed side), three height sensors ([E] in the diagram on the previous page) measure the height of the stack, and an end sensor detects when all the paper is used up.
  • Page 358 PAPER STACK TRANSPORT MECHANISM 2.6 PAPER STACK TRANSPORT MECHANISM G569D104.WMF When the paper in the right tray is used up, the tray motor [A] and stack transport clutch [B] turn on. Then the rear fence [C] moves the stack of paper from the left tray to the right tray.

  • Page 359: Right Tray Paper End Detection

    RIGHT TRAY PAPER END DETECTION 2.7 RIGHT TRAY PAPER END DETECTION G569D106.WMF G569D111.WMF The paper end sensor [A] detects when copy paper in the right tray runs out. When there is paper in the tray, the paper pushes up the paper end feeler [B] and causes the actuator to enter the sensor.
  • Page 361 TWO-TRAY FINISHER G565...
  • Page 363 COVERS 1. REPLACEMENT AND ADJUSTMENT 1.1 COVERS 1.1.1 EXTERNAL COVERS 1. Top cover [A] ( x 4) NOTE: If the shift tray below is blocking the screw hole, remove the shift tray. 2. Bracket [B] ( x 1) 3. Front door [C] 4.

  • Page 364: Positioning Roller

    POSITIONING ROLLER 1.2 POSITIONING ROLLER 1. Open the front door. 2. Positioning roller [A] ( x 1) 3. Belt [B] G565R103.WMF 1.3 TRAY 1 EXIT SENSOR 1. Top cover ( 1.1.1 EXTERNAL COVERS) 2. Open transport door [A] 3. Bracket [B] ( x 1, ( x 1) 4.
  • Page 365 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR 1.4 ENTRANCE SENSOR/STAPLER TRAY ENTRANCE SENSOR 1. Entrance sensor bracket [A] ( x 1, x 1) 2. Entrance sensor [B] ( x 1) 3. Stapler tray entrance sensor bracket [C] ( x 1, x 1) 4.
  • Page 366 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCH 1.6 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCH G565R201.WMF G565R109.WMF G565R110.WMF 1. External covers ( 1.1.1 EXTERNAL COVERS) 2. Place one hand under tray 2 (the lower tray), press in on the gear [A] to release the tray, and then support it with your hand as it descends.

  • Page 367: Exit Guide Plate Motor

    EXIT GUIDE PLATE MOTOR 1.7 EXIT GUIDE PLATE MOTOR 1. Tray 1 back fence ( 1.6 UPPER STACK HEIGHT SENSORS/TRAY 1 UPPER LIMIT SWITCH) 2. Exit guide plate motor [A] ( x2, NOTE: Disengage the shaft of the exit guide plate motor from the ring.
  • Page 368 LIFT MOTORS 4. Motor bracket [C] ( x 3, x 2) G565R204.WMF 5. Tray 1 lift motor [D] ( x 2, drive belt) 6. Tray 2 lift motor [E] ( x 2, drive belt) G565R205.WMF G565 11-6...

  • Page 369: Lower Exit Sensor

    LOWER EXIT SENSOR 1.9 LOWER EXIT SENSOR 1. Front door, external and internal covers. ( 1.1 COVERS) 2. Exit guide plate motor ( 1.7 EXIT GUIDE PLATE MOTOR) 3. Guide plate [A] ( x 1) NOTE: Pull the shaft toward you through the round hole.

  • Page 370: Lower Stack Height Sensors

    LOWER STACK HEIGHT SENSORS 1.10 LOWER STACK HEIGHT SENSORS 1. Stapler tray ( 1.5 STAPLER TRAY) 2. Sensor bracket [A] ( x 1, x 2) 3. Bracket [B] ( x 1) 4. Feeler [C] 5. Lower stack height sensors [D] G565R116.WMF 1.11 TRAY 2 SHUNT POSITION SENSOR 1.

  • Page 371: Stapler Unit

    STAPLER UNIT 1.12 STAPLER UNIT 1. Open the front door 2. Stapler unit [A] ( x 1, x 2) NOTE: Hold the stapler holder [B] with one hand as you remove the stapler. Do not twist or rotate the stapler bracket as you remove it.

  • Page 372: Tray 1 Interior

    TRAY 1 INTERIOR 1.14 TRAY 1 INTERIOR 1.14.1 TRAY 1 COVERS 1. Tray 1 [A] ( x 1) 2. Rear tray cover [B] ( x 1) 3. Front tray cover [C] ( x 1) 4. Bottom tray cover [D] ( x 2) G565R207.WMF 5.
  • Page 373 TRAY 1 INTERIOR 1.14.2 TRAY SHIFT SENSORS AND TRAY RELEASE SENSOR 1. Tray 1 covers ( 1.14.1 TRAY 1 COVERS) 2. Gear disk [A] ( x 1) 3. Tray shift sensors [B] ( x 1 each). 4. Tray release sensor [C] ( x 1) G565R210.WMF 1.14.3 TRAY 1 SHIFT MOTOR 1.

  • Page 374: Finisher Main Board

    FINISHER MAIN BOARD 1.15 FINISHER MAIN BOARD 1. Rear cover ( 1.1.1 EXTERNAL COVERS) 2. Main PCB [A] ( x 6, All ) G565R206.WMF 1.16 PUNCH HOLE POSITION ADJUSTMENT To adjust the position of the punch holes in the paper feed direction, use the appropriate SP mode.
  • Page 375 JAM DETECTION 2. TROUBLESHOOTING 2.1 JAM DETECTION Mode Content Shift 1 Shift 2 Staple Entrance sensor: After the exit sensor in the main machine no detection went off, the entrance sensor did not switch on for at least 2 s. Entrance sensor: After the entrance sensor switched on, it did no detection...

  • Page 376: Dip Switch Settings

    DIP SWITCH SETTINGS 3. SERVICE TABLES 3.1 DIP SWITCH SETTINGS The DIP switches should not be set to any combination other than those described in the table below. DPS101 Mode Description Default. Free run. No paper. Transportation See the note below. NOTE: The following procedure repositions the shift trays to the shipping position.
  • Page 377 GENERAL LAYOUT 4. DETAILED DESCRIPTIONS 4.1 GENERAL LAYOUT G565D118.WMF 1. Upper junction gate 5. Stapler 2. Punch unit (option) 6. Stapler tray 3. Stapler junction gate 7. Tray 2 4. Pre-stack tray 8. Tray 1 Tray junction gate: Directs paper either to the upper or lower exit. In staple mode, the stack always goes out to the lower exit.
  • Page 378 DRIVE LAYOUT 4.2 DRIVE LAYOUT G565D104.WMF G565D103.WMF 1. Tray 1 lift motor 10. Lower transport motor 2. Entrance roller 11. Pre-stack motor 3. Tray 2 lift motor 12. Upper transport motor 4. Upper exit roller 13. Punch motor 5. Tray 1 shift motor 14.

  • Page 379: Junction Gates

    JUNCTION GATES 4.3 JUNCTION GATES The two junction gates can direct paper to three destinations. In sort/stack mode for tray 1, the tray junction solenoid [A] is on, and the prints go to the upper exit (tray 1 is at the upper exit for sort/stack mode). G565D205.WMF In sort/stack mode for tray 2, both the tray junction gate solenoid [A] and stapler junction gate solenoid...

  • Page 380: Tray Shifting

    TRAY SHIFTING 4.4 TRAY SHIFTING 4.4.1 TRAY SHIFT MECHANISMS G565D106.WMF Tray 1 (Upper Tray) In sort/stack mode, tray 1 [A] moves from side to side to separate the printed sets. The tray 1 shift motor [B], inside the shift tray, controls the horizontal position of tray 1 through the timing belt [C] and gear disk [D].
  • Page 381 TRAY SHIFTING Tray 2 (Lower Tray) G565D105.WMF In sort/stack mode, tray 2 [A] moves from side to side to separate the sets of prints. The shift mechanism for tray 2 is similar to that used for tray 1. However, when the tray 2 shift motor [B] turns on, the arm [D] moves the entire end fence [C] from side to side (not just the tray).
  • Page 382 TRAY UP/DOWN MECHANISMS 4.5 TRAY UP/DOWN MECHANISMS 4.5.1 TRAY 1 G565D204.WMF Introduction The tray 1 lift motor [A] controls the vertical position of tray 1 [B] through gears and timing belts [C]. Normal and sort/stack modes When the main switch is turned on, the tray is initialized at the upper position. To do this, the tray is moved up until upper stack height sensor 1 [D] is de-actuated.
  • Page 383 TRAY UP/DOWN MECHANISMS Staple Mode G565D204.WMF In staple mode, stapled stacks can be delivered to either tray, but they can only go to the lower exit. So, if tray 1 is selected, tray 1 [A] moves down to the lower paper exit.
  • Page 384 TRAY UP/DOWN MECHANISMS Tray 1 release mechanism When tray 1 is selected for staple mode, tray 1 must be moved down to the lower paper exit. However, to move past the sensors at the lower exit, the tray must be moved away from the finisher.
  • Page 385 TRAY UP/DOWN MECHANISMS 4.5.2 TRAY 2 Overflow condition Multi Tray Staple Mode Normal Mode G565D500.WMF G565D109.WMF The tray 2 lift motor [A] controls the vertical position of tray 2 [B] through gears and timing belts [C]. The paper height detection is the same as for tray 1. When the tray lowers during printing, the tray is judged to be overflowing when the tray 2 overflow sensor 1 [D] is off and the tray 2 overflow sensor-2 [F] is on (see ‘Normal Mode’...
  • Page 386 TRAY UP/DOWN MECHANISMS 4.5.3 PRE-STACK MECHANISM G565D200.WMF NOTE: This feature is available only when using A4 L, LT L, and B5 L. During stapling, the main machine must wait. This mechanism reduces the wait by holding the first two sheets of a job while the previous job is still being stapled. It only works during the second and subsequent sets of a multi-set print job.

  • Page 387: Jogger Unit Paper Positioning Mechanism

    JOGGER UNIT PAPER POSITIONING MECHANISM 4.6 JOGGER UNIT PAPER POSITIONING MECHANISM G565D110.WMF In staple mode, each sheet of print paper is vertically and horizontally aligned when it arrives in the stapler tray. Vertical Paper Alignment After the trailing edge of the paper passes the stapler tray entrance sensor [A], the positioning roller solenoid [B] is energized for a specified time to push the positioning roller [C] into contact with the paper.

  • Page 388: Stapler Mechanism

    STAPLER MECHANISM 4.7 STAPLER MECHANISM 4.7.1 STAPLER MOVEMENT G565D112.WMF G565D113.WMF The stapler can be moved from side to side or rotated according to the requirements of the selected stapling mode. Stapler Rotation After the start key is pressed, the stapler rotation motor [A] rotates the staple unit [B] until the stapler rotation HP sensor [C] is activated.
  • Page 389 STAPLER MECHANISM 4.7.2 STAPLER G565D208.WMF The staple hammer is driven by the stapler hammer motor [A] inside the stapler. As soon as the paper stack is aligned, the staple hammer motor starts. When stapling is finished, the staple hammer HP sensor [B] is turned on, and the staple hammer motor then stops.

  • Page 390: Feed Out And Transport

    STAPLER MECHANISM 4.7.3 FEED OUT AND TRANSPORT G565D115.WMF G565D114.WMF When stapling starts, the exit guide plate motor [A] switches on and opens the exit guide plate [B], so that the stapled stack can exit to the tray. The exit guide plate sensor [C] detects when to switch off the exit guide plate motor.
  • Page 391 PUNCH UNIT (OPTIONAL) 4.8 PUNCH UNIT (OPTIONAL) The punch unit punches holes in printed sheets, one by one. The punch unit is provided with a new punch mechanism to improve the accuracy of punching. G565D102.WMF G565D101.WMF 4.8.1 PUNCH DRIVE MECHANISM The punch drive mechanism is driven by the punch motor [A].

  • Page 392: Punch Waste Collection

    PUNCH UNIT (OPTIONAL) 4.8.2 PUNCH WASTE COLLECTION G565D153.WMF Waste punchouts are collected in the punch waste hopper [A] below the punch unit inside the finisher. When the top of the punchout waste in the hopper reaches and actuates the hopper sensor [B], a message will be displayed on the operation panel after the current job is completed.
  • Page 393 FOUR-BIN MAILBOX G566...

  • Page 395: Exterior Cover Removal

    EXTERIOR COVER REMOVAL 1. REPLACEMENT AND ADJUSTMENT 1.1 EXTERIOR COVER REMOVAL G566R101.WMF 1. Trays [A] NOTE: To remove the trays, grasp the edges and lift. 2. Front cover [B] (! x 1) 3. Rear cover [C] (! x 1) 4. Upper cover [D] 12-1 G566...
  • Page 396 TRAY PAPER/OVERFLOW/VERTICAL TRANSPORT SENSORS 1.2 TRAY PAPER/OVERFLOW/VERTICAL TRANSPORT SENSORS G566R103.WMF G566R104.WMF 1. Trays 2. Bin cover [A] 3. Tray paper sensor [B] (" x 1) Overflow sensor [C] (" x 1) Vertical transport sensor [D] (" x 1) 4. Remove both the tray paper and overflow sensors as shown in the illustration. For the vertical transport sensor, lift up the locking pawls (slightly).

  • Page 397: Main Motor Replacement

    MAIN MOTOR REPLACEMENT 1.3 MAIN MOTOR REPLACEMENT G566R102.WMF 1. Rear cover (☛ 1.1 EXTERIOR COVER REMOVAL) 2. Control board [A] (! x 2, all connectors) 3. Timing belt [B] 4. Main motor bracket [C] 5. Main motor [D] (! x 2) 12-3 G566...
  • Page 398 COMPONENT LAYOUT 2. DETAILED DESCRIPTIONS 2.1 COMPONENT LAYOUT 2.1.1 MECHANICAL COMPONENT LAYOUT G566D101.WMF 1. 4th Tray 5. Turn Gates 2. 3rd Tray 6. Vertical Transport Roller 3. 2nd Tray 7. Tray Feed Out Roller 4. 1st Tray 2.1.2 DRIVE LAYOUT G566D102.WMF 1.
  • Page 399 ELECTRICAL COMPONENT DESCRIPTIONS 2.2 ELECTRICAL COMPONENT DESCRIPTIONS G566D103.WMF 1. Main control PCB 10. Lower vertical transport sensor 2. Main motor 11. Tray 1 paper overflow sensor 3. Junction gate solenoid 3 12. Tray 1 paper sensor 4. Door sensor 13. Tray 2 paper sensor 5.

  • Page 400: Basic Operation

    BASIC OPERATION 2.3 BASIC OPERATION The mailbox is connected to the main unit with a 10-pin connector. When the leading edge of the paper activates the exit sensor in the printer’s main body, the mailbox main motor turns on and the mailbox rollers begin to turn.
  • Page 401 PAPER OVERFLOW DETECTION 2.4 PAPER OVERFLOW DETECTION Each tray has an overflow sensor. They monitor the trays so that the amount of paper on the tray does not exceed the tray capacity. If a printing job is done that exceeds the capacity of one or more of the trays, the main unit recognizes the overload, displays an error message and stops the printing job.
  • Page 403 SPECIFICATIONS...
  • Page 405 Monochrome: 7 seconds or less (from tray 1) Warm-up Time Less than 120 seconds (at 23°C/50%) Print Paper Standard tray: 500 sheets x 2 Capacity: By-pass tray: 100 sheets Optional paper feed tray: 500 sheets x 1, 500 sheets x 2, Optional LCT: 2000 sheets 13-1 G060...
  • Page 406 40 dB or less NOTE: The above measurements were made in accordance with Ricoh standard methodology. Dimensions (W x D x H): 575 x 678 x 715 mm (22.6” x 26.7” x 28.2”) Weight: Less than 82 kg (181 lb.) G060 13-2...
  • Page 407 114 x 162 mm C5 Env. 162 x 229 mm DL Env. 110 x 220 mm Remarks: Supported: the sensor detects the paper size. Supported: the user specifies the paper size. Supported: depends on a technician adjustment Not supported 13-3 G060...
  • Page 408 90 x 148 mm Maximum: 305 x 458 mm Com10 Env. 4.125 x 9.5” Monarch Env. 3.875 x 7.5” C6 Env. 114 x 162 mm C5 Env. 162 x 229 mm DL Env. 110 x 220 mm Remarks: Supported Not supported G060 13-4...
  • Page 409 This utility solves problems with Windows 2000. (Win2000) DeskTopBinder V2 Lite DeskTopBinder V2 Lite itself can be used as personal document management software and can manage both image data (Win95/98, 2000, NT4) converted from paper documents and application files saved in each client’s PC. 13-5 G060...
  • Page 410 SPECIFICATIONS 3. MACHINE CONFIGURATION G060V112.JPG Machine Item Remarks Code Main Unit G060 Options Requires the HDD or 128MB DIMM memory, duplex unit and one of the three paper feed options. Finisher G565 Finisher and mailbox cannot both be installed. Finisher and mailbox cannot both be...
  • Page 411 Includes the K PCU. Maintenance Kit G G774 Includes the fusing oil supply unit. Maintenance Kit H Includes the feed roller, pick-up roller, and separation roller. NOTE: All the above items are user installable except for the punch unit. 13-7 G060...
  • Page 412 5 steps (100%, 75%, 50%, 25%, Near End) Power Source: DC 24V, 5V (from the main unit) Power Consumption: 30 W Dimensions (W x D x H): 540 x 600 x 270 mm (21.3” x 23.7” x 10.7”) Weight 25 kg (55.2 lb.) G060 13-8...
  • Page 413 30 sheets: A4 (LEF) & A3, B5 (LEF) & B4, 8½" x 11" (LEF) & 11” x 17” Staple position: 7 positions 1-staple: 4 positions (Top Left, Top Right, Top Left-Oblique, Top Right-Oblique) 2-staples: 3 positions (Left, Top, Right) 13-9 G060...
  • Page 414 DC 24V, 5V (from the main unit) Power Consumption: 17 W Dimensions (W x D x H): 540 x 600 x 400 mm (21.3” x 23.6” x 15.8”) (when installed in the machine) Weight 7 kg (15.5 lb.) G060 13-10...
  • Page 415 G570 SERVICE MANUAL...
  • Page 417 COPIER FEATURE EXPANDER G570...
  • Page 419 INSTALLATION REQUIREMENTS 1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS 1.1.1 ENVIRONMENT 10 °C to 32 °C (50 °F to 89.6 °F) 1. Temperature Range: 2. Humidity Range: 15% to 80% RH 3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight) 4.

  • Page 420: Machine Space Requirements

    INSTALLATION REQUIREMENTS 1.1.3 MACHINE SPACE REQUIREMENTS CF Expander with Rack A: Over 460 mm (18.1") from the printer mainframe B: Over 100 mm (3.9") from the printer mainframe C: Over 550 mm (21.7") from the printer mainframe D: Over 700 mm (27.6") from the printer mainframe G570I902.WMF G570...
  • Page 421 INSTALLATION REQUIREMENTS CF Expander without Rack A: Over 460 mm (18") B: Over 100 mm (4") C: Over 100 mm (4") D: Over 100 mm (4") E: Over 100 mm (4") F: Over 700 mm (28") G: Over 450 mm (17.7") G570I901.WMF G570...
  • Page 422 OPTIONAL UNIT COMBINATIONS 1.1.4 POWER REQUIREMENTS CAUTION 1. Make sure the plug is inserted firmly into the outlet. 2. Avoid using an outlet extension plug or cord, except for an accessory power strip for the 230V machine. 3. Make sure the outlet the machine is plugged into is properly grounded. 1.
  • Page 423 INSTALLATION WORK FLOW 1.3 INSTALLATION WORK FLOW Unpack the printer. Will the paper feed unit (PFU) or LCT be installed? 1. Place the printer on the PFU or LCT. 2. Install the PFU or LCT. Will the two-tray finisher be installed? Install the controller options (if required).
  • Page 424 MACHINE INSTALLATION 1.4 MACHINE INSTALLATION If the customer has a service contract, change the settings of the following SP modes depending on the contract type. Item SP No. Function Default Meter charge SP5-930-1 Specifies whether the meter charge mode is enabled or disabled. Meter charge mode enabled: •...
  • Page 425 MACHINE INSTALLATION Item SP No. Function Default Counter reset SP7-825-1 Resets the counters to 0. Important: This must be done at installation after all the above settings have been finished. The negative counters used in meter charge mode will be reset to zero. NOTE: 1) The default setting for this machine is meter-charge mode off.
  • Page 426 MACHINE INSTALLATION MACHINE INSTALLATION NOTE: The following is the procedure for installing the Copier Feature Expander in machines equipped with the optional rack. For the printer mainframe and printer option installation procedures, please refer to the Operating Instructions “Set-up Guide”. To avoid a possible build-up of ozone, make sure the machine is installed in a room that is well ventilated.
  • Page 427 MACHINE INSTALLATION 1.5.1 RACK Accessories Check List Description Quantity 1. Left Side Stand ..............1 2. Right Side Stand ..............1 3. Table Board ................1 4. Backboard................1 5. Left Arm ................1 6. Right Arm ................1 7. Left Securing Bracket............1 8.
  • Page 428 MACHINE INSTALLATION 4. With the 2 square holes [A] in the table board in front of you as shown, attach the left [B] and right [C] arms. When attaching the right arm, secure the ground wires [D] with screws [E] as shown. NOTE: Make sure the square holes in the table board is facing you during this procedure.
  • Page 429 MACHINE INSTALLATION Docking the Rack and Printer Mainframe NOTE: If the Finisher is going to be installed, the mounting bracket of the rail should be attached after docking the mainframe with the rack. In addition, the Finisher should be attached after docking is complete.
  • Page 430 MACHINE INSTALLATION G570I206.WMF 6. Attach the right bridging bracket [A] to the rack’s right stand (2 screws [B]). 7. Attach the left bridging bracket [C] to the lower left corner of the paper feed unit (2 stepped screws [D], 2 spring washers [E] and 2 washers [F]). 8.
  • Page 431 MACHINE INSTALLATION 1.5.2 CF EXPANDER Accessories Check List Description Quantity 1. Scanner Unit ................. 1 2. Main Switch Cover ..............1 3. Screw (M3 x 6) ..............3 4. Screw (M3 x 6) ..............2 5. IPU Board ................1 6.
  • Page 432 MACHINE INSTALLATION G570I205.WMF G570I701.WMF 2. Replace the printer module [A] in the upper slot (CN7) with DIMM #1 (SYSTEM) [B]. 3. Insert DIMM #2 (PRT/SCN) [C] into the center slot (CN8). 4. Insert the 128MB memory [D]. NOTE: 1) It is not necessary to install the additional memory if the present memory is 192MB or more.
  • Page 433 MACHINE INSTALLATION G570I204.WMF 6. Remove the scanner connector cover [A]. 7. Install the IPU board [B] ( x 2). 8. Reinsert the controller into the printer using the 2 screws (M3 x 6) enclosed as accessories instead of the original screws. NOTE: Make sure that the IPU board is firmly connected to the controller board.
  • Page 434 MACHINE INSTALLATION G570I105.WMF G570I208.WMF 9. Place the cushion [A] on the table board [B]. 10. Place the scanner unit [C] on the table board so that the scanner unit legs [D] line up with the indents [E] in the table as shown. 11.
  • Page 435 MACHINE INSTALLATION For 120V machines G570I602.WMF 14. Connect the printer power cord [A] to the output port on the scanner, then plug the scanner power cord [B] into the power outlet. 15. Attach the printer main switch cover. NOTE: Make sure that the wall outlet is near the machine and freely accessible, so that in the event of an emergency the cord can be easily unplugged.
  • Page 436 MACHINE INSTALLATION 16. Select the language in the UP mode. 17. Set the date and time. 18. Enter SP Mode. 19. Clear the scanner settings by using SP5-801-9. 20. Clear the network application settings by using SP5-801-10. 21. Clear the IPU settings by using SP5-801-12. 22.
  • Page 437 MACHINE INSTALLATION 1.5.3 40GB HDD Accessories Check List Description Quantity 1. 40GB HDD ................1 2. Power Cable ................. 1 3. Harness................. 1 4. Screw (M3x6) ................ 2 5. Key Top (Document Server) ..........1 40 GB HDD Installation 1. Remove the controller board [A] (2 screws).
  • Page 438 MACHINE INSTALLATION 5. Remove the cover key top [A] and replace it with the document box key top [B]. G570I218.WMF G570 1-20...
  • Page 439 MACHINE INSTALLATION 1.5.4 ARDF Accessories Check List Description Quantity 1. Stepped Screw ..............2 2. Screw (M4 x 10) ..............2 3. Knob Screw ................4 4. Decal – Attention ..............1 5. Installation Procedure ............1 ARDF Installation G564I151.WMF 1.
  • Page 440 MACHINE INSTALLATION G564I104.WMF G564I102.WMF 4. Attach the left [A] and right [B] stopper brackets with knob screws [C] ( x 4). 5. Connect the I/F cable [D] ( x 1) to the main machine. 6. Peel off the platen sheet [E] and place it on the exposure glass. G570 1-22...
  • Page 441 MACHINE INSTALLATION G564I103.WMF G564I105.WMF 7. Line up the rear left corner of the platen sheet flush against corner [A] on the exposure glass. 8. Close the ARDF. 9. Attach the decal [B] to the cover so that the arrow on the decal lines up with the groove [C] in the left scale as shown.
  • Page 442 MACHINE INSTALLATION 1.5.5 MULTI-BIN OUTPUT TRAY Accessories Check List Description Quantity 1. Front Tray Holder ..............1 2. Rear Tray Holder ..............1 3. Tray ..................2 4. Screw (3 x 1 4) ..............4 5. Discharge Brush ..............2 6.
  • Page 443 MACHINE INSTALLATION 6. Install the front [A] and rear [B] tray holders on the top cover ( x 2 for each). 7. Install the upper [C] and lower [D] trays. 8. Turn the main switch on; select the SP mode menu, SP6–901–1; and change the multi-bin output tray setting.
  • Page 444 MACHINE INSTALLATION 1.5.6 ANTI-CONDENSATION HEATER 1. Remove the rear scale [A] ( x 3). 2. Remove the exposure glass [B] with the left scale [C] ( x 2). NOTE: You do not have to remove the ADF exposure glass. If the glass is removed, position the glass marker [D] at the rear-left corner when reattaching.
  • Page 445 USER MAINTENANCE 2. PREVENTIVE MAINTENANCE 2.1 USER MAINTENANCE The following maintenance kits are available for the customer to do PM's. Type A: Color (C/M/Y) PCU 50k copies Type B: Color (C/M/Y) Development Unit 100k copies Type C: Fusing Unit 100k copies Type D: Black Development Unit / Dust Filter 100k copies Type E: Waste Toner Bottle...
  • Page 446 USER MAINTENANCE Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect Printer Mainframe Item 100k 150k Remarks Included in Black PCU maintenance kit F Included in Color (Y/M/C) PCU maintenance kit A Included in Black Development Unit maintenance kit D Color (C/M/Y) Development Included in Unit...
  • Page 447 SERVICE MAINTENANCE 2.2 SERVICE MAINTENANCE NOTE: After replacing the transfer unit, make sure to reset the maintenance counter using SP7-804-16 and 7-804-27. After replacing paper feed rollers, reset the maintenance counters for these also: By-pass tray (7-804-10), Tray 1 (7-804-11), Tray 2 (7-804-12), Tray 3/LCT (7-804-13), Tray 4 (7-804-14) Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect Printer Mainframe...
  • Page 448 SERVICE MAINTENANCE CF Expander Item 100k 1000k Remarks 1st Mirror Optics cloth 2nd Mirror Optics cloth 3rd Mirror Optics cloth APS Sensor Dry cloth Xenon Exposure Lamp Dry cloth Exposure Glass (Sheet Dry cloth or alcohol through) ARDF Item 400k Remarks Pick-up Roller Damp cloth or alcohol...
  • Page 449 SPECIAL TOOLS 3. REPLACEMENT AND ADJUSTMENT CAUTION Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. NOTE: This manual uses the following symbols. : See or Refer to : Screws : Connectors 3.1 SPECIAL TOOLS Part Number...
  • Page 450 IMAGE ADJUSTMENT 3.3 IMAGE ADJUSTMENT 3.3.1 PRINTING Leading edge registration See the service manual for the printer mainframe. Side-to-side registration See the service manual for the printer mainframe. 3.3.2 SCANNING Before doing the following scanner adjustments, perform or check the printing registration/side-to-side adjustment and the blank margin adjustment.
  • Page 451 IMAGE ADJUSTMENT Main scan dot position correction NOTE: Before adjusting the scanner, adjust the printer registration. 1. Enter the SP mode and open SP4-010 and SP4-011. 2. Check that each value corresponds to the factory-set value. 3. Press the Interrupt key and copy the C-4 chart in the full-color photo mode. NOTE: Be sure to copy in the photo mode.
  • Page 452 IMAGE ADJUSTMENT 3.3.3 ARDF ARDF side-to-side and leading edge registration G570R911.WMF A: Leading edge registration B: Side-to-side registration G570R908.WMF Make a temporary test chart as shown above using 11 x 17 paper. 1. Place the temporary test chart on the ARDF and make a copy from one of the feed stations.
  • Page 453 IMAGE ADJUSTMENT 3.3.4 PRINTER GAMMA CORRECTION NOTE: Normally, the ACC is enough to adjust the color balance to achieve the optimum print output. The printer gamma correction is only required for fine-tuning to meet user requirements. The printer gamma curve created during ACC can be modified using SP modes. The gamma data for highlight, middle, shadow areas, and IDmax can be adjusted.
  • Page 454 IMAGE ADJUSTMENT Adjustment Reference For Gamma Correction The following tables show the adjustment reference for gamma correction in the photo mode. The tables show the level of the color scale on the C4 test chart and on the tone control test sheet printed in the printer SP mode. For example, for K at 1200 x 1200 dpi, grade 12 on the tone control test sheet should be the same as grade 8 on the C4 chart.
  • Page 455 IMAGE ADJUSTMENT Copy Mode KCMY Color Balance Adjustment The adjustment uses only “Offset” values. NOTE: Never change “Option” values (default value is 0). Highlight (Low ID) Levels 2 through 5 in the C4 chart 10-level scale Middle (Middle ID) Levels 3 through 7 in the C4 chart 10-level scale Shadow (High ID) Levels 6 through 9 in the C4 chart 10-level scale Level 10 in the C4 chart 10-level scale (affects the entire image...
  • Page 456 IMAGE ADJUSTMENT Adjustment Procedure 1. Copy the C-4 test chart in the mode that you are going to adjust. 2. Enter the SP mode. 3. Select “Copy SP”. 4. Select SP4-9xx that you are going to adjust. 5. Adjust the offset values until the copy quality conforms to the standard ( the table below).
  • Page 457 IMAGE ADJUSTMENT <Standard Copy Quality in B/W Text/Photo Mode> Standard Copy Quality in B/W Text/Photo Mode Step Item to Adjust Level on the C-4 chart (K) Adjustment Standard ID max: Adjust the offset value so that the density of level 10 matches that of level 10 on the C-4 chart.
  • Page 458 REPLACEMENT 3.4 REPLACEMENT 3.4.1 EXPOSURE GLASS 1. Rear scale [A] ( x 3) 2. Exposure glass with left scale [B] ( x 2) 3. ARDF exposure glass [C] NOTE: When reattaching the exposure glass and ARDF exposure glass, position the glass marker [D] at the rear- left corner.
  • Page 459 REPLACEMENT 3.4.3 SENSOR BOARD UNIT (SBU) 1. Open the ARDF/platen cover 2. Rear cover ( 3.1.6) 3. Right cover [A] ( x 3) 4. Inner cover [B] ( x 4) G570R103.WMF 5. Sensor board unit [C] ( x 4, x G570R104.WMF 6.

  • Page 460: Exposure Lamp Stabilizer

    REPLACEMENT 3.4.4 EXPOSURE LAMP STABILIZER 1. Exposure glass with left scale ( 3.4.1) 2. Sensor board unit ( 3.1.3) 3. Exposure lamp stabilizer [A] ( x 2, x 2) G570R105.WMF 3.4.5 XENON LAMP 1. Exposure glass with left scale ( 3.4.1) 2.
  • Page 461 REPLACEMENT 8. Xenon lamp (2 clamps) G570R108.WMF Reassembling 1. Take up the cable slack. 2. Adjust the cable clamp position [G] if necessary. G570R109.WMF 3-13 G570...

  • Page 462: Scanner Motor

    REPLACEMENT 3.4.6 SCANNER POWER SUPPLY UNIT (PSU) 1. Rear cover [A] ( x 3) 2. Right cover [B] ( x 3) 3. Left cover [C] ( x 3) 4. Rear frame [D] ( x12, x 2) G570R110.WMF 5. Scanner power supply unit [E] ( x10,  x 7, Ground wire screw x 2) G570R111.WMF 3.4.7 SCANNER MOTOR...

  • Page 463: Front Scanner Wire

    REPLACEMENT 3.4.8 FRONT SCANNER WIRE 1. Front frame ( 3.1.5) 2. Front scanner wire clamp [A] 3. Front scanner wire bracket [B] ( x 1) 4. Front scanner wire and scanner drive pulley [C] ( x 1) G570R113.WMF 3-15 G570...
  • Page 464 REPLACEMENT Reassembling the Front Scanner Wire 1. Position the center ball [A] in the middle of the forked holder. 2. Pass the right end (with the ring) [B] through the square hole, and the left end (with the ball) [C] through the notch.
  • Page 465 REPLACEMENT 6. Hook the right end of the wire onto the front scanner wire bracket [I], with the end going via the front track of the right pulley [J] and the front track of the movable pulley [K]. NOTE: Do not secure the scanner wire bracket with the screw yet.
  • Page 466 REPLACEMENT 3.4.9 REAR SCANNER WIRE 1. Rear frame ( 3.1.6) 2. Rear rail frame [A] ( x 5) G570R118.WMF 3. Rear scanner wire clamp [B] 4. Rear scanner wire bracket [C] ( x 5. Scanner motor gear [D] ( x 1) 6.
  • Page 467 REPLACEMENT Reassembling the Rear Scanner Wire 1. Position the center ball [A] in the middle of the forked holder. 2. Pass the left end (with the ball) [B] through the drive pulley notch, and the right end (with the ring) [C] through the drive pulley hole.
  • Page 468 REPLACEMENT 3.4.10 NVRAM REPLACEMENT PROCEDURE Make sure you have the SMC report (factory settings) that comes with the printer before beginning the following procedure. NVRAM on the Controller (IC9) 1. Enter SP mode and print out the SMC reports with SP5-990-1 if possible. 2.
  • Page 469 REPLACEMENT NVRAM on the BCU (IC20) 1. Enter SP mode and print out the SMC reports with SP5-990-1 if possible. 2. Turn off the main switch and unplug the power cord. 3. Replace the NVRAM on the BCU and reassemble the machine. 4.
  • Page 470 REPLACEMENT 3.4.11 REQUIRED ACTIONS WHEN REPLACING ITEMS ITEMS BEFORE REPLACING AFTER REPLACING Scanner unit None 1. Adjust the registration for the scanner and ARDF. 2. Do ACC for the copier application. 3. Do ACC for the printer application. Printer mainframe None 1.
  • Page 471 PRINTER ENGINE 3.5 PRINTER ENGINE 3.5.1 TONER SUPPLY UNIT CAUTION: 1) Do not touch the PCU development drums or the transfer belt. Do not let any metal object touch the PCU development sleeves. 2) Having removed the PCUs, cover them with paper or cloth. Keep them in a dark place.
  • Page 472 PRINTER ENGINE G060R902.WMF 3. Development unit left guide [C] ( x 1) 4. Registration upper stay [D] ( x 4) G060R903.WMF CAUTION: 1) When you remove a toner supply pipe, some toner spills out. Before removing it, place some paper or cloth beneath the toner supply unit and waste toner collection path.
  • Page 473 PRINTER ENGINE Reinstalling the M Toner Supply Unit G060R904.WMF 1. Wind the harness [A] on the shaft. 2. Insert the toner collection pipe [B]. NOTE: Check that the pipe does not come off the unit. G060R905.WMF 3. Remove the toner supply unit bushing [C]. 3-25 G570...
  • Page 474 PRINTER ENGINE G060R906.WMF 4. Install the unit [D] and secure it with the screws. 5. Unwind the harness and connect it. 6. Install the bushing. 7. Connect the toner supply pipe and the waste toner collection pipe [E]. 8. Check that the pipes [F] do not come off the unit.
  • Page 475 PRINTER ENGINE K, C, and Y Toner Supply Units G060R908.WMF 1. Development unit plate and development unit guide ( M toner Supply Unit) 2. PCU 3C guide rail [A] ( x 1) NOTE: Pull the front plate [B] slightly. G060R909.WMF 3.
  • Page 476 PRINTER ENGINE 3.5.2 BCU NOTE: 1) After replacing the BCU, remove the NVRAM on the old board and install it on the new board. 2) A DIP switch setting is required, if the new board has a DIP switch. ( Following page - DIP Switch Settings) 1.
  • Page 477 PRINTER ENGINE DIP switch settings NOTE: This setting is very important. If the switch is not set correctly, a paper jam or fusing problem will occur ( Caution below) DIP switch settings (service parts default: All OFF) DIP SW No. Fusing clutch is not installed.

  • Page 478: Touch Panel Position Adjustment

    OTHERS 3.6 OTHERS 3.6.1 TOUCH PANEL POSITION ADJUSTMENT NOTE: It is necessary to calibrate the touch panel in the following cases: • When the operation panel is replaced. • When the NVRAM expansion board is replaced. • When the touch panel detection function is not working correctly NOTE: Do not attempt to use items [2] to [9] on the Self-Diagnostic Menu.
  • Page 479 (G080) to a G060 printer. Preparation Items needed for conversion. DIMM #1 for G570 Copy Feature P/N: G5706691 (See TSB G060/G570 – 036) Flashcards loaded with the following G570 Copy Feature Expander firmware: CF NIB, Scanner Application, Fax Application and Operation Panel (LCDC) Procedure Turn the main power switch OFF.
  • Page 480 OTHERS Rev. 07/2003 ⇒ 6. Install the CF Expander into the G060 mainframe. NOTE: Note: Do not turn the main power on at this time. If it is turned on SC672/990 will be displayed but will not affect the update.
  • Page 481 OTHERS Rev. 07/2003 ⇒ III. Turn the main switch ON. After the following message is displayed, press the button for the firmware you are updating (Operation Panel, Engine, etc.). PCcard -> ROM Page01 ROM:G0775611C NEW:G0775611F Engine ROM:RB1.10:23 NEW:RB111C:23 New Version (IC Card) Current Version Exit (0) - Engine...
  • Page 483 PROCESS CONTROL ERROR CONDITIONS 4. TROUBLESHOOTING 4.1 PROCESS CONTROL ERROR CONDITIONS 4.1.1 DEVELOPER INITIALIZATION RESULT SP-3-005-6 (Developer Initialization Result) Result Description Possible Causes Action Developer When initializing only When done in SP mode, do performed initialization is not the black developer, the the developer initialization performed.
  • Page 484 PROCESS CONTROL ERROR CONDITIONS Result Description Possible Causes Action Toner supply During toner fill-up 1. Check if the toner cartridge is properly set. error mode, Vt does not 2. Check if the amount of toner left in the toner cartridge reach the target is insufficient.
  • Page 485 PROCESS CONTROL ERROR CONDITIONS 4.1.2 PROCESS CONTROL SELF-CHECK RESULT SP3-975-1 (Process Control Self-check Result) Result Description Possible Causes Action Process control self- Do the process control performed check is not done. self-check again. Successfully Process control self- completed check successfully completed.
  • Page 486 PROCESS CONTROL ERROR CONDITIONS 4.1.3 LINE POSITION ADJUSTMENT RESULT SP5-993-7 (Line Position Adjustment Result) Result Description Note Successfully Data sampling was correctly done and line position completed adjustment was successfully completed. Out of adjustment The calculated result for line position correction is greater than ±2 mm.
  • Page 487 PROCESS CONTROL ERROR CONDITIONS Possible causes of errors in the line position adjustment Possible Possible Cause Action Error Code The pattern does not reach the proper density. 1. Dirty ID sensor (toner, dust, or 04, 05, 06, 07, 1. Clean the ID sensors. foreign material) 08, 09, 10 2.
  • Page 488 PROCESS CONTROL ERROR CONDITIONS Possible Possible Cause Action Error Code The MUSIC CPU is abnormal (2) No error code is displayed. However, the machine keeps displaying “execution” on the screen. The green LED on the BICU keeps blinking faintly (this is normal) even under one of the following conditions.

  • Page 489: Scanner Test Mode

    SCANNER TEST MODE 4.2 SCANNER TEST MODE 4.2.1 VPU TEST MODE To make sure the scanner VPU control is functioning, output the VPU test pattern with SP4-907. After you have set the SP mode settings and pressed the start key, the VPU test pattern is printed out.
  • Page 490 SCANNER TEST MODE 4.2.2 IPU TEST MODE You can check the IPU board with the SP mode menu, SP4-904-1 or 2. If no error is detected, the test ends, and the completion code appears in the operation panel display. If an error is detected, the test is interrupted and an error code is displayed.
  • Page 491 SERVICE CALL CONDITIONS 4.3 SERVICE CALL CONDITIONS 4.3.1 SUMMARY There are 2 levels of service call conditions. Level Definition Reset Procedure Fusing unit SCs displayed on the Turn the main switch off then on operation panel. The machine is disabled. before entering SP mode.
  • Page 492 SERVICE CALL CONDITIONS Class 1 Section SC Code Detailed section 530 - Fan motor 540 - Fusing Paper feed / Fusing 560 - Others 570 - Unique for a specific model 600 - Electrical counters 620 - Mechanical counters 630 - Account control Communication 640 -...
  • Page 493 SC TABLE 4.4 SC TABLE NOTE: “CF” in the SC number column indicates a code related to the CF expander. Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The standard white level • Exposure lamp SC 101 Exposure lamp 1.
  • Page 494 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The scanner home • Scanner PSU or SBU SC 121 Scanner home SC 120 1. Turn the main switch off and on. position error 2 and 122 2.
  • Page 495 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The white level cannot be • Dirty exposure glass SC142 White level 1. Turn on the main switch off and on. detection error 2. Clean the exposure glass, white plate, (CF) adjusted within the target or optics section...
  • Page 496 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The polygon mirror motor • Polygon mirror motor SC201 Polygon motor 1. Turn the main switch off and on. error 2. Check the cables. does not reach the error •...
  • Page 497 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Damaged or SC 221 Synch. detection Main scan length detection After doing any of the following, print ten signal error 2 is not properly completed jobs or more to see if the same SC code disconnected cable ten consecutive times.
  • Page 498 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Poor connection SC 230 FGATE error The BCU generates the 1. Turn the main switch off and on. 230-1: Y FGATE signal based on the 2. Check the cables between the LD between BCU and LD 230-2: M registration sensor ON...
  • Page 499 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • LD worn out SC 240 LD over The power supply for the LD 1. Turn the main switch off and on. 240-1: Y unit exceeds 67 mA. 2.
  • Page 500 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Pattern sampling SC 285 Line position Line position adjustment 1. Turn the main switch off and on. adjustment fails three consecutive 2. Check and fix the problem that error due to (MUSIC) error times.
  • Page 501 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Defective motor SC 380 Black When the motor speed is 1. Turn the main switch off and on. • Defective BCU development within the target level, the 2.
  • Page 502 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Unsuitable toner SC 386 Development Any of the following 1. Turn the main switch off and on . gamma error K conditions happens three 2. Check the process control self-check density •...
  • Page 503 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Power pack SC 391- Charge AC: The high voltage supply 1. Turn the main switch off and on. output error board sends the feedback 2. Check the connector. disconnected •...
  • Page 504 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Thermistor 2 SC 461- Thermistor 2 When the temperature 1. Turn the main switch off and on. error (open detected by the thermistor 2, 2. Check the cable connections. defective •...
  • Page 505 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Defective high SC 490 Transfer bias / The high voltage supply 1. Turn the main switch off and on. paper attraction board (T/PA/CL) monitors 2. Check the transfer unit and replace voltage supply board roller bias leak the circuit and detects...
  • Page 506 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type SC 503- Tray 3 error For the paper feed unit: For the paper feed unit: 1. Turn the main switch off and on. • Defective tray lift 2. Check the cable connections. (Paper Feed Unit When the tray lift motor is 3.
  • Page 507 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • If the following condition SC 503- Tray 3 error For the paper feed unit: 1. Turn the main switch off and on. • Defective tray lift 2. Check the cable connections. (Paper Feed Unit occurs 3 consecutive 3.
  • Page 508 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Defective tray lift SC 504- Tray 4 error (3 When the main switch is 1. Turn the main switch off and on. Tray Paper Feed turned or when the tray is 2.
  • Page 509 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Loose connection SC 544 Heating roller During stand-by mode or a 1. Check the connection between the fusing lamp low print job, the detected fusing unit and main frame. between the fusing temperature heating roller temperature...
  • Page 510 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Defective PSU SC 553 Pressure roller The detected pressure roller 1. Replace the fusing unit. • Defective BCU fusing lamp temperature stays at 200°C 2. Replace the PSU. overheat or more for five seconds.
  • Page 511 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • After the ARDF is • Incorrect installation SC 620 ARDF 1. Turn the main switch off and on. communication 2. Check the cable connection of the (CF) detected, the break signal of ARDF •...
  • Page 512 Rev. 09/2003 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type SC 642 Communication • The operation panel does • Controller defective 1. Turn the main switch off an on. timeout error • Operation panel 2. Check the cable connection between (CF) not respond to the frame between...
  • Page 513 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • After the machine is • Controller stalled SC 672 Controller-to- 1. Turn the main switch off and on. • Controller board operation panel 2. Check the condition of the controller (CF) powered on, the communication...
  • Page 514 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • During data transfer, a • Scanner unit cable SC 685 SBU-IPU 1. Turn the main switch off and on. communication 2. Shut out the external noise. (CF) checksum error occurs.
  • Page 515 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • After the machine is • Board connector SC 691 Scanner startup 1. Turn the main switch off and on. error 2. Check the cable connection between (CF) powered on or recovering between controller controller and bridge board.
  • Page 516 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The jogger fences of the • Defective jogger H.P. SC 722 Finisher jogger 1. Turn the main switch off and on. motor error 2. Check the connection of jogger H.P. finisher donot return to sensor •...
  • Page 517 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • The upper stack height 1 • Loose connection SC 726 Finisher shift tray 1. Turn the main switch off and on. • Defective upper stack 1 lift motor error 2.
  • Page 518 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type • Loose connection SC 731 Finisher exit The exit guide plate open 1. Turn the main switch off and on. • Defective exit guide guide plate motor sensor is not activated 2.
  • Page 519 Rev. 09/2003 SC TABLE ⇒ SC 800 Startup without Video transfer to the engine • Defective BCU 1. Turn the main switch off and on. video output end is started, but the engine 2. Check the cable connection. (CF) error (K) does not issue a video 3.
  • Page 520 Rev. 09/2003 SC TABLE • • SC 818 Watch-dog error While the system program is • Defective controller 1. Turn the main switch off and on. running, other processes do • Software error 2. Replace the controller. not operate at all. 3.
  • Page 521 Rev. 09/2003 SC TABLE [0801] CPU error Same as [0001] [4005] SC 821 Self-diagnosis The CPU checks if the ASIC • System firmware 1. Turn the main switch off and on. error: ASIC timer works properly 2. Reinstall the controller system [0D05] problem compared with the CPU...
  • Page 522 Rev. 09/2003 SC TABLE • An RTC device is • RTC defective SC 826 Self-diagnostic 1. Turn the main switch off and on. Error: RTC/ recognized, and the • NVRAM without RTC 2. Replace the NVRAM with another (CF) Optional NVRAM NVRAM with an RTC device.
  • Page 523 Rev. 09/2003 SC TABLE SC829 Self-diagnosis error: optional RAM [XXXX]: Detailed error code [0302] Composition The result of checking the • Not specified RAM 1. Turn the main switch off and on. error (Slot 0) composition data of the 2. Replace the RAM DIMM. DIMM installed RAM in Slot 0 (CN5) on the •...
  • Page 524 Rev. 09/2003 SC TABLE • Defective IEEE1394 SC 851 IEEE1394 The 1394 interface is 1. Turn the main switch off and on. interface error unusable. • Defective controller. 2. Replace the IEEE1394 interface board. 3. Replace the controller. SC 860 HDD: The controller detects that •...
  • Page 525 Rev. 09/2003 SC TABLE ⇒ SC 991 Software The software performs an • Incorrect program This SC is not displayed on the LCD Performance unexpected operation. (logged only). argument or other Error - Logged parameter • Insufficient working Note: Unlike SC990, the software/machine continue memory to function without requiring...
  • Page 526 Rev. 09/2003 SC TABLE • The download (program, • BCU Board installed SC 999 Program 1. Turn the main switch off and on. download error print data, language data) incorrectly 2. If you can download necessary (CF) programs, do it by using an from the IC card does not •...
  • Page 527 Rev. 09/2003 SC TABLE NOTE 1: If a problem always occurs in a specific condition (for example. printer driver setting, image file), the problem may be caused by a software error. In this case, the following data and information needs to be sent back to your product specialist. •...
  • Page 528 Rev. 09/2003 TROUBLESHOOTING GUIDE 4.5 TROUBLESHOOTING GUIDE 4.5.1 IMAGE QUALITY The table below shows the troubleshooting procedure for the following image problems. • Smeared image for 4C thin lines or White lines in solid image areas • Dirty background • Fireflies •...
  • Page 529 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Dirty background Dirty background may When the developer has deteriorated or Perform forced toner refresh mode (SP3-921-1 or continuously appear on the when prints are made in a very low left side (relative to paper humidity condition, dirty background may The machine automatically does this in the feed) under very low...
  • Page 530 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Crow marks When making duplex prints in A charge is applied to the paper at each Using SP2-301 (Transfer Current), increase the low temperature and humidity color station in order to attract each paper transfer current for black in the mode in conditions, crow marks may toner onto the paper.
  • Page 531 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Image density change Image density is too low or If the machine has never been turned off Change the settings of the following SP modes: high. and Energy Saver 2 (Auto Off mode) is SP3-906-3 Non-use Time 1 disabled, the machine has never 0 (Default) to 500...
  • Page 532 Rev. 09/2003 TROUBLESHOOTING GUIDE 4.5.2 COLOR SHIFT The following briefly explain the factors causing color shifts and what to do on the machine to correct it: • Temperature change causes the optical components in the laser optics housing unit to contract, causing the main The black development motor drives scan magnification to change.
  • Page 533 Rev. 09/2003 TROUBLESHOOTING GUIDE As explained on the previous page, there are several types of color shift problem. The following table shows the symptoms, factors, action required, and the page to see for details. Symptom Factors Action Required Refer to # Color shift on entire image in •...
  • Page 534 Rev. 09/2003 TROUBLESHOOTING GUIDE µ Adjustment Standard: Max. 200 As a machine capability, maximum amount of color shift is 200 µm. Adjusting the SP modes (motor speed, registration, and magnification) can improve the color shifts level; however, there is a limit. Preparation When color shift is reported, the following procedure should be done before adjusting the machine and/or SP modes.
  • Page 535 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Sub-scan Leading Color shift, Registration roller Normal Paper SP1-004-4 Check the magenta line position against the black line. edge especially 100 mm speed is not 1200 dpi If the registration roller is too fast or slow, the magenta...
  • Page 536 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Sub-scan Entire Color shift on the SP mode setting Normal Paper SP5-993- Measure the gap between the black line and other image entire image, and is not suitable for 600 dpi...
  • Page 537 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Main-scan Entire Color shifts on the Main-scan SP5-993- Measure the gap between the black line and other image entire image, and magnification is 013 (Y) colors (YMC) using a magnification scope.
  • Page 538 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Main-scan Entire Color shifts on the Main-scan SP5-993- Measure the gap between the black line and other image entire image and registration is not 010 (Y) colors (YMC) using a magnification scope.
  • Page 539 SERVICE PROGRAM MODE – CF CONFIGURATION 5. SERVICE TABLES 5.1 SERVICE PROGRAM MODE – CF CONFIGURATION CAUTION Before accessing the service menu, do the following: Confirm that there is no print data in the printer buffer (the Data In LED must not be lit or blinking).
  • Page 540 SERVICE PROGRAM MODE – CF CONFIGURATION SP Mode Button Summary Here is a short summary of the touch-panel buttons.   ‘ ’ “ ” • – — „ G570S902.WMF Opens all SP groups and sublevels. Closes all open groups and sublevels and restores the initial SP mode display. Opens the copy window (copy mode) so you can make test copies.
  • Page 541 SERVICE PROGRAM MODE – CF CONFIGURATION Switching Between SP Mode and Copy Mode for Test Printing 1) In the SP mode, select the test print and then press Copy Window. 2) Use the copy window (copier mode), to select the appropriate settings (paper size, etc.) for the test print.
  • Page 542 SERVICE PROGRAM MODE – CF CONFIGURATION Exiting Service Mode Press the “Exit” key on the touch-panel. NOTE: To make the following settings effective, you must turn the main switch off and on after exiting service mode. SP Modes Related to the Engine SP Modes Related to the Controller SP2-208-009 SP5-009-001...

  • Page 543: Service Mode

    SERVICE MODE 5.2 SERVICE MODE 5.2.1 REMARKS Display on the Touch Panel Screen Since the maximum number of characters which can be displayed on the touch panel screen is limited (20 characters), the description of SP modes displayed on the screen needs to be abbreviated. The following are the major abbreviations used for the SP modes for which the full description is over 20 characters.
  • Page 544 SERVICE MODE As shown in the following table, the process speed (mm/s) depends on the print mode (B&W or Color), resolution, and/or type of paper selected. Some SP mode settings depend on the process speed. Resolution Line speed Print speed Mode (dpi) (mm/s)
  • Page 545 PRINTER SP MODE 5.3 PRINTER SP MODE 5.3.1 SP MODES Mode No. Function / [ Setting ] (Class 1 and 2) [Bit Switch] Adjusts bit switch settings. DFU Bit Switch 1 Setting Bit Switch 2 Setting NOTE: Currently the bit switches are not being used. Bit Switch 3 Setting All data has to be set to “0”.
  • Page 546 PRINTER SP MODE Mode No. Function / [ Setting ] (Class 1 and 2) [Data Save] Data Save Stores the print gamma adjusted with the “Gamma Adj.” menu item as the current setting. Before the machine stores the new ‘current setting’, it moves the data currently stored as the ‘current setting’...
  • Page 547 COPY SP MODE 5.4 COPY SP MODE 5.4.1 SP MODES SP1-XXX (Feed) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Lead Edge Reg.] Leading Edge Registration (Paper Type, [Color ], Process Speed) Normal [K] 62.5 Adjusts the leading edge registration by changing the registration clutch operation timing for each Normal [K] 125 mode.
  • Page 548 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Dev. Motor Speed2] Development Drive Motor Speed 2 ([Color], Process Speed) Adjusts the black development drive motor speed for the B&W 125mm/s process speed. The value stored in this SP mode is different from SP1-004- 002 ( the note for SP 1-004).
  • Page 549 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) 25 Process Speed Selects the power-on default target fusing operation temperature. The target operating fusing temperature depends on the process speed. When the machine is switched on, it starts warming up for the process speed specified in this SP mode.
  • Page 550 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) 11 H:N[FC] D 125 [ 100 to 190 / NA: 165 EU: 170 / 5°C/step] 13 H:OHP [FC] [ 100 to 190 / 180 / 5°C/step] 15 P:N [K] S 125 [ 0 to 190 / NA: 145 EU: 155 / 5°C/step] 16 P:N [K] S 185...
  • Page 551 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Tray 2 B4/LG Specifies the paper size for tray 2. [ 0 or 1 / 0 / - ] Alphanumeric 0: B4 lengthwise, 1: LG lengthwise This specifies which size is detected for a sensor output of 1101 (see section 6 for details).
  • Page 552 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Temperature Cor. 1] Fusing Temperature Correction (Correction Timing) Sheet Setting Specifies the number of sheets to determine whether or not to apply the fusing temperature correction.
  • Page 553 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [OHP/TH Fusing] OHP/Thick Paper Fusing Temperature Correction ( H eating or P ressure Roller) Specifies the temperature for starting a print job. The fusing section is already warmed up when the last print job was completed. If prints are made on OHP or thick paper at this time, the fusing temperature tends to be higher than the target, causing exit roller marks or a paper jam in the fusing section.
  • Page 554 COPY SP MODE SP2-XXX (Drum) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Charge Bias] Charge Roller Bias (DC or AC component: [Color], Process Speed) U: Upper, L: Lower DC:[K] 62.5 Adjusts the DC component of the charge roller bias in the various print modes.
  • Page 555 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) AC U Limit[FC] Sets the upper limit of the AC component adjustable range for color. During machine initialization and process control self-check, the AC component of the charge roller bias is automatically adjusted within the range specified in the SP2-001-021 and 022.
  • Page 556 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) LD Power Control for CF ([Color Mode, Color] [ 0 to 1023 / 604 / 1/step ] DFU CF:[K,K] 1 [ 0 to 1023 / 604 / 1/step ] DFU CF:[K,K] 2 CF[FC,K] [ 0 to 1023 / 720 / 1/step ] DFU...
  • Page 557 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Forced Toner Supply] ([Color]) Forces toner to be supplied to the development unit for the number of times specified by this SP mode. 1 time: The toner supply clutch turns on for 0.7 s and off for 1.3 s.
  • Page 558 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Toner Near/End] Toner Near End / End Detection Threshold ([Color]) Start [K] When the amount of toner amount left in the cartridge becomes less than this value, the machine starts monitoring the Vt values for toner near end detection.
  • Page 559 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [TD Vcnt Control] TD Sensor Vcnt Control Initialization Enables or disables the Vcnt Auto Adjustment when detecting a new development unit. When the machine detects a new development unit, developer initialization automatically starts.
  • Page 560 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Transfer Current] Transfer Current ([Color Mode, Color], Paper Tray or By-pass, Simplex or Duplex, Process Speed) Paper Type -> TH: Thick Paper, SP: Special Paper Adjusts the transfer current for each color and each print mode.
  • Page 561 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [ 0 to 50 / 7 / 1 µA/step ] [FC,Y]SP S 62.5 [ 0 to 50 / 6 / 1 µA/step ] [FC,M]SP S 62.5 [ 0 to 50 / 7 / 1 µA/step ] [FC,C]SP S 62.5 [ 0 to 50 / 15 / 1 µA/step ]...
  • Page 562 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [PA Roller Current] Paper Attraction Roller Current ([Color], Simplex or Duplex, Process Speed): Current Adjustment (Paper or By-pass): Paper Size Correction Adjusts the paper attraction roller current for color printing. If paper misfeeds occur at the transfer unit in color mode, check and/or adjust the paper attraction roller current.
  • Page 563 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Mirror Motor] Mirror Positioning Motor ([Color]) Displays the result of the latest line position adjustment. Changing this affects the mirror position, which corrects the optically skewed image; however, this will be automatically corrected at the next line position adjustment.
  • Page 564 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Main Scan Reg Cor] Main-scan Registration Correction ([Color]) Specifies the correction to the main-scan length. Main-scan length differs for each machine due to variations in parts used in the laser optics housing unit.
  • Page 565 COPY SP MODE SP3-XXX (Process) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [TD Initial] TD Sensor Initialization ([Color]) Initializes the developer. DFU Press the Enter key to execute the initialization after the machine asks “Execute?”. [All Color] Result Displays the developer initialization result.
  • Page 566 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Dev. Gamma Target] Development Gamma Target ([Color]) Adjusts the development gamma by changing the Vref value used for toner density control. Vref is automatically corrected so that the gamma measured during the process control self-check becomes “the value set with this SP mode ±...
  • Page 567 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Enables or disables the process control self-check before printing the ACC pattern. [ 0 to 2 / 2 / 1/step ] Alphanumeric 0: Disable 1: Process Control 2: Auto TD Adj.
  • Page 568 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [PC Self-check] Process Control Self-checks Job End Specifies the execution timing of the job end process control self-check. [ 0 to 999 / 200 / 1 print/step ] The job end process control self-check is automatically done after a job is completed when 200 prints have been made since the last self-...
  • Page 569 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Vmin Display] Vmin Display ([Color]) Displays the current Vmin value for K [Color] Displays the lowest current Vmin value for the colors (CMY). [Vt Current Display] Vt Current Display ([Color]) Displays the current Vt value.
  • Page 570 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Mode Set Enables/disables refresh mode. [ 0 to 2 / 2 / 1/step ] Alphanumeric 0: Disabled 1: Mode 1 (Done at power on and toner end recovery) 2: Mode 2 (Done at power on, toner end recovery, and after the specified number of prints.)
  • Page 571 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Process Control Result] Process Control Self-check Result P Ctrl Result Displays the result of the latest process control self-check. [ 0 to 9999 / - / 1/step ] All colors are displayed.
  • Page 572 COPY SP MODE SP4-XXX (Scanner) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [SubScanMagnification] Sub-scan Magnification Adjustment SubScanMagnification Adjusts the sub-scan magnification by changing the scanner motor speed. [ -1.0 to 1.0 / 0 / 0.1%/step ] FA [Leading Edge Reg.] Leading Edge Registration Adjustment Leading Edge Reg.
  • Page 573 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [IPU Test Pattern] IPU Test Pattern Selects the IPU test pattern. [ 0 to 16 / 0 / 1/step ] 0: Scanned image 1: Grid pattern 2: Slant grid pattern 3: Gradation main scan1 4: Gradation sub scan1...
  • Page 574 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [DF: Density Adj.] DF Density Adjustment DF: Density Adj. Adjusts the white shading parameter when scanning an image with the ARDF. [ 83 to 100 / 86 / 1 %/ step ] Adjusts the density level if the ID of outputs made in the DF and Platen mode is different.
  • Page 575 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Option: Highlight Adjusts the option data of the printer gamma for black in the B&W and Photo mode. Option: Middle Option: Shadow [ 0 to 255 / 0 / 1 /step ] DFU Option: IDmax [Gamma [K] Letter ] Printer Gamma Adjustment for Black/Letter mode Offset: Highlight...
  • Page 576 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Gamma [K] Photo ] Printer Gamma Adjustment for Black/Photo mode Offset: Highlight Adjusts the offset data of the printer gamma for black in Photo mode. Offset: Middle [ 0 to 30 / 15 / 1 /step ] Offset: Shadow...
  • Page 577 COPY SP MODE SP5-XXX (Mode) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Language Selection] Language Selection Selects the language for the control panel. [ 0 to 16 / 2 / 1/step ] Data Language Data language No language Norwegian...
  • Page 578 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [ROM Update Display] ROM Update Enables or disables the ROM Update utility. When enabled, this utility will be displayed in the user program mode. [ 0 or 1 / 1 /- ] 0: Enable, 1: Disable [Double Count] Double Count...
  • Page 579 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Memory Clear 1] All module Resets all the controller and engine settings to their defaults and the counters to 0. DFU Clears all the engine settings and counters. DFU ENG All SCS / SRM Initializes the system settings.
  • Page 580 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Facsimile Sets the fax number for a service representative. This number is printed on the Counter List, which can be printed with the user’s “Counter”. This can be up to 20 characters (both numbers and alphabetic characters can be input).
  • Page 581 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) 39 Apple Talk Type Sets the AppleTalk type for the network. 40 Working Zone: AT Sets the AppleTalk working zone for the network. 47 Job Analysis Timeout Sets the Centronics job analysis timeout for the network.
  • Page 582 [ 0 to 7 / 0 / 1/step ] FA Model Name NetBeui AficioAP3800 Ricoh Aficio AP3800C Ricoh ColorLaser AP828 ColorAP828 Savin SLP38c SLP38c Gestetner DSc38 DSc38 DSc38 DSc38 Infotec IP 280 IP280 Lanier 2138 2138 [ACS Mode] ACS Mode...
  • Page 583 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Menu Selects the method for displaying the alert when the life of the parts in a maintenance kit has almost ended. [ 0 or 1 / 1 / - ] Alphanumeric 0: Click 2 1: Click 1 The following table shows the machine condition...
  • Page 584 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Debug Serial Output Debug Serial Output [Touch Panel Correction] Touch Panel Correction Log Touch Panel Calibration Displays whether the touch panel has been calibrated after clearing all memory. [ 0 or 1 / 0 / - ] 0: Not calibrated 1: Calibrated...
  • Page 585 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Line Position Adj.] Line Positioning Adjustment ([Color]) M: Main-scan, S: Sub-scan, Reg.: Registration, Mag.: Magnification For example: M Reg = Main scan registration Mode Selection Specifies when the automatic line position adjustment is done.
  • Page 586 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Result Displays the result of the latest line position adjustment in 4 digits. First 2 digits: Error detected on the front ID sensor Last 2 digits: Error detected on the rear ID sensor Refer to the Troubleshooting section for more details about the two-digit codes.
  • Page 587 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) 23 Interrupt 2 Performs the line position adjustment when the number of prints reaches the number specified in this SP mode regardless of the temperature change.
  • Page 588 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Pattern Selects a test pattern. [ 0 to 23 / 0 / 1/step ] 0: None 1: 1-dot sub-scan line 2: 2-dot sub-scan line 3: 1-dot main-scan line 4: 2-dot main-scan line 5: 1-dot grid pattern (fine) 6: 2-dot grid pattern (fine)
  • Page 589 COPY SP MODE SP6-XXX (Peripherals) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [DF Registration Adj.] DF Registration Adjustment Side-to-Side Adjusts the side-to-side and leading registration of Leading Edge originals with the ARDF. [ -30 to 30 / 0 / 0.1 mm/step ] Buckle: Duplex Front Adjusts the amount of paper buckle to correct Buckle: Duplex Rear...
  • Page 590 COPY SP MODE [DF Magnification Adj.] DF Magnification Adjustment DF Magnification Adj. Adjusts the magnification in the sub-scan direction for the ARDF. [ -5.0 to 5.0 / 0 / 0.1 %/step ] [Punch Position] Punch 1 Adjusts the punching position. Punch 1 Punch 2 US: 2 punch holes...
  • Page 591 COPY SP MODE SP7-XXX (Data Log) Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Original Counters] Total Counter Displays the total original count (number of Copies originals fed) for the selected mode. Document Box Scanner Others [M/C Counter] Meter Charge Counter ( P rint, D evelopment) Total...
  • Page 592 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Total Scan Counter] Total Scan Counter Displays the total number of scans. [ 0 to 9999999 / 0 / 1 scan/step ] [D Unit Op Ctr] Development Unit Operation Counter Print: B&W Displays the number of prints made with black development unit operation only.
  • Page 593 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Sort Displays the total number of copies made in the copy mode by each operation mode. Staple Series Erase Duplex Double Copy Duplex Original Interrupt Copy Combined 1 Side Combined 2 Side Batch...
  • Page 594 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) HLT (Sideways) Displays the number of copies made from the document server and classed by paper size. Others A3 (Lengthwise) A4 (Lengthwise) A5 (Lengthwise) B4 (Lengthwise) B5 (Lengthwise) DLT (Lengthwise) LG (Lengthwise)
  • Page 595 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Latest10Sclog] Latest Logs the SC codes detected. The 10 most recently detected SC Codes are not Latest –1 displayed on the screen, but can be seen on the Latest –2 SMC (logging) outputs.
  • Page 596 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) F Staple Displays the number of jams according to the location where jams were detected. F Exit F Punch F Jam Clear [Original Jam Detection] At Power On Displays the total number of original jams by location.
  • Page 597 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [PM Counter] ( S heets or R otations, Unit, [Color]) Dev.: Development Unit, PF: Paper Feed Rollers, Oil Supply: Oil Supply Unit, Fusing: Fusing Unit, Transfer: Transfer Unit S:PCU [K] Displays the number of sheets printed for each current maintenance unit.
  • Page 598 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [PM Counter Clear] (Unit, [Color]) Dev.: Development Unit, PF: Paper Feed Rollers, Transfer: Transfer Unit PCU [K] Clears the PM counter. Press the Enter key after the machine asks PCU [Y] “Execute?”.
  • Page 599 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) Toner [K] Displays the total number of toner cartridges replaced. Toner [C] [ 0 to 65535 / - / 1 cartridge/step ] Toner [M] Toner [Y] [Co.
  • Page 600 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Print: Printer Gamma] Print: Printer Gamma Prints all data lists. (same function as SP5-990- 001) DFU [Alert Display] Fusing: Alert Specifies the timing for displaying the near-end condition.
  • Page 601 COPY SP MODE Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Check Sum] Engine Main Displays the check sum of the firmware. Engine MUSIC 5-63 G570...
  • Page 602 COPY SP MODE NOTE 1: Memory Clear (SP5-801 & 7-808) The following tables list the items that are cleared. The serial number information, meter charge setting (SP5-930), and meter charge counters (SP7-003) are not cleared. Mode No. SP Modes or User Setting to be cleared (Class 1, 2, and 3) [Memory Clear] All module...
  • Page 603 COPY SP MODE 5.4.2 INPUT CHECK TABLE Main Frame Input Check: SP5-803 When entering the Input Check mode, 8 digits display the result for a section. Each digit corresponds to a different device as shown in the table. Bit No. Result 0 or 1 0 or 1...
  • Page 604 COPY SP MODE SP5-803 Reading Description -XXX Paper Feed Relay Sensor Paper not detected Paper detected Vertical Transport Sensor Paper not detected Paper detected Upper Relay Sensor (PFU) Paper not detected Paper detected Lower Relay Sensor (PFU) Paper not detected Paper detected Registration Sensor Paper not detected...
  • Page 605 COPY SP MODE Reading SP5-803 Description -XXX Mail Box 1 Tray 1 Paper Overflow Sensor Not full Full Tray 1 Paper Sensor Paper not detected Paper detected Tray 2 Paper Overflow Sensor Not full Full Tray 2 Paper Sensor Paper not detected Paper detected Tray 3 Paper Overflow Sensor Not full...
  • Page 606 COPY SP MODE Table 2: Paper Size Switch (Tray 2) 0: Not pushed, 1: pushed Models Switch Location North America Europe/Asia 11" x 17" SEF 11" x 17" SEF A3 SEF A3 SEF " x 14" SEF B4 SEF " x 11" SEF *2 A4 SEF *2 11"...
  • Page 607 COPY SP MODE 5.4.3 OUTPUT CHECK TABLE CH: Charge PF: P aper F eed TS: T oner S upply CW: Clockwise CCW: Counterclockwise MB: 4-bin M ail b ox DI: D uplex I nverter SP5- Description 804-XXX Regist CL Registration Clutch By-pass CL By-pass Feed Clutch PF CL (1)
  • Page 608 COPY SP MODE SP5- Description 804-XXX Transfer [K] Transfer Current for Black Cleaning Bias Transfer Belt Cleaning Roller Bias PA Roller Bias Paper Attraction Roller Bias TS CL [Y] Toner Supply Clutch for Yellow TS CL [M] Toner Supply Clutch for Magenta TS CL [C] Toner Supply Clutch for Cyan TS CL [K]...
  • Page 609 COPY SP MODE SP5- Description 804-XXX DevPWM TRG[M] Development PWM Trigger for Magenta DevPWM TRG[Y] Development PWM Trigger for Yellow CHdcPWM TRG[K] Charge DC PWM Trigger for Black CHdcPWM TRG[C] Charge DC PWM Trigger for Cyan CHdcPWM TRG[M] Charge DC PWM Trigger for Magenta CHdcPWM TRG[Y] Charge DC PWM Trigger for Yellow CHac1 TRG[FC]...
  • Page 610 COPY SP MODE SP5- Description 804-XXX PF M370CCW Duplex Feed Motor / 370 / Counterclockwise DI M2 OFF Duplex Inverter Motor 2 / OFF K Dev M H Development Motor - K / High Speed K Dev M M Development Motor - K / Middle Speed K Dev M L Development Motor - K / Low Speed Color Dev M H...
  • Page 611 COPY SP MODE 5.4.4 TEST PATTERN (SP5-997) Test Pattern Selection (SP5-997-002) 0: None 1: 1-dot sub-scan line 2: 2-dot sub-scan line Test Pattern Printting 3: 1-dot main-scan line 4: 2-dot main-scan line 5: 1-dot grid pattern (fine) Selects the tray in which desired paper size is 6: 2-dot grid pattern (fine) SP5-997-001...
  • Page 612 SCANNER SP 5.5 SCANNER SP 5.5.1 SP MODES SP1-xxx (System and Others) Mode No. Function / [Setting] (Class 1, 2, and 3) [System] Model Name Displays the model name. Scanner Firmware Displays the scanner firmware version. Version Scanner Firmware Displays the firmware’s part number. Number Detail Model Name Displays the detail model name.
  • Page 613 SCANNER SP SP2-XXX (Scanning-image quality) Mode Number Function / [Setting] (Class 1, 2, and 3) [Text mode settings] MTF Filter Coefficient Selects the MTF filter coefficient in the main (Main scan) scan direction for Text mode. Select a higher number for a stronger filter. If this is “0”, the MTF filter is not applied.
  • Page 614 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) Notch No.3: Contrast Adjusts the image density for each image density level for Text mode when using binary picture processing mode. [ 0 to 255 / 128 / 1/step ] DFU Notch No.3: Threshold [ 0 to 255 / 100 / 1/step ] DFU [ 0 to 255 / 128 / 1/step ] DFU...
  • Page 615 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) [ 0 to 255 / 128 / 1/step ] DFU Notch No. 4(Middle): Contrast [ 0 to 255 / 128 / 1/step ] DFU Notch No. 4(Middle): Threshold [ 0 to 255 / 128 / 1/step ] DFU Notch No.3: Brightness...
  • Page 616 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) [ 0 to 255 / 145 / 1/step ] DFU Notch No.6: Threshold [ 0 to 255 / 128 / 1/step ] DFU Notch No.5: Brightness Notch No.5: Contrast [ 0 to 255 / 128 / 1/step ] DFU [ 0 to 255 / 135 / 1/step ] DFU Notch No.5: Threshold...
  • Page 617 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) [ 0 to 255 / 160 / 1/step ] DFU Notch No.7(Lighter): Threshold [ 0 to 255 / 128 / 1/step ] DFU Notch No.6: Brightness [ 0 to 255 / 128 / 1/step ] DFU Notch No.6: Contrast [ 0 to 255 / 145 / 1/step ] DFU Notch No.6: Threshold...
  • Page 618 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) Notch No.7(Lighter): R Adjusts the image density for each image - Brightness density level for Text mode when using binary picture processing mode. [ 0 to 255 / 195 / 1/step ] DFU Notch No.7(Lighter): G [ 0 to 255 / 194 / 1/step ] DFU - Brightness...
  • Page 619 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) [ 0 to 255 / 128 / 1/step ] DFU Notch No.5: G - Threshold [ 0 to 255 / 128 / 1/step ] DFU Notch No.5: B - Threshold [ 0 to 255 / 128 / 1/step ] DFU Notch No.4(Middle): R...
  • Page 620 SCANNER SP Mode Number Function / [Setting] (Class 1, 2, and 3) [ 0 to 255 / 128 / 1/step ] DFU Notch No.2: R - Threshold Notch No.2: G - [ 0 to 255 / 128 / 1/step ] DFU Threshold Notch No.2: B - [ 0 to 255 / 128 / 1/step ] DFU...
  • Page 621 SCANNER SP Mode Number Function and [Setting] [Display timer of N/W error] Display timer of N/W Selects the length of time that the network error error message for the scanner utilities is displayed. If this is “0”, the error message is displayed until the error is solved.
  • Page 622 REBOOT / SYSTEM SETTING RESET 5.6 REBOOT / SYSTEM SETTING RESET 5.6.1 SOFTWARE RESET The software can be rebooted when the machine hangs up. To reboot the software, use the following procedure. Turn the main power switch off and on. -or- Press and hold down  together for over 10 seconds.
  • Page 623 REBOOT / SYSTEM SETTING RESET Copier Setting Reset The copy settings in the UP mode can be reset to their defaults. Use the following procedure. 1. Press User Tools/Counter 2. Hold down  and then press Copier/Document Server Settings. NOTE: You must press  first. G570S903.WMF 3.
  • Page 624 16 languages. * The firmware with an asterisk mark is used in both the printer (G060) version and CF (G060+G570) version. Other firmware is unique for the CF version. (For example, if you insert the IC card containing controller firmware for the printer version, “Download Error SC999”...
  • Page 625 FIRMWARE UPDATE PROCEDURE 5.7.3 FIRMWARE UPGRADE CAUTION 1. Turn off the main switch whenever inserting or removing an IC card. 2. Open the front cover whenever updating the firmware. 3. Do not turn off the machine while downloading the firmware. 1.
  • Page 626 FIRMWARE UPDATE PROCEDURE 7. After the firmware update is completed, PCcard -> ROM Page01 “Update done” or “Power Off On” is displayed. Turn off the main switch and remove the IC card. Update done. 8. If more firmware needs to be Engine Card No.:1/1 downloaded, make sure that the main switch is turned off and repeat steps 3...
  • Page 627 CONTROLLER SELF-DIAGNOSTICS 5.8 CONTROLLER SELF-DIAGNOSTICS 5.8.1 OVERVIEW There are three types of self-diagnostics for the controller. • Power-on self-diagnostics: The machine automatically starts the self-diagnostics just after the power has been turned on. • Detailed self-diagnostics: The machine does the detailed self-diagnostics by using a loop-back connector (P/N G0219350) •...
  • Page 628 CONTROLLER SELF-DIAGNOSTICS 5.8.2 DETAILED SELF-DIAGNOSTICS In addition to the self-diagnostic test initiated every time the main machine is powered on, you can set the machine in a more detailed diagnostic mode manually in order to test other components or conditions that are not tested during self- diagnosis after power on.
  • Page 629 USER PROGRAM MODE 5.9 USER PROGRAM MODE The user program (UP) mode is accessed by users and operators, and by sales and service staff. UP mode is used to input the copier’s default settings. The system/copier settings can be reset at any time by the user. ( 5.6) 5.9.1 HOW TO USE UP MODE UP Mode Initial Screen: User Tools/Counter Display To enter the UP mode, press User Tools/Counter...
  • Page 630 USER PROGRAM MODE Copier/Document Server Features In the User/Tools Counter display, press Copy/Document Server Settings. G570S905.WMF Press a tab to display the settings. If the Next button is lit in the lower right corner, press to display more options. Perform the settings, press Exit to return to the User Tools/Counter display, and then press Exit to return to the copy window.
  • Page 631 USER PROGRAM MODE Counter In the User/Tools Counter display, press Counter. G570S907.WMF Maintenance In the User/Tools Counter display, press Maintenance. G570S908.WMF 5-93 G570...
  • Page 632 DIP SWITCHES 5.10 DIP SWITCHES Controller Board DIP SW No. Boot-up from flash ROM Boot-up from IC card 2 to 4 Factory Use Only: Keep these switches OFF. NOTE: If a download attempt failed, you must boot up the machine from the IC card.
  • Page 633 SCANNING 6. DETAILED DESCRIPTIONS 6.1 SCANNING 6.1.1 OVERVIEW G570D101.WMF 1. Scanner HP sensor 6. 1st scanner (1st carriage) 2. ADF exposure glass 7. Scanner motor 3. Exposure glass 8. Sensor board unit (SBU) 4. 2nd scanner (2nd carriage) 9. Original length sensor 5.

  • Page 634: Scanner Drive

    SCANNING 6.1.2 SCANNER DRIVE G570D103.WMF The 1st and 2nd scanners [A] are driven by the scanner motor [B] through the scanner drive pulley, scanner drive shaft [C], and two scanner wires [D]. - Book mode - The SBU board controls the scanner drive motor. The 2nd scanner speed is half that of the 1st scanner.
  • Page 635 SCANNING 6.1.3 ORIGINAL SIZE DETECTION G570D501.WMF • The original width sensors [A] detect the original width, and the original length sensors [B] detect the original length. • The SBU controller on the SBU board checks each sensor status when the platen cover sensor is activated as it is closed.
  • Page 636 SCANNING G570D540.WMF Width Original Size Length Sensor Sensor SP4-301 display Metric Inch version version 11” x 17” 10” x 14” 8.5” x 14” (8” x 13”) A4-L 8.5” x 11” B5-L A4-S 11” x 8.5” B5-S A5-L, A5-S 5.5” x 8.5”, 8.5” x 5.5” NOTE: L: Lengthwise, S: Sideways, O: Paper present, X: Paper not present For other combinations, "Cannot detect original size."...
  • Page 637 SCANNING 6.1.4 OTHERS DC Power Supply The scanner power supply unit (scanner PSU) supplies power to the scanner unit. Overcurrent Control The scanner PSU has an overcurrent control function. The SBU cuts electricity when the current of a specific circuit exceeds its limit. When an overcurrent condition is detected, nothing is displayed on the operation panel because the power to the operation panel is cut.

  • Page 638: Image Processing

    IMAGE PROCESSING 6.2 IMAGE PROCESSING 6.2.1 OVERVIEW S B U SCANNER PRINTER F C U (Option) H D D (Option) LD Board Controller B C U M e m o r y G570D900.WMF • The CCD (Charged Coupled Device) generates three analog video signals. •...

  • Page 639: Sbu Block Diagram

    IMAGE PROCESSING 6.2.2 SBU BLOCK DIAGRAM R(B) 10 bit 10 bit Analog Amplifier Field 8 bit A/D Converter M e m o r y 10 bit Analog Amplifier 10 bit S B U Field 8 bit C C D A S I C A/D Converter Controller M e m o r y...
  • Page 640 IMAGE PROCESSING Black Level Correction • Improves image reproduction for high-density areas. • Reads the black video level at black elements on the CCD. These pixels are masked off, and should produce a pure black signal. • This is subtracted from the value of each pixel. •...

  • Page 641: Shading Correction

    IMAGE PROCESSING 6.2.3 IPU BLOCK DIAGRAM S B U • Shading Correction • Picture Elemnet Correction • Color Correction • Scanner γ Correction • Main Scan Magnification • Filter • ASIC1 A D S Controller B C U • Printer γ Correction •...
  • Page 642 IMAGE PROCESSING Picture Element (Dot Position) Correction Picture element correction does two things. 1. Completion of the scan line correction process. 2. Correction if the CCD is not perpendicular to the light. • The green CCD line is taken as a standard. •...
  • Page 643 IMAGE PROCESSING Scanner Gamma Correction (RGB Gamma Correction) 1023 Dark Light Dark Light Fig. 2 Fig. 1 G570D972.WMF G570D973.WMF The RGB video signals from the CCD are sent to the IPU section. This signal is proportional to the intensity of light reflected from the original image (Fig. 1). Scanner gamma correction inverts the video signals.
  • Page 644 IMAGE PROCESSING Filtering Appropriate software filters are applied to the RGB video signals. • Varies depending on the results of auto text/photo separation (or on the selected original mode). • RGB smoothing is applied to photo areas • Edge emphasis applied to text areas. Background Density Control •...
  • Page 645 IMAGE PROCESSING Color Conversion Transparency for each color toner is not ideal. Color conversion compensates for the differences between the ideal and actual characteristics. A matrix converts the RGB video signals into CMYK video signals while the original is scanned once. Conversion Matrix The following color conversion table is an example of the results from the matrix operation.
  • Page 646 IMAGE PROCESSING Main Scan Magnification While the machine changes the scanner speed to reduce or enlarge the original in the sub-scan direction, the ASIC2 chip on the IPU board handles reduction and enlargement in the main scan direction. • Scanning and laser writing are done at a fixed pitch (CCD elements cannot be squeezed or expanded).
  • Page 647 IMAGE PROCESSING Printer Gamma Correction Fig. 1 Fig. 2 G570D989.WMF G570D990.WMF Ideally, the gamma curves for Yellow, Magenta, Cyan, and Black should be identical, as shown in figure 1. However, slight variations in the electrical components can result in varying gamma curves, as shown in figure 2. •...
  • Page 648 IMAGE PROCESSING ID Max. This mode adjusts the total image density as shown in figure 3. Fig. 3 G570D991.WMF Shadow (High ID) The High ID mode adjusts the image density between Level 6 and Level 9 of the color gradation scale on the C-4 test chart (figure 4).
  • Page 649 IMAGE PROCESSING Auto Color Calibration Test Pattern The test pattern has eight 17-step gradation scales for each color (CMYK), including background white, for Text and Photo modes. ACC automatically calibrates the printer Dark Light gamma curve. The user starts the ACC process.
  • Page 650 PRINTER ENGINE 6.3 PRINTER ENGINE 6.3.1 DIFFERENCES IN THE PRINTER MAINFRAME To improve reproduction in copy mode, the machine generates the print image with 2 bits per pixel. If the CF expander is installed on the printer mainframe, different parameters are used for copy and print modes as shown in the table below.

  • Page 651: Scanner Functions

    SCANNER FUNCTIONS 6.4 SCANNER FUNCTIONS 6.4.1 IMAGE PROCESSING FOR SCANNER MODE The image processing for scanner mode is done in the IPU chip on the BICU board. The IPU chip chooses the most suitable image processing methods (gamma tables, dither patterns, etc) depending on the settings made in the driver. The image compression method for binary picture processing can be selected with scanner SP1-004 (either MR, MH, or MMR).
  • Page 652 HARD DISK DRIVES 6.5 HARD DISK DRIVES A 40GB hard disk is provided as an option for the copier feature expander. A 20GB hard disk is only used for printer functions. The hard disks are partitioned as listed in the table. Partition 40GB HDD 20GB HDD...

  • Page 653: Image Data Path

    IMAGE DATA PATH 6.6 IMAGE DATA PATH S B U SCANNER PRINTER F C U I P U (Option) H D D (Option) LD Board Controller B C U M e m o r y G570D900.WMF Copier Application SBU → IPU → Controller (HDD/Memory) → IPU → Controller (straight through) → Printer Application Controller →...
  • Page 655 SPECIFICATIONS SPECIFICATIONS 1. GENERAL SPECIFICATIONS (COPY MODE) Configuration: Add-on scanner for printer mainframe Number of scans: Resolution: Scan: 600 dpi Print: 600 dpi Gradation: Scan: 8 bits/pixel Print: 2 bits/pixel Original type: Sheets, book, objects Maximum original A3/11” x 17” size: Original reference Left rear corner...
  • Page 656 SPECIFICATIONS Power source: System: 120 V, 60 Hz: 12 A (for North America) 220 - 240 V, 50/60 Hz: 8 A (for Europe/Asia) Scanner: 120 V, 60 Hz: 2 A (for North America) 220 - 240 V, 50/60 Hz: 1.1 A (for Europe/Asia) Maximum power System: 1,440 W or less consumption...
  • Page 657 SPECIFICATIONS 1) Printer mainframe with CF Expander, One-tray Paper Feed Unit, and Rack [A]: 45 mm [B]: 1,100 mm [C]: 975 mm G570V213.WMF 2) Printer mainframe with CF Expander, One-tray Paper Feed Unit, Duplex unit, Finisher, and Rack G570V211.WMF [D]: 150 mm [E]: 1,100 mm [F]: 1,480 mm G570...
  • Page 658 SPECIFICATIONS 3) Printer mainframe with CF Expander, Large Capacity Tray (Two-tray Paper Feed Unit), Duplex unit, Finisher, and Rack G570V212.WMF [G]: 150 mm [H]: 1,200 mm G570...
  • Page 659 SPECIFICATIONS 2. GENERAL SPECIFICATIONS (SCANNER MODE) Standard Scanner Main scan/Sub scan 600 dpi Resolution: Available scanning Twain Mode: Resolution Range: 100 ~ 1200 dpi Delivery Mode: 100/200/300/400/600 dpi Grayscales: 1 bit or 8 bits/pixel each for RGB Scanning Without 40GB HDD Throughput B/W: 21 spm (A4/8...
  • Page 660 SPECIFICATIONS 3. SUPPORTED PAPER SIZES 3.1 PLATEN/ARDF ORIGINAL SIZE DETECTION Platen ARDF Size (width x length) [mm] Inches Metric Inches Metric A3 (297 x 420) L B4 (257 x 364) L A4 (210 x 297) L Yes** A4 (297 x 210) S B5 (182 x 257) L B5 (257 x 182) S A5 (148 x 210) L...
  • Page 661 SPECIFICATIONS 3.2 PAPER FEED Inches Metric By-pass Paper Size (W x L) Tray Tray Tray Tray 1 Tray 1 2/3/4 2/3/4 A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm A5 SEF 148 x 210 mm...
  • Page 662 SPECIFICATIONS 3.3 PAPER EXIT Internal External Multi-bin Tray Tray Paper Size (W x L) Finisher Output Duplex (Face (Face Tray Down) A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm A5 SEF 148 x 210 mm...
  • Page 663 SPECIFICATIONS 4. SOFTWARE ACCESSORIES 4.1 SCANNER The scanner driver and utility software are provided on one CD-ROM. Scanner Drivers • Network Twain Driver for Win95/98/ME/NT4.0/2000 Scanner Utilities • Scan Router V2 Lite (Cherry-Lite) for Win95/98/ME/NT4.0/2000 • Desk Top Binder V2 Lite (Plumeria-Lite) for Win95/98/ME/NT4.0/2000 G570...
  • Page 664 SPECIFICATIONS 5. MACHINE CONFIGURATION G570V102.WMF Machine Item Remarks Code Mainframe Printer G060 Copier Feature Expander G570 Peripherals Requires the HDD or 128MB DIMM Finisher G565 memory, duplex unit, and one of the three paper feed options. Paper Feed Unit (500 x 1)
  • Page 665 SPECIFICATIONS Machine Item Remarks Code Controller Options 64MB DIMM Memory G579 128MB DIMM Memory G580 256MB DIMM Memory G581 NVRAM Memory G311 IEEE1394 I/F Board G590 At least 64 MB of DIMM is required HDD Type 1 G308 Only for printer features HDD Type 2 G309 For both printer and copier features...
  • Page 666 SPECIFICATIONS 6. OPTIONAL EQUIPMENT Rack Dimensions (W × D × H): 675 mm x 758 mm x 1110 mm (26.6” x 29.8” x 43.7”) Weight: 30 kg ARDF Paper Size/Weight: Size A3 to B6, DLT to HLT Simplex Weight 45 to 90 kg (11 to 34 lb.) Size A3 to B5, DLT to HLT Duplex...
  • Page 667 SPECIFICATIONS Multi-bin Output Tray Number of Bins Paper Size Maximum: A3/11" x 17" (SEF) Minimum: A5 (LEF)/8 " x 11" Paper Weight 60 to 105 g/m (16 to 28 lb.) Stack Capacity Tray 1: 100 sheets (80 g/m , 20 lb.) Tray 2: 100 sheets (A4/smaller than 8 ”...
  • Page 669 ARDF G564...
  • Page 671 COVERS 1. REPLACEMENT AND ADJUSTMENT 1.1 COVERS G564R110.WMF G564R111.WMF [A]: Front cover ( x 2) [B]: Rear cover ( x 2) [C]: Top cover ( x 1, x 2) [D]: Original tray ( x 1,  x 1) [E]: Platen sheet (Velcro pads) [F]: Original exit tray ( x 2).
  • Page 672 ORIGINAL FEED UNIT 1.2 ORIGINAL FEED UNIT Open the top cover. [A]: Original feed unit Press it toward you on its shaft to release and lift out. G564R101.WMF 1.3 ORIGINAL PICK-UP ROLLER Original feed unit ( 1.2) [A]: Pick-up roller ( x 1) G564R102.WMF G564...

  • Page 673: Original Feed Belt

    ORIGINAL FEED BELT 1.4 ORIGINAL FEED BELT G564R103.WMF G564R104.WMF Original feed unit and original pick-up roller ( 1.2, 1.3) [A]: Shaft ( x 1) NOTE: Before removing the shaft, note carefully the positioning of the spring [B]. This must be reset during re-installation. [C]: Feed belt cover (Timing belt, gear, shaft, springs x 2) NOTE: Do not lose the springs.
  • Page 674 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS 1.5 SKEW CORRECTION/INTERVAL/ REGISTRATION/ORIGINAL WIDTH SENSORS G564R105.WMF G564R106.WMF Open the top cover. [A]: Upper original guide ( x 3). [B]: Skew correction sensor ( x 1) [C]: Interval sensor ( x 1) [D]: Registration sensor ( x 1) [E]: Original width sensor bracket ( x 1, x 4) [F]: Original width sensors G564...

  • Page 675: Original Length Sensors

    ORIGINAL LENGTH SENSORS 1.6 ORIGINAL LENGTH SENSORS Raise the original table. [A]: Lower cover of original tray ( x 4) [B]: Original length sensor-1 ( x 1) [C]: Original length sensor-2 ( x 1) G564R107.WMF 1.7 SEPARATION ROLLER Original feed unit ( 1.2) [A]: Separation roller cover [B]: Separation roller ( x 1) G564R108.WMF...
  • Page 676 INVERTER /ORIGINAL SET SENSORS 1.8 INVERTER /ORIGINAL SET SENSORS Rear cover. ( 1.1) [A]: Lower the original stopper by rotating the pick-up motor Original feed unit ( 1.2) [B]: Feed guide plate ( x 4, stepped screw) NOTE: Raise the original tray before you re-install the paper feed guide.

  • Page 677: Transport Motor And Inverter Motor

    TRANSPORT MOTOR AND INVERTER MOTOR 1.10 TRANSPORT MOTOR AND INVERTER MOTOR G564R113.WMF G564R112.WMF Rear cover ( 1.1) [A]: Pick-up roller assembly ( x 1,  x 3, x 3) [B]: Motor bracket ( x 3, x 2, Timing belt x 2) [C]: Transport motor ( x 2, Spring x 1) [D]: Inverter motor ( x 2) G564...
  • Page 678 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH 1.11 FEED MOTOR, SKEW CORRECTION ROLLER CLUTCH G564R115.WMF Rear cover ( 1.1) [A]: Motor bracket ( x 5, x 1) [B]: Feed motor ( x 2) [C]: Clutch stopper ( x 1) [D]: Skew correction roller clutch ( x 1) G564...
  • Page 679 EXIT SENSOR 1.12 EXIT SENSOR Open the ARDF. [A]: Pull the platen sheet off halfway. [B]: Open the exit guide plate. [C]: Exit guide plate cover ( x 2) [D]: Exit sensor ( x 1, x 1) G5641R116.WMF 1.13 STAMP SOLENOID Rear cover ( 1.1) Open exit guide plate ( 1.12) [A]: Exit guide plate cover ( x 1)
  • Page 680 TIMING CHARTS 2. TROUBLESHOOTING 2.1 TIMING CHARTS 2.1.1 A4(S)/LT(S) SINGLE-SIDED ORIGINAL MODE 2000 2000 (ms) 1000 1500 1000 1500 R X D Original Set Sensor O F F 1600 pps C C W Pick-up Motor O F F 1600 pps 1600 pps Original Stopper H.P Sn.
  • Page 681 TIMING CHARTS 2.1.2 A4(S)/LT(S) DOUBLE-SIDED ORIGINAL MODE 5 0 0 5 0 0 1 0 0 0 1 5 0 0 2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 5 0 0 1 0 0 0 1 5 0 0 2 0 0 0 2 5 0 0 R X D T X D...
  • Page 682 JAM DETECTION 2.2 JAM DETECTION G564T905.WMF 1. Registration sensor 4. Inverter sensor 2. Interval sensor 5. Exit sensor 3. Skew correction sensor 6. Scanning position Jam Site Cause Original stopper HP Original stopper home position could not be detected within 1000 ms sensor (Jam 1) after the pick-up motor switched on and started rotating counter- clockwise.
  • Page 683 DIP SWITCHES 3. SERVICE TABLES 3.1 DIP SWITCHES DPS101 Description Normal operating mode, with/without stamp. Not used Not used Not used Feed motor rotation (pull-out mode) 6800 pps (1-2 phase) Feed motor rotation (feed mode) 4385 pps (1-2 phase) Transport motor rotation 8268 pps (2W1-2 phase) Inverter motor rotation 7720 pps (1-2 phase) Free run: one-sided original 100% (color mode) Free run: one-sided original 200% (color mode)

  • Page 684: Main Components

    MAIN COMPONENTS 4. DETAILED DESCRIPTIONS 4.1 MAIN COMPONENTS G564D103.WMF 1 Pick-up roller 10 Exit sensor 2 Original tray 11 Idle roller 3 3 Original length sensor 1 12 Idle roller 2 4 Original length sensor 2 13 Transport roller 5 Reverse table 14 Registration sensor 6 Inverter roller 15 Idle roller 1...
  • Page 685 DRIVE LAYOUT 4.2 DRIVE LAYOUT G564D102.WMF 1 Feed motor 7 Inverter roller 2 Feed belt 8 Exit roller 3 Pick-up roller 9 Separation roller 4 Pick-up motor 10 Transport roller 5 Transport motor 11 Skew correction roller 6 Inverter motor 8-15 G564...

  • Page 686: Original Size Detection

    ORIGINAL SIZE DETECTION 4.3 ORIGINAL SIZE DETECTION 4.3.1 BASIC MECHANISM   ‘ ’ [B] B5 [C] LG G564D110.WMF The original size is detected by four original width sensors [A] and two original length sensors, [B] and [C]. The machine determines the original width when the leading edge of the original activates the registration sensor.
  • Page 687 ORIGINAL SIZE DETECTION Width Sensor Length Sensor Size (Width x Length)   ‘ ’ A3 L* (297 x 420 mm) B4 L (257 x 364 mm) A4 L (210 x 297 mm) A4 S* (297 x 210 mm) B5 L (182 x 257 mm) B5 S (257 x 182 mm) A5 L (148 x 210 mm) A5 S (210 x 148 mm)

  • Page 688: Mixed Original Size Mode

    ORIGINAL SIZE DETECTION 4.3.2 MIXED ORIGINAL SIZE MODE This section explains what happens when the user selects mixed original size mode. Because this ADF is a sheet-through document feeder, the method for original document width detection is the same as when the originals are the same size, but the document length detection method is different.
  • Page 689 ORIGINAL FEED-IN MECHANISM 4.4 ORIGINAL FEED-IN MECHANISM 4.4.1 PICK-UP AND SEPARATION G564D109.WMF G564D505.WMF When the original is put on the original table, it contacts the original stopper [A] and pushes the actuator [B] out of the original set sensor [C]. When Start , is pressed, the pick-up motor [D] turns on and the original stopper cam [E] rotates.

  • Page 690: Original Skew Correction

    ORIGINAL FEED-IN MECHANISM 4.4.2 ORIGINAL SKEW CORRECTION G564D202.WMF This mechanism is the same as the skew correction used by the registration roller in the main machine. The feed motor and the skew correction clutch control the skew correction roller. Immediately after separation, the skew correction sensor [A] detects the leading edge of the original.

  • Page 691: Original Transport And Exit

    ORIGINAL TRANSPORT AND EXIT 4.5 ORIGINAL TRANSPORT AND EXIT 4.5.1 SINGLE-SIDED ORIGINALS G564D104.WMF The transport motor drives the transport roller [A] and the exit roller [B]. When the leading edge of the original activates the interval sensor [C], the transport motor rotates the transport roller.
  • Page 692 ORIGINAL TRANSPORT AND EXIT 4.5.2 DOUBLE-SIDED ORIGINALS Shortly after the transport motor has been turned on, the inverter solenoid is activated and junction gate [A] opens. The original is then scanned and transported towards the reverse table [B]. G564D105.WMF Shortly after the original exit sensor [C] detects the trailing edge of the original, the inverter solenoid turns off and the junction gate [D] closes.
  • Page 693 STAMP 4.6 STAMP G564D201.WMF NOTE: This function is only for fax mode. The stamp [A] is located between the transport roller [B] and the exit roller [C]. When the original reaches the stamp, the transport motor stops and the stamp solenoid turns on if the page is sent successfully (immediate transmission) or stored successfully (memory transmission).
  • Page 695 FAX UNIT G307...

  • Page 697: Fax Unit

    FAX UNIT 1. INSTALLATION 1.1 FAX UNIT 1.1.1 CAUTIONS NOTE: 1) Never install telephone wiring during a lightning storm. 2) Never install telephone jacks in wet locations unless the jack is specifically designed for wet locations. 3) Never touch uninsulated telephone wires or terminals unless the telephone line has been disconnected at the network interface.

  • Page 698: Fax Option Installation

    FAX UNIT 1.1.2 FAX OPTION INSTALLATION G307I501.WMF G307I104.WMF CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the main switch and disconnect the power cord and the network cable. 1.
  • Page 699 FAX UNIT G307I106.WMFWMF G307I507.WMF G307I105.WMF 5. Attach the serial number decal [A] to the rear cover. 6. Attach the super G3 decal [B] as shown 7. If the ADF has been installed, insert the stamp cartridge [C] into the ADF as shown.

  • Page 700: Installing The Handset

    FAX UNIT 1.1.3 INSTALLING THE HANDSET G307I114.WMF NOTE: The optional handset is for the U.S. model only. 1. Remove the thumb screw [A] on the left spacer. 2. Install the handset bracket [B] on the left arm (2 screws, 1 thumb screw). 3.

  • Page 701: Fax Unit Options

    FAX UNIT OPTIONS 1.2 FAX UNIT OPTIONS 1.2.1 G3 INTERFACE UNIT INSTALLATION G307I511.WMF CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the main switch and disconnect the power cord and the network.
  • Page 702 FAX UNIT OPTIONS G307I101.WMF 7. Remove the rear left cover plate [A] and install the fax unit [B] (2 screws each). NOTE: Make sure that the controller unit is installed when inserting the fax unit. If the controller unit is installed after the fax unit has been installed, this may cause poor connection between the fax unit and controller unit.
  • Page 703 FAX UNIT OPTIONS 1.2.2 ISDN OPTION INSTALLATION G307I521.WMF CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the main switch and disconnect the power cord and the network cable. 1.
  • Page 704 FAX UNIT OPTIONS G307I101.WMF 7. Remove the rear left cover [A] and install the fax unit [B] ( x 2 each). NOTE: Make sure that the controller unit is installed when inserting the fax unit. If the controller unit is installed after the fax unit has been installed, this may cause poor connection between the fax unit and controller unit.
  • Page 705 FAX UNIT OPTIONS 1.2.3 FAX FUNCTION UPGRADE UNIT INSTALLATION G307I103.WMF CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the main switch and disconnect the power cord and the network cable.
  • Page 706 FAX UNIT OPTIONS 1.2.4 EXPANSION MEMORY INSTALLATION G307I102.WMF CAUTION Before installing this option, do the following: 1. Print out all data in the printer buffer. 2. Turn off the main switch and disconnect the power cord and the network cable. 1.

  • Page 707: Error Codes

    ERROR CODES 2. TROUBLESHOOTING 2.1 ERROR CODES If an error code occurs, retry the communication. If the same problem occurs, try to fix the problem as suggested below. Note that some error codes appear only in the error code display and on the service report. Code Meaning Suggested Cause/Action...
  • Page 708 ERROR CODES Code Meaning Suggested Cause/Action • Check the line connection. 0-06 The other terminal did not • Check the FCU - NCU connectors. reply to DCS • Try adjusting the tx level and/or cable equalizer settings. • Replace the NCU or FCU. •...
  • Page 709 ERROR CODES Code Meaning Suggested Cause/Action 0-15 The other terminal is not The other terminal is not capable of accepting the capable of specific following functions, or the other terminal’s memory functions. is full. • Confidential rx • Transfer function •...
  • Page 710 ERROR CODES Code Meaning Suggested Cause/Action • Check the line connection. 0-23 Too many errors during • Check the FCU - NCU connectors. reception • Replace the NCU or FCU. • Defective remote terminal. • Check for line noise or other line problems. •...
  • Page 711 ERROR CODES Code Meaning Suggested Cause/Action • The calling terminal could not detect a JM due to 0-77 The called terminal fell back to T.30 mode, because it noise, etc. • A network that has narrow bandwidth cannot could not detect a CJ in response to JM pass JM to the other end.
  • Page 712 ERROR CODES Code Meaning Suggested Cause/Action • Replace the FCU. 2-12 Modem clock irregularity • Turn off the machine, then turn it back on. 2-13 Modem initialization error • Update the modem ROM. • Replace the FCU. • Replace the FCU. 2-20 Abnormal coding/decoding (cpu not ready)
  • Page 713 ERROR CODES Code Meaning Suggested Cause/Action • Replace the FCU. 5-00 Data construction not possible 5-01 Data reconstruction not possible 5-10 DCR timer expired • Temporary memory shortage. 5-20 Storage impossible because • Test the SAF memory. of a lack of memory •...
  • Page 714 ERROR CODES Code Meaning Suggested Cause/Action • Check for line noise. 6-10 G3 ECM - error frames still • Adjust the tx level (use NCU parameter 01 or the received at the other end after all communication dedicated tx parameter for that address). attempts at 2400 bps •...

  • Page 715: Error Codes For The Isdn Option

    ERROR CODES FOR THE ISDN OPTION 2.2 ERROR CODES FOR THE ISDN OPTION The tables on the following pages show the error codes for the ISDN option. The meaning of the numbers in the Action column is as follows. 1. Check Layer 1 signaling with a protocol analyzer to determine the cause of the problem.
  • Page 716 ERROR CODES FOR THE ISDN OPTION 2.2.1 D-CHANNEL LAYER MANAGEMENT Code Probable Cause Action 7-00 Link reset 7-01 Link set-up failed because of time-out. 7-02 Link release failed because of time-out. 7-03 Link set-up parameter error 2.2.2 D-CHANNEL, LAYER 1 Code Probable Cause Action...
  • Page 717 ERROR CODES FOR THE ISDN OPTION 2.2.4 D-CHANNEL NETWORK LAYER Code Probable Cause Action 7-40 Insufficient mandatory information elements 7-41 Abnormal LI for a mandatory information element 7-42 T301 timeout; timeout while waiting for R:CONN 7-43 T303 timeout; timeout while waiting for R: CALL-PROC etc. 7-44 T304 timeout;...

  • Page 718: Transport Layer

    ERROR CODES FOR THE ISDN OPTION 2.2.6 B-CHANNEL NETWORK LAYER Code Probable Cause Action 7-80 A packet having an abnormal GFI was received 7-81 A packet was received that had a logical channel number different from the logical channel being used for the communication 7-82 A packet containing a format error was received 7-83...

  • Page 719: Session Layer

    ERROR CODES FOR THE ISDN OPTION 2.2.8 SESSION LAYER Code Probable Cause Action 8-30 Invalid frame received 8-31 RSSN received 8-32 CSA received 8-34 Calling terminal identification error in CSS 8-35 Date and time error in CSS 8-36 Window size error in CSS 8-37 Service identification error in CSS 8-38...

  • Page 720: Document Layer

    ERROR CODES FOR THE ISDN OPTION 2.2.9 DOCUMENT LAYER Code Probable Cause Action 8-60 T.62 coding format error (LI error) 8-61 A mandatory PI was absent, or the LI for a mandatory PI was 0 Calling/called terminal identification LI was different from that specified 8-62 by F.184 (LI = 24) 8-63...

  • Page 721: Fax Sc Codes

    FAX SC CODES 2.3 FAX SC CODES 2.3.1 OVERVIEW When the FCU detects a Fax SC Code condition other than SC1201 and SC1207, it resets itself automatically (default setting). This initializes the FCU without erasing files in the SAF memory or resetting the switches. NOTE: For details on Fax SC Codes 1201 and 1207, refer to the following sections.

  • Page 722: Fax Sc Code Table

    FAX SC CODES 2.3.4 FAX SC CODE TABLE Suggested Sys Switch Sys Switch SC Code Description Action 1F bit 7 = 0 1F bit 7 = 1 1101 FCU error Initialize the fax unit. Automatic SC Code (See section 2.3.1.for reset display the initialization...

  • Page 723: Isdn Test Function

    ISDN TEST FUNCTION 2.4 ISDN TEST FUNCTION 2.4.1 LEDS There are four LEDs on the G4 board. These LEDs show the status of the machine. LED 1 LED 2 LED 3 LED 4 Initial Settings O=ON, --=OFF Initial check (if the flash ROM is updated) Handshaking with the FCU ready Standby Mode Ready to communicate...
  • Page 724 ISDN TEST FUNCTION 2.4.2 BACK-TO-BACK TEST To make a back-to-back test, you need: • Two machines, one with the CiG4 board (G4 board used in the FX4, FR4, Adam, NAD, Stinger, and Russian) and the other with the SiG4 board (G4 board used with the Schmidt 3, S4, J-CF, and Kaiser 1).
  • Page 725 SERVICE PROGRAM MODE 3. SERVICE TABLES CAUTION Never turn off the main power switch when the power LED is lit or flashing. To avoid damaging the hard disk or memory, press the operation power switch to switch the power off, wait for the power LED to go off, and then switch the main power switch off.
  • Page 726 SERVICE PROGRAM MODE SP Mode Button Summary Here is a short summary of the touch-panel buttons. G307S902.WMF Opens all SP groups and sublevels. Closes all open groups and sublevels and restores the initial SP mode display. Not used for the Fax SP mode. Enter the SP mode directly with the number keys if you know the SP number and then press .
  • Page 727 SERVICE PROGRAM MODE Switching Between SP Mode and Copy Mode for Test Printing 1) In the SP mode, select the test print and then press Copy Window. 2) Use the copy window (copier mode), to select the appropriate settings (paper size, etc.) for the test print. 3) Press Start D to execute the test print.

  • Page 728: Service Program Mode Tables

    SERVICE PROGRAM MODE 3.1.2 SERVICE PROGRAM MODE TABLES Section 3.2 Bit Switches SP1-XXX (Bit Switches) Mode No. Function System Switch 001 – 032 00 – 1F Change the bit switches for system settings for the fax option Section 3.2 Bit Switches Scanner Switch 001 –...
  • Page 729 SERVICE PROGRAM MODE Mode No. Function G3-1 NCU Parameters 001 – 023 CC, 01 – 22 NCU parameter settings for the standard G3 board. Section 3.3 NCU Parameters G3-2 NCU Parameters 001 – 023 CC, 01 – 22 NCU parameter settings for the optional G3 board.
  • Page 730 SERVICE PROGRAM MODE SP4-XXX (ROM Versions) Mode No. Function FCU ROM Version Displays the FCU ROM version. Error Codes Displays the latest 64 fax error codes. G3-1 ROM Version Displays the G3-1 modem version. G3-2 ROM Version Displays the G3-2 modem version. G4 ROM Version Displays the G4 (ISDN) ROM version.
  • Page 731 SERVICE PROGRAM MODE Mode No. Function G3-1 (1 Prints the protocol dump list of the last Communication) communication for the G3-1 line. G3-2 (All Prints the protocol dump list of all Communications) communications for the G3-2 line. G3-2 (1 Prints the protocol dump list of the last Communication) communication for the G3-2 line.
  • Page 732 SERVICE PROGRAM MODE SP7-XXX (Test Modes) These are test modes for PTT approval. Function G3-1 Modem Tests G3-1 DTMF Tests Ringer Test G3-1 V34 (S2400baud) G3-1 V34 (S2800baud) G3-1 V34 (S3000baud) G3-1 V34 (S3200baud) G3-1 V34 (S3429baud) Recorded Message Test G3-2 Modem Tests G3-2 DTMF Tests G3-2 V34 (S2400baud)

  • Page 733: Bit Switches

    BIT SWITCHES 3.2 BIT SWITCHES WARNING Do not adjust a bit switch or use a setting that is described as “Not used”, as this may cause the machine to malfunction or to operate in a manner that is not accepted by local regulations. Such bits are for use only in other areas, such as Japan.
  • Page 734 BIT SWITCHES System Switch 00 SP No. 1-101-001 FUNCTION COMMENTS Rx level calculation Example: 0000 32 V34 288/264 L 01 00 03 04 The four-digit hexadecimal value (N) after “L” indicates the rx level. The high byte is given first, followed by the low byte. Divide the decimal value of N by - 16 to get the rx level.
  • Page 735 BIT SWITCHES I/O rate 0: 0 ms/line 10: 10 ms/line 25: 2.5 ms/line 20: 20 ms/line 5: 5 ms/line 40: 40 ms/line Note: “40” is displayed while receiving a fax message using AI short protocol. G4 Communication Parameters Compression mode MMR: MMR compression MR: MR compression MH: MH compression Resolution...
  • Page 736 BIT SWITCHES System Switch 02 SP No. 1-101-003 FUNCTION COMMENTS (0,0): All RDS systems are always locked out. Memory read/write by RDS Bit 7 Setting (0,1), (1,0): Normally, RDS systems are locked out, Always disabled but the user can temporarily switch RDS on to allow User selectable RDS operations to take place.
  • Page 737 BIT SWITCHES System Switch 04 SP No. 1-101-005 FUNCTION COMMENTS Memory file transfer operation If the machine is unable to print fax messages due 0: User level to a mechanical problem, change this bit to 0 to 1: Service level transfer all messages in the memory (including confidential rx messages) to an another terminal.
  • Page 738 BIT SWITCHES System Switch 09 SP No. 1-101-010 FUNCTION COMMENTS Addition of image data from If this feature is enabled, the top half of the first confidential transmissions on page of confidential messages will be printed on the transmission result report transmission result reports.
  • Page 739 BIT SWITCHES System Switch 0A SP No. 1-101-011 FUNCTION COMMENTS Not used Do not change the settings. Continuous polling reception This feature allows a series of stations to be polled 0: Disabled 1: Enabled in a continuous cycle. This will continue until the polling reception file is erased.
  • Page 740 BIT SWITCHES System Switch 0F SP No. 1-101-016 FUNCTION COMMENTS Country/area code for This country/area code determines the factory functional settings (Hex) settings of bit switches and RAM addresses. However, it has no effect on the NCU parameter 00: France 11: USA settings and communication parameter RAM 01: Germany 12: Asia...
  • Page 741 BIT SWITCHES System Switch 11 SP No. 1-101-018 FUNCTION COMMENTS 1: The machine uses TTI_2 when the user dials the Type of TTI used for transmission using the ten-key destination using the ten-key pad. It is also used for polling transmission and manual transmission using the handset.
  • Page 742 BIT SWITCHES Rev. 11/2003 System Switch 16 SP No. 1-101-023 FUNCTION COMMENTS Parallel Broadcasting 1: When the G4 or/and G3 unit is installed, the machine sends messages simultaneously using 0: Disabled both available ports (PSTN/ISDN) during 1: Enabled broadcasting. Priority setting for the G3 line. This function allows the user to select the default G3 line type.
  • Page 743 BIT SWITCHES System Switch 1D SP No. 1-101-030 FUNCTION COMMENTS 1: RTI/CSI/CPS is displayed on the top line of the RTI/CSI/CPS display 0: Disabled LCD panel during communication. 1: Enabled Not used Do not change the settings. System Switch 1E SP No.
  • Page 744 BIT SWITCHES System Switch 1E SP No. 1-101-031 FUNCTION COMMENTS Action when authorized If authorized reception is enabled but the user has reception is enabled but stored no acceptable sender RTIs or CSIs, the authorized RTIs/CSIs are not machine will not be able to receive any fax yet programmed messages.
  • Page 745 BIT SWITCHES System Switch 1F SP No. 1-101-032 FUNCTION COMMENTS Not used Do not change the settings. Report printout after an original 0: When an original jams, or the SAF memory jam during SAF storage or if overflows during scanning, a report will be the SAF memory fills up printed.

  • Page 746: Scanner Switches

    BIT SWITCHES 3.2.2 SCANNER SWITCHES Scanner Switch 00 - Not used (do not change the settings) Scanner Switch 01 SP No. 1-102-002 FUNCTION COMMENTS Scan density step value When scan density is adjusted manually away from (Text mode) the Normal setting, the threshold value for binary picture processing changes for each step from the value specified by Scanner Switch 02, by the amount programmed here.
  • Page 747 BIT SWITCHES Scanner Switch 05 SP No. 1-102-006 FUNCTION COMMENTS Binary picture processing: This setting determines the threshold value for Threshold for colored binary picture processing in colored background background special original 2 special original 2 mode (when the scan density mode - Normal setting (center setting is at the center).
  • Page 748 BIT SWITCHES Scanner Switch 0B SP No. 1-102-012 FUNCTION COMMENTS Scan margin setting (right and left margin in book scan ADF mode) The setting can be between 0 and F (H) (unit 0.5 mm). Default setting: 2 mm Scan margin setting (top and bottom margin in book scan and ADF mode) The setting can be between 0 and 7 (H) (unit 0.5 mm).
  • Page 749 BIT SWITCHES Scanner Switch 0D SP No. 1-102-014 FUNCTION COMMENTS Not used Do not change the settings. 0: The machine scans the original as 210 mm (8.5") Scan width for A5 lengthwise or B5 lengthwise originals width. The transmitted image has a blank area on 0: 210 mm (8.5”) the right.

  • Page 750: Printer Switches

    BIT SWITCHES 3.2.3 PRINTER SWITCHES Printer Switch 00 SP No. 1-103-001 FUNCTION COMMENTS Page separation mark 0: No marks are printed. 0: Disabled 1: If a received page has to be printed out on two 1: Enabled sheets, an asterisk inside square brackets is printed at the bottom right hand corner of the first sheet, and a “2”...
  • Page 751 BIT SWITCHES Relationship between available paper sizes and printer width used in the setup protocol Available Paper Size Printer width used in the Protocol (NSF/DIS) A4 or 8.5" x 11" 297 mm width 256 mm width A5 or 8.5" x 5.5" 216 mm width No paper available (Paper end) 216 mm width...
  • Page 752 BIT SWITCHES Printer Switch 03 SP No. 1-103-004 FUNCTION COMMENTS Page separation threshold (with reduction disabled with switch 03-0 above) If the incoming page is up to x mm longer than the length of copy paper, the excess portion will not be printed. If the incoming page is more than x mm longer than the length of copy paper, the excess portion will be printed on the next page.
  • Page 753 BIT SWITCHES Printer Switch 06 SP No. 1-103-007 FUNCTION COMMENTS Printing while a paper cassette is pulled out, when the Just Size Printing feature is Cross reference enabled. Just size printing on/off – User switch 05, bit 5 0 : Printing will not start 1 : Printing will start if another cassette has a suitable size of paper, based on the paper size...
  • Page 754 BIT SWITCHES Printer Switch 0E SP No. 1-103-015 FUNCTION COMMENTS 1: If all paper sizes in the machine require page Page separation 0: Enabled separation to print a received fax message, the 1: Disabled machine does not print the message (Substitute Reception is used).

  • Page 755: Communication Switches

    BIT SWITCHES 3.2.4 COMMUNICATION SWITCHES Communication Switch 00 SP No. 1-104-001 FUNCTION COMMENTS Compression modes available These bits determine the compression capabilities in receive mode to be declared in phase B (handshaking) of the T.30 Bit 1 Modes protocol. MH only MH/MR MH/MR/MMR MH/MR/MMR/...
  • Page 756 BIT SWITCHES Communication Switch 01 SP No. 1-104-002 FUNCTION COMMENTS If this bit is set to 0, ECM is switched off for all 0: Off 1: On communications. In addition, V.8 protocol and JBIG compression are switched off automatically. Not used Do not change the setting.
  • Page 757 BIT SWITCHES Communication Switch 02 SP No. 1-104-003 FUNCTION COMMENTS 0: The next page will be sent even if RTN or PIN is Hang-up decision when a negative code (RTN or PIN) is received. received during G3 immediate 1: The machine will send DCN and hang up if it transmission receives RTN or PIN.
  • Page 758 BIT SWITCHES Communication Switch 07 SP No. 1-104-008 FUNCTION COMMENTS Fallback from G4 to G3 if the Also see system switch 0A bit 7. other terminal is not a G4 Refer to G4 Internal Switches 17, 18, 1A, 1B, and terminal 1C for the CPS code set (Cause Value set) that 0: Disabled...
  • Page 759 BIT SWITCHES Communication Switch 0B SP No. 1-104-012 FUNCTION COMMENTS Use of Economy Transmission These bits determine whether the machine uses the during a Transfer operation to Economy Transmission feature when it is carrying end receivers out a Transfer operation as a Transfer Station. 0: Disabled 1: Enabled Use of Economy Transmission during a Transfer operation to...
  • Page 760 BIT SWITCHES Communication Switch 0C SP No. 1-104-013 FUNCTION COMMENTS Number of digits compared to 00 - 1F (0 to 31 digits) find the requester’s fax number After the machine receives a transfer request, the from the programmed machine compares the own telephone number sent Quick/Speed Dials when acting from the Requesting Terminal with all Quick/Speed as a Transfer Station...
  • Page 761 BIT SWITCHES Communication Switch 0F - Not used (do not change the settings.) Communication Switch 10 SP No. 1-104-017 FUNCTION COMMENTS Memory transmission: 01 - FE (Hex) times Maximum number of dialing attempts to the same destination Communication Switch 11 - Not used (do not change the settings.) Communication Switch 12 SP No.
  • Page 762 BIT SWITCHES Communication Switch 16 SP No. 1-104-023 FUNCTION COMMENTS Standard G3 unit Set this bit to 0 if the user wants to use only the 0: Disabled ISDN line (option G4 unit), even for G3 1: Enabled communications. However, for ISDN on hook dialing, bit 7 of user parameter 30 must be set to 1.
  • Page 763 BIT SWITCHES Communication Switch 18 - Not used (do not change the settings) Communication Switch 19 - Not used (do not change the settings) Communication Switch 1A - Not used (do not change the settings) Communication Switch 1B SP No. 1-104-028 FUNCTION COMMENTS Extension access code (0 to 7)
  • Page 764 BIT SWITCHES 3.2.5 G3 SWITCHES G3 Switch 00 SP No. 1-105-001 FUNCTION COMMENTS Monitor speaker during (0, 0): The monitor speaker is disabled all through communication (tx and rx) the communication. Bit 1 Bit 0 Setting (0, 1): The monitor speaker is on up to phase B in Disabled the T.30 protocol.
  • Page 765 BIT SWITCHES G3 Switch 03 SP No. 1-105-004 FUNCTION COMMENTS 0: The machine will hang up if it receives the same DIS detection number (Echo countermeasure) DIS frame twice. 0: 1 1: Before sending DCS, the machine will wait for the 1: 2 second DIS which is caused by echo on the line.
  • Page 766 BIT SWITCHES G3 Switch 05 SP No. 1-105-006 FUNCTION COMMENTS Initial Tx modem rate These bits set the initial starting modem rate for Bit 3 2 1 0 Setting (bps) transmission. 0 0 0 1 2.4 k 0 0 1 0 4.8 k Use the dedicated transmission parameters if you 0 0 1 1 7.2 k need to change this for specific receivers.
  • Page 767 BIT SWITCHES G3 Switch 06 SP No. 1-105-007 FUNCTION COMMENTS Modem types available for The setting of these bits is used to inform the reception transmitting terminal of the available modem type for Bit 7 6 5 4 Setting the machine in receive mode. 0 0 0 1 V.27ter 0 0 1 0 V.27ter, V.29 If V.34 is not selected, V.8 protocol must be...
  • Page 768 BIT SWITCHES G3 Switch 08 - Not used (do not change the settings) G3 Switch 09 SP No. 1-105-010 FUNCTION COMMENTS ISDN cable equalizer Use a higher setting if there is signal loss at higher (tx mode: Internal) frequencies because of the length of wire between Bit 1 Bit 0 Setting the modem and the telephone exchange.
  • Page 769 BIT SWITCHES G3 Switch 0A SP No. 1-105-011 Not used Do not change the settings. Maximum allowable frame This bit set the maximum interval between EOL interval during image data (end-of-line) signals and the maximum interval reception. between ECM frames from the other end. 0: 5 s 1: 13 s Try using a longer setting if error code 0-21 is frequent.
  • Page 770 BIT SWITCHES G3 Switch 0D SP No. 1-105-014 FUNCTION COMMENTS Not used Do not change the settings. Data rate threshold during V.34 The machine changes the modulation parameters in reception the MPh signal to lower the initial modem rate Bit 5 4 3 2 Setting during V.34 reception.
  • Page 771 BIT SWITCHES 3.2.6 G3-2 SWITCHES These switches require an optional G3 interface unit. G3-2 Switch 00 SP No. 1-106-001 FUNCTION COMMENTS (0, 0): The monitor speaker is disabled all through Monitor speaker during communication (tx and rx) the communication. Bit 1 Bit 0 Setting (0, 1): The monitor speaker is on up to phase B in...
  • Page 772 BIT SWITCHES G3-2 Switch 03 SP No. 1-106-004 FUNCTION COMMENTS DIS detection number 0: The machine will hang up if it receives the same (Echo countermeasure) DIS frame twice. 0: 1 1: Before sending DCS, the machine will wait for the 1: 2 second DIS which is caused by echo on the line.
  • Page 773 BIT SWITCHES G3-2 Switch 05 SP No. 1-106-006 FUNCTION COMMENTS Initial Tx modem rate These bits set the initial starting modem rate for Bit 3 2 1 0 Setting (bps) transmission. 0 0 0 1 2.4 k 0 0 1 0 4.8 k Use the dedicated transmission parameters if you 0 0 1 1...
  • Page 774 BIT SWITCHES G3-2 Switch 06 SP No. 1-106-007 FUNCTION COMMENTS Modem types available for The setting of these bits is used to inform the reception transmitting terminal of the available modem type for Bit 7 6 5 4 Setting the machine in receive mode. 0 0 0 1 V.27ter 0 0 1 0...
  • Page 775 BIT SWITCHES G3-2 Switch 08 - Not used (do not change the settings) G3-2 Switch 09 - Not used (do not change the settings) G3-2 Switch 0A SP No. 1-106-011 FUNCTION COMMENTS Maximum allowable carrier These bits set the acceptable modem carrier drop drop during image data time.
  • Page 776 BIT SWITCHES G3-2 Switch 0B SP No. 1-106-012 FUNCTION COMMENTS Protocol requirements: Europe The machine does not automatically reset these bits 0: Disabled 1: Enabled for each country after a country code (System Switch 0F) is programmed. Protocol requirements: Spain Change the required bits manually at installation.

  • Page 777: G4 Internal Switches

    BIT SWITCHES 3.2.7 G4 INTERNAL SWITCHES G4 Internal Switch 00 FUNCTION COMMENTS Country code Bit 4 Country Germany (1TR6 mode) Universal (Europe Euro ISDN) Note: In Germany, use the Universal setting for the Euro ISDN lines. G4 Internal Switch 01 - Not used (do not change these settings) G4 Internal Switch 02 - Not used (do not change these settings) G4 Internal Switch 03 FUNCTION...
  • Page 778 BIT SWITCHES G4 Internal Switch 05 FUNCTION COMMENTS Not used Do not change these settings. Protocol ID check The Protocol ID is in the CR packet. 0: Yes 1: No Not used Do not change these settings. G4 Internal Switch 06 - Not used (do not change these settings) G4 Internal Switch 07 - Not used (do not change these settings) G4 Internal Switch 08 - Not used (do not change these settings) G4 Internal Switch 09 - Not used (do not change these settings)
  • Page 779 BIT SWITCHES G4 Internal Switch 13: D channel layer 3 (Attachment IE in S: SETUP) FUNCTION COMMENTS Not used Do not change these settings. Information transfer capability shift 1: The machine changes the ISDN G3 down to retry transmission information transfer capability informed in the [SETUP] signal to “Speech”...
  • Page 780 BIT SWITCHES G4 Internal Switch 13: D channel layer 3 (Attachment IE in S: SETUP) FUNCTION COMMENTS 0: Fallback occurs when a CPS code is the Condition for fallback from G4 to same as the CPS code settings specified by G4 internal switches 17, 18, 1A, 1B, and 0: Refer to the CPS code setting 1: Fallback in response to any CPS If you wish to enable fallback when any CPS...
  • Page 781 BIT SWITCHES G4 Internal Switch 15: D channel layer 3 (Judgement R: MSG) FUNCTION COMMENTS Action when receiving [SETUP] This bit depends on user requirements. If it is signal containing no called at 1, communication will be halted if the other subaddress terminal has not input the subaddress.
  • Page 782 BIT SWITCHES G4 Internal Switch 16: D channel layer 3 (Approval) FUNCTION COMMENTS Transfer capabilities (SI) informed This bit determines whether transfer capabilities informed in the Service Indicator in 1TR6 ISDN G3 transmission for 1TR6 ISDN G3 transmission. This switch is 0: G3 Fax effective in coping with communication 1: Analog...
  • Page 783 BIT SWITCHES G4 to G3 fallback Bit 0 of Communication Switch 07 must be at 0, or fallback from G4 to G3 will be disabled. The CPS codes for which fallback occurs are decided as follows. • G4 bit switch 17, bit 7 - If set to “0”, fallback occurs on receipt of a code from a set that depends on the country code.

  • Page 784: G4 Parameter Switches

    BIT SWITCHES 3.2.8 G4 PARAMETER SWITCHES G4 Parameter Switch 00 FUNCTION COMMENTS Network type Do not change the default setting. Bit 2 Type Circuit switched ISDN Other settings: Not used Not used Do not change the default settings. G4 Parameter Switch 01 FUNCTION COMMENTS Voice coding...
  • Page 785 BIT SWITCHES G4 Parameter Switch 05 FUNCTION COMMENTS Not used Do not change these settings. B-channel T3 timer 1: This switch is useful when used in 0: 30s 1: 57s combination with the Communication Bit SW 07 bit 4. This is to cope with communication problems where G4 communication fails on the ISDN B- channel.
  • Page 786 BIT SWITCHES G4 Parameter Switch 09 - Not used (do not change these settings) G4 Parameter Switch 0A - Not used (do not change these settings) G4 Parameter Switch 0B FUNCTION COMMENTS Transport block size This value must match the value set in the Bit 3 Value other terminal.

  • Page 787: Ncu Parameters

    NCU PARAMETERS 3.3 NCU PARAMETERS The following tables give the RAM addresses and the parameter calculation units that the machine uses for ringing signal detection and automatic dialing. The factory settings for each country are also given. Most of these must be changed by RAM read/write (SP2-102), but some can be changed using NCU Parameter programming (SP2-103, 104 and 105);...
  • Page 788 NCU PARAMETERS Address Function Unit Remarks 680500 Country/Area code for NCU Use the Hex value to program the country/area code directly into this parameters address, or use the decimal value to program it using SP2-103-001 Country/Area Decimal Hex France Germany Italy Austria Belgium...
  • Page 789 NCU PARAMETERS Address Function Unit Remarks 680504 PSTN dial tone frequency upper limit Hz (BCD) If both addresses contain (high byte) FF(H), tone detection is disabled. 680505 PSTN dial tone frequency upper limit (low byte) 680506 PSTN dial tone frequency lower limit Hz (BCD) If both addresses contain (high byte)
  • Page 790 NCU PARAMETERS Address Function Unit Remarks 68051B PABX dial tone detection time 20 ms If 68051B contains FF, the machine pauses for 68051C PABX dial tone reset time (LOW) the pause time (680520 / 68051D PABX dial tone reset time (HIGH) 680521).
  • Page 791 NCU PARAMETERS Address Function Unit Remarks 680534 International dial tone frequency Hz (BCD) If both addresses contain upper limit (high byte) FF(H), tone detection is disabled. 680535 International dial tone frequency upper limit (low byte) 680536 International dial tone frequency Hz (BCD) If both addresses contain lower limit (high byte)
  • Page 792 NCU PARAMETERS Address Function Unit Remarks 680543 Country dial tone detection time 20 ms If 680543 contains FF, the machine pauses for 680544 Country dial tone reset time (LOW) the pause time (680548 / 680545 Country dial tone reset time (HIGH) 680549).
  • Page 793 NCU PARAMETERS Address Function Unit Remarks 680557 Time between 68054Dh (NCU 1 ms This parameter takes parameter 14) and 68054Eh (NCU effect when the country parameter 15) code is set to France. 680558 Not used Do not change the setting. 680559 Grounding time (ground start mode) 20 ms...
  • Page 794 NCU PARAMETERS Address Function Unit Remarks 680572 Acceptable ringing signal frequency: 1000/ N SP2-103-003 (parameter range 1, upper limit (Hz). 02). 680573 Acceptable ringing signal frequency: SP2-103-004 (parameter range 1, lower limit 03). 680574 Acceptable ringing signal frequency: SP2-103-005 (parameter range 2, upper limit 04).
  • Page 795 NCU PARAMETERS Address Function Unit Remarks 6805A1 Acceptable CED detection frequency BCD (Hz) If both addresses contain upper limit (high byte) FF(H), tone detection is disabled. 6805A2 Acceptable CED detection frequency upper limit (low byte) 6805A3 Acceptable CED detection frequency BCD (Hz) If both addresses contain lower limit (high byte)
  • Page 796 NCU PARAMETERS Address Function Unit Remarks 6805B8 PABX: 1100 Hz tone transmission - 0.5N (dB) 6805B7 6805B8 level 6805B9 PABX: 2100 Hz tone transmission - 0.5N (dB) 6805B7 6805B9 level 6805BA ISDN: Tx level from the modem - dBm The setting must be between -12dBm and - 15dBm.
  • Page 797 NCU PARAMETERS NOTES 1. If a setting is not required, store FF in the address. 2. Italy and Belgium only RAM address 68055E: the lower four bits have the following meaning. Bit 2 - 1: International dial tone cadence detection enabled (Belgium) Bit 1 - Not used Bit 0 - 1: PSTN dial tone cadence detection enabled (Italy) If bit 0 or bit 2 is set to 1, the functions of the following RAM addresses are...

  • Page 798: Dedicated Transmission Parameters

    DEDICATED TRANSMISSION PARAMETERS 3.4 DEDICATED TRANSMISSION PARAMETERS Each Quick Dial Key and Speed Dial Code has eight bytes of programmable parameters allocated to it. If transmissions to a particular machine often experience problems, store that terminal’s fax number as a Quick Dial or Speed Dial, and adjust the parameters allocated to that number.
  • Page 799 DEDICATED TRANSMISSION PARAMETERS 3.4.2 PARAMETERS The initial settings of the following parameters are all FF(H) - all the parameters are disabled. Switch 01 FUNCTION AND COMMENTS ITU-T T1 time (for PSTN G3 mode) If the connection time to a particular terminal is longer than the NCU parameter setting, adjust this byte.
  • Page 800 DEDICATED TRANSMISSION PARAMETERS Switch 03 FUNCTION COMMENTS Initial Tx modem rate If training with a particular remote terminal always Bit3 2 1 0 Setting (bps) takes too long, the initial modem rate may be too 0 0 0 0 Not used high.
  • Page 801 DEDICATED TRANSMISSION PARAMETERS Switch 04 FUNCTION COMMENTS V.8 protocol If transmissions to a specific destination always end 0 : Off at a lower modem rate (14,400 bps or lower), 1 : Disabled disable V.8 protocol so as not to use V.34 protocol. 0: V.34 communication will not be possible.
  • Page 802 DEDICATED TRANSMISSION PARAMETERS Switch 09 - Optional ISDN G4 kit required FUNCTION COMMENTS Layer 3 protocol If the setting is “Disabled”, the current setting of G4 Bits 3 2 1 0 Setting parameter switch 6 (bit 0) is used. 0 0 0 0 ISO 8208 0 0 0 1 T.70 NULL 1 1 1 1 Disabled Packet modulus...

  • Page 803: Service Ram Addresses

    SERVICE RAM ADDRESSES 3.5 SERVICE RAM ADDRESSES CAUTION Do not change the settings which are marked as “Not used” or “Read only.” 680001 to 680004(H) - ROM version (Read only) 680001(H) - Revision number (BCD) 680002(H) - Year (BCD) 680003(H) - Month (BCD) 680004(H) - Day (BCD) 680006 to 680015(H) - Machine’s serial number (16 digits - ASCII) 680018(H) - Total program checksum (low)
  • Page 804 SERVICE RAM ADDRESSES 6800D3(H) - User parameter switch 03 (SWUSR_03: Automatic report printout) Bit 0: Transmission result report (memory transmissions) 0: Off, 1: On Bit 1: Not used Bit 2: Memory storage report 0: Off, 1: On Bit 3: Polling reserve report (polling reception) 0: Off, 1: On Bit 4: Polling result report (polling reception) 0: Off, 1: On Bit 5: Transmission result report (immediate transmissions) 0: Off, 1: On Bit 6: Polling clear report 0: Off, 1: On...
  • Page 805 SERVICE RAM ADDRESSES 6800D8(H) - User parameter switch 08 (SWUSR_08) Bits 0 and 1: Not used. Bit 2: Authorized reception 0: Only faxes from senders whose RTIs/CSIs are specified for this feature are accepted. 1: Only faxes from senders whose RTIs/CSIs are not specified for this feature are accepted.
  • Page 806 SERVICE RAM ADDRESSES 6800DE(H) - User parameter switch 14 (SWUSR_0E) Bit 0: Message printout while the machine is in Night Printing mode 0: On, 1: Off Bit 1: Maximum document length detection 0: Double letter, 1: Longer than double-letter (well log) – up to 1,200 mm Bit 2: Batch transmission 0: Off, 1: On Bit 3: Fax mode settings, such as resolution, before a mode key (Copy/Fax/Printer /Scanner) is pressed...
  • Page 807 SERVICE RAM ADDRESSES 6800E3(H) - User parameter switch 19 (SWUSR_13) Bit 0: Offset sort function for the fax (only using the shift tray on the 1,000 sheet finisher) 0: Disabled, 1: Enabled Bit 1: Journal format 0: The Journal is separated into transmissions and receptions 1: The Journal is separated into G3-1, G3-2, G3-3 and G4 communications Bit 2: Action when the paper cassette that was selected by the specified cassette selection feature becomes empty.
  • Page 808 SERVICE RAM ADDRESSES 6800E8(H) - User parameter switch 24 (SWUSR_18) Bits 0 and 1: File retention time (Cross reference: System switch 02 bit 4) Setting File retention impossible 24 hours File retention impossible 72 hours Bits 2 to 7: Not used 6800E9(H) - User parameter switch 25 (SWUSR_19) Bits 0 to 3: Not used Bit 4: RDS operation...
  • Page 809 SERVICE RAM ADDRESSES NOTE: If the number of characters is less than the maximum (20 for RTI, 64 for TTI), add a stop code (FF[H]) after the last character. 6802E0 to 6802E2(H) - PSTN-1 line settings 6802E0 Bits 0 and 1: PSTN access method from behind a PABX. Setting Loop start Ground start...
  • Page 810 SERVICE RAM ADDRESSES 68030C(H) - Network type used for the service station number 0 1 (H) - PSTN-1 0 2 (H) - PSTN-2 1 0 (H) - G4 0 7 (H) - G3 auto selection 680310 to 680317(H) - Last power off time (Read only) 680310(H) - 01(H) - 24-hour clock, 00(H) - 12-hour clock (AM), 02(H) - 12-hour clock (PM) 680311(H) - Year (BCD)
  • Page 811 SERVICE RAM ADDRESSES 6803A6 to 6803AB(H) - Modem ROM version (Read only) 6803A6(H) - Part number (low) 6803A7(H) - Part number (high) 6803A8(H) - Control (low) 6803A9(H) - Control (high) 6803AA(H) - DSP (low) 6803AB(H) - DSP (high) 680406(H) - Time for economy transmission (hour in 24h clock format - BCD) 680407(H) - Time for economy transmission (minute - BCD) 680422(H) - Transmission monitor volume 00 - 07(H) 680423(H) - Reception monitor volume 00 - 07(H)
  • Page 813 OVERVIEW 4. DETAILED SECTION DESCRIPTIONS 4.1 OVERVIEW Fax Function Upgrade N C U S G 3 C C U I F F C U SIG4 C C U I F N C U M B U Expansion M e m o r y G307D501.WMF The basic fax unit consists of three PCBs: an FCU, an MBU and an NCU.
  • Page 814 BOARDS 4.2 BOARDS 4.2.1 FCU ISDN S R A M F l a s h R O M (256 kB) (2 MB) M B U CPU BUS FACE2 V.34 C P U D C R V I F F B I F C U I F M O D E M ( R U 3 0 )
  • Page 815 BOARDS DRAM • The 8 MB of DRAM is shared as follows. SAF memory : 2 MB Working memory : 2 MB Page memory : 4 MB • The SAF memory is backed up by a rechargeable battery. Memory back-up •...
  • Page 816 BOARDS 4.2.3 NCU (US) J P 7 O H D I S W . Surge D B 1 Protection TRXD Noise C M L Over- Filter Relay RING DC Loop current Transformer Protection Surge Protection J P 8 Current Sensor O H D I S W C M L S W Hook0...
  • Page 817 BOARDS 4.2.4 NCU (EUROPE/ASIA) Noise SHUNT CML Relay Filter D C L S W Filter (16Hz) DO Sw. RING TRXD Current Sensor Loop OHDI Sw. D O S W O H D I S W GS Sw. C M L L S W Hook0 Hook1 SHUNT...

  • Page 818: Sg3 Board

    BOARDS 4.2.5 SG3 BOARD Standard D T M F Hybrid IC C C P Receiver F C U Flash ROM C P U D P R A M D M A C JBIGIF T O N E MN195003MFL ( R U 8 ) (4MB) Modem M o d e m...

  • Page 819: Sig4 Board

    BOARDS 4.2.6 SIG4 BOARD Flash SiG4 DR AM R O M SYSTEM BUS LAPD ISDN Reset ICCP I S D N Circuit Controller Interface Analog I/F C O D E C Circuit M O D E M G307D500.WMF The SiG4 (Standard ISDN G4) board contains ICCP (ISDN Communication Control Processor), Flash ROM, DRAM, LAPD controller, CODEC, ISDN interface and analog interface.
  • Page 820 VIDEO DATA PATH 4.3 VIDEO DATA PATH 4.3.1 TRANSMISSION S CA NN E R IP U F C U FB I FA CE 2 P age M em ory D CR S AF S G 3 Q M - Q M - D CR D CR C O DE R...
  • Page 821 VIDEO DATA PATH Memory Transmission and Parallel Memory Transmission The base copier's scanner scans the original at the selected resolution in inch format. The IPU processes the data and transfers it to the FCU. NOTE: When scanning a fax original, the IPU uses the MTF, independent dot erase and thresholding parameter settings programmed in the fax unit’s scanner bit switches, not the copier's SP modes.
  • Page 822 VIDEO DATA PATH 4.3.2 RECEPTION A nalog G 3 A nalog G 3 IS D N G 3 IS D N G 4 N C U N C U S iG 4 M odem M odem Q M - C O D E R S A F D C R C C D...
  • Page 823 VIDEO DATA PATH First, the FCU stores the incoming data from either an analog line or an ISDN line to the SAF memory. (The data goes to the FACE at the same time, and is checked for error lines/frames.) The FCU then decompresses the data and transfers it to page memory. If image rotation will be done, the image is rotated in the page memory.
  • Page 824 FAX COMMUNICATION FEATURES 4.4 FAX COMMUNICATION FEATURES 4.4.1 PERSONAL, INFORMATION, AND TRANSFER BOXES When an incoming message has a SUB or SEP code attached, the machine will look for a Personal Box, Transfer Box or Information Box with an identical SUB or SEP code.
  • Page 825 FAX COMMUNICATION FEATURES Transfer Box The user can create transfer boxes in the machine’s memory for forwarding incoming fax messages. Each box must have a name and a code. Each box must also have destinations associated with it; any message arriving in this box will automatically be sent on to these destinations.
  • Page 826 FAX COMMUNICATION FEATURES Information Box (Polling Tx) The user can set up documents in memory to be picked up by another machine. The user makes an information box for each document. The information box is identified by a code. Anybody who wishes to call the fax machine and receive the document from the information box has to input this code as the SEP code when calling the machine.
  • Page 827 FAX COMMUNICATION FEATURES 4.4.2 MULTI-PORT COMMUNICATION When the optional ISDN unit or optional extra G3 interface unit is installed, communication can take place at the same time through the two or three lines at once. Available Protocol Option Available Line Type Combinations Standard only PSTN...

  • Page 828: Document Server

    FAX COMMUNICATION FEATURES 4.4.3 DOCUMENT SERVER Controller C o m o r e s s e d M M R P a g e S c a n n e r M e m o r y F C U F A C E 2 D C R M o d e m...

  • Page 829: Lan Fax Driver

    FAX COMMUNICATION FEATURES 4.4.4 LAN FAX DRIVER Application Fax Driver C o m p r e s s e d M M R Fax Number Address/Book C O N T R O L L E R F C U F A C E 2 D C R M o d e m N C U...
  • Page 830 FAX COMMUNICATION FEATURES The fax driver makes print data from an application, then compresses the print data using MMR. PJL commands are added to the compressed data and the destination telephone number and the line selection are included in the PJL commands. The telephone number can be taken from an address book application.
  • Page 831 SPECIFICATIONS SPECIFICATIONS 1. GENERAL SPECIFICATIONS Type: Desktop type transceiver Circuit: PSTN (max. 2 channels) PABX ISDN Connection: Direct couple Original Size: Book (Face down) Maximum Length: 432 mm [17 ins] Maximum Width: 297 mm [11.7 ins] ARDF (Face up) (Single-sided document) Length: 128 - 1200 mm [5.0 - 47.2 ins] Width: 105 - 297 mm [4.1 - 11.7 inch] (Double-sided document)
  • Page 832 SPECIFICATIONS Modulation: V.34, V.33, V.17 (TCM), V.29 (QAM), V.27ter (PHM), V.8, V.21 (FM) Data Rate: G3: 33600/31200/28800/26400/24000/21600/ 19200/16800/14400/12000/9600/7200/4800/2400 bps Automatic fallback G4: 64 kbps/56 kbps I/O Rate: With ECM: 0 ms/line Without ECM: 2.5, 5, 10, 20, or 40 ms/line Memory Capacity: ECM: 128 KB Standard: 2 MB...

  • Page 833: Capabilities Of Programmable Items

    SPECIFICATIONS 2. CAPABILITIES OF PROGRAMMABLE ITEMS The following table shows how the capabilities of each programmable item will change after the optional Fax Function Upgrade Unit is installed. With Fax Function Item Standard Upgrade Unit Quick Dial 1200 Groups Destination per Group Boxes (Information/Personal/Transfer) Destinations dialed from the ten-key pad 1000...
  • Page 834 SPECIFICATIONS 3. MACHINE CONFIGURATION G307I107.WMF Description Description Description NCU board Fax Function Upgrade SiG4 board Unit FCU board Expansion Memory Optional G3 board MBU board CCUIF Optional NCU board Item Machine Code Remarks Fax Option G307 1, 2, 3 G3 Interface Unit G324 6, 8, 9 Either a G3 interface unit or an...
  • Page 835 G082...
  • Page 837 INSTALLATION 1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS 1.1.1 ENVIRONMENT 1. Temperature Range: 10°C to 32°C (50°F to 89.6°F) 2. Humidity Range: 15% to 80% RH 3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight) 4. Ventilation: 3 times/hr/person or more 5.
  • Page 838 INSTALLATION REQUIREMENTS 1.1.3 MACHINE SPACE REQUIREMENT Place the machine near the power source, providing clearance as shown. 575mm (23") A: Over 460 mm (18") B: Over 100 mm (4") C: Over 550 mm (22") D: Over 700 mm (28") G082I801.WMF 1450mm (57") G082I802.WMF 1.1.4 POWER REQUIREMENTS...
  • Page 839 INSTALLATION 1.2 OPTIONAL UNIT COMBINATIONS Item Options Alternative Required PFU (1 Tray) Items 2, 3 PFU (2 Trays) Items 1, 3 Items 1, 2 Two-tray finisher Item 6 • Item 7 • Item 1, 2 or 3 3 types of punch kit Item 4 Four-bin mailbox Items 4, 5...
  • Page 840 INSTALLATION FLOW CHART 1.3 INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently. Unpack the printer. Will the paper feed unit or LCT be installed? Place the printer on the paper feed unit or LCT. Install the paper feed unit or LCT.
  • Page 841 INSTALLATION 1.4 MACHINE INSTALLATION Refer to the Operating Instructions for details. If the customer has a service contract, change the settings of the following SP modes depending on the contract type. Item SP No. Function Default Meter charge SP5-930-1 Specifies whether the meter charge mode is enabled or disabled.
  • Page 842 MACHINE INSTALLATION Item SP No. Function Default Counter reset SP7-825-1 Resets the counters to 0. Important: This must be done at installation after all the above settings have been finished. The negative counters used in meter charge mode will be reset to zero. NOTE: 1) The default setting for this machine is meter-charge mode off.
  • Page 843 INSTALLATION 1.5 OPTIONAL UNIT INSTALLATION 1.5.1 LIST OF OPTIONS The available options are listed below. Except for the punch unit and DIMM memories, installation is explained in the Operating Instructions. • Paper Feed Unit (500 sheets x 1) • Paper Feed Unit (500 sheets x 2) •...
  • Page 844 OPTIONAL UNIT INSTALLATION 1.5.2 DIMM MEMORY INSTALLATION G082I902.WMF G082I901.WMF CAUTION Make sure no data is coming into the machine. Turn the main switch off before removing the controller box. 1. Remove the controller box [A] (! x 2). 2. Remove the controller cover [B] (! x 18, " x 2). 3.
  • Page 845 INSTALLATION 1.5.3 PUNCH UNIT INSTALLATION ☛ G060 Printer Service Manual, Section 1: Installation. G082...
  • Page 847 PREVENTIVE MAINTENANCE 2. PREVENTIVE MAINTENANCE ☛ G060 Printer Service Manual, Section 2: Preventive Maintenance. NOTE: LED behavior is different from the G060 printer as follows. PRODUCT NEAR END CONDITION END CONDITION G082 Printer Blinking Lighting G060 Printer Lighting Lighting G082...
  • Page 849 CONTROLLER 3. REPLACEMENT AND ADJUSTMENT 3.1 CONTROLLER NOTE: After replacing the controller, remove the NVRAM, HDD, DIMM, BIOS ROM, and battery on the old board and install them on the new board. 1. Controller box [A] (! x 2) 2. Controller cover [B] (! x 18, " x 2) G082R101.WMF 3.
  • Page 850 1. Controller box [A] (! x 2) 2. Controller cover [B] (! x 18, " x 2) G082R101.WMF 3. Controller PSU [C] (! x 4, " x 1) G082R104.WMF 3.3 PRINTER ENGINE ☛ G060 Printer Service Manual, Section 3: Replacement and Adjustment. G082...
  • Page 851 CONTROLLER SELF-DIAGNOSTICS ERRORS 4. TROUBLE SHOOTING 4.1 CONTROLLER SELF-DIAGNOSTICS ERRORS When a controller self-diagnostic error occurs, the error code number is displayed on the operation panel LCD and booting up stops. After pressing “Enter” key, the machine will continue to boot up. Error Possible Cause/ Symptom...
  • Page 852 4.2 INTERNAL ERROR When an internal error occurs, the message ”Printer Error Power Off On / Error Reoccur Call Service” is displayed on the operation panel LCD. 4.3 SERVICE CALL CONDITIONS ☛ G060 Printer Service Manual, Section 4: Troubleshooting. G082...
  • Page 853 SERVICE PROGRAM MODE 5. SERVICE TABLES 5.1 SERVICE PROGRAM MODE CAUTION Before accessing the service menu, do the following: Confirm that there is no print data in the printer buffer (the Data In LED must not be lit or blinking). If there is data in the buffer, wait until all data has been printed.
  • Page 854 SERVICE PROGRAM MODE Accessing the Required Program Use the “Up/Down arrow” keys to scroll through the menu listing. 1. Service: Controller service modes 2. Engine: Engine service modes 3. End: Exit service mode To select an item, press the “right-arrow” key. Then the sub-menu will appear. Scroll through the sub menu items using the “Up/Down arrow”...
  • Page 855 PRINTER CONTROLLER SERVICE MODE Rev. 10/2003 5.2 PRINTER CONTROLLER SERVICE MODE 5.2.1 SERVICE MODE MENU (“1. SERVICE") Mode No. Function / [ Setting ] (Class 1 and 2) [Clear Setting] Clear Setting Initializes settings in the “System” menu of the user mode.
  • Page 856 PRINTER ENGINE SERVICE MODE 5.3 PRINTER ENGINE SERVICE MODE ☛ G060 Printer Service Manual, Section 5.3: Printer Engine Service Mode. G082...
  • Page 857 Boot program Printer Controller 3. Controller System program ☛ G060 Printer Service Manual, Section 5.4.4: Firmware Upgrade. NOTE: When upgrading all three types of firmware at the same time, you can upgrade them in any order. 5.4.2 FIRMWARE UPGRADE OVERVIEW Before attempting to upgrade the firmware, you must obtain the latest firmware version from the TSC Website at http://tsc.ricohcorp.com.
  • Page 858 FIRMWARE UPDATE PROCEDURE 5.4.4 FIRMWARE UPGRADE CAUTION 1. Open the front cover whenever updating the firmware. 2. Do not turn off the machine while downloading the firmware. Upgrading Printer Firmware To upgrade the firmware, you must connect the printer to your PC with an Ethernet cross-over cable.
  • Page 859 FIRMWARE UPDATE PROCEDURE Preparation on the PC 1. Set the TCP/IP address for your PC (e.g. 133.139.157.010). NOTE: Do not use the IP address of the printer. 2. Set the Subnet Mask (e.g. 255.255.255.0). 3. Reboot the PC. Upgrade Procedure 1.
  • Page 860 FIRMWARE UPDATE PROCEDURE Updating using the lpr Command Preparation on the printer 1. Turn the main switch on. 2. Wait until “Ready” is displayed. Ready G082S910.WMF 3. Print out Configuration Page in case you need to refer to the current settings. 4.
  • Page 861 FIRMWARE UPDATE PROCEDURE 4. Wait until the “Data In” LED blinks. 5. Check that the massages “Upgrading System” Upgrading System and “Do Not Power Off” are displayed. Do Not Power Off NOTE: Do NOT turn the main switch off before the messages disappear. G082S912.WMF 6.
  • Page 862 FIRMWARE UPDATE PROCEDURE 5. At the Command prompt, transfer the firmware to the printer using the “Copy” command “copy filename lpt1 /b”. 6. During the transfer process, the printer LCD will display the number of bytes that have been transferred. Upon completion, the printer displays “Download done Programming…”...
  • Page 863 CONTROLLER SELF-DIAGNOSTICS 5.5 CONTROLLER SELF-DIAGNOSTICS 5.5.1 OVERVIEW There are two types of self-diagnostics for the controller. • Power-on self-diagnostics: The machine automatically starts the self-diagnostics just after the power has been turned on. • SC detection: The machine automatically detects SC conditions at power-on or during operation.
  • Page 864 USER PROGRAM MODE 5.6 USER PROGRAM MODE Press the “Menu” key to scroll through the menu listing. User Mode Tree USER MODE READY COUNTER CHECK AND PRINT SECURE PRINT PRINT MENU TRAY SETUP MENU RESETS SYSTEM SETUP PRINTER SETUP PS SETUP PCL SETUP COLORWISE SETUP VISUALCAL...
  • Page 865 CONTROLLER 6. DETAILED SECTION DESCRIPTIONS 6.1 CONTROLLER 6.1.1 BLOCK DIAGRAM AND FUNCTIONS Intel Pentium III Intel 440 BX PC100 SDRAM 700 MHz NVRAM North Bridge Memory EFI ASIC Ethernet Chip (VXMCT) Controller EFI ASIC (VXMCT) PCI BUS South Bridge BIOS EFI ASIC (VXMCT) Strata...
  • Page 866 CONTROLLER Networking The standard networks and cabling configuration includes: • Ethernet 10BaseT (Unshielded Twisted Pair) • Fast Ethernet 100Base-TX (Unshielded Twisted Pair) IX ASIC Increases the speed of I/O functions including: • Parallel Port • Peripheral Control Engine Video Interface The engine interface’s responsibilities include: •...
  • Page 867 CONTROLLER Memory The dynamic memory is used for System and Frame Buffer memory PC100 Synchronous DRAM in 168 pin DIMMs. Non-Volatile Memory There are three types of nonvolatile memory used on this machine: The 256KB Flash Memory contains the BIOS data, the 16MB Flash Memory contains the diagnostics and drivers to support firmware update, and the NVRAM contains various parameters such as SP and UP Mode data.
  • Page 868 CONTROLLER Compression The Fiery uses ECT compression to optimize the use of memory by reducing file sizes using proprietary techniques. This step allows the Fiery to store many more pages in the frame buffer than would be available normally. Options The printer will be available with the following types of options: •...
  • Page 869 CONTROLLER 6.1.2 BOARD LAYOUT SDRAM Slot SDRAM SDRAM Slot SDRAM North Bridge NVRAM ASIC (VXMCT) ASIC (VXMCT) ASIC (VXMCT) IEEE 1284 ASIC ASIC (IX) (VXMCT) Network I/F (RJ-45) South Bridge Lithium Battely Strata BIOS Flash G082D902.WMF G082...
  • Page 870 CONTROLLER 6.1.3 PRINT DATA PROCESSING IO/Print/ Video Drivers Connectivity PDLs Compression Page Mgr Device Mgr PostScript generation Page Ethernet parsing Compression PostScript Spooling, PDL Finishing, Decomp, switching Engine loading Video PJL parsing Page Parallel PCL 5e/5c Compression generation G082D904.WMF The key roles of each part of the print system are outlined below. •...
  • Page 871 Macintosh: Mac OS 8.7.2 or later Windows: Windows 95, 98, 2000, ME, XP, or NT (v4.0 with Service Pack 4) 6.1.5 POINT-TO-POINT DIAGRAM The following shows the differences from the G060 printer. Controller SDRAM 128 MB SDRAM...
  • Page 872 PRINTER ENGINE 6.2 PRINTER ENGINE ☛ G060 Printer Service Manual, Section 6: Detailed Section Descriptions. G082...
  • Page 873 SPECIFICATIONS SPECIFICATIONS 1. GENERAL SPECIFICATIONS Configuration: Desktop Print Process: Dry electrostatic transfer system Printer Languages: PCL5c: CLJ5 class compatible Adobe PostScript 3 (Genuine): Interpreter 3011.103 Resolution: PCL5c : 600 x 600 dpi : 600 x 600 dpi, 1200 x 1200 dpi Gradation 1 bit/pixel Printing speed:...
  • Page 874 SPECIFICATIONS Print Paper Size: (Refer to “Supported Paper Sizes”.) Minimum Maximum Tray 1 A4/8 " x 11" (LEF) Tray 2 A5 (LEF)/8 " x 11" A3/11" x 17" By-pass 90 x 148 mm 305 x 458 mm/12" x 18" Optional Tray A5 (LEF)/8 "...
  • Page 875 SPECIFICATIONS 1.1 SUPPORTED PAPER SIZES 1.1.1 PAPER FEED North America Europe/Asia By-pass Paper Size (W x L) Tray Tray Tray Tray 1 Tray 1 2/3/4 2/3/4 A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm A5 SEF...
  • Page 876 SPECIFICATIONS 1.1.2 PAPER EXIT Internal Tray External Tray 4-bin Paper Size (W x L) Finisher Duplex Mailbox (Face Down) (Face Up) A3 W 12" x 18" A3 SEF 297 x 420 mm A4 SEF 210 x 297 mm A4 LEF 297 x 210 mm A5 SEF 148 x 210 mm...
  • Page 877 SPECIFICATIONS 2. SOFTWARE ACCESSORIES The printer drivers and utility software are provided on one CD-ROM. An auto-run installer allows you to select which components to install. 2.1 PRINTER DRIVERS Printer Windows Windows Windows NT4.0 Macintosh Language 95/98/ME 2000/XP PCL 5c NOTE: 1) The printer drivers for Windows NT 4.0 are only for the Intel x86 platform.
  • Page 878 SPECIFICATIONS 3. MACHINE CONFIGURATION G082V900.JPG Machine Item Remarks Code Main Unit G060 Options Requires the duplex unit and one of the three paper feed options. Finisher G565 Finisher and mailbox cannot both be installed. Finisher and mailbox cannot both be...
  • Page 879 SPECIFICATIONS 4. OPTIONAL EQUIPMENT 4.1 500-SHEET TRAY Paper Size: Maximum: A3/11" x 17" (SEF) Minimum: A5 (LEF)/8 " x 11" Paper Weight: 60 to 105 g/m (16 to 28 lb.) Tray Capacity: 500 sheets (80 g/m , 20 lb.) Paper Feed System: FRR system Paper Height Detection: 3 steps (100%, 50%, Near End)
  • Page 880 SPECIFICATIONS 4.4 TWO-TRAY FINISHER & PUNCH UNIT Print Paper Size: No punch mode: A3/11" x 17" to A5 (LEF)/8 " x 11" Punch mode: 2 holes: A3/11" x 17" to A4/8 " x 11" (SEF) A4/8 " x 11" to A5 (LEF) 3 holes: A3, B4, 11"...
  • Page 881 SPECIFICATIONS Staple replenishment: Cartridge (5000 staples) Power consumption: 48 W Dimensions (W x D x H): 680 x 620 x 1030 mm (26.8" x 24.4" x 40.6") Weight Without punch unit: 53 kg (116.9 lb.) With punch unit: 55 Kg (121.3 lb.) 4.5 FOUR-BIN MAILBOX Number of bins 4 bins...
  • Page 883 TECHNICAL SERVICE BULLETINS...
  • Page 884                                 NJN g NNE NJN g ENf..f.NNE ENf..f.NNE         NJN g NJN g...
  • Page 885                                         NJN g NJN g NN.
  • Page 886 4. Y drum gear ( x 1) ( 3.10.1 REGISTRATION CLUTCH) 5. Lower gear guide ( 3.10.3 DEVELOPMENT DRIVE MOTOR - CMY) NOTE: To remove the B, Y, and C development clutches, you do not have to remove the lower gear guide. 3-41 G060...
  • Page 887                                 NJN g NNG NJN g ENfGNf.NNE ENfGNf.NNE         NJN g NJN g...
  • Page 888 TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: BULLETIN NUMBER: G060 - 004 G060 - 004 11/28/2001 11/28/2001 BULLETIN NUMBER: BULLETIN NUMBER: G060 - 004 G060 - 004 11/28/2001 11/28/2001 APPLICABLE MODEL APPLICABLE MODEL: : : :...
  • Page 889 Tech Service Bulletin No. G060 – 004 Page 2 of 3 Duplex Unit: • Do not lift the printer by the inverter unit (left side of the machine). Paper Supply Units: • When transporting the machine with the Paper Supply Unit installed: •...
  • Page 890 Tech Service Bulletin No. G060 – 004 Page 3 of 3 When transporting finisher (used for demonstration or show) by truck without a carton: Transport Preparation Procedure: 1. Remove the output trays. 2. Move the trays to the proper position for transportation (procedure on next page).
  • Page 891 TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: BULLETIN NUMBER: G060 - 005 G060 - 005 12/26/2001 12/26/2001 BULLETIN NUMBER: BULLETIN NUMBER: G060 - 005 G060 - 005 12/26/2001 12/26/2001 APPLICABLE MODEL APPLICABLE MODEL: : : :...
  • Page 892 Tech Service Bulletin No. G060 – 005 Page 2 of 3 SOLUTION (During production) Possible Causes Countermeasure Cut-in Lot No. Excessive oil The condition of the oil supply felt with the shield tape Z1830x soaked through and units without a problem have been selected.
  • Page 893 Tech Service Bulletin No. G060 – 005 Page 3 of 3 ACTION REQUIRED (in the field) Please check the following items when installing machines and/or replacing the oil supply unit. 1. Make sure that the carton of the oil supply unit is not stained with oil. If the carton is stained with oil, replace the oil supply unit with a new one.
  • Page 894 TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: BULLETIN NUMBER: G060 - G060 - 006 03/20/2002 03/20/2002 BULLETIN NUMBER: BULLETIN NUMBER: G060 - G060 - 03/20/2002 03/20/2002 APPLICABLE MODEL APPLICABLE MODEL: : : :...
  • Page 895 The actual operating temperature has not been changed, only the display trigger temperature. FIELD COUNTERMEASURE: Update the engine firmware to version B1.17C or newer on G060-17 machines if the serial number is between P60112xxxxx - P60201xxxxx and the engine firmware is ver B1.15E.
  • Page 896 * DIMM #2 (PRT/SCN) purchased separately) please refer to * 40 GB HDD the G060 Service Manual, G570 section, Page 1-13, for installation * Already Installed instructions. To identify if the printer was pre-configured to support the copier feature expander, remove the...
  • Page 897 Tech Service Bulletin No. G060 – 007 Page 2 of 3 Installation Workflow: Is the G060 a preconfigured model? Not Sure See the first page to identify Unpack the printer Unpack the printer Will a paper feed unit (PFU) or LCT be installed? Install additional memory into the controller (if required) 1.
  • Page 898 Tech Service Bulletin No. G060 – 007 Page 3 of 3 Installation Workflow continued: Will a finisher be installed? Install the punch unit (if required) Install the Multi-bin output tray (if required) Install the finisher Select the language Set the date and time...
  • Page 899 PCU during this time. NOTE: The lines are not visible with the G060, as a different printer gamma is used -- the gamma used on the G082 is designed to show more detail in halftone areas.
  • Page 900 Tech Service Bulletin No. G060/G570/G082 – 008 Page 2 of 2 Please see the following notes for machine installation and short-haul transport: 1. At Machine Installation: The transport unit lever has been removed and placed inside the machine as shown in the illustration. This lever must be re-installed when the machine arrives at the customer’s location.
  • Page 901 PCU during this time. NOTE: The lines are not visible with the G060, as a different printer gamma is used -- the gamma used on the G082 is designed to show more detail in halftone areas.
  • Page 902 Tech Service Bulletin No. G060/G570/G082 – 008 REISSUE ! Page 2 of 2 Please see the following notes for machine installation and short-haul transport: 1. At Machine Installation: The transport unit lever has been removed and placed inside the machine as shown in the illustration. This lever must be re-installed when the machine arrives at the customer’s location.
  • Page 903 Imaging Unit Duct Note: All parts listed above must be replaced as a set. UNITS AFFECTED: All G060 Printers manufactured after the Serial Numbers listed below will have the new style Imaging Unit installed during production. MODEL NAME SERIAL NUMBER...
  • Page 904 Bracket Gear Note: All parts listed above must be replaced together as a set. UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Paper Exit Gear and Bracket installed during production. MODEL NAME...
  • Page 905 PAGE ITEM G0601292 G0771292 Sheet – Jam Removal UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Sheet – Jam Removal installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/DSc38S P6011100001 Ricoh AP3800C/ AP3800CMF...
  • Page 906 Tube – M Toner Supply AA063656 Guide Coil – M Tube DENOTES NEW ITEM NUMBER UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Toner Supply Tube installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/DSc38S...
  • Page 907 DESCRIPTION PAGE ITEM G0603674 Release Lever Stopper UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Release Lever Stopper Removed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/DSc38S P601070011 Ricoh AP3800C/ AP3800CMF...
  • Page 908 ITEM G0123897 Film - Toner End Sensor Harness DENOTES NEW ITEM NUMBER UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Right Frame installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/DSc38S...
  • Page 909 PAGE ITEM G0604483 G0604479 Shaft – Paper Sensor UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Shaft – Paper Sensor installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/DSc38S P6011200001 Ricoh AP3800C/ AP3800CMF...
  • Page 910 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 - 010 09/18/2002 APPLICABLE MODEL: GESTETNER – DSc38/DSc38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38c/SLP38cS SUBJECT: PAPER JAM AT REGISTRATION AREA SYMPTOM: Registration jams may occur during multi-print duplex jobs, which are then logged in the following SP modes.
  • Page 911 Tech Service Bulletin No. G060/G570 – 010 Page 2 of 3 SOLUTION: Replace the Guide Plate with the newly registered “Guide Plate – Middle Registration assembly (#G0602613): Make sure that the main switch is turned off and the power cord is unplugged.
  • Page 912 Open the Right Door Unit [G] and remove it (3 connectors, 1 snap-ring). Replace the Guide Plate [H] with the new #G0602613 assembly (2 screws). Note: Clean the Registration Rollers with a damp cloth. Reattach all parts removed above. UNITS AFFECTED: B060/G570 Serial Number cut-in not available at time of publication.
  • Page 913 Please refer to the following table for the cut-in serial number of this modification UNITS AFFECTED: All G060 copiers manufactured after the Serial Numbers listed below will have the new style ((Part Name)) installed during production MODEL NAME...
  • Page 914 This will prevent it from touching the PCUs. • [B] Wire contact • [C] Transfer entrance guide • [D] Tension springs NOTE: Be careful that the springs do not pop out when removing or reinstalling. Continued… Tech Service Bulletin No. G060/G570 – 011 Page 3 of 3...
  • Page 915 Remove the 4 transfer charge brushes (2 screws each). Use a screwdriver to remove excess toner/dust from the brush fibers, being sure to stroke the fibers in the direction that they lean. Then, clean off the fibers with a dry cloth. NOTE: If the fibers are stroked in the opposite direction this may lead to vertical white lines on the outputs.
  • Page 916 DESCRIPTION PAGE ITEM G0603866 G0603703 Drive Roller UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Drive Roller installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/ DSc38S P6011000006 Ricoh AP3800C/ AP3800CMF...
  • Page 917 G0603705 Cushion – Transfer Brush DENOTES NEW ITEM NUMBER UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Cushion – Transfer Brush installed during production MODEL NAME SERIAL NUMBER Gestetner DSc38/ DSc38S...
  • Page 918 ITEM GA003029 GA003044 Decal – Vertical Transport 2 UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Cushion – Transfer Brush installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38/ DSc38S P6011000001...
  • Page 919 Grip Shaft Note: All parts listed above must be replaced as a set. UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Lever – Vertical Transport installed during production. MODEL NAME SERIAL NUMBER...
  • Page 920 NEW PART NO. DESCRIPTION PAGE ITEM G0603692 G0603698 Stay UNITS AFFECTED: All G060/G570 Printers manufactured after the Serial Numbers listed below will have the new style Stay installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38 P6010800001 Ricoh AP3800C P6010800001...
  • Page 921 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 014 10/09/2002 APPLICABLE MODEL: GESTETNER – DSC38 RICOH – AP3800C SAVIN – SLP38C SUBJECT: TONER END MIS-DETECTION SYMPTOM: Toner end might be detected even when some amount of toner still remains in the toner cartridge.
  • Page 922 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 - 015 10/11/2002 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS 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 923 4.4 TWO-TRAY FINISHER & PUNCH UNIT ...........13-9 4.5 FOUR-BIN MAILBOX ..............13-10 FIRMWARE HISTORY FIRMWARE HISTORY ..............14-1 1 MAIN ENGINE FIRMWARE MODIFICATION HISTORY ......14-1 2 MUSIC ENGINE FIRMWARE MODIFICATION HISTORY ......14-5 3 CONTROLLER FIRMWARE MODIFICATION HISTORY......14-6 4 NIB FIRMWARE MODIFICATION HISTORY ..........14-9 G060...
  • Page 924 Rev. 10/2002 INSTALLATI0N G060 TWO-TRAY PAPER FEED UNIT G568 G082 PREVENTIVE MAINTENCE G060 LARGE CAPACITY TRAY G569 REPLACEMENT AND ADJUSTMENT G060 TWO-TRAY FINISHER G565 TROUBLESHOOTING G060 FOUR-BIN MAILBOX G566 SERVICE TABLES G060 SPECIFICATIONS G060 DETAILED DESCRIPTIONS G060 COPIER FEATURE EXPANDER G570...
  • Page 925 FIRMWARE HISTORY...

  • Page 927: Firmware History

    FIRMWARE HISTORY Rev. 10/2002 ⇒ FIRMWARE HISTORY 1. MAIN ENGINE FIRMWARE MODIFICATION HISTORY Please check the http://tsc.ricohcorp.com website for current firmware downloads. G060 MAIN ENGINE FIRMWARE MODIFICATION HISTORY FIRMWARE SERIAL FIRMWARE DESCRIPTION OF MODIFICATION LEVEL NUMBER VERSION Installed from the first mass production.
  • Page 928 18th, 2002, and most machines with Ver. B1.15E have been reworked locally: However, some of these machines have been released to the market without modification. Therefore please update the engine firmware to ver B1.17C or newer on G060-17 machines in the following serial number range: P60112xxxxx – P60201xxxxx.
  • Page 929 If machine enters Energy Saver 1 Mode then cools down for more than 1 minute, it will not display “Ready” after recovery warm-up (only for G060-17 models). When a B/W job is performed, the coverage counters (SP7-833-1 to -4) for CMY are not set to 0 as they should be, i.e.
  • Page 930 June B1.18B SC230 at automatic line position 2002 adjustment Side effect for firmware version B1.18 SC545 modification (only for G060-17 models): The machine does not display “Ready” after recovery warm-up from Energy Saver 1 Mode in phase control mode. G060...
  • Page 931 July 2001 1.04 The firmware header has been corrected to G0775624 March 1.06 allow the MUSIC firmware to be updated 2002 using the IC card. The firmware header has been corrected G0775624 A 1.07 for Japanese models only. 2002 14-5 G060...
  • Page 932 HDD format cannot be done when SC860 is detected. CRD version of PS3 has been updated to Ver. 1.2.1. Presentation color profile version of PCL has been updated to Ver. 1.2.1. (Photographic color profile stays the same as Ver. 1.1.2a.) G060 14-6...
  • Page 933 Series Print mode. Letterhead Mode has been added. The following has been fixed: G0775910 E 2.12 While downloading PS fonts to a machine G0775911 E with the HDD option installed, the correct PS serial number cannot be output. 14-7 G060...
  • Page 934 DeviceGray command is used. Change in Specification: 1. Supports the Status Readback function of the PCL5e. 2. When the machine has no HDD option, the PCL HDD Directory List (and font source) will not be printed on the PCL Configuration Page. G060 14-8...
  • Page 935 TCP Ports 11021 and 11023 (Design use) have been closed. There were two error messages displayed when no files were available for download using FTP. The two messages were merged to “550: No such file or directory”. Continued On Next Page 14-9 G060...
  • Page 936 CERT on Feb.12, 2002 has been resolved and tested using the PROTOS c06-snmpv1 test suite. CERT :http://www.cert.org/advisories/CA- 2002-03.html PROTOS c06-snmpv1 test suite :http://www.ee.oulu.fi/research/ouspg/proto s/testing/c06/snmpv1/ TCP ports for disabled services (e.g. FTP) were open. An unnecessary TCP port was open. G060 14-10...
  • Page 937 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 - 016 10/23/2002 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: DOCUMENT SERVER FUNCTION ENHANCEMENT It is now possible to retrieve transmitted facsimile and scanned documents using Desk TopBinder. FUNCTIONS...
  • Page 938 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 016 Reissue 11/11/2002 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: DOCUMENT SERVER FUNCTION ENHANCEMENT It is now possible to retrieve transmitted facsimile and scanned documents using Desk TopBinder.
  • Page 939 SAVIN – SLP38C/SLP38CS SUBJECT: MANDATORY FIRMWARE UPGRADE Please be advised that there is a bug in the System firmware on the G060 CMF version printers (from initial production through September 02 kitted versions). This bug may cause the G060 CMF to count black prints as color prints when the Meter Charge Mode set to “ON”...
  • Page 940 While investigating this issue, it became apparent that there was some confusion in the field regarding the proper usage of the various meter modes for billing purposes. For all G060 CMF units, that have CPP Contracts as the billing method, the following recommended settings should be utilized.
  • Page 941 COUNTING METHODS: METER CHARGE MODE ON / METER CHARGE MODE OFF The total counter of the G060 printer has two different modes of operation 1. Meter Charge Mode Enabled [ON] => set to ON if the customer is charged based on page or development count 2.
  • Page 942 Tech Service Bulletin No. G060/G570 – 017 Page 4 of 5 Copier Press the User Tools/Counter key Touch counter Display or print the counter page User Tools/Counter Counter Counter Meter Charge Mode OFF: Used for customers who are not charged by cost per page or developments.
  • Page 943 Tech Service Bulletin No. G060/G570 – 017 Page 5 of 5 Compensation Profile Form Complete this form for each of your G060 products equipped with the Copier Feature Expander. Dealer Name: Address: Service Manager: Phone Number: Serial Number: Contract Type...
  • Page 944 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 018 01/30/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSC388 RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: SC 999 & SERVICE MANUAL – INSERT GENERAL: The following SC code has been added to the controller (printer) and system (CF) firmware.
  • Page 945 Tech Service Bulletin No. G060/G570 – Draft Page 2 of 2 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 •...
  • Page 946 • Logging (SP5-990-004) • Printer driver settings used when the problem occurs • All data displayed on the screen (SC code, error code, and program address where the problem is logged.) • Image file which causes the problem, if possible G060 4-32...
  • Page 947 Rev. 01/2003 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type ⇒ SC 999 Program • The download (program, • BCU Board installed 1. Turn the main switch off and on. download error 2. If you can download necessary (CF) print data, language data) incorrectly...
  • Page 948 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 019 01/31/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSc38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38cS SUBJECT: DUPLEX PRINTING IN LETTERHEAD MODE SYMPTOM: When printing odd pages in duplex mode with direction-sensitive paper (ex. letterhead, pre-punched, and/or pre-printed paper), the last page is printed on the rear side instead of the front.
  • Page 949 Tech Service Bulletin No. G060/G570 – 019 Page 2 of 3 1. Normal paper from paper trays: The last page is not passed through the duplex unit since normal paper is not direction-sensitive. Simplex 2. Letterhead paper from paper trays: The last (3rd) sheet of paper is passed through the duplex unit simply to invert it, which allows Pg.
  • Page 950 Tech Service Bulletin No. G060/G570 – 019 Page 3 of 3 Even though the cover sheet is one-sided, the 1st sheet of paper will still be sent through the duplex unit and inverted, as the job has been selected as a duplex job in the driver. This cover sheet image is then printed on the rear side, i.e.
  • Page 951 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 020 01/31/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSc38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38cS SUBJECT: BLACK DEVELOPMENT DRIVE UNIT FUSING CLUTCH GENERAL: A fusing clutch has been added to the black development drive unit. The fusing clutch switches on in order to operate the fusing unit.
  • Page 952 Tech Service Bulletin No. G060/G570 – 020 Page 2 of 3 DIP Switch Settings When replacing the BCU board with a new one that has DIP switch on it, check and see if the old board also has a DIP switch. If there is no DIP switch on the old board, keep the DIP switch on the new board switched OFF.
  • Page 953 BCU Board DIP Switch Settings A fusing clutch has been added to the G060 series. To regulate the new clutch, a DIP Switch has been added to the BCU board. The new board can be used in both new machines (with the fusing clutch) and older machines (without the clutch).
  • Page 954 For this modification, the BCU board has also been changed. For details of these changes please see TSB G060/G570 – 020. The following parts updates are being issued for all G060 Parts Catalogs. Please update you parts catalog with the following information.
  • Page 955 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 022 01/31/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSc38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38cS 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 956 Fusing clutch is installed installed NOTE: A DIP switch has been added to the BCU board (P/N G0775069 or later). This setting is very important. If the switch is not set correctly, a paper jam or fusing problem will occur. G060 5-60...
  • Page 957 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 023 02/13/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: FUSING MISFEEDS & DAMAGE GENERAL: This Technical Service Bulletin has been issued in response to cases of fusing unit damage in the field resulting from incorrect user operation.
  • Page 958 Tech Service Bulletin No. G060 – 023 Page 2 of 3 Detailed Notes for the 3 Cause/Solutions from the Above Table NOTE 1: Avoiding paper types not supported on this printer Please advise users not to use the following paper types on this printer: •...
  • Page 959 If the S/N is in the range mentioned in TSB G060 - 010 (July-Aug ’01 machines), please install the new Guide Plate Middle Registration (P/N G0602613).
  • Page 960 G060-17: P8920700001 to P8920700100; P8920800001 to P8920800050 UNITS AFFECTED: All G060 Printers manufactured other than those serial numbers listed below will have the new style EMAC2 and version B1.21installed during production. Machines equipped with the EMAC2 that require an upgrade to version B1.21 or later:...
  • Page 961 Tech Service Bulletin No. G060/G570 – 024 Page 2 of 4 SYMPTOM: The following problem has recently been reported from the field. After replacing the Laser Optics Housing Unit and when printing color images, the color(s) are missing on output prints without any SC code notification.
  • Page 962 Tech Service Bulletin No. G060/G570 – 024 Page 3 of 4 There is a space [C] that allows some movement along from the mounting plane [D]. However, the movement along this plane will not cause the missing color problem. If the mirror is angled away from the mounting plane, colors may be lost NOTE: To minimize the problem occurrence on the service parts, a modification is under investigation.
  • Page 963 Tech Service Bulletin No. G060/G570 – 024 Page 4 of 4 3. Remove the sponge [C]. Note 1: Be sure not to touch any of the mirror or lens surfaces. Note 2: Be sure that dust does not get into the unit.
  • Page 964 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 025 03/14/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: REQUIRED ACTION FOR INSTALLING CF EXPANDER SYMPTOM: The right frame of the CF Rack can pinch the IPU connector, causing an SC error (mainly SC672) to occur, or a blank operation panel display at power on.
  • Page 965 SUBJECT: TOTAL COUNTER & IC - EEPROM GENERAL: The following parts were omitted from the G060 Parts Catalog. Please update your parts catalog with the following information. The following parts updates are being issued for all G060 Parts Catalogs. REFERENCE...
  • Page 966 2) clarify the differences between SP7-833 and SP7-908 NOTE: SP7-908-1 thru 8 has been applied to the G060 from March ’02 production, and both SP7-833 and 908 have been applied on the G082 from the first mass production run. Also, SP7-908-5 thru 8 contains the same data as SP7-833-11 thru 14.
  • Page 967 Tech Service Bulletin No. G060/G570 – 027 Page 2 of 3 2. Difference between SP7-833 and SP7-908 Both calculate the pixel coverage ratios mentioned above for each toner color, however the calculation is different for Bk pages printed in Color development mode (i.e. development with the transfer unit in contact with all 4 PCUs).

  • Page 968: Parts Information

    IC - EEPROM I2C BUS 32K DIP 14075751 IC - NVRAM I2C BUS 64K DIP UNITS AFFECTED: All G060 printers manufactured after the serial numbers listed below will have the new style IC - NVRAM I2C BUS 64K DIP installed during production. MODEL NAME SERIAL NUMBER...
  • Page 969 2.5K prints before detecting the end condition. The unit life is 1860 revolutions. Increment: Delays the alert display timing. Decrement: Hastens the alert display timing. 1.0K prints = 93 [ 0 to 10000 / 1628 / 1 K revolutions/step ] 5-43 G060...
  • Page 970 [ 0 to 100.00 / - / 0.01 %/step ] Last [M] Last [Y] [Firmware PN] Firmware Part Number Controller Displays the part number of the firmware. Engine Displays the part number of the firmware. Finisher Mail Box Duplex MUSIC Factory Printer Test G060 5-44...
  • Page 971 PRINTER ENGINE SERVICE MODE Rev. 03/2003 Mode No. Function / [ Setting ] (Class 1, 2, and 3) [Firmware Ver.] Controller Displays the firmware version. Engine Finisher Mail Box Duplex MUSIC Factory Printer Test 5-45 G060...
  • Page 972 DESCRIPTION PAGE ITEM G0603990 G0773706 DC Motor – 1.56W UNITS AFFECTED: All G060 printers manufactured after the serial numbers listed below will have the new style DC Motor installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38 Lanier 2138 P6011200613...
  • Page 973 The shape of the strippers for the Fusing Belt and Pressure Roller has been changed and the spring pressure has been reduced to ensure that the strippers do not scratch the Fusing Belt or Pressure Roller. The following parts updates are being issued for all G060/G570 Parts Catalogs. Page 44...
  • Page 974 Tech Service Bulletin No. G060/G570 – 029 UNITS AFFECTED: All G060 printers manufactured after the serial numbers listed below will have the new style Fusing Strippers installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38 Lanier 2138 P6021200020 Ricoh Aficio AP3800C...
  • Page 975 RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: PARTS CATALOG UPDATES GENERAL: The following parts updates are being issued for all G060 Parts Catalogs. • UPDATE 1: Paper Tray 1 – The Paper Tray 1 has been changed due to standardization with other models. Please update your G060 Parts Catalog with the following information.
  • Page 976 Tech Service Bulletin No. G060/G570 – 030 • UPDATE 2: Paper Feed Unit 1 – The Paper Feed Unit 1 has been changed due to standardization with other models. Please update your G060 Parts Catalog with the following information. REFERENCE OLD PART NO.
  • Page 977 Tech Service Bulletin No. G060/G570 – 030 • UPDATE 3: Lower Middle Guide – The Lower Middle Guide and Lower Middle Guide Plate Adhesion have been registered. Please update your G060 Parts Catalog with the following information. Page 28 REFERENCE NEW PART NO.
  • Page 978 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 - 031 06/30/2003 APPLICABLE MODEL: GESTETNER – DSC38S LANIER – 2138CMF RICOH – AP3800CMF SAVIN – SLP38CS SUBJECT: SENSOR STOPPER GENERAL: The shape of the sensor stopper has been change to prevent interference with the rear scanner cover. The following part update is being issued for all G570 Parts Catalogs.
  • Page 979 RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: PARTS CATALOG UPDATES GENERAL: The following parts updates are being issued for all G060/G570 Parts Catalogs. • UPDATE 1: Upper Cover – The exit tray upper cover has been changed due to parts standardization with other models.
  • Page 980 Tech Service Bulletin No. G060/G570 – 032 UNITS AFFECTED: All G060/G570 printers manufactured after the serial numbers listed below will have the new part installed during production. MODEL NAME SERIAL NUMBER Ricoh Aficio AP3800C P6020500862 Savin SLP38c Gestetner DSc38 Lanier 2138 •...
  • Page 981 Tech Service Bulletin No. G060/G570 – 032 • UPDATE 3: Torsion Springs– Please delete the Rear and Front Torsion Springs (Item #23 & 24) from the parts catalog descriptions page. These springs are included with Item #3; Release Shaft P/N G0603694).
  • Page 982 Power is not supplied when the main switch is turned ON after replacing the PSU [A], Harness - AC Switch [B] or Bracket – PSU Fan [C]. NOTE: This may occur on all G060 and G080 series models. CAUSE: When replacing the above-mentioned parts, the harness may be damaged when it comes in contact with the edge of the bracket or PSU bracket.
  • Page 983 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 034 07/23/2003 APPLICABLE MODEL: GESTETNER – DSC38/DSC38S LANIER – 2138AH/2138CMF RICOH – AP3800C/AP3800CMF SAVIN – SLP38C/SLP38CS SUBJECT: COLOR SHIFT DUE TO ERROR IN INSTALLATION PROCEDURE SYMPTOM: Color shift after adjusting the fusing unit line speed at unit replacement.
  • Page 984 SUBJECT: ROM DIMM - PDL GENERAL: The Euro currency symbol has been added to 112 fonts in the ROM DIMM - PDL. The following part update is being issued for all G060 Parts Catalogs. G060 only REFERENCE OLD PART NO.
  • Page 985 Tech Service Bulletin No. G060/G570 – 035 UNITS AFFECTED: All G060 printers manufactured after the serial numbers listed below will have the new style ROM DIMM - PDL installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38 P6021000151 Lanier 2138...
  • Page 986 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 036 07/29/2003 APPLICABLE MODEL: GESTETNER – DSC38S LANIER – 2138CMF RICOH – AP3800CMF SAVIN – SLP38CS SUBJECT: DIMM 1 - SYSTEM GENERAL: The contents of the DIMM 1 - System firmware have been changed: The meter click counter specification has been changed so that copies made in SP mode are not counted.
  • Page 987 Tech Service Bulletin No. G060/G570 – 036 UNITS AFFECTED: All G570 Copier Feature Expander Type 3800C’s manufactured after the serial numbers listed below will have the new style DIMM 1 - System installed during production. MODEL NAME SERIAL NUMBER Copier Feature...
  • Page 988 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 037 07/30/2003 APPLICABLE MODEL: GESTETNER – DSC38S LANIER – 2138CMF RICOH – AP3800CMF SAVIN – SLP38CS SUBJECT: SERVICE MANUAL - INSERT The Service Manual pages listed below must be replaced with the pages supplied.
  • Page 989 SP4-907-1 VPU Test Pattern: R ............4-7 SP4-907-2 VPU Test Pattern: G ............4-7 SP4-907-3 VPU Test Pattern: B ............4-7 4.2.2 IPU TEST MODE................4-8 SP4-904-1 Register Write/Read Check Result ........4-8 SP4-904-2 Image Path Check Result ...........4-8 4.3 SERVICE CALL CONDITIONS ..............4-9 xiii G060...
  • Page 990 (G080) to a G060 printer. Preparation Items needed for conversion. DIMM #1 for G570 Copy Feature P/N: G5706691 (See TSB G060/G570 – 036) Flashcards loaded with the following G570 Copy Feature Expander firmware: CF NIB, Scanner Application, Fax Application and Operation Panel (LCDC) Procedure Turn the main power switch OFF.
  • Page 991 OTHERS Rev. 07/2003 ⇒ 6. Install the CF Expander into the G060 mainframe. NOTE: Note: Do not turn the main power on at this time. If it is turned on SC672/990 will be displayed but will not affect the update.
  • Page 992 OTHERS Rev. 07/2003 ⇒ III. Turn the main switch ON. After the following message is displayed, press the button for the firmware you are updating (Operation Panel, Engine, etc.). PCcard -> ROM Page01 ROM:G0775611C NEW:G0775611F Engine ROM:RB1.10:23 NEW:RB111C:23 New Version (IC Card) Current Version Exit (0) - Engine...
  • Page 993 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 038 08/04/2003 APPLICABLE MODEL: GESTETNER – DSC38 LANIER – 2138AH RICOH – AP3800C SAVIN – SLP38C SUBJECT: MAIN-SCAN MAGNIFICATION ERROR SYMPTOM: The image appears further enlarged or reduced along the main scan direction in relation to the magnification setting for the original data.
  • Page 994 Production line 1. Pick-Off Pawls The edges of the pawls have been rounded to minimize belt or roller damage with a paper jam. See Technical Service Bulletin G060/G570 – 029 for more information. REFERENCE OLD PART NO. NEW PART NO.
  • Page 995 Tech Service Bulletin No. G060/G570 – 039 UNITS AFFECTED: 1. Pick-Off Pawls All G060 printers manufactured after the serial numbers listed below will have the new style Fusing Strippers installed during production. MODEL NAME SERIAL NUMBER Gestetner DSc38, DSC38S Lanier 2138, 2138CMF...
  • Page 996 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 040 09/04/2003 APPLICABLE MODEL: GESTETNER – DSC38S LANIER – 2138CMF RICOH – AP3800CMF SAVIN – SLP38CS SUBJECT: SERVICE MANUAL - INSERT The Service Manual pages listed below must be replaced with the pages supplied.
  • Page 997 Table 4: Original Size Detection ............5-68 5.4.3 OUTPUT CHECK TABLE ...............5-69 5.4.4 TEST PATTERN (SP5-997) ............5-73 5.5 SCANNER SP ..................5-74 5.5.1 SP MODES..................5-74 SP1-xxx (System and Others) ............5-74 SP2-XXX (Scanning-image quality) ............5-75 SP8-XXX (Delivery) ................5-82 5.6 REBOOT / SYSTEM SETTING RESET ..........5-84 G060...
  • Page 998 Rev. 09/2003 SC TABLE Related SC No. Item Definition Possible Cause Troubleshooting Procedure Type SC 642 Communication • The operation panel does • Controller defective 1. Turn the main switch off an on. timeout error • Operation panel 2. Check the cable connection between (CF) not respond to the frame between...
  • Page 999 Rev. 09/2003 SC TABLE ⇒ SC 800 Startup without Video transfer to the engine • Defective BCU 1. Turn the main switch off and on. video output end is started, but the engine 2. Check the cable connection. (CF) error (K) does not issue a video 3.
  • Page 1000 Rev. 09/2003 SC TABLE • • SC 818 Watch-dog error While the system program is • Defective controller 1. Turn the main switch off and on. running, other processes do • Software error 2. Replace the controller. not operate at all. 3.
  • Page 1001 Rev. 09/2003 SC TABLE [0801] CPU error Same as [0001] [4005] SC 821 Self-diagnosis The CPU checks if the ASIC • System firmware 1. Turn the main switch off and on. error: ASIC timer works properly 2. Reinstall the controller system [0D05] problem compared with the CPU...
  • Page 1002 Rev. 09/2003 SC TABLE • An RTC device is • RTC defective SC 826 Self-diagnostic 1. Turn the main switch off and on. Error: RTC/ recognized, and the • NVRAM without RTC 2. Replace the NVRAM with another (CF) Optional NVRAM NVRAM with an RTC device.
  • Page 1003 Rev. 09/2003 SC TABLE SC829 Self-diagnosis error: optional RAM [XXXX]: Detailed error code [0302] Composition The result of checking the • Not specified RAM 1. Turn the main switch off and on. error (Slot 0) composition data of the 2. Replace the RAM DIMM. DIMM installed RAM in Slot 0 (CN5) on the •...
  • Page 1004 Rev. 09/2003 SC TABLE • Defective IEEE1394 SC 851 IEEE1394 The 1394 interface is 1. Turn the main switch off and on. interface error unusable. • Defective controller. 2. Replace the IEEE1394 interface board. 3. Replace the controller. SC 860 HDD: The controller detects that •...
  • Page 1005 Rev. 09/2003 SC TABLE ⇒ SC 991 Software The software performs an • Incorrect program This SC is not displayed on the LCD Performance unexpected operation. (logged only). argument or other Error - Logged parameter • Insufficient working Note: Unlike SC990, the software/machine continue memory to function without requiring...
  • Page 1006 Rev. 09/2003 SC TABLE • The download (program, • BCU Board installed SC 999 Program 1. Turn the main switch off and on. download error print data, language data) incorrectly 2. If you can download necessary (CF) programs, do it by using an from the IC card does not •...
  • Page 1007 Rev. 09/2003 SC TABLE NOTE 1: If a problem always occurs in a specific condition (for example. printer driver setting, image file), the problem may be caused by a software error. In this case, the following data and information needs to be sent back to your product specialist. •...
  • Page 1008 Rev. 09/2003 TROUBLESHOOTING GUIDE 4.5 TROUBLESHOOTING GUIDE 4.5.1 IMAGE QUALITY The table below shows the troubleshooting procedure for the following image problems. • Smeared image for 4C thin lines or White lines in solid image areas • Dirty background • Fireflies •...
  • Page 1009 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Dirty background Dirty background may When the developer has deteriorated or Perform forced toner refresh mode (SP3-921-1 or continuously appear on the when prints are made in a very low left side (relative to paper humidity condition, dirty background may The machine automatically does this in the feed) under very low...
  • Page 1010 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Crow marks When making duplex prints in A charge is applied to the paper at each Using SP2-301 (Transfer Current), increase the low temperature and humidity color station in order to attract each paper transfer current for black in the mode in conditions, crow marks may toner onto the paper.
  • Page 1011 Rev. 09/2003 TROUBLESHOOTING GUIDE Subject Symptom Cause Action Image density change Image density is too low or If the machine has never been turned off Change the settings of the following SP modes: high. and Energy Saver 2 (Auto Off mode) is SP3-906-3 Non-use Time 1 disabled, the machine has never 0 (Default) to 500...
  • Page 1012 Rev. 09/2003 TROUBLESHOOTING GUIDE 4.5.2 COLOR SHIFT The following briefly explain the factors causing color shifts and what to do on the machine to correct it: • Temperature change causes the optical components in the laser optics housing unit to contract, causing the main The black development motor drives scan magnification to change.
  • Page 1013 Rev. 09/2003 TROUBLESHOOTING GUIDE As explained on the previous page, there are several types of color shift problem. The following table shows the symptoms, factors, action required, and the page to see for details. Symptom Factors Action Required Refer to # Color shift on entire image in •...
  • Page 1014 Rev. 09/2003 TROUBLESHOOTING GUIDE µ Adjustment Standard: Max. 200 As a machine capability, maximum amount of color shift is 200 µm. Adjusting the SP modes (motor speed, registration, and magnification) can improve the color shifts level; however, there is a limit. Preparation When color shift is reported, the following procedure should be done before adjusting the machine and/or SP modes.
  • Page 1015 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Sub-scan Leading Color shift, Registration roller Normal Paper SP1-004-4 Check the magenta line position against the black line. edge especially 100 mm speed is not 1200 dpi If the registration roller is too fast or slow, the magenta...
  • Page 1016 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Sub-scan Entire Color shift on the SP mode setting Normal Paper SP5-993- Measure the gap between the black line and other image entire image, and is not suitable for 600 dpi...
  • Page 1017 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Main-scan Entire Color shifts on the Main-scan SP5-993- Measure the gap between the black line and other image entire image, and magnification is 013 (Y) colors (YMC) using a magnification scope.
  • Page 1018 Rev. 09/2003 TROUBLESHOOTING GUIDE Action Required Direction Area Symptom Possible Cause Procedure / Remarks Output Mode SP Mode Main-scan Entire Color shifts on the Main-scan SP5-993- Measure the gap between the black line and other image entire image and registration is not 010 (Y) colors (YMC) using a magnification scope.
  • Page 1019 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: G060/G570 – 041 09/05/2003 APPLICABLE MODEL: GESTETNER – DSC38 LANIER – 2138AH RICOH – AP3800C SAVIN – SLP38C SUBJECT: SERVICE MANUAL - INSERT The Service Manual pages listed below must be replaced with the pages supplied.
  • Page 1020 Registration roller speed adjustment (For B&W mode).......4-50 4.5 ELECTRICAL COMPONENT DEFECTS ..........4-51 4.5.1 SENSORS ..................4-51 4.6 BLOWN FUSE CONDITIONS ..............4-52 4.7 LEDS (BCU) ....................4-52 SERVICE TABLES 5 SERVICE TABLES................ 5-1 5.1 SERVICE PROGRAM MODE..............5-1 5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...5-1 G060...
  • Page 1021 BCU NVRAM A read/write diagnostics error 1. Turn the main switch OFF/ON. read/write is detected when the main SW 2. Replace the NVRAM. NVRAM (BCU) diagnostics is turned ON. error Note: This only occurs with the 8kB NVRAM. G060 4-24...
  • Page 1022 • Loose connection error hammer motor turns on. connector is properly connected. • Overload caused by 3. Check if the staple jam occurs. stapling too many 4. Replace the staple hammer motor. pages • Defective staple hammer motor 4-25 G060...
  • Page 1023 • Defective stapler 2. Check if the stapler rotation motor motor error specified time after the stapler connector is properly connected. rotation motor rotation motor starts rotating. 3. Replace the stapler rotation motor. • Motor overload G060 4-26...
  • Page 1024 4. Replace the tray 2 lift motor. • Motor overload • The lower stack height sensor 1 is deactivated consecutively (not detecting paper) for 15 seconds after the shift tray starts moving down. 4-27 G060...
  • Page 1025 2. Check and/or replace the RAM DIMM. [766D] Memory error Unexpected system memory 3. Check and/or replace the ROM • Defective controller size DIMM. • Software error 4. Replace the controller. 5. See NOTE at the end of the SC table. G060 4-28...
  • Page 1026 [0D05] problem with the CPU timer. If the ASIC firmware. • Defective RAM-DIMM timer does not function in the 3. Replace the RAM-DIMM. • Defective controller specified range, this SC code 4. Replace the controller board. is displayed. 4-29 G060...
  • Page 1027 Verification Error detected during a 1. Turn the main switch off and on. error write/verify check for the 2. Replace the SRAM DIMM. • Defective SRAM standard RAM (SRAM DIMM). 3. Replace the controller. DIMM • Defective controller G060 4-30...
  • Page 1028 1. Turn the main switch off and on. error: I/F error BCU is not properly • Defective controller 2. Check the connection between the [0F21] connected. BCU and controller. • Defective BCU 3. Replace the controller. 4. Replace the BCU 4-31 G060...
  • Page 1029 • Defective cables 2. Check the connection between the the power is supplied to the HDD and controller. • Defective HDD HDD. 3. Check and replace the cables. • Defective controller 4. Replace the HDD. 5. Replace the controller. G060 4-32...
  • Page 1030 RAM-DIMM, ROM- turned on. DIMM are properly connected. DIMM • Defective controller 3. Reinstall the controller system firmware. • Software problem 4. Replace the controller. SC 999 Firmware error See G570 SM page 4-43 for description of SC 999 4-33 G060...
  • Page 1031 • Logging (SP5-990-004) • Printer driver settings used when the problem occurs • All data displayed on the screen (SC code, error code, and program address where the problem is logged.) • Image file which causes the problem, if possible G060 4-34...
  • Page 1032 When paper touches the If 4C thin lines become smeared: appear in solid image areas. spurs and the spurs do not rotate, the spurs scratch the mage. G060T501.WMF If white lines appear in solid image areas: G060T502.WMF 4-35 G060...
  • Page 1033 Making prints with a low image area ratio causes the toner-carrier attraction to increase, resulting in low image density. Activating the Auto TD Adjustment corrects toner density within the target range; however, it takes up to 6 minutes to complete the self-check and Auto TD Adjustment. G060 4-36...
  • Page 1034 ID proper development potential gap during machine operation. without adjusting the toner concentration. Over the course of the print operation, the ID will then get closer and closer to the target level. 4-37 G060...
  • Page 1035 (i.e. not processed as text/line data), decrease the setting for Photo from 260% to 170 - 190%. NOTE: If the toner limit is lowered too much, it may cause the density of shadow areas to be not smooth. G060 4-38...
  • Page 1036 G060T503.WMF • Paper skew directly affects the color shift between the front and rear sides. There are several factors. One of them is the position of the side fences. 4-39 G060...
  • Page 1037 Color shifts between the front and rear sides • Side fences are not properly set. Reposition the paper attraction roller unit. • Pressure between the paper attraction roller and transfer belt is not even at the front and rear sides. G060 4-40...
  • Page 1038 5. Take the required action explained in each section depending on the type of color shift. 6. Do the ‘Auto Adjust’ in the User Program mode after the adjustment is done in step 5, and check the result. 7. Repeat steps 3 to 6 until the color shift is acceptable. 4-41 G060...
  • Page 1039 Then, repeat this step until the shift between magenta (by-pass feed) and black is minimized. NOTE: Fusing roller speed can be adjusted with ‘’Custom Adjust’ in Fuser Adjust in the User Program Mode, instead of with SP mode. G060 4-42...
  • Page 1040 Correction [dots] = +(40/42.4) = Approx. +1 • If the magenta line has shifted down in relation to black by 70µm in 600dpi mode, subtract 2 from the current setting of SP5-993-17. Correction [dots] = -(70/42.4) = Approx. –2 4-43 G060...
  • Page 1041 Correction [%] = (0.1/287) x 10000 = Approx. +4 • If the magenta line is reduced by 0.05 mm in relation to the black line, subtract “2” from the current setting of SP5-993-014. Correction [%] = -(0.05/287) x 10000 = Approx. -2 G060 4-44...
  • Page 1042 • Check if the transfer belt is in correct position, if the toward the trailing tension springs are properly set, or if the paper edge. attraction roller is properly installed.. 3.7.4 Transfer Belt) 4-45 G060...
  • Page 1043 (percentage) of SP1- 004-001, 002, or 007 depending on the mode selected. • SP1-004-001 Normal paper, Color mode, 1200 dpi (62.5 mm/s) G060T505.WMF • SP1-004-002 Normal Paper, Color mode, 600 dpi (125 mm/s) • SP1-004-007 Thick Paper (62.5 mm/s) G060 4-46...

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G570G082

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