Ricoh G108 Service Manual
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Ricoh G108 Service Manual

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G108

SERVICE MANUAL

002011MIU
RICOH GROUP COMPANIES

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Summary of Contents for Ricoh G108

  • Page 1: Service Manual

    G108 SERVICE MANUAL 002011MIU RICOH GROUP COMPANIES...
  • Page 3 ® ® RICOH GROUP COMPANIES...
  • Page 5 G108 SERVICE MANUAL 002011MIU...
  • Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
  • Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
  • Page 11 LEGEND PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN G108 P7431cn LP031c Aficio CL1000N CLP831 DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 6/2004 Original Printing...

  • Page 13: Table Of Contents

    G108 TABLE OF CONTENTS INSTALLATION 1. INSTALLATION................1-1 1.1 INSTALLATION REQUIREMENTS ............1-1 1.1.1 ENVIRONMENT ................1-1 1.1.2 MACHINE LEVEL ................1-1 1.1.3 MACHINE SPACE REQUIREMENT..........1-2 Printer Only...................1-2 Printer and Duplex Unit.................1-2 1.1.4 POWER REQUIREMENT..............1-3 1.2 INSTALLATION PROCEDURE ..............1-4 1.2.1 INSTALLING THE PRINTER............1-4 1.2.2 NECESSARY SETTINGS..............1-4...
  • Page 14 3.12.3 FUSING FAN ................3-28 3.13 INTERLOCK SWITCH ................3-29 3.13.1 FRONT COVER SWITCH ............3-29 3.13.2 TOP AND REAR COVER SWITCHES .........3-29 3.14 REGISTRATION..................3-30 3.14.1 LEADING EDGE REGISTRATION ..........3-30 3.14.2 SIDE-TO-SIDE REGISTRATION..........3-31 TROUBLESHOOTING 4. TROUBLESHOOTING ..............4-1 4.1 SERVICE CALL..................4-1 4.1.1 SUMMARY ..................4-1 G108...
  • Page 15 Possible Cause ...................4-12 Countermeasures ................4-12 4.2.9 BLACK LINE...................4-13 Symptom.....................4-13 Possible Cause ...................4-13 Countermeasures ................4-13 4.2.10 VERTICAL LINE ................4-13 Symptom.....................4-13 Possible Cause ...................4-13 Countermeasures ................4-13 4.2.11 VERTICAL LINES NOT ACCEPTABLY STRAIGHT.....4-14 Symptom.....................4-14 Possible Cause ...................4-14 Countermeasures ................4-14 4.2.12 BANDING ..................4-14 Symptom.....................4-14 G108...
  • Page 16 Symptom.....................4-19 Possible Cause ...................4-19 Countermeasures ................4-19 4.2.22 BLANK IMAGE ................4-19 Symptom.....................4-19 Possible Cause ...................4-19 Countermeasures ................4-19 4.2.23 INSUFFICIENT FUSING ..............4-20 Symptom.....................4-20 Possible Cause ...................4-20 Countermeasures ................4-20 4.2.24 UNEVEN DENSITY BETWEEN LEFT AND RIGHT SIDES ..4-20 Symptom.....................4-20 Possible Cause ...................4-20 G108...
  • Page 17 5.1.4 MEMORY CLEAR/COUNTER CLEAR ...........5-36 5.1.5 TELEPHONE NUMBER SETTING (SP5-812)........5-37 5.2 FIRMWARE UPDATE ................5-38 5.2.1 TYPES OF FIRMWARE ..............5-38 5.2.2 PRECAUTIONS................5-38 Handling SD Card ................5-38 Upload or Download ................5-38 Network Connection................5-38 5.2.3 FILE ARRANGEMENT ..............5-39 How The Program Works..............5-39 Example....................5-39 5.2.4 UPDATING ..................5-40 G108...
  • Page 18 6.1.5 PRINTING PROCEDURE..............6-6 6.2 TONER MASS AMOUNT CONTROL............6-8 6.2.1 OVERVIEW ..................6-8 6.2.2 ID SENSOR CALIBRATION .............6-8 6.2.3 TEST PATTERN PROCESSING ............6-9 6.2.4 REFERENCE EQUATION PROCESSING ........6-10 6.2.5 DEVELOPMENT BIAS ADJUSTMENT ..........6-10 6.3 OPTICAL HOUSING UNIT ..............6-11 6.3.1 OPTICAL PATH................6-11 G108...
  • Page 19 Messages ...................6-30 Near-Full and Full ................6-30 6.7 PAPER TRAY UNIT ................6-31 6.7.1 OVERVIEW ..................6-31 6.7.2 PAPER LIFT ...................6-32 6.7.3 PAPER FEED .................6-33 Paper Feed Roller................6-33 Drive ....................6-33 6.7.4 PAPER SIZE AND PAPER TRAY DETECTION......6-34 Mechanism ..................6-34 Paper Size ..................6-34 G108...
  • Page 20 6.11.5 NETWORK DATA PROTECTION UNIT ........6-49 NDPU and DES ..................6-49 Supported Network Interface ..............6-49 6.12 ETHERNET BOARD ................6-50 6.12.1 ETHERNET BOARD LAYOUT .............6-50 6.12.2 ETHERNET ..................6-51 6.13 USB 2.0 ....................6-52 6.13.1 GENERAL FEATURES ..............6-52 Overview.....................6-52 Plug and Play..................6-52 G108 viii...
  • Page 21 SPECIFICATIONS 1. PRINTER DRIVERS..................7-1 2. SUPPORTED PAPER SIZES...............7-3 3. SOFTWARE ACCESSORIES ..............7-3 3.1 PRINTER DRIVERS ................7-4 3.2 UTILITY SOFTWARE ................7-4 4. MACHINE CONFIGURATION ..............7-5 5. MACHINE CONFIGURATION ..............7-7 5.1 PAPER TRAY UNIT................7-7 5.2 LEGAL PAPER TRAY .................7-7 DUPLEX UNIT...................7-7 G108...
  • Page 22 PAPER FEED UNIT G389 SEE SECTION G389 FOR DETAILED TABLE OF CONTENTS DUPLEX UNIT G390 SEE SECTION G390 FOR DETAILED TABLE OF CONTENTS G108...

  • Page 23: 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.

  • Page 24: 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 25: Symbols And Abbreviations

    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 27 INSTALLATION PREVENTIVE MAINTENANCE REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING SERVICE TABLES G390 DUPLEX UNIT AD460 DETAILED DESCRIPTIONS SPECIFICATIONS G389 PAPER FEED UNIT TYPE 1000...

  • Page 29: Installation

    INSTALLATION...

  • Page 31: Installation Requirements

    8. Install the machine on a strong, level base. 9. Do not install the machine in an area that can be subjected to strong vibrations. 1.1.2 MACHINE LEVEL Front to back: 1 degree or less Left to right: 1 degree or less G108...

  • Page 32: Machine Space Requirement

    [D] (rear): 250 mm (10") G108I915.WMF Printer and Duplex Unit [A] (right): 500 mm (20") [B] (front): 700 mm (28") [C] (left): 500 mm (20") [D] (rear): 700 mm (28") G108I916.WMF NOTE: The added space necessary for maintenance work is included. G108...

  • Page 33: Power Requirement

    1. Input voltage level: 120 V, 60 Hz, 11 A or less 220 V ~ 240 V, 50 Hz: More than 6 A 2. Permissible voltage fluctuation: ±10 % 3. Do not put or place anything on the power cord. G108...

  • Page 34: Installation Procedure

    Displays the fax number of the service station. The number is Fax Telephone Number printed on the counter list when the Meter Charge is enabled. The user can send a fax message with the counter list. To type SP5-812-002 the fax number, see 5.1.5. G108...

  • Page 35: Moving The Machine

    NOTE: Do not remove the waste toner bottle. If you remove it, the waste toner may fall from the waste toner path. 6. Protect the photoconductor unit surface with paper or cloth. 7. Clean the units and components in the printer. 8. Secure the paper tray and all exterior covers with tape. G108...

  • Page 37: Preventive Maintenance

    PREVENTIVE MAINTENANCE...

  • Page 39: User Maintenance

    2) When replacing the OPC belt unit or Fusing unit, the user executes the following mode: Menu > Maintenance > Maint. Reset > PCU (or > Fusing Unit). This mode and SP7-905-001 (PM Parts Clear, OPC Belt) have the same function. G108...

  • Page 40: Service Maintenance

    1) The actual life is decided by the number of developments. The values in this table are calculated under the conditions above. 2) These are the maintenance yields for these parts based upon the above conditions. Any differing part yields for these items are based upon different formulas (conditions). G108...

  • Page 41: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 43: Exterior Covers

    3. Open the rear cover [C]. 4. Open the front cover [D]. 5. Top cover ( x 3) NOTE: Unsnap the cover from the front and gradually work your way around the covers, carefully lifting the edges as you proceed. G108R901.WMF G108...

  • Page 44: Right Cover

    G108R902.WMF 3.1.3 LEFT COVER 1. Top cover ( 3.1.1) 2. Left cover [A] ( x 2) NOTE: When removing the left cover, carefully lift from the bottom of the cover and remove. G108R903.WMF G108...

  • Page 45: Front Cover

    NOTE: The hinges are strongly spring-loaded, be certain to press down the left hinge, angle the cover out, then press down the right hinge to fully remove the cover. When reinstalling, the longer of the two retainer bracket screws is used in the upper screw location on the bracket. G108...

  • Page 46: Optics Unit

    4. Optics unit cover [A] ( x 2) G108R914.WMF 5. Optics unit [B] ( x 1, x 4) NOTE: Use extreme caution when disconnecting the laser unit’s connector. The connector has a press-lock tab on top. G108...

  • Page 47: Opc

    SP7-905-001 (PM Parts Clear, OPC Belt). G108R930.WMF 3.3.2 OPC BELT SENSOR 1. OPC belt 2. Top cover ( 3.1.1) 3. Sensor bracket (with the OPC belt sensor) [A] ( x 1, x 1) 4. OPC belt sensor [B] G108R924.WMF G108...

  • Page 48: Charge Roller And Cleaning Roller

    8. Right holder with drive gear [I] NOTE: 1) Be certain to protect G108R938.W the OPC Belt from excessive exposure to light. 2) If replacement of either the Charge Roller and/or Cleaning Roller becomes necessary, you must replace the entire OPC Belt Unit. G108...

  • Page 49: Erase Lamp

    3.3.4 ERASE LAMP G108R910.WMF 1. OPC belt unit ( 3.3.1) 2. Transfer belt unit ( 3.5.1) 3. Erase lamp [A] ( x 1, x 2) G108...

  • Page 50: Development

    NOTE: The connector is on the input output device [B]. 8. Receptor of the toner end sensor [C] ( x 1) G108R927.WMF Reassembling Attach the upper end of the emitter with the 3x6 screw. Attach the lower with the 3x8 screw. G108...

  • Page 51: Development Unit Sensor And Development Clutch

    NOTE: The connector is on the input output device [B]. 7. Sensor bracket (with the development unit sensor) [C] x 2) 8. Development unit sensor (with the circuit board) [D] ( x 2) G108R928.WMF 9. Development clutch [E] ( x 2) G108R946.WMF G108...

  • Page 52: Transfer Belt

    1) 5. ID sensor [C] x 1, x 2) G108R923.WMF Reassembling Remove the paper tray from the printer when you reassemble. The paper tray pushes up the lever [D] on the right end of the erase lamp base. G108 3-10...

  • Page 53: Transfer Belt Cleaning Unit And Waste Toner Duct3-11

    1. Open the top cover [A]. 2. Cleaning unit cover [B]. 3. Transfer belt cleaning unit [C]. 4. Waste toner duct [D]. ( x 2) Necessary Setting After replacing the transfer belt cleaning unit, execute SP7-905-004 (PM Parts Clear, Transfer Roller). 3-11 G108...

  • Page 54: Waste Toner Collection Unit

    You cannot remove the waste toner sensor from the bottle holder. Replace the waste toner sensor with the bottle holder. 1. Right cover ( 3.1.2) 2. Waste toner bottle 3. Bottle holder [A] ( x 1, x 2) G108R925.WMF G108 3-12...

  • Page 55: Waste Toner Duct

    2. Cover the area below the waste toner duct with paper or cloth. NOTE: When you remove the waste toner duct, waste toner comes out of the duct. 3. Support bracket [A] ( x 1) 4. Waste toner duct [B] 3-13 G108...

  • Page 56: Paper Feed

    3. Paper guide 2 [B] ( x 2) 4. Paper sensor assembly [C] x 2) 5. OHP sensor [D] x 1, x 2) 6. Paper end sensor [E] ( x 1) 7. Registration sensor [F] x 1) G108R920.WMF G108 3-14...

  • Page 57: Temperature Sensor, Paper Size Sensor And Paper Tray Sensor

    5. Left rail of the paper tray [B] ( x 2) NOTE: The screws are behind the direct current unit. 6. Paper size sensor and paper tray sensor [C] ( x 1, x 2) NOTE: Pass the connector through the opening behind the direct current unit. 3-15 G108...

  • Page 58: Paper Transfer And Paper Exit

    Parts Clear, Transfer Roller). G108R935.WMF 3.8.2 PAPER EXIT SENSOR AND PAPER OVERFLOW SENSOR 1. Open the rear cover [A]. 2. Paper exit unit [B] ( x 4) 3. Paper exit sensor [C] 4. Paper overflow sensor [D] G108R921.WMF G108 3-16...

  • Page 59: Discharge Brush

    PAPER TRANSFER AND PAPER EXIT 3.8.3 DISCHARGE BRUSH 1. Open the rear cover [A]. 2. Paper exit unit [B] ( x 4) G108R933.WMF 3. Lock shaft cover [C] 4. Lock shaft [D] ( x 2) 5. Discharge brush [E] G108R934.WMF 3-17 G108...

  • Page 60: Fusing Unit And Fusing Lamp

    7. Screw at the right end of the fusing lamp [H] 8. Screw at the terminal of the fusing lamp [I] 9. Bottom cover [J] ( x 4) NOTE: One screw is at the right end [K]. The other three are on the bottom. G108R942.WMF G108 3-18...
  • Page 61 FUSING UNIT AND FUSING LAMP 10. Left bracket [A] ( x 2) 11. Fusing lamp [B] G108R943.WMF 3-19 G108...

  • Page 62: Circuit Board

    4. Install the new Zero-Counter NVRAM. 5. Plug in the power cord, power ON the main switch, and have the regional personnel add in the destination code and controller serial number. NOTE: The default destination code is Japan. G108 3-20...

  • Page 63: Input Output Device

    2. IOD cover [A] ( x 5) 3. Input output device [B] (Flat cable x 2, All x 6) Reassembling Make sure that the left end of the IOD cover is under the top end of the BCU cover when you reassemble. 3-21 G108...

  • Page 64: Direct Current Unit

    's on the BCU 5. Safety-switch connector cover [A] 6. Controller box [B] ( x 3) 7. Ground wire [C] ( x 1) 8. Left frame [D] ( x 1, x 4) 9. Power supply unit [E] (All x 7) G108 3-22...

  • Page 65: High Voltage Unit

    You can get an electrical shock if you touch the unit when the printer plug is connected to the A.C. outlet. G108R909.WMF 1. Controller box ( 3.10.3) 2. High voltage unit [A] ( x 7 for terminals, x 4) 3-23 G108...

  • Page 66: Drive Path

    3.11.1 MAIN MOTOR DRIVE PATH G108R911.WMF 1. Top cover ( 3.1.1) 2. Right cover ( 3.1.2) 3. Main motor [A] ( x 4) 4. Gear box [B] ( x 4) 5. Release the cable holder [C] from the gear assemblies. G108 3-24...
  • Page 67 12. Paper transfer clutch [E] ( x 1) 13. Registration clutch [F] ( x 1) 14. Paper feed clutch [G] ( x 1) 15. Right frame [H] ( x 6) 16. Lower gear assembly [I] ( x 4) 3-25 G108...

  • Page 68: Development Motor Drive Path

    7. Waste toner bottle [E] 8. Bottle holder [F] ( x 2) 9. Development clutch C [G] ( x 1) 10. Development units 11. Development unit drive gears [H] ( x 1) 12. Development gear assembly [I] ( x 4) G108 3-26...

  • Page 69: Exhaust Fan

    3.12.2 PSU FAN 1. Top cover ( 3.1.1) 2. PSU fan assembly [A] ( x 1) 3. PSU fan [B] Reassembling Put the side with the fan label [C] to the left side of the printer when you reassemble. G108R916.WMF 3-27 G108...

  • Page 70: Fusing Fan

    1. Open the rear cover [A]. 2. Paper exit unit [B] with the base [C] ( x 4) 3. Fan bracket [D] ( x 2) 4. Fusing fan duct [E] ( x 4) 5. Fusing fan [F] ( x 1) G108 3-28...

  • Page 71: Interlock Switch

    3.13.2 TOP AND REAR COVER SWITCHES 1. Top cover ( 3.1.1) 2. Switch cover 1 [A] ( x 1) 3. Rear cover switch [B] 4. Switch cover 2 [C] ( x 1) 5. Top cover switch [D] G108R919.WMF 3-29 G108...

  • Page 72: Registration

    +0.7 mm; when you specify "-10," the margin changes by -1.4 mm. NOTE: The diagrams below illustrate examples of adjustment results. Actual results may be different from these examples. ±0.0 mm -4.9 mm +4.9 mm G108R949.WMF G108R950.WMF G108R951.WMF G108 3-30...

  • Page 73: Side-To-Side Registration

    • Engine SP1-002-002: Tray 2 (Optional paper feed unit) • Engine SP1-002-003: Duplex (Optional duplex unit) NOTE: The diagrams below illustrate examples of adjustment results. Actual results may be different from these examples. -3.5 mm ±0.0 mm +3.5 mm G108R952.WMF G108R953.WMF G108R949.WMF 3-31 G108...

  • Page 75: Troubleshooting

    TROUBLESHOOTING...

  • Page 77: Service Call

    SC code is shown. NOTE: 1) If the problem concerns electrical circuit boards, first disconnect, then reconnect the connectors before replacing the PCBs. 2) If the problem concerns a motor-lock, first check the mechanical load before replacing motors or sensors. G108...

  • Page 78: Sc Code Classification

    680 - Unique for a specific model 800 - Error after ready condition 820 - Diagnostics error Controller 860 - Hard disk 880 - Unique for a specific model 900 - Counter Others 920 - Memory 990 - Others G108...

  • Page 79: Sc Table

    • Defective fusing lamp • Defective power supply unit • Defective BCU OPC belt sensor error • Defective OPC belt unit • Dirty OPC belt • Loose connection • Defective OPC belt sensor • Defective input output device • Defective BCU G108...
  • Page 80 Toner end sensor error 1 toner end sensor Toner end sensor error 2 • Defective PCB of the receptor of the toner end sensor • Defective input output device • Defective PCB of the emitter of the toner end sensor • Defective BCU G108...
  • Page 81 • Loose connection [3004] Command error • Defective HDD • Defective controller Self-diagnostic error: NIB [6101] MAC address check sum error • Defective controller [6104] PHY IC error • Defective controller • Defective controller [6105] PHY IC loop-back error G108...
  • Page 82 HDD: Access error • Corrupted SD card data SD card authentication error • Defective SD card • Loose connection SD card error • Defective SD card • Defective SD card SD card access error • Defective SD card controller G108...

  • Page 83: Possible Cause

    • Defective software Software error 1 • Defective controller • Software error • Defective software Software error 2 • Software error Unexpected SC Application start error • Loose connection of RAM-DIMM, ROM- DIMM • Defective controller • Software problem G108...

  • Page 84: Image Quality

    There are parts of the image missing especially at the edges. Possible Cause 1) Insufficient toner mass amount and/or charge amount in the development procedure. 2) The OPC belt is damaged. G108T902.TIF Countermeasures 1) Replace the development unit. 2) Replace the OPC belt unit. G108...

  • Page 85: Jitter

    4) Failure in the development unit drive path. G108T903.TIF Countermeasures 1) Replace the gears on the OPC belt drive path. 2) Replace the OPC belt unit. 3) Replace the gearbox. 4) Replace the gears in the development unit drive path. G108...

  • Page 86: Symptom

    1) Check that the printer is installed on a level surface. 2) Shake the toner cartridge horizontally several times. 3) Replace the development unit. 4) Close the rear cover correctly. 5) Replace the OPC belt unit. 6) Replace the development solenoid G108 4-10...

  • Page 87: Symptom

    2) The development roller’s surface is damaged. Countermeasures 1) Execute the test print. G108T906.TIF 2) Isolate the development unit that causes the white line. 3) Remove any foreign particles from the development roller. 4-11 G108...

  • Page 88: Symptom

    2) Stain on the OPC belt charge roller. 3) Stain on the OPC belt. 4) Stain on the transfer belt. Countermeasures 1) Replace the development unit. 2) Replace the OPC belt unit. 3) Replace the transfer belt unit. G108T908.TIF G108 4-12...

  • Page 89: Countermeasures

    Countermeasures 1) Clean the stain on the OPC belt unit. 2) Clean the stain on the transfer belt. G108T910.TIF 3) Remove the transfer unit cleaning unit. Then clean the inside and outside of the waste toner feeder. 4-13 G108...

  • Page 90: Countermeasures

    2) The OPC belt and the transfer belt fail to maintain the regular and proper rotation due to the impact caused during the retraction of the toner cartridge. G108T912.TIF Countermeasures 1) Replace the OPC belt unit. 2) Replace the development unit. G108 4-14...

  • Page 91: Countermeasures

    Check the seal on the transfer-belt cleaning unit. Replace the transfer- belt cleaning unit if necessary. c) Check the waste toner path. If waste toner stays, remove it with a vacuum cleaner. 2) Clean or replace the development unit. 4-15 G108...

  • Page 92: White Spots / Black Spots

    If it is on the transfer belt, the G108T916.TIF cause is the retract error of the transfer belt or cleaning roller. 2) Replace the spring clutch or the development solenoid. 3) Replace the transfer roller clutch. 4) Replace the transfer-belt cleaning solenoid. G108 4-16...

  • Page 93: Incorrect Color Registration

    Countermeasures 1) Check that the rear cover is correctly locked. 2) Replace the papers with new papers. 3) Replace the development unit. 4) Check that the transfer roller unit is correctly installed. 5) Replace the high voltage unit. 4-17 G108...

  • Page 94: Residual Image

    2) The fusing temperature is not correctly controlled. 3) The paper type is not set correctly. Countermeasures 1) Replace the fusing unit. 2) Check the mode setting of the paper. G108T920.TIF G108 4-18...

  • Page 95: Back Stain

    G108T922.TIF connection). Countermeasures 1) Check the laser beam path and remove unwanted particles. 2) Replace the development unit. 3) Check the development solenoid. 4) Check the transfer roller unit is correctly installed. 5) Replace the high voltage unit. 4-19 G108...

  • Page 96: Countermeasures

    4) Check that the transfer roller unit is correctly installed. 5) Replace the transfer roller unit. 6) Check that the rear cover is correctly locked. 7) Replace the) rear cover. 8) Clean the dust-shield glass of the optics unit. 9) Replace the optics unit. G108 4-20...

  • Page 97: Uneven Density Among Different

    • The ID sensor connection • The ID sensor • The cleaning mechanism of the ID sensor NOTE: The printer operates even when the message "TMAs" is displayed. In this condition, the image density of the printed output can be incorrect. 4-21 G108...

  • Page 98: Electrical Component

    The message "Remove Misfeed Paper Tray" Interrupted Paper is displayed. DCN19 size/tray The message "Load Paper: Tray 1 or Form interrupted Feed" is displayed. NOTE: The connectors provided here are located on the I/O device PCB. G108 4-22...

  • Page 99: Blown Fuse Condition

    Error Error LED 2 Normal Error The BCU has no LED. 4.4 DUPLEX UNIT For information on problems that may occur with the optional duplex unit, refer to the service manual section for the optional duplex unit (G390). 4-23 G108...

  • Page 101: Service Tables

    SERVICE TABLES...

  • Page 103: Service Program Mode

    Press and hold both keys for at least five seconds. Note: The display continues to show “Ready” during this time. 2. Next, release the up-arrow and down-arrow keys and immediately (within approximately two-seconds) press the Enter key [E]. The message "SYSTEM ver. x.xx" is displayed. G108...

  • Page 104: Selecting A Service Program

    Quitting SP Mode 1. Press the Escape key several times until the message "SYSTEM ver. x.xx" is displayed. 2. Press the up-arrow key or the down-arrow key to select the following menu item: • 3. End 3. Press the Enter key. G108...

  • Page 105: Tables

    Sets the resolution and the print mode of the printer gamma adjustment. The asterisk (*) shows which mode is selected. • *1200 x 600 Photo • 600 x 600 Text • 1200 x 600 Text • 600 x 600 Photo G108...
  • Page 106 [0 to 255 / 176 / 1/step] 1104 052* Set Magenta 12 [0 to 255 / 192 / 1/step] 1104 053* Set Magenta 13 [0 to 255 / 208 / 1/step] 1104 054* Set Magenta 14 [0 to 255 / 224 / 1/step] G108...
  • Page 107 SP1-101-002). 1106 Toner Limit Adjusts the maximum amount of toner for image development. 1106 001* Toner Limit Photo [100 to 400 / 260 / 1 %/step] 1106 002* Toner Limit Text [100 to 400 / 190 / 1 %/step] G108...

  • Page 108: Bit Switches

    [F] is bit 0. bit0 6. Press the Escape key several times until the menu "1. Service" is shown. 7. Select "End" by pressing the Enter key. Use the up or down arrow keys to locate “3. End.” G108...

  • Page 109: Adjusting Printer Gamma

    Make sure an asterisk ( ) is shown. Form Feed #Enter The asterisk shows which mode is selected. NOTE: The mode is printed on the second line [B] of the color Power  Alert Data In calibration test sheet. 5. Select Service SP1-103-001 G108S901.WMF (ToneCtlSheet). G108...
  • Page 110 • To change the value, push the up-arrow key or the down-arrow key. • To set a digit, press the Enter key. • Repeat for each digit. NOTE: Maximum density value for each is 255. The minimum is 0. G108...

  • Page 111: Toner Control Set (Service Sp1-101)

    If you specify a new setting and execute Service SP1-105 (ToneCtlSave), this new setting is saved as the current setting. In addition, the previous setting (Service SP1-101-002) is also updated. Service SP1-105 (ToneCtlSave) does not change the factory (default) settings (Service SP1-101-001). G108...

  • Page 112: Engine

    5 in the SP, 1002 002* Paper Tray 2 the margin changes by 0.5 mm. For example: 1002 003* Paper Duplex when you specify "+5," the margin changes by +0.5 mm; when you specify "-10," the margin changes by -1.0 mm. G108 5-10...

  • Page 113: Sp2: Drum

    NOTE: The bias CBV is the bias that is charged on the OPC belt unit. This bias is different from the bias that is charged on the charge roller. 2312 Transfer Belt Cleaner Bias [-20 ∼ +20 / 0 / 5 /step] Adjusts the bias for the transfer-belt cleaning unit. 5-11 G108...

  • Page 114: Sp5: Mode

    Sets the error alarm level. If an SC code is generated, the error alarm counter increases by +1. If no SC code is generated while the specified number of paper is output, the jam alarm counter decreases by -1. The error alarm is issued when the error alarm counter reaches +5. G108 5-12...
  • Page 115 Destination Shows the destination code. 5811 Serial Number 5811 002 Display Controller Serial Shows the serial number. Number 5811 010 Display Engine Serial Number 5811 011 Set Engine Serial Number Ask your supervisor for the information on this 5-13 G108...
  • Page 116 Remote Service Address 5821 001* CSS-PI Device Code [0 ∼ 4 / 0 / 1/step] DFU 5821 002* RCG IP Address [00000000h ∼ FFFFFFFFh / 00000000h / 1/step] Specifies the IP address of the RCG (Remote Communication Gate). G108 5-14...
  • Page 117 SMB Workgroup Name Displays the workgroup name. 5832 HDD Initialization Initializes the hard disk. Use this SP mode only when a hard disk error occurs. This SP initializes the whole area (the all partitions) in the hard disk. 5-15 G108...
  • Page 118 5840 020* WEP mode [0~1/0/1] 0: Max. 64-bit (10 characters) 1: Max. 128-bit (10, 26 characters) Determines the operation mode of the WEP key. Displayed only when the option 801.11b for wireless LAN is installed. G108 5-16...
  • Page 119 Specifies the number of maximum entries. 5845 050 Initialize All Data Initializes all data. 5856* Remote Update [0 to 1 / 0 / 1/step] 0: Disable, 1: Enable Allows the technician to upgrade the firmware using a parallel cable 5-17 G108...
  • Page 120 The user may turn off the main power switch before the log is written in the file. To prevent this possible problem, you can prepare a log file beforehand. The controller takes a shorter time to save logs since the log file is already generated. G108 5-18...
  • Page 121 [0 to 1 / 0 / 1/step] Determines whether the FROM item of the mail header is switched to the validated account after the SMTP server is validated. 0: No. “From” item not switched, 1: Yes. “From” item switched. 5-19 G108...
  • Page 122 5907 [Plug/Play] Plug & Play Name Selection 5907 001* Plug/Play Specifies the manufacturer and model name. [0 to 7 / 0 / 1/step] FA 0: Ricoh Aficio CL1000N 1: Savin CLP831 2: NRG P7431cn 3: Gestetner P7431cn 4: Lanier LP031c...
  • Page 123 Note that 5996 003 [M] Over All coloration (calibration) can be changed if you 5996 004 [Y] Over All change the value of a color. 5997 Fuser SC Clear 5998 Engine Memory Clear 5.1.4 5-21 G108...

  • Page 124: Sp7: Data Log

    7506 142* B5 SEF 7506 164* LG SEF 7506 166* LT SEF 7506 172* HLT SEF 7506 255* Others 7507 Jam History 7507 001* Latest Shows the 10 most recently detected paper 7507 002* Latest 1 jams. 7507 010* Latest 9 G108 5-22...
  • Page 125 10 pages per job; 7806 003 3 P/J "Over 21 P/J" indicates 21 pages and more per 7806 004 4 P/J job. 7806 005 5 P/J 7806 006 6-10 P/J 7806 007 11-20 P/J 7806 008 Over 21 P/J 5-23 G108...
  • Page 126 7901 Assert Info 7901 001 File Name Keeps the location where a problem is detected in the program. The data stored in this SP is 7901 002 # of Lines used for problem analysis. DFU 7901 003 Location G108 5-24...
  • Page 127 7910 183 FONT 3 7910 153 R98 7910 200 Factory 7910 154 R16 7910 204 Printer 7910 155 RPGL 7910 209 Test Suite 7910 156 R55 7910 210 MIB 7910 157 RTIFF 7910 211 Web System 7910 158 PCL 5-25 G108...
  • Page 128 Engine SP7-805, "SP7803" is the value 7951 005 Pickup Roller displayed by Engine SP7-803, and "SP7950" is 7951 006 Pickup Roller 2 the value displayed by Engine SP7-950. These SPs show what percentage of life is already consumed. G108 5-26...
  • Page 129 ImgEdt image editing performed on the original with the copier GUI (Image editing includes, for example, border removal, adding stamps, and page numbering.) black in the YMCK mode local storage; document server Lsize large size magnification one color 5-27 G108...
  • Page 130 The number of times the application program retrieves data from the document server 8034* P: Pjob/DesApl [0~9999999/ 0 / 1/step] O: Pjob/DesApl 8037* • When documents already stored on the document server are printed, the counter of the application program that executes the print job increases. G108 5-28...
  • Page 131 • If the finisher runs out of staples during stapling, the job is counted at the time the error occurs. (Not applicable to this product.) • The first test print and subsequent test prints to adjust settings are added to the number of pages of the copy job (SP8-072). 5-29 G108...
  • Page 132 • The counter increases by +1 when both sides (front/back) are printed. The counter does not increase when one of the two sides is not printed (e.g., the last page of the documents that have three pages, five pages, seven pages, and so on). G108 5-30...
  • Page 133 NOTE: A duplex-printed cover is counted as two. Series/Book The number of pages printed in series (one side) or in the booklet mode User Stamp The number of pages where stamps were applied (including page numbering and date stamping) 5-31 G108...
  • Page 134 (to measure the service life of each feed roller) when the paper is fed. • Blank sheets (covers, chapter covers, slip sheets) are also counted. • During duplex printing, a sheet printed on two sides and a sheet printed on one side are each counted as 1 sheet. G108 5-32...
  • Page 135 The number of pages printed by the printer emulation mode [0~9999999/ 0 / 1/step] 8514* P: PrtPGS/Emul RPCS RTIFF RPDL PCL5e/5c PCL XL IPDL-C GL/GL2 BM-Links (for local models only) Other • These counters display the same result. 5-33 G108...
  • Page 136 The number of A3/DLT, duplex printing, or staples [0~9999999/ 0 / 1/step] A3/DLT Staple Duplex • Note that these counters are not for the printer’s application program. 8771* Dev Counter The number of rotations of the development rollers [0~9999999/ 0 / 1/step] Total G108 5-34...
  • Page 137 Down Time/SC The total downtime caused by SC codes Down Time/PrtJam The total downtime caused by paper jams Down Time/OrgJam The total downtime caused by original jams Down Time/TonEnd The total downtime caused by toner ends 5-35 G108...

  • Page 138: Memory Clear/Counter Clear

    TM1 and TM2). 7808 001 Counter Clear SP7-401, 403, 502, 504, 506, 507 SP8-00x, 02x, 03x, 06x, 07x, 42x, 43x, 44x, 451, 46x, 471, 48x, 51x, 52x, 771, 781, 801, 831, 841, 851, 861, 871, 881, 891, 901, 941 G108 5-36...

  • Page 139: Telephone Number Setting (Sp5-812)

    6. To select the character, with the character displayed, press the Enter key. 7. To move the cursor, push the up-arrow key [B] or the down-arrow key [C]. 8. Set all necessary characters. 9. To quit the program, press the Escape key [A]. 5-37 G108...

  • Page 140: Firmware Update

    • Download: To copy data from the SD card to the printer Network Connection Explain to the user that they cannot use the printer at the time of firmware update. Disconnect the printer from the network. Incoming print jobs may affect firmware update. G108 5-38...

  • Page 141: File Arrangement

    NOTE: The file information identifies the firmware. But this information does not guarantee that the firmware data is not corrupted. • For the G108 printer, the SD card cannot have been previously formatted using a windows FAT16, FAT32 or NTFS file system. To properly re-format the SD card (original format) for use with this product download and use the utility available as a download from…...

  • Page 142: Updating

    14. Remove the SD card from the slot. 15. Physically re-connect the printer to the network. 16. Turn on the main power switch. 17. Print the configuration page (Menu > List/Test Print > Config.Page). Make sure all the firmware was correctly updated. G108 5-40...

  • Page 143: Error Handling

    NVRAM data ( Downloading NVRAM Data). 5. Exit the SP mode. 6. Turn off the main power switch. 7. Insert an SD card into Slot 1. 8. Turn on the main power switch. 9. Enter SP mode. 5-41 G108...

  • Page 144: Downloading Nvram Data

    ( Uploading NVRAM Data). 8. Exit the SP mode. 9. Turn off the main power switch. 10. Remove the SD card. 11. Turn on the main power switch. 12. Check that the NVRAM data was correctly downloaded. G108 5-42...

  • Page 145: Error Code Table

    Replace the update data for the module on the SD failed card and tray again, or replace controller board. Electronic confirmation check SD update data is incorrect. The data on the SD card failed is for another machine. Acquire correct update data then install again. 5-43 G108...

  • Page 146: Sd Card Appli Move

    You may need to check the SD card and its data to solve a problem in the future. • You cannot copy PostScript data to another SD card. You can copy an application program to the SD card that saves PostScript data. G108 5-44...

  • Page 147: Move Exec

    8. Follow the instruction on the operation panel. 9. Exit SP mode. 10. Turn off the main power switch. 11. Remove the SD card from Slot 1. 12. Turn on the main power switch. 13. Make sure that the application programs operate correctly. 5-45 G108...

  • Page 148: Undo Exec

    12. Remove the SD card from Slot 2. 13. Remove the other SD card from Slot 1. 14. Insert the necessary SD card to Slot 2. 15. Turn on the main power switch. 16. Check that the application programs operate correctly. G108 5-46...

  • Page 149: Controller Self-Diagnostics

    Error Logged Real Time Clock SC826 Detailed Check Real Time Clock Check SC826 Font ROM Sum Check Network Check Error Logged Error Logged Engine I/F Check Error Logged Interrupt Check Error Logged Memory Chip Check Error Logged G108S907.WMF 5-47 G108...

  • Page 150: Detailed Self-Diagnostics

    4. The machine begins the self-diagnostics. The machine will print a diagnostic report when it finishes the self-diagnostics. • Examine the diagnostics report and check the result. • Use Engine SP7-832-001 (Diag. Result) to see the return code. • For the error codes, see section 4.1. G108 5-48...

  • Page 151: Toner Density (Mass Amount) Control

    100 minutes have passed (whichever occurs first). Intervals (page or minute) Control Remarks Switch Execution Execution Execution Execution (SP7-907) The development bias is adjusted. executed executed executed executed The development bias executed executed executed executed is not adjusted. 5-49 G108...

  • Page 152: Adjusting Development Bias

    • 0: Successful adjustment. M development status • 1: Not successful • 0: Successful Y development status • 1: Not successful — NOTE: The default development bias is used if the latest TMA or development bias adjustment is not successful. G108 5-50...

  • Page 153: User Program Mode

    • PDF Config. Page • Letterhead Mode • Color Setting • Hex Dump • RAM Disk • Color Profile • Operations Test • Notify by Email Language Host Interface • I/O Buffer • I/O Timeout • Network Setup 5-51 G108...

  • Page 154: Dip Switches

    DIP SWITCHES 5.7 DIP SWITCHES Controller Board All switches are off. BCU Board There are no DIP switches on the BCU. G108 5-52...

  • Page 155: Detailed Descriptions

    DETAILED DESCRIPTIONS...

  • Page 157: Overview

    8. OPC belt handle 21. Erase lamp 9. OPC Belt 22. Paper feed roller 10. Input output device PCB 23. Registration roller 11. Development unit K 24. Transfer roller 12. Development unit Y 25. Transfer belt 13. Development unit M G108...

  • Page 158: Paper Path

    3. Paper tray (standard) 2. Paper gate 4. Paper tray unit (optional) The diagram shows the paper path when the optional duplex unit and the optional paper tray unit are installed. (Note: Only one optional Paper Tray Unit can be installed.) G108...

  • Page 159: Drive Layout

    Development motor [C] • Development clutch K [A] → Development unit K • Development clutch Y [B] → Development unit Y • Development clutch M [D] → Development unit M • Development clutch C [E] → Development unit C G108...

  • Page 160: Controller

    Main motor Erase lamp PSU fan Development motor Interlock switch Fusing fan Power supply unit Optional paper tray unit Operation panel (Base Engine Polygon Control Unit) mirror unit motor Main switch Gate Synchronization array detector Optics unit Controller G108D918.WMF G108...

  • Page 161: Base Engine Control Unit (Bcu)

    Controller PCB. Power Supply Unit and High Voltage Unit The power supply unit changes alternating electrical current to direct current. The high voltage unit supplies high-voltage current. The output from the High voltage Unit is controlled by the BECU. G108...

  • Page 162: Printing Process

    (The separation pad ensures only one sheet is transported from the cassette at one time.) 6. Paper registration: The registration roller pauses the paper’s transport momentarily and at the correct time moves the sheet to the paper transfer roller. G108...
  • Page 163 2) The waste-toner collection unit moves the waste toner to the waste toner bottle. 8. Fusing: Using heat and pressure the fusing unit fuses toner images onto the paper. 9. Paper exit: The paper exit unit transports the paper to the paper exit tray. G108...

  • Page 164: Overview

    (develop) a rectangular “pattern” image [B]. 2. This cyan pattern on the transfer belt [A] reflects the light from the ID sensor [C]. 3. The BCU examines the signal level from this sensor, and properly calibrates the ID sensor. G108D929.WMF G108...

  • Page 165: Test Pattern Processing

    The first image [Y ] is lower in density than the second image [Y ]. The second image is lower in density than the third image G108...

  • Page 166: Reference Equation Processing

    Based on the determined equations, this machine adjusts the development bias of each development roller. If the machine, for some reason cannot determine an appropriate linear equation, a default voltage is supplied to the development roller and the calculation will be attempted on the next cycle. G108 6-10...

  • Page 167: Optical Housing Unit

    7. The barrel toroidal lens [F] focuses the laser beam on the third mirror, and ensures uniform pixel spacing and diameter. 8. The third mirror [A] reflects the laser beam. 9. The fourth mirror [C] reflects the laser beam. 6-11 G108...

  • Page 168: Laser Synchronization

    The table lists some specifications of the optical housing unit. Rated output of laser diode 5 mW Laser beam wavelength Approx. 785 nm Scanning resolution 600 dpi Scanning width 314 mm Number of rotations of polygon mirror (per minute) 35,904 rpm Polygon mirror faces G108 6-12...

  • Page 169: Optics Unit Fan

    G108D956.WMF 6.3.5 LASER EXPOSURE The optical housing unit [A] contains the laser and mirror components. Laser light emitted from the optics unit “writes” the latent image on the OPC belt [B]. G108D922.WMF 6-13 G108...

  • Page 170: Safety Switch

    [F] is not attached to a safety switch. The printer can operate even when you pull the lever (so long as the rear cover stays closed). NOTE: The top cover also does not have such a lever. G108 6-14...

  • Page 171: Opc Belt

    (waste toner) goes into the waste toner duct [F]. The waste toner feeder [D] moves waste toner towards the right end of the waste toner duct. At this time the waste toner enters the waste-toner collection unit. G108D927.WMF 6-15 G108...

  • Page 172: Charge Roller And Cleaning Roller

    The left end of the charge roller is attached to the BRV [B] terminal on the HVU. The left end of the cleaning roller is attached to CLV [A] terminal on the HVU. G108 6-16...

  • Page 173: Opc Belt Sensor

    OPC belt and the transfer belt, quenches any residual electrical charges remaining on the OPC belt. The harness from the erase lamp connects to DCN15 on the input output device (IOD) PCB. G108D932.WMF 6-17 G108...

  • Page 174: Development Unit

    The plate located on the front left corner of the development unit pushes the feeler. The left end of the feeler (interrupter) then moves out of the development unit sensor. This then activates the development unit sensor. G108D938.WMF G108 6-18...

  • Page 175: Drive

    DEVELOPMENT UNIT 6.5.3 DRIVE G108D904.WMF For the development process, the G108 utilizes a single (one) development motor [A] and four development clutches [B]. When each development clutch is on (activated), rotational drive is transferred to the development drive gear [C] (shown below).

  • Page 176: Development Unit Contact Mechanism

    OPC belt.) 5. The development roller contacts the OPC belt. (A black tab located on the left front-side of the development unit keeps the unit from moving too far forward.) G108 6-20...

  • Page 177: Spring Clutch

    The development unit K [A] and the development unit Y [B] are attached to DBVKY terminal [E] on the HVU. The development unit M [C] and the development unit C [D] are attached to DBVMC terminal [F] on the HVU. 6-21 G108...

  • Page 178: Toner End Sensor

    (YMC) becomes empty, the machine stops color printing. Monochrome black printing continues. If the black development unit becomes empty, the machine stops printing. NOTE: The figure (250 images) is calculated under these conditions: 1 A4/LT size, two pages per job, 50% color ratio, 5% coverage. G108 6-22...

  • Page 179: Transfer Belt

    The OPC belt [A] and the transfer belt [B] are in contact with each other. Because of this, the transfer belt’s rotation is in synchronization with the OPC belt. The main motor drives the OPC belt and contact with the OPC belt drives the transfer belt. 6-23 G108...

  • Page 180: Transfer Belt Sensor And Id Sensor

    G108D929.WMF Transfer Belt Sensor The G108 uses a reflective photosensor called the transfer belt sensor [B], located below the left side of the transfer belt, to detect belt rotation The transfer belt sensor first emits light on to the band [A], located on the left end of the transfer belt, and then receives the reflection from this band.

  • Page 181: Id Sensor Cleaning

    [B] above the right rail of the paper tray. Each time you insert of extract the paper tray from the printer, the cleaning Mylar cleans the surface of the first Mylar strip, the protective Mylar. 6-25 G108...

  • Page 182: Transfer Belt Cleaning

    At this time, the toner goes into the waste-toner collection unit. Drive The main motor drives the right side gear of the cleaning roller via idle gears. The left side gear of the cleaning roