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Ricoh Bizworks 106 Service Manual

G025/g027
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G025/G027
SERVICE MANUAL

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Summary of Contents for Ricoh Bizworks 106

  • Page 1 G025/G027 SERVICE MANUAL...
  • Page 2 ø IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine power cord is unplugged. 2. The wall outlet should be near the machine and easily accessible. 3.
  • Page 3 LASER SAFETY The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer.
  • Page 4 Trademarks Microsoft, Windows, and MS-DOS are registered trademarks of Microsoft Corporation. General Notice: Other product names used herein are for identification purpose only and may be trademarks of their respective companies. We disclaim any and all rights in those marks.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. OVERALL MACHINE INFORMATION ........1-1 1.1 SPECIFICATIONS ..................1-1 1.2 FEATURES....................1-4 1.3 COMPONENT LAYOUT ................1-7 1.3.1 MECHANICAL COMPONENTS............1-7 1.3.2 ELECTRICAL COMPONENTS ............1-9 1.4 OVERALL MACHINE CONTROL ............1-11 1.5 VIDEO DATA PATH ................1-12 1.5.1 COPYING ..................
  • Page 6 2.2.7 PAPER FEED AND REGISTRATION..........2-16 Overview .................... 2-16 Paper feed Mechanism ..............2-17 Registration ..................2-20 Paper Width and Paper End Detection ..........2-21 Jam Detection ..................2-22 2.2.8 FUSING ..................2-23 Overview .................... 2-23 Power Save Control ................2-24 2.2.9 COVER SWITCH ................
  • Page 7 4.2.7 RAM DISPLAY/REWRITE [FUNCTION 82] ........4-7 Hexadecimal Mode ................4-7 Binary Mode ..................4-8 4.2.8 RAM DUMP [FUNCTION 83] ............4-9 4.2.9 RAM TEST [FUNCTION 91] ............4-10 4.2.10 KEY TEST [FUNCTION 92] ............4-11 4.2.11 LED TEST [FUNCTION 93] ............4-12 4.2.12 LCD TEST [FUNCTION 94] ............
  • Page 8 6.5.4 CONTROL BOARD AND SCANER CONTOROL BOARD REMOVAL ..................6-45 6.5.5 MECHANICAL CONTROL BOARD REMOVAL......6-48 6.5.6 POWER SUPPLY UNIT REMOVAL ..........6-49 6.5.7 NETWORK CONTROL BOARD REMOVAL ........6-50 6.6 ADJUSTMENT..................6-51 6.6.1 REGISTRATION ADJUSTMENT ........... 6-51 6.6.2 READ START TIMING (FLATBED) AND CCD UNIT STOP POSITION (ADF) ADJUSTMENT (G027 ONLY) ....
  • Page 9 7.2.5 SCANNER HOME POSITION ERROR (ERROR CODE 90) (G027 ONLY) .................. 7-21 7.2.6 PAPER NON-FEED (PRINTER) ............ 7-21 7.2.7 PAPER JAM (REGISTRATION AREA).......... 7-22 7.2.8 PAPER JAM (FUSING EXIT AREA) ..........7-23 7.2.9 PAPER SKEW (PRINTER) ............7-24 7.2.10 PAPER MULTI-FEED (PRINTER) ..........7-24 7.3 ERROR CODES ..................

  • Page 10: Overall Machine Information

    18 May, 1999 SPECIFICATIONS 1. OVERALL MACHINE INFORMATION 1.1 SPECIFICATIONS Type Multi-functional Product G025: ADF Scanner, Fax, Copier, PC Printer G027: ADF/Flatbed Scanner, Fax, Copier, PC Printer Circuit PSTN, PABX Connection Direct Couple (G025/G027) Document Size Flatbed Scanner Width: Within 216 mm [8.5"] Length: Within 355.6 mm [14"] Width: 91 mm - 216 mm [3.6"...
  • Page 11 SPECIFICATIONS 18 May, 1999 Modulation V17 (TCM), V29 (QAM), V27ter (PHM), V21 (FM) Data Rate 14400/12000/9600/7200/4800/2400 Automatic fall-back I/O Rate With ECM: 0 ms/line Without ECM: 5, 10, 20 or 40 ms/line Transmission Time ADF mode: 8 seconds Flatbed mode: 12 seconds Condition: 14400 bps;...
  • Page 12 18 May, 1999 SPECIFICATIONS Stand-by: 220 V: 51 W 240 V: 52 W Printing: 220 V: 222 W 240 V: 221 W Copying: 220 V: 223 W 240 V: 220 W Fax transmitting: 220 V: 67 W 240 V: 67 W Fax receiving: 220 V: 188 W 240 V: 197 W...

  • Page 13: Features

    FEATURES 18 May, 1999 1.2 FEATURES Equipment Features G025 G027 Flatbed Scanner Paper Feed Unit Option Option Software Counter Parallel Interface Second Printer Interface Video Processing Features Features G025 G027 Auto Image Density Control Halftone (Dithering & Error diffusion) Resolution Smoothing Copier Features Features...
  • Page 14 18 May, 1999 FEATURES Communication Features - User Selectable Features G025 G027 Authorized Reception Auto Dialing (pulse or DTMF) Auto Image Density Selection Direct Fax Number Entry Immediate Redialing Immediate Transmission Name Dial (25 stations) On Hook Dial Quick Dial (5 stations) Reception Modes (Fax, Tel) Remote Control Features (Tel→...
  • Page 15 FEATURES 18 May, 1999 Report - User-initiated Features G025 G027 Help List Journal Dial List Service Mode Features Features G025 G027 Bit switch programming Speaker test Cable Equalizer Country code DTMF tone test Modem test Operation panel test RAM display/rewrite RAM dump RAM test Software updating...

  • Page 16: Component Layout

    18 May, 1999 COMPONENT LAYOUT 1.3 COMPONENT LAYOUT 1.3.1 MECHANICAL COMPONENTS G025 G027V101.WMF Name Description Pick-up Roller Picks up pages of the document from the document table one at a time. Separation Tab Prevents more than one sheet from feeding into the scanner.
  • Page 17 COMPONENT LAYOUT 18 May, 1999 G027 model G027V512.WMF Name Description Exposure Glass The original is placed here for scanning. Pick-up Roller Picks up pages of the document from the document table one at a time. Separation Tab Prevents more than one sheet from feeding into the scanner.

  • Page 18: Electrical Components

    18 May, 1999 COMPONENT LAYOUT 1.3.2 ELECTRICAL COMPONENTS G027 model G025 model G027V518.WMF G027V513.WMF G027 G025 Name Description Toner End Sensor This detects when the toner has run out. Paper Width Sensor This detects whether the paper in the upper paper tray is wider than 203 millimeters or not.
  • Page 19 COMPONENT LAYOUT 18 May, 1999 G027 model (G025 model parts are in the same location as G027) G027V519.WMF Name Description Fan Motor Blows hot air out of the machine. Control Board Controls the machine. Scanner Control Board Controls the scanner components. (SCB) Network Control Board Contains relays and switches to interface the...

  • Page 20: Overall Machine Control

    18 May, 1999 OVERALL MACHINE CONTROL OVERALL MACHINE CONTROL O p e r a t i o n P a n e l C C D U n i t S C B L C 8 2 1 0 3 G S P C Driver A D F M o t o r...

  • Page 21: Video Data Path

    VIDEO DATA PATH 18 May, 1999 1.5 VIDEO DATA PATH 1.5.1 COPYING G027V510.WMF The CCD generates an analog video signal from the light reflected from the original. The scanned data passes to the scanner control board (SCB). The SCB converts scanned video data from the analog signal to a digital signal.

  • Page 22: Pc Printing

    18 May, 1999 VIDEO DATA PATH 1.5.2 PC PRINTING G027V511.WMF Data from the PC passes to the control board through the IEEE1284 driver. If the analog switch is changed over the second printer by pressing the second printer key on the operation panel, the video data passes to the second printer. The control board does digital video data processing such as halftone (dither/error diffusion), reduction/enlargement, and smoothing.

  • Page 23: Pc Scanning

    VIDEO DATA PATH 18 May, 1999 1.5.3 PC SCANNING Original CCD Unit LED Array C C D S C B Amplifier G S P C LC82103 Data IEEE1284 Xipchip P L D Driver Page Memory (DRAM) Control Board G027V515.WMF The CCD generates an analog video signal from the light reflected from the original.

  • Page 24: Transmission

    18 May, 1999 VIDEO DATA PATH 1.5.4 TRANSMISSION Original CCD Unit LED Array C C D S C B Amplifier G S P C L C 8 2 1 0 3 Control Board Xipchip P L D To the network P a g e M e m o r y N C U Data...

  • Page 25: Reception

    VIDEO DATA PATH 18 May, 1999 1.5.5 RECEPTION Control Board G E P C From the M C B network Xipchip P L D Laser Diode Driver N C U Page Memory Amplifier M O D E M (DRAM) O P C D r u m RECEPTION.WMF Data from the line passes to the modem through the network control board (NCU) and amplifier.

  • Page 26: Power Distribution

    18 May, 1999 POWER DISTRIBUTION 1.6 POWER DISTRIBUTION P S U M C B AC Main Interlock Switch Toner Cassette Power Fuse Main Switch Fuse Fuse +24V Fuse Power Pack DC Power (High Voltage Supply Block Supply Block) + 2 4 V D Relay Bias Transfer...

  • Page 27: Detailed Section Descriptions

    18 May, 1999 SCANNING 2. DETAILED SECTION DESCRIPTIONS 2.1 SCANNING 2.1.1 OVERVIEW (G027 ONLY) G027D501.WMF The CCD unit [A] consists of a LED array [B], three mirrors, a lens [C], and a CCD [D]. During a copy cycle, the light from the LED array is reflected off the original, and then is transferred onto the CCD via the mirrors and the lens.

  • Page 28: Ccd Unit Drive (G027 Only)

    SCANNING 18 May, 1999 2.1.2 CCD UNIT DRIVE (G027 ONLY) G027D502.WMF A stepper motor [A] drives the CCD unit [B]. The motor uses the timing belt [C] and the drive belt [D] to move the CCD along the guide rail [E]. The home position sensor [F] detects when the CCD unit is in the home position.

  • Page 29: Book Scanning

    18 May, 1999 SCANNING Book Scanning After shading, the CCD unit stops temporarily at the reading stand-by position [J] while the scan parameters (X/Y coordinates) are initialized. Then, it scans across the original. Scanning speed depends on the reproduction ratio. Full size (100%) scanning speed is 37.6 mm/s.

  • Page 30: Auto Document Feeder (Adf)

    SCANNING 18 May, 1999 2.1.3 AUTO DOCUMENT FEEDER (ADF) Overview G027D504.WMF The ADF feeds from the bottom page of the document stack on the ADF table. During scanning, the page moves past the CCD unit, which is locked in position. The document sensor [A] detects documents set on the table.

  • Page 31: Platen Cover Switch (G027 Only)

    18 May, 1999 SCANNING Platen Cover switch (G027 only) G027D505.WMF The platen cover switch [A] detects if the platen cover is opened or closed. If a document is set on the ADF without first opening the platen cover after copying in the book scanner mode, “Original left”...

  • Page 32: Printing

    PRINTING 18 May, 1999 2.2 PRINTING 2.2.1 PRINTING PROCESSES AROUND THE DRUM G027D534.WMF This machine uses a “write to black” system, using negative toner. Charge: The charge brush roller [A] gives the OPC drum [B] surface a negative charge of -750 volts. Exposure: A laser [C] writes a latent image on the drum.

  • Page 33: Charge

    18 May, 1999 PRINTING 2.2.2 CHARGE G027D535.WMF The OPC (Organic Photoconductor) drum [A] used in this machine is small in diameter (24 mm). This allows a very compact design. A charge brush roller [B] charges the photoconductor. The charge brush has the advantage of not generating ozone.

  • Page 34: Laser Exposure

    PRINTING 18 May, 1999 2.2.3 LASER EXPOSURE Overview G027D500.BMP Laser Unit Layout A : Laser Diode Unit F : Laser Synchronization Detector B : Polygon Mirror Motor G : Cylindrical Lens C : F-theta Lens H : Synchronization Detector Lens D : First Mirror J : Shutter E : Second Mirror...

  • Page 35: Block Diagram

    18 May, 1999 PRINTING Block Diagram Mechanical Laser Diode Unit Control Board + 5 V Regulator Laser Diode V I D E O Driver L D E N A A P C S H P G S Y C I + 2 4 V D Polygon Mirror P M E N A...

  • Page 36: Development

    PRINTING 18 May, 1999 2.2.4 DEVELOPMENT Overview G027D535.WMF This machine uses monocomponent toner, which is composed of resin and ferrite. The toner mixing bar [A] stirs and carries toner to the toner application roller [B]. The toner application roller supplies toner to the development roller [C]. As the development roller turns past the toner metering blade [D], only a thin coating of negatively charged toner particles stays adhered.
  • Page 37 18 May, 1999 PRINTING G027D510.WMF The voltage to the development roller and the toner application roller is supplied through the terminals [A and B] from the mechanical control board. 2-11...

  • Page 38: Toner End Detection

    PRINTING 18 May, 1999 TONER END DETECTION G027D511.WMF Toner near-end is detected by the toner end sensor [A], which is below the toner tank of the toner cassette. G027D532.WMF While the main motor is rotating, the machine monitors the voltage (TONEND) output from the toner end sensor.
  • Page 39 18 May, 1999 PRINTING Toner end condition If the machine makes more than 100 copies during the toner near-end condition or the mechanical control board detects a low output for more than 9.2 seconds, it disables copying and “Add toner” is displayed on the LCD. This is the toner end condition.

  • Page 40: Transfer And Separation

    PRINTING 18 May, 1999 2.2.5 TRANSFER AND SEPARATION Overview G027D512.WMF This machine uses a transfer roller [A], which touches the OPC drum [B] surface. A constant current of +4.3 µA (6.0 µA for envelopes) is applied to the transfer roller from the mechanical control board [C].

  • Page 41: Drum Cleaning

    18 May, 1999 PRINTING 2.2.6 DRUM CLEANING G027D513.WMF The cleaning blade and the used toner tank are contained in the toner cassette. A counter blade system is used for drum cleaning. The cleaning blade [A] removes any toner remaining on the drum after the image is transferred to the paper. This removed toner is stored in the used toner tank [B].

  • Page 42: Paper Feed And Registration

    PRINTING 18 May, 1999 2.2.7 PAPER FEED AND REGISTRATION Overview G027D514.WMF The upper paper tray [A] holds 100 sheets. The left side fence on the paper tray is adjustable to fit to the paper size. The paper feed roller [B] is located on the right side of the machine so that it can feed a narrow sheet of paper.

  • Page 43: Paper Feed Mechanism

    18 May, 1999 PRINTING Paper Feed Mechanism Idling condition G027D515.WMF The paper feed roller [A] always rotates while the main motor rotates, since drive from the motor is transmitted to the feed roller gear [B] (which is fixed to the roller shaft through the paper feed drive gear [C]).
  • Page 44 PRINTING 18 May, 1999 Pick-up cam drive mechanism G027D516.WMF When the machine sends the trigger signal to feed paper, the paper pick-up solenoid [A] is energized for 0.3 seconds to release the cam stopper [B]. The pressure of the cam spring [C] then causes the pick-up cam [D] to rotate counterclockwise as shown in the illustration.
  • Page 45 18 May, 1999 PRINTING Upper tray bottom plate operation G027D518.WMF The position of the upper tray bottom plate [A] is determined by the pick-up cam [B]. When at the idle position, the cam holds the bottom plate away from the feed roller.

  • Page 46: Registration

    PRINTING 18 May, 1999 Registration G027D519.WMF The registration sensor [A] is installed in the exit of the paper feed section. This sensor detects the leading edge of the paper and synchronizes paper feed with the writing of the image on the drum, so that the image and paper match up properly. This sensor also detects paper feed jams.

  • Page 47: Paper Width And Paper End Detection

    18 May, 1999 PRINTING PAPER WIDTH AND PAPER END DETECTION G027R110.WMF The laser unit [A] has two sensors built into it. One, the paper width sensor [B], measures the width of the paper in the upper tray. The other, the paper end sensor [C] detects the presence or absence of paper.

  • Page 48: Jam Detection

    PRINTING 18 May, 1999 Jam Detection Paper jam at the upper paper tray When the registration sensor does not turn on within 5.5 seconds after the paper pick-up solenoid for the upper tray turns on (Error 50). Paper jam at the optional lower paper tray When the registration sensor does not turn on within 7.0 seconds after the paper feed solenoid for the lower paper tray turns on (Error 54).

  • Page 49: Fusing

    18 May, 1999 PRINTING 2.2.8 FUSING Overview G027D522.WMF After the image is transferred, the copy paper enters the fusing unit. The image is fused to the copy paper by applying heat and pressure through the use of a hot roller [A] and pressure roller [B]. The CPU monitors the hot roller temperature through a thermistor [C] that is in contact with the hot roller surface.

  • Page 50: Power Save Control

    PRINTING 18 May, 1999 Power Save Control When the main switch is turned on, the machine turns on the fusing lamp. For printing, the machine raises the fusing temperature to 180°C. The fusing temperature is kept at 180°C during printing. [t1] [t2] 1 8 0 °...
  • Page 51 18 May, 1999 PRINTING Power Saver Mode After t1 + t2 time passed following printing, copying, scanning, or key input, the fusing lamp goes off (power saver mode turns on). The default mode has power saver mode on. However, selecting SW user 02 as follows can turn it off.

  • Page 52: Cover Switch

    PRINTING 18 May, 1999 2.2.9 COVER SWITCH G027D523.WMF When the upper unit is opened, the interlock switch [A] will be opened and power supply to the following parts will be cut. • Power pack • Laser diode driver • Fan motor •...

  • Page 53: Paper Feed Drive Release And Fusing Drive Release

    18 May, 1999 PRINTING 2.2.10 PAPER FEED DRIVE RELEASE AND FUSING DRIVE RELEASE G027D524.WMF The main motor drives the paper feed unit, the transfer roller, the toner cassette, and fusing unit through a series of gears as follows. Main motor [A] Idle gear 1 [B] Idle gear 2 [C] Idle gear 3 [H]...
  • Page 54 PRINTING 18 May, 1999 When the paper release lever [L] on the right side of the machine is lifted, the paper feed drive gear [D] and idle gear [J] disengage so that jammed paper can be removed. G027D525.WMF 2-28...

  • Page 55: Paper Exit Change Mechanism (G025 Only)

    18 May, 1999 PRINTING 2.2.11 PAPER EXIT CHANGE MECHANISM (G025 ONLY) G027D544.TIF G027D546.TIF G027D545.TIF When the document tray is positioned horizontally, the machine feeds out a sheet of paper to the paper exit [A]. When the document tray rises up, the actuator [B] is pushed by the projection [C] on the reverse side of the document tray.

  • Page 56: Pcbs

    PCBS 18 May, 1999 2.3 PCBS 2.3.1 CONTROL BOARD S e c o n d S C B Printer IEEE1284 IEEE1284 Analog Driver Switch Xipchip P L D M C B E E P R O M R T C (8KB) Speaker M D M...

  • Page 57: Components

    18 May, 1999 PCBS Components 1. Xipchip This is a multi-function peripheral controller. It functions as a CPU and an image processor. 2. Memory • Flash ROM (4 MB/1 MB): For the firmware • EEPROM (8 KB): For individual data such as country code, factory adjustments and so on.

  • Page 58: Mcb (Mechanical Control Board)

    PCBS 18 May, 1999 2.3.2 MCB (MECHANICAL CONTROL BOARD) G027D542.WMF Overall The mechanical control board (MCB) controls devices related to the printer and optional paper feed unit. The MCB contains a CPU (H8), peripheral control gate array (GEPC), video I/F chips, motor drivers, power pack, and on-board sensors.

  • Page 59: Scb (Scanner Control Board)

    18 May, 1999 PCBS 2.3.3 SCB (SCANNER CONTROL BOARD) G027D543.WMF Overall The scanner control board (SCB) controls devices related to the scanner unit and operation panel. The SCB contains a CPU (H8), peripheral control gate array (GSPC), image processing LSI (LC82103), motor drivers, and an IEEE1284 connector for the second printer.

  • Page 60: Ncu (Usa)

    PCBS 18 May, 1999 2.3.4 NCU (USA) B R 1 O H D I S W T R X D Current RING Sensor O H D I S W Hook0 N C U Hook1 Ex Ring Ring Detection RITONE Relay Ext.

  • Page 61: Ncu (Europe/Asia)

    18 May, 1999 PCBS 2.3.5 NCU (EUROPE/ASIA) R I T O N E S H U N T C M L R e l a y Filter (16Hz) DO Sw. R I N G T R X D Current Sensor Loop Closure Circuit OHDI Sw.

  • Page 62: Installation

    18 May, 1999 INSTALLING THE MACHINE 3. INSTALLATION 3.1 INSTALLING THE MACHINE Refer to Operator’s Manual for information on the installation environment and how to install and set up the machine. G027 model only G027R010.WMF The CCD unit lock [A] prevents the CCD unit from moving during transportation. Slide the lock to the "UNLOCK"...

  • Page 63: Minimum Space Requirements

    MINIMUM SPACE REQUIREMENTS 18 May, 1999 3.2 MINIMUM SPACE REQUIREMENTS Place the machine near the power source, providing clearance as shown: G027I502.WMF...

  • Page 64: Service Tables And Procedures

    18 May, 1999 SERVICE LEVEL FUNCTIONS 4. SERVICE TABLES AND PROCEDURES 4.1 SERVICE LEVEL FUNCTIONS 4.1.1 SERVICE LEVEL FUNCTION LIST Service Function Functions Description User Parameters Set the following parameters: User, service, and country switches Modem Test Send the following signals from the modem to the NCU: 14400/12000/9600TCM/7200TCM/9600/7200/ 4800/2400/300 bps, 2100/1100 Hz...

  • Page 65: Service Function Operation

    SERVICE FUNCTION OPERATION 18 May, 1999 4.2 SERVICE FUNCTION OPERATION 4.2.1 USER PARAMETER (BIT SWITCH) PROGRAMMING 1. Enter service function mode. F u n c t i o n n o . : 2. Press [5] [2]. ú 5 2 U s e r P a r a m .

  • Page 66: Modem Test [Function 71]

    18 May, 1999 SERVICE FUNCTION OPERATION 4.2.2 MODEM TEST [FUNCTION 71] F u n c t i o n n o . : 1. Enter service mode. 2. Press [7] [1]. 7 1 M o d e m T e s t 3.

  • Page 67: Output Level [Function 73]

    SERVICE FUNCTION OPERATION 18 May, 1999 4.2.4 OUTPUT LEVEL [FUNCTION 73] 1. Enter service mode. F u n c t i o n n o . : 2. Press [7] [3]. 7 3 O u t p u t L e v e l 3.

  • Page 68: System Parameter List [Function 81]

    18 May, 1999 SERVICE FUNCTION OPERATION 5. Press [1] or [Zoom−] to select RAM clear 1 mode. A r e Y o u S u r e ? Press [2] or [Zoom+] to select RAM clear 2 mode. P l e a s e w a i t 6.

  • Page 69: System Parameter List Details

    SERVICE FUNCTION OPERATION 18 May, 1999 System parameter list details *** System Parameter List (28.Apr.1999 13:30) *** INTERNATIONAL MARKETING DIV. +81 45 123 4567 ROM Version V3.00 24.Apr.99 16:12/Flash 0.0 040299 (093b) Output Level -7db SwFunc00-05 (Upper:Default, Lower:Current) 00 00000010 01 10000010 02 00000000 03 00000000...

  • Page 70: Ram Display/Rewrite [Function 82]

    18 May, 1999 SERVICE FUNCTION OPERATION 4.2.7 RAM DISPLAY/REWRITE [FUNCTION 82] 1. Enter service mode. F u n c t i o n n o . : 2. Press [8] [2]. 8 2 C h a n g e Me m o r y 3.

  • Page 71: Binary Mode

    SERVICE FUNCTION OPERATION 18 May, 1999 7. Press [Start] to move the cursor to the data field. A D : 0 0 0 0 0 0 3 0 8. Press [#] or [∗] or [0] – [Fax/Copy] to change the data.

  • Page 72: Ram Dump [Function 83]

    18 May, 1999 SERVICE FUNCTION OPERATION NOTE: If necessary, press [Start] to display the A D : 0 0 0 0 0 0 0 address field again. 17. Press [OK] to store the new data. H e x B i n 18.

  • Page 73: Ram Test [Function 91]

    SERVICE FUNCTION OPERATION 18 May, 1999 8. Change the value of the digit by using [0] to [Fax/Copy]. Example: To change the value to 2, press [2]. E n d : 0 0 0 0 0 9. Press [OK]. P r i n t i g . . . Printing starts.

  • Page 74: Key Test [Function 92]

    18 May, 1999 SERVICE FUNCTION OPERATION 5. After testing is finished, the test result is displayed. Example: If there is no error, “RAM Test OK” is R A M T e s t displayed for two seconds then, “9 General Tests”...

  • Page 75: Led Test [Function 93]

    SERVICE FUNCTION OPERATION 18 May, 1999 Displayed Actual Key Names Displayed Actual Key Names Names Names Sec.Prt Second Printer On Hook On Hook Dial Clear Clear Key:1 Key:2 Key:3 Key:4 Key:5 Txt/Pho Text/Photo Key:6 Tel/Fax Tel/Fax Key:7 F/C Sel Fax/Copy Key:8 Density Density...

  • Page 76: Lcd Test [Function 94]

    18 May, 1999 SERVICE FUNCTION OPERATION 4.2.12 LCD TEST [FUNCTION 94] 1. Enter service mode. F u n c t i o n n o . : 2. Press [9] [4]. L C D T e s t 3. Press [OK]. NOTE: All the LCD pixels turn black.

  • Page 77: Bit Switches

    BIT SWITCHES 18 May, 1999 4.3 BIT SWITCHES ø CAUTION Do not adjust bit switches labeled “Not used”, as this may cause the machine to malfunction. Such bits are only for use in other regions, such as Japan. ø CAUTION Do not turn off the power while the LCD displays “Please wait”...
  • Page 78 18 May, 1999 BIT SWITCHES SwFunc 01 (Function Switch 01) FUNCTION NOTE Authorized reception 0: Disabled 1: Enabled TTI printing 0: Off 1: On SwFunc 02 (Function Switch 02) FUNCTION NOTE PSTN access number for loop start The bits show the PSTN access number for loop start that is programmed in Function 12 (Dial mode).
  • Page 79 BIT SWITCHES 18 May, 1999 SwFunc 04 (Function Switch 04) FUNCTION NOTE Language selection The default language depends on the Country Code. Bit 3 2 1 0 Language 0 0 0 0 English Even if the language is changed, the country 0 0 0 1 French code does not automatically change.

  • Page 80: User Switch Parameters (Swuser)

    18 May, 1999 BIT SWITCHES 4.3.2 USER SWITCH PARAMETERS (SWUSER) 00: SwUser 00 (User Switch 00) FUNCTION NOTE Automatically reduce received images to Default: On (except Germany) fit on the page If this bit is changed to 0, some parts of the 0: Off 1: On image may be lost.
  • Page 81 BIT SWITCHES 18 May, 1999 02: SwUser 02 (User Switch 02) FUNCTION NOTE Not used Do not change these settings Toner saving mode Default: Off 0: Off 1: On Printer resolution Default: 600 dpi 0: 600 dpi 1: 300 dpi Power saver mode Default: On Bit 5 Bit 4 Setting...

  • Page 82: Country Code

    18 May, 1999 BIT SWITCHES 4.3.3 COUNTRY CODE The number stored with this procedure is higher by one from the number stored with SwCntry 03. Example: France – CC = 01, SwCntry 03 = 00 Also, CC is displayed as a decimal number. However, the bit switch setting is displayed as a binary number, and hex coding is used.

  • Page 83: Service Switch Parameters (Swserv)

    BIT SWITCHES 18 May, 1999 4.3.4 SERVICE SWITCH PARAMETERS (SWSERV) NOTE: The Service Switches and the Country Switches appear under the user parameter menu, when using the service mode. The default settings are shown on the system parameter list. Please refer to section 4.2.6 for more detailed information.
  • Page 84 18 May, 1999 BIT SWITCHES S02: SwServ 02 (Service Switch 02) FUNCTION NOTE PABX cable equalizer (RX mode) Use a higher setting if there is signal loss at higher frequencies because of the length of Bit 1 Bit 0 Setting wire between the modem and the telephone None exchange.
  • Page 85 BIT SWITCHES 18 May, 1999 S03: SwServ 03 (Service Switch 03) FUNCTION NOTE Acceptable total error lines or ratio If the error line ratio of a page exceeds the acceptable ratio, RTN will be sent to the other 0: 57 lines or 5% end.
  • Page 86 18 May, 1999 BIT SWITCHES S0A: SwServ 0A (Service Switch 0A) FUNCTION NOTE Reading start timing for scanning a 51(H) to AF(H) document in flatbed mode—count starts Unit = 1 step (0.042 mm) [1.7 mils] when the CCD unit leaves the home "...

  • Page 87: Country Switch Parameters (Swcntry)

    BIT SWITCHES 18 May, 1999 4.3.5 COUNTRY SWITCH PARAMETERS (SWCNTRY) C00: SwCntry 00 (Country Switch 00) FUNCTION NOTE Not used Do not change these settings 5–6 Maximum allowable carrier drop during These bits set the acceptable modem carrier image data reception drop time.
  • Page 88 18 May, 1999 BIT SWITCHES C02: SwCntry 02 (Country Switch 02) FUNCTION NOTE PSTN access method programming 0: PSTN access method can be programmed (Function 12) in Function 12 (Dialing Mode). 0: Disabled 1: Enabled Default: Enabled (except U.S.A.) 1–2 Date display type Europe: 15 APR 1999 11:55 Bit 2 Bit 1 Setting...
  • Page 89 BIT SWITCHES 18 May, 1999 C03: SwCntry 03 (Country Switch 03) FUNCTION NOTE Country code This parameter is an alternate method to parameter CC for entering the country code. 5 4 3 2 1 0 Country Both methods change the same memory 0 0 0 0 0 0 00(H) France location.
  • Page 90 18 May, 1999 BIT SWITCHES C04: SwCntry 04 (Country Switch 04) FUNCTION NOTE Paper size group selection for the The following paper sizes can be selected upper tray Bit 1 Bit 0 Group Europe/Asia: Europe/Asia Paper width >= 203 mm A4 Æ...
  • Page 91 BIT SWITCHES 18 May, 1999 C05: SwCntry 05 (Country Switch 05) FUNCTION NOTE Training count at the same rate Default: 1 time (except France) 0: 1 time 1: 2 times Time between dialing completion and Default: 3 seconds (except Europe) sending the first CNG 0: 3 seconds 1: 0.5 seconds Sending all spaces when the CSI is not...

  • Page 92: Ncu Parameters

    18 May, 1999 NCU PARAMETERS 4.4 NCU PARAMETERS ø CAUTION Do not adjust parameters labeled “Not used”, as this may cause the machine to malfunction. Such bits are only for use in other regions, such as Japan. ø CAUTION Do not turn off the power when the LCD displays “Please wait” or “Registered”.
  • Page 93 NCU PARAMETERS 18 May, 1999 Address Function Unit Remarks 0F4C PABX dial tone required 0: Disabled 1: Enabled 0F4D PABX dial tone 1 frequency 10 Hz Range: 0 to 1200 Hz 0F4E PABX dial tone 1 bandwidth Range: 0 to 400 Hz 0F4F PABX dial tone 2 frequency 10 Hz...
  • Page 94 18 May, 1999 NCU PARAMETERS Address Function Unit Remarks 0F76 PABX busy tone 2 frequency 10 Hz Range: 0 to 1000 Hz 0F77 PABX busy tone 2 bandwidth Range: 0 to 250 Hz 0F78 PABX busy tone threshold 0.5 dB (Signed values) Note 1 Range: -50 to 3 dB 0F79...
  • Page 95 NCU PARAMETERS 18 May, 1999 Address Function Unit Remarks 0FA3 International access number 1 (1 digit) ASCII There can be up to four international access 0FA4 International access number 1 (2 digit) numbers. 0FA5 International access number 1 (3 digit) Example: For codes of 0FA6 International access number 1 (4...
  • Page 96 18 May, 1999 NCU PARAMETERS Address Function Unit Remarks 0FC7 Modem turn-on level (incoming signal 0.5 dB detection level) (Signed values) Note 1 Range: -50 to 3 dB 0FC8 Tx level from the modem 0FC9 1100Hz tone transmission level from the modem 0FCA 2100Hz tone transmission level from the...

  • Page 97: Service Ram Addresses

    SERVICE RAM ADDRESSES 18 May, 1999 4.5 SERVICE RAM ADDRESSES ø CAUTION Do not adjust an item labeled “Not used”, as this may cause the machine to malfunction. Such bits are only for use in other regions, such as Japan. ø...
  • Page 98 18 May, 1999 SERVICE RAM ADDRESSES 1055 to 1058(H) – PC scan counter 1059 to 105C(H) – Total print counter 105D to 371C(H) – Journal log 371D to 3992(H) – Latest 30 error codes (Read only) One error record consists of 21 bytes of data. The format is as follows: 1st to 11th bytes –...

  • Page 99: Preventive Maintenance

    18 May, 1999 MAINTENANCE ITEMS AND METHODS 5. PREVENTIVE MAINTENANCE 5.1 MAINTENANCE ITEMS AND METHODS The G series models do not require preventive maintenance. However, if the machine is serviced, the following items must be done. Action Symbol: L: Lubricate I: Inspect C: Clean A: Adjust Item Action Method...

  • Page 100: Replacement And Adjustment

    18 May, 1999 EXTERIOR 6. REPLACEMENT AND ADJUSTMENT 6.1 EXTERIOR 6.1.1 OPERATION PANEL REMOVAL (G025 ONLY) A: Upper paper tray G027R100.WMF B: Upper cover C: 2 flat cables D: ADF right cover (4 hooks) E: ADF left cover (4 hooks) F: Grounding wire (1 Philips screw) G027R102.WMF...

  • Page 101: Upper Unit Removal (G025 Only)

    EXTERIOR 18 May, 1999 6.1.2 UPPER UNIT REMOVAL (G025 ONLY) A: Document tray G027R103.WMF B: Upper unit (2 tapping screws) C: 6 connectors D: Grounding wire (1 Philips screw) G027R105.WMF...

  • Page 102: Upper Cover Removal (G027 Only)

    18 May, 1999 EXTERIOR 6.1.3 UPPER COVER REMOVAL (G027 ONLY) A: Upper paper tray B: Document exit tray G027R500.TIF C: ADF upper cover G027R501.TIF NOTE: Do not damage the mylar [D].
  • Page 103 EXTERIOR 18 May, 1999 E: ADF right cover (3 hooks) F: ADF left cover (3 hooks) G027R502.TIF G027R503.TIF G: Motor connector H: Platen cover switch connector G027R504.TIF...
  • Page 104 18 May, 1999 EXTERIOR I: 2 sensor connectors G027R505.TIF J: Grounding wire (1 Philips screw) G027R506.TIF...
  • Page 105 EXTERIOR 18 May, 1999 Platen cover unit G027R507.TIF K: Upper cover (2 Philips screws) G027R508.TIF...

  • Page 106: Right Cover Removal

    18 May, 1999 EXTERIOR 6.1.4 RIGHT COVER REMOVAL G025 Preparation 1) Remove the upper unit. (See Upper Unit Removal.) A: Front cover G027R107.WMF B: Right cover (2 tapping screws and 7 hooks) G027R108.WMF NOTE: To remove the right cover, unhook the upper 2 hooks after removing the 2 tapping screws.
  • Page 107 EXTERIOR 18 May, 1999 G027 Preparation 1) Remove the upper cover. (See Upper Cover Removal.) 2) Open the upper unit. A: Right cover (4 tapping screws and 6 hooks) G027R510.TIF CAUTION: Do not close the upper unit when the right cover has been removed. Otherwise, the lower ring of the gas spring may suddenly slip off the anchor post and possibly cause injury and damage to the frame NOTE: The right cover holds the interlock switch actuator, gas spring, and drive...

  • Page 108: Upper Unit Removal (G027 Only)

    18 May, 1999 EXTERIOR 6.1.5 UPPER UNIT REMOVAL (G027 ONLY) Preparation 1) Set the CCD unit lock lever to the lock position as shown in the diagram. 2) Remove the upper cover. (See Upper Cover Removal.) 3) Open the upper unit. G027R500.WMF...
  • Page 109 EXTERIOR 18 May, 1999 A: Cable cover (3 hooks) B: 2 flat cables and 8 connectors C: 2 Grounding wires (2 Philips screws) G027R512.TIF D: 2 gas springs E: 2 snap rings ø WARNING 1. Do not release the gas springs from their anchor posts while the upper unit is closed.

  • Page 110: Optics

    18 May, 1999 OPTICS 6.2 OPTICS 6.2.1 ADF UNIT REMOVAL G025 Preparation: Remove the following parts. (See Operation Panel Removal and Upper Unit Removal.) 1) Upper paper tray 2) Upper cover 3) 2 flat cables 4) ADF right and left covers 5) Grounding wire 6) Document tray 7) Upper unit...
  • Page 111 OPTICS 18 May, 1999 G027 Preparation: Remove the following parts. (See Upper Cover Removal.) 1) ADF upper cover 2) ADF right and left covers 3) ADF motor connector 4) Platen cover switch connector 5) 2 sensor connectors 6) Grounding wire A: ADF unit (4 hooks) G027R513.TIF 6-12...

  • Page 112: Ccd Unit Removal

    18 May, 1999 OPTICS 6.2.2 CCD UNIT REMOVAL G025 Preparation (See Upper Unit Removal) 1) Remove the upper unit. A: Release (pull) the flat cable lock B: Remove the flat cable C: Remove the CCD unit (2 tapping screws) G027R111.WMF 6-13...
  • Page 113 OPTICS 18 May, 1999 G027 Preparation 1) Remove the upper cover. (See Exterior Cover Removal.) A: Slide the CCD unit away from the home position B: Release (pull) the flat cable lock C: Remove the flat cable D: Remove the CCD unit (2 tapping screws) While removing the tapping screws, hold down the CCD unit to prevent it from being twisted, which could cause the CCD base plate [E] to come off the rail.

  • Page 114: Laser Unit Removal

    18 May, 1999 OPTICS 6.2.3 LASER UNIT REMOVAL ø ø ø ø WARNING FOR THE LASER UNIT This machine contains a laser beam generator. Laser beams can cause permanent eye damage. Do not open the laser unit or look along the laser beam path while the main power is on.
  • Page 115 OPTICS 18 May, 1999 Reinstallation Route the cable as shown. G027R110.WMF Do the registration adjustment. NOTE: 1) Make sure the two paper sensor actuators [E] are positioned in the slits of the upper tray bottom plate correctly. 2) Do not damage the mylar. 6-16...
  • Page 116 18 May, 1999 OPTICS G027 Preparation 1) Remove the upper cover. (See Exterior Cover Removal.) 2) Open the upper unit. Cable cover (3 hooks) G027R515.TIF A: 2 flat cables C: Cable clamp G027R516.TIF 6-17...
  • Page 117 OPTICS 18 May, 1999 D: Grounding wire (1 Philips screw) G027R517.TIF Interlock switch actuator (2 Philips screws) G027R518.TIF 6-18...
  • Page 118 18 May, 1999 OPTICS F: Gas spring cover (1 tapping screw) G: Fan motor and fan motor cover (2 tapping screws) H: Fan motor connector G027R001.WMF 6-19...
  • Page 119 OPTICS 18 May, 1999 I: 2 gas springs J: 2 snap rings Open the upper unit to 90 G027R519.TIF degrees and attach the gas spring to the maintenance pin.[K] [L] Cable clamp G027R520.TIF ø WARNING 1. Do not release the gas springs from their anchor posts while the upper unit is closed.
  • Page 120 18 May, 1999 OPTICS M: Laser diode connector N: Polygon mirror motor connector O: 2 paper sensor connectors Laser unit (3 tapping screws) [O] [P] G027R109.WMF Reinstallation Route the cable as shown. G027R110.WMF Do the registration adjustment. NOTE: 1) Make sure the two paper sensor actuators [Q] are positioned in the slits in the upper tray bottom plate correctly.

  • Page 121: Ccd Drive Motor Removal (G027 Only)

    OPTICS 18 May, 1999 6.2.4 CCD DRIVE MOTOR REMOVAL (G027 ONLY) Preparation 1) Remove the upper unit. (See Upper Unit Removal.) 2) Turn the upper unit upside down. A: Scanner under cover (3 Philips screws) B: Release the tension pulley (1 Philips screw). C: Timing belt D: CCD drive motor E: 2 Philips screws...

  • Page 122: Paper Feed

    18 May, 1999 PAPER FEED PAPER FEED 6.3.1 PAPER FEED ROLLER REMOVAL Preparation 1) Remove the toner cassette. 2) Remove the upper unit. (See Upper Unit Removal.) 3) Remove the Laser unit. (See Laser Unit Removal.) 4) Remove the main motor bracket. (See Main Motor Removal.) A: Gear B: Gear G027R524.TIF...
  • Page 123 PAPER FEED 18 May, 1999 F: Paper feed roller guide (1 tapping screw) G027R526.WMF Hook the cam spring [G] in the cut out in the frame as shown below. H: Paper feed roller G027R527.WMF 6-24...
  • Page 124 18 May, 1999 PAPER FEED I: Gear J: Pick up cam K: 2 Guide rollers G027R117.WMF Reinstallation 1) Make sure that the end of the cam spring [L] is hooked in the cut out in the frame as shown below. 2) Make sure the friction pad spring [M] is set properly in the square notch as shown below.
  • Page 125 PAPER FEED 18 May, 1999 3) Make sure the guide rollers are positioned correctly as shown. G027R530.WMF NOTE: Apply grease (KS-660) to the guide roller shaft [T] to ensure ground contact. 4) Install the paper feed roller assembly, so that the 2 pins [N] are set in the holes [O] in the frame, while pressing the friction pad.
  • Page 126 18 May, 1999 PAPER FEED 6) Unhook the end of the cam spring [Q] from the cutout in the frame and make sure it is located on the pick up cam as shown. 7) Install the toner end sensor [R] and the cable as shown. G027R532.WMF 8) Install the gears.

  • Page 127: Paper Pick-Up Solenoid Removal

    PAPER FEED 18 May, 1999 6.3.2 PAPER PICK-UP SOLENOID REMOVAL Preparation 1) Remove the lower unit shell. (See Lower Unit Shell Removal) 2) Turn the lower unit shell upside down. A: Paper pick-up solenoid (1 tapping screw) G027R533.TIF 6-28...

  • Page 128: Fusing

    18 May, 1999 FUSING FUSING 6.4.1 FUSING UNIT REMOVAL Preparation 1) Remove the toner cassette. 2) Remove the upper unit. 3) Remove the right cover. (See Right Cover Removal) A: Interlock switch actuator B: Release lever and gears C: Gear NOTE: The following illustration is for the G025 model.
  • Page 129 FUSING 18 May, 1999 D: 2 fusing lead wires E: Fusing unit F: 4 tapping screws G: Thermistor connector NOTE: The following illustration is for the G025 model. G027 model illustrations are not included in this manual, because the procedures for the G027 model are the same as for the G025.

  • Page 130: Pressure Roller Removal

    18 May, 1999 FUSING 6.4.2 PRESSURE ROLLER REMOVAL Preparation 1) Remove the fusing unit. (See Fusing Unit Removal.) A: Fusing lower unit (2 white-painted tapping screws) CAUTION: Hold the fusing unit’s upper and lower sections securely together while removing the 2 screws. Otherwise the fusing unit might be damaged. G027R123.WMF B: Fusing pressure roller G027R124.WMF...

  • Page 131: Hot Roller And Lamp Removal

    FUSING 18 May, 1999 6.4.3 HOT ROLLER AND LAMP REMOVAL Preparation 1) Remove the fusing unit. (See Fusing Unit Removal.) 2) Remove the fusing lower unit. (See Pressure Roller Removal.) A: Rotate the stripper pawls away from the hot roller and secure them with tape. B: Lamp terminal (1 Philips screw) C: Fusing lamp D: Hot roller...

  • Page 132: Hot Roller Stripper Pawl Removal

    18 May, 1999 FUSING 6.4.4 HOT ROLLER STRIPPER PAWL REMOVAL Preparation 1) Remove the fusing unit. (See Fusing Unit Removal.) 2) Remove the hot roller. (See Hot Roller and Lamp Removal.) A: 4 hot roller stripper pawls B: 4 springs G027R026.WMF Reinstallation Do not deform the springs...

  • Page 133: Fusing Thermofuse Removal

    FUSING 18 May, 1999 6.4.5 FUSING THERMOFUSE REMOVAL Preparation 1) Remove the fusing unit. (See Fusing Unit Removal.) 2) Remove the hot roller. (See Hot Roller and Lamp Removal.) A: Fusing thermofuse (2 Philips screws) G027R027.WMF Reinstallation CAUTION: 1) Do not deform the thermofuse. 2) Do not install the thermofuse upside down.

  • Page 134: Fusing Thermistor Removal

    18 May, 1999 FUSING 6.4.6 FUSING THERMISTOR REMOVAL Preparation 1) Remove the fusing unit. A: Fusing thermistor (1 Philips screw) G027R029.WMF Reinstallation CAUTION: Do not deform the thermistor. 6-35...

  • Page 135: Others

    OTHERS 18 May, 1999 6.5 OTHERS 6.5.1 MAIN MOTOR REMOVAL Preparation 1) Remove the upper unit. (See Upper Unit Removal.) 2) Remove the right cover. (See Right Cover Removal.) A: Interlock switch actuator B: Cable guide (2 tapping screws) C: Main motor connector G027R541.TIF D: Gear G027R551.TIF...
  • Page 136 18 May, 1999 OTHERS E: Main motor bracket F: 4 tapping screws G: 5 Philips screws NOTE: Remove 1 grounding wire (G027 only) G027R131.WMF Do not remove the bracket joining screw [H] G027R132.WMF 6-37...
  • Page 137 OTHERS 18 May, 1999 I: Main motor (2 Philips screws) G027R033.WMF Reinstallation NOTE: 1) Install the main motor so that the cable [J] faces down as shown. 2) Make sure the main motor cable is secured under the cable cover [K]. 3) Make sure no wires are pinched under the main motor bracket.

  • Page 138: Transfer Roller Removal

    18 May, 1999 OTHERS 6.5.2 TRANSFER ROLLER REMOVAL Preparation 1) Remove the toner cassette. A: Transfer roller upper bushings. B: Transfer roller C: Gear G027R556.WMF Do not touch the transfer roller surface with bare hands. Reinstallation Make sure the upper bushings are set correctly as shown. 6-39...

  • Page 139: Lower Unit Shell Removal

    OTHERS 18 May, 1999 6.5.3 LOWER UNIT SHELL REMOVAL Preparation 1) Remove the upper unit. (See Upper Unit Removal.) 2) Remove the Laser unit. (See Laser Unit Removal.) 3) Remove the fusing unit. (See Fusing Unit Removal.) 4) Remove the main motor. (See Main Motor Removal.) 5) Remove the transfer roller.
  • Page 140 18 May, 1999 OTHERS B: Toner cassette stopper springs C: Push the stopper holder and turn it clockwise to remove. G027R570.WMF G027R558.WMF 6-41...
  • Page 141 OTHERS 18 May, 1999 G025 D: 4 Philips screws Lift the lower unit shell [E] slightly and remove the paper feed clutch solenoid connector [F]. G027R039.WMF G027R040.WMF 6-42...
  • Page 142 18 May, 1999 OTHERS G027 D: 5 Philips screws Lift the lower unit shell [E] slightly and remove the paper feed clutch solenoid connector [F]. G027R559.WMF G027R571.WMF 6-43...
  • Page 143 OTHERS 18 May, 1999 G025/G027 Reinstallation NOTE: 1) Make sure no wires are pinched under the frame unit. 2) Do not damage the terminal plates. Confirm the following ground contacts: G: Between paper pick-up solenoid and base frame. H: Between the grounding terminal of the upper tray bottom plate and base frame. I: Between the grounding terminal of the fusing unit and base frame.

  • Page 144: Control Board And Scaner Contorol Board Removal

    18 May, 1999 OTHERS 6.5.4 CONTROL BOARD AND SCANER CONTOROL BOARD REMOVAL ø ø ø ø CAUTION FOR LITHIUM BATTERY (MEMORY BACK-UP) The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the same or an equivalent type recommended by the manufacturer.
  • Page 145 OTHERS 18 May, 1999 F: Shield cover (3 Philips screws) G025 G027R043.WMF G027 G027R004.WMF 6-46...
  • Page 146 18 May, 1999 OTHERS G: Printer connector screws (2 Philips screws and 2 hexagon screws) H: Control board and scanner control board (5 Philips screws) G025 G027R044.WMF G027 G027R003.WMF Reinstallation Execute RAM clear. (Refer to the section 4.) Do the ‘registration’ adjustment. Do the ‘read start timing and CCD unit stop position’...

  • Page 147: Mechanical Control Board Removal

    OTHERS 18 May, 1999 6.5.5 MECHANICAL CONTROL BOARD REMOVAL Preparation 1) Remove the lower unit shell. 2) Remove the control board and scanner control board unit. A: Connectors (CN8, CN12) B: Mechanical control board (5 Philips screws) G027R045.WMF Reinstallation Make sure that the insulation sheet is placed under the mechanical control board. Do the registration adjustment.

  • Page 148: Power Supply Unit Removal

    18 May, 1999 OTHERS 6.5.6 POWER SUPPLY UNIT REMOVAL Preparation 1) Remove the lower unit shell. (See Lower Unit Shell Removal.) A: Power supply unit (4 Philips screws) G027R046.WMF 6-49...

  • Page 149: Network Control Board Removal

    OTHERS 18 May, 1999 6.5.7 NETWORK CONTROL BOARD REMOVAL Preparation 1) Remove the lower unit shell. A: Network control board (2 Philips screws) G027R005.WMF 6-50...

  • Page 150: Adjustment

    18 May, 1999 ADJUSTMENT 6.6 ADJUSTMENT 6.6.1 REGISTRATION ADJUSTMENT Adjustment Standard: 5.1 ± 0.5 millimeters Adjustment Tool: Service Switch 04: Start timing for data writing. (00 (H) to FF (H), 0.1 millimeter/unit) The factory setting of Service Switch 04 is on the “System Parameter List”. Personal computer (with Windows 95 or 98 installed.) WinRICOHE (Test pattern 0210) NOTE: Carefully read the “readme.txt”...
  • Page 151 ADJUSTMENT 18 May, 1999 4. Measure “a” on the test print. 5. Adjust the registration to the standard amount by changing the setting of Service Switch 04. (Refer to Section 4.) G027R576.WMF The changed value will not be registered until the main switch is turned off and on. 6-52...
  • Page 152 18 May, 1999 ADJUSTMENT 6.6.2 READ START TIMING (FLATBED) AND CCD UNIT STOP POSITION (ADF) ADJUSTMENT (G027 ONLY) Adjustment Standard: 2 ± 0.5 millimeters Adjustment Tool: Service Switch 0A: Start timing for scanning documents in flatbed mode count starts when the CCD —...
  • Page 153 ADJUSTMENT 18 May, 1999 G027R577.WMF 6-54...
  • Page 154 18 May, 1999 ADJUSTMENT 6.6.3 READ START POINT OF HORIZONTAL SCANNING ADJUSTMENT (FLATBED AND ADF) (G027 ONLY) Adjustment Standard: 2 ± 0.5 millimeters Adjustment Tool: Service Switch 08: Starting point for horizontal scanning in ADF mode. 00 (H) to FF (H), 1 dot / unit (0.0847 millimeters / unit) Service Switch 0F: Starting point for horizontal scanning in flatbed mode.
  • Page 155 ADJUSTMENT 18 May, 1999 G027R578.WMF 6-56...

  • Page 156: Firmware Updating

    18 May, 1999 ADJUSTMENT 6.6.4 FIRMWARE UPDATING Tool: Personal computer (with Windows 95 or 98 installed.) WinRICOHE Procedure: CAUTION: Do not turn off the power while “Please wait” or “Registered” is displayed. 1. Print out the system parameter list. (Refer to the section 4.) 2.
  • Page 157 ADJUSTMENT 18 May, 1999 Select “Comet Firm Files” [D] from the file types and remove the checkmark next to “Interval” [E]. 7. Open the folder that contains the new firmware file. 8. Select the new firmware file [F]. (In this case comet.brn.) 9.

  • Page 158: Firmware Recovery

    18 May, 1999 ADJUSTMENT 6.6.5 FIRMWARE RECOVERY Tools: Personal computer (with Windows 95 or 98 installed) WinRICOHE Procedure: CAUTION: Do not turn off the power while “Please wait” or “Registered” is displayed. 1. Turn off the main switch and then remove the SIMM from the control board. 2.
  • Page 159 ADJUSTMENT 18 May, 1999 6. Select “Comet Firm Files” [E] from the file types and remove the checkmark next to “Interval” [F]. 7. Open the folder that contains the recovery firmware file. 8. Select the recovery file [G]. 9. Click “Start” [H]. After clicking “Start”, the start key changes to a counter and indicates the number of completed steps as the firmware is recovered.

  • Page 160: Additionnal Module Update

    18 May, 1999 ADJUSTMENT 6.6.6 ADDITIONNAL MODULE UPDATE Tool: Same as ‘Firmware Updating’ Procedure: CAUTION: Do not turn off the power while “Please wait” or “Registered” is displayed. 1. Print out the system parameter list. (Refer to section 4.) 2. Turn off the main switch and then remove the SIMM from the control board. 3.
  • Page 161 ADJUSTMENT 18 May, 1999 Select “Comet Firm Files” [D] from the file types and remove the checkmark next to “Interval” [E]. 7. Open the folder that contains the new firmware file. 8. Select the new additional module file [F]. (In this case optflash.brn.) 9.

  • Page 162: Connector Layout

    18 May, 1999 CONNECTOR LAYOUT CONNECTOR LAYOUT 6.7.1 MECHANICAL CONTROL BOARD CN11 CN12 CN13 14 Pin 4 Pin 6 Pin 13 Pin 2 Pin Power supply unit Toner sensor Main motor Optional cassette Paper pick-up solenoid 24 Pin Control board 3 Pin Fan motor 2 Pin...

  • Page 163: Scanner Control Board

    CONNECTOR LAYOUT 18 May, 1999 6.7.3 SCANNER CONTROL BOARD 12 Pin 13 Pin Operation panel Operation panel CN11: A CN12: B 2 Pin 3 Pin Platen cover switch CCD (video) CN7: W CN4: W 3 Pin 7 Pin Scanner HP sensor CN8: A CN3: A 3 Pin...

  • Page 164: Troubleshooting

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7. TROUBLESHOOTING 7.1 COPY QUALITY TROUBLESHOOTING If there is a copy quality problem that cannot be solved easily, try using the following troubleshooting procedures, while referring to the point to point diagram. The procedures are not exhaustive, but they may help you to find the problem. 1.

  • Page 165: Blank Copies

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.1 BLANK COPIES Possible Cause (Scanner): • When the CCD unit does not move and “Error 90” is displayed (G027 only): -Malfunction in the CCD unit drive mechanism • When the CCD unit moves then stops at the front side and “Error 90” is displayed (G027 only): -Defective CCD unit home position sensor •...
  • Page 166 18 May, 1999 COPY QUALITY TROUBLESHOOTING 3) Push the interlock switch actuator. 4) During power-on initializing, check the bias voltages at each terminal with a digital multi-meter. The specified voltages are as follows: Toner application bias:-650 V Development bias: -400 V → +250 V Charge voltage: -1200 V 5.

  • Page 167: Black Copies

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.2 BLACK COPIES Possible Causes (Scanner) • Defective CCD unit • Defective scanner control board (SCB) Action: 1. Check the connection between the SCB (CN12, CN4) and the scanner junction board (SJB) (CN1,CN3). 2. Check the connection between the SJB (CN2) and the CCD unit. 3.

  • Page 168: Dirty Background

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.3 DIRTY BACKGROUND G027T503.WMF G027T502.WMF Possible Cause (Scanner) • Scanner shading correction error or incorrect threshold level. Action: 1. Clean the shading plate. Possible Causes (Printer) • Defective toner cassette • The charge voltage is not properly supplied. •...

  • Page 169: Uneven Image Density

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.4 UNEVEN IMAGE DENSITY G027T503.WMF G027T504.WMF Possible Causes (Scanner) • Defective CCD unit Action: 1. Check the connections between the scanner control board (SCB) (CN12, CN4) and the SJB (CN1, CN3). 2. Check the connections between the scanner junction board (SJB) (CN2) and the CCD unit.

  • Page 170: Vertical Black Lines

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.5 VERTICAL BLACK LINES G027T503.WMF G027T505.WMF Possible Causes (Scanner) When the problem occurs during flatbed copying mode (G027 only): -Defective CCD unit • When the problem occurs during only ADF copying mode: -Dust or scratches on the ADF paper guide -Dirty white plate in the ADF NOTE: The G025 model does not have flatbed equipment.

  • Page 171: Horizontal Black Lines

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.6 HORIZONTAL BLACK LINES G027T506.WMF G027T507.WMF Possible Cause (Printer): • Defective toner cassette Action: • Check that the surface of the drum is not damaged.

  • Page 172: Vertical White Lines

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.7 VERTICAL WHITE LINES G027T508.WMF G027T503.WMF Possible Cause (Scanner): • Defective CCD unit Action: • Replace the CCD unit. Possible Causes (Printer): • Defective toner cassette • The laser optic components are dirty. • The transfer roller surface is dirty or damaged. •...

  • Page 173: Horizontal White Lines

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.8 HORIZONTAL WHITE LINES G027T507.WMF G027T509.WMF Possible Causes (Printer): • Defective toner cassette • The development bias is not stable. • Transfer current is not stable. • Defective mechanical control board (MCB) Action: 1. Check the development bias. (Refer to Section 7.1.1 Blank Copies.) 2.

  • Page 174: Black Dots/Spots

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.9 BLACK DOTS/SPOTS G027T510.WMF Possible Cause (Scanner): • Dust on the exposure glass (the dots appear irregularly) (G027 only) Action: • Clean the exposure glass (G027 only). Possible Causes (Printer): • Defective toner cassette •...

  • Page 175: White Spots In Black Image Areas

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.10 WHITE SPOTS IN BLACK IMAGE AREAS G027T511.WMF Possible Causes (Printer): • The drum surface damaged. (This is likely if the dots appear at 75.4-millimeter intervals.) • The transfer roller surface is damaged. (This is likely if the dots appear at 44-millimeter interval.) Action: 1.

  • Page 176: Faint Copies

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.11 FAINT COPIES G027T503.WMF G027T512.WMF Possible Causes (Scanner): • Dirty shading plate and/or exposure glass (G027 only) • Defective CCD unit Action: • Clean the white plate (for both book and ADF modes). • Clean the exposure glass (G027 only). Possible Causes (Printer): •...

  • Page 177: Vertical Black Streaks

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.12 VERTICAL BLACK STREAKS G027T513.WMF G027T503.WMF Possible Cause (Scanner): • Dirty exposure glass (G027 only) Action: • Clean the exposure glass. Possible Cause (Printer): • Defective toner cassette Action: • Replace the toner cassette. 7-14...

  • Page 178: Unfused Copies

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.13 UNFUSED COPIES Possible Cause (Printer): • The thermistor is defective. • The fusing pressure roller spring mechanism is defective. • The wrong type of toner cassette is being used. • A non-recommended type of paper is being used. Action: 1.

  • Page 179: Toner On The Back Of The Printout

    COPY QUALITY TROUBLESHOOTING 18 May, 1999 7.1.15 TONER ON THE BACK OF THE PRINTOUT Possible Causes (printer): • Dirty transfer roller • Dirty fusing pressure roller Action: 1. Check if the transfer roller is dirty with toner, and clean or replace it if necessary.

  • Page 180: Misaligned Output (Image Shifted To The Right Or Left)

    18 May, 1999 COPY QUALITY TROUBLESHOOTING 7.1.16 MISALIGNED OUTPUT (IMAGE SHIFTED TO THE RIGHT OR LEFT) Possible Causes (Scanner): • Incorrect setting of the document guide • Improper setting of the starting point for horizontal scanning Action: • Set the document guide correctly. •...

  • Page 181: Mechanical Problems

    MECHANICAL PROBLEMS 18 May, 1999 7.2 MECHANICAL PROBLEMS 7.2.1 ADF NON-FEED Possible Causes: • An unsuitable document type or size, or curled document is used. • The pick-up and feed rollers are dirty or worn out. • Defective ADF motor •...

  • Page 182: Adf Jam

    18 May, 1999 MECHANICAL PROBLEMS 7.2.2 ADF JAM Possible Causes: • An unsuitable type or size of document is used. • The document is too long. • The ADF rollers (pick-up, feed, feed-in and feed-out) are dirty. • Obstruction in the document paper path. •...

  • Page 183: Adf Skew

    MECHANICAL PROBLEMS 18 May, 1999 7.2.3 ADF SKEW Possible Causes: • An unsuitable document type or size is used. • The document guide is not set properly. • The scanner rollers (pick-up, feed, feed-in, and feed-out) are dirty. • Obstruction in the document paper path Action: 1.

  • Page 184: Scanner Home Position Error (Error Code 90) (G027 Only)

    18 May, 1999 MECHANICAL PROBLEMS 7.2.5 SCANNER HOME POSITION ERROR (ERROR CODE 90) (G027 ONLY) Possible Causes: • The CCD unit lock is at the lock position. (This lock should be unlocked at installation.) • The CCD unit drive belt is out of position. •...

  • Page 185: Paper Jam (Registration Area)

    MECHANICAL PROBLEMS 18 May, 1999 7.2.7 PAPER JAM (REGISTRATION AREA) Possible Causes: • A non-recommended type of paper is used. • The paper feed roller is dirty. • Defective registration sensor • Obstruction in the paper path • Defective mechanical control board (MCB) Action: 1.

  • Page 186: Paper Jam (Fusing Exit Area)

    18 May, 1999 MECHANICAL PROBLEMS 7.2.8 PAPER JAM (FUSING EXIT AREA) Possible Causes: • A non-recommended type of paper is used. • Obstruction in the paper path • Defective registration sensor • Malfunctions in the fusing drive mechanism • Defective paper feed exit sensor •...

  • Page 187: Paper Skew (Printer)

    MECHANICAL PROBLEMS 18 May, 1999 7.2.9 PAPER SKEW (PRINTER) Possible Causes: • A non-recommended type of paper is used. • Incorrect positioning of the paper guide in the upper paper tray • The paper feed roller is worn out or damaged. •...

  • Page 188: Error Codes

    18 May, 1999 ERROR CODES 7.3 ERROR CODES These error codes are listed in the system parameter list. Fatal errors When a fatal error occurs, an error code is displayed in the LCD. (For example, “Error 59”.) The machine cannot clear fatal errors by turning the power off and on. A fatal error can be canceled using the RAM display/rewrite mode (Service function 82).
  • Page 189 ERROR CODES 18 May, 1999 Error Error Type Description Semi- Fatal Code Error fatal Error Error CFR or FTT not DIS was received when the received after machine was waiting for CFR or modem training FTT after modem training, because the other end could not receive DCS and TCF Training error...
  • Page 190 18 May, 1999 ERROR CODES Error Error Type Description Semi- Fatal Code Error fatal Error Error Paper jam in the The registration sensor did not turn transfer area or off, because the paper was too inside the fusing long. unit Paper jam in the Paper jam in the fusing exit area.
  • Page 191 ERROR CODES 18 May, 1999 Error Error Type Description Semi- Fatal Code Error fatal Error Error Fusing unit error Fusing lamp at a high temperature in higher temperature waiting mode. Fusing unit error Thermistor error Fusing unit error Over the comparator’s temperature limit (235ºC.) Power pack error Charge voltage did not change...

  • Page 192: Paper Feed Unit (G512)

    PAPER FEED UNIT (Machine Code: G512)

  • Page 193: Overall Information

    18 May, 1999 OVERALL INFORMATION 1. OVERALL INFORMATION 1.1 SPECIFICATIONS Paper Size: A4, 8½" x 11" 250 sheets (Plain paper) Capacity: 332 mm x 523 mm x 79 mm Size (W x D x H): (13.1" x 20.6" x 3.1") 2.8 kg [6.2 lb.] Weight: 1.2 COMPONENT LAYOUT...

  • Page 194: Detailed Section Descriptions

    DETAILED SECTION DESCRIPTIONS 18 May, 1999 2. DETAILED SECTION DESCRIPTIONS 2.1.1 OPTIONAL PAPER FEED UNIT Overview G512D526.WMF An optional paper feed unit [A], which holds 250 sheets can be installed in the machine. The optional paper feed unit uses two semicircular pick-up rollers [B] and two corner separators.
  • Page 195 18 May, 1999 DETAILED SECTION DESCRIPTIONS Paper Feed Mechanism G512D527.WMF The paper feed motor [A] drives the pick-up rollers [B] and feed rollers [C]. When the machine feeds a sheet of paper from the optional paper feed unit, the solenoid [D] of the paper feed clutch is energized to release the stopper [E], and the rotation of the paper feed motor is transmitted to the pick-up roller shaft.
  • Page 196 DETAILED SECTION DESCRIPTIONS 18 May, 1999 Optional Paper Feed Unit Detection When the machine is turned on or the printer is reset, the machine monitors if the optional paper feed unit is installed. The machine cannot detect the optional paper feed unit if it is installed while the power is on.

  • Page 197: Installation

    18 May, 1999 INSTALLATION 3. INSTALLATION Refer to the Operator’s Manual for how to install and set up the lower paper feed unit. G512-5...

  • Page 198: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT 18 May, 1999 4. REPLACEMENT AND ADJUSTMENT 4.1.1 PAPER FEED TRAY MOTOR AND SOLENOID REMOVAL Preparation 1) Remove the lower tray. 2) Turn the optional paper feed unit upside down. A: Paper pick-up roller assembly (2 bushing hooks) B: Paper feed roller assembly (3 hooks) G512R534.TIF Turn over the optional paper feed unit.
  • Page 199 18 May, 1999 REPLACEMENT AND ADJUSTMENT E: Paper feed tray motor connector (CN2) F: Paper feed tray solenoid connector (CN3) G512R536.TIF G: Drive unit (1 tapping screw) G512R537.TIF G512-7...
  • Page 200 REPLACEMENT AND ADJUSTMENT 18 May, 1999 H: Feed motor (2 Philips screws) G512R538.TIF I: Paper feed tray solenoid (1 Philips screw) G512R539.TIF Reinstallation Make sure the drive unit does not pinch the harness. G512-8...

  • Page 201: Paper Pick-Up Roller Removal

    18 May, 1999 REPLACEMENT AND ADJUSTMENT 4.1.2 PAPER PICK-UP ROLLER REMOVAL Preparation 1) Remove the lower tray. 2) Turn the optional paper feed unit upside down. A: Paper pick-up roller (3 hooks) G512R540.TIF G512-9...
  • Page 202 ELECTRICAL COMPONENTS LAYOUT G027 model G025 model G025V502.WMF G025ELECOM1.WMF G027 G025 Description P-to-P Location Sensors Toner End Sensor (S1) Paper Width Sensor (S2) Paper End Sensor (S3) Home Position Sensor (S4) Document Sensor (G036 only) (S5) ADF Registration Sensor (G036 only) (S6) Motors Main Motor...
  • Page 203 G027 model (G025 model parts are in the same location as G027 model) G025V503.WMF OPTIONAL PAPER FEED UNIT G025V504.WMF Description P-to-P Location Paper Feed Unit Control Board PCB1 Paper Tray Sensor Paper Feed Motor Paper Feed Solenoid SOL1 Paper End Sensor...
  • Page 204 G025/G027 POINT-TO-POINT DIAGRAM May 14, 1999 OPTIONAL PAPER FEED UNIT MECHANICAL CONTROL BOARD (PCB2) SCANNER CONTROL OPERATION CONTROL CN2-1 BOARD (PCB3) PANEL (PCB1) M O T B B CN5-4 CN1-12 DB0[ Paper CN2-2 CN5-3 CN1-11 [24]+24VDM CN1-13 CN12-1 DB1[ [0]GND CN2-3 BOARD (PCB5) CN5-2...

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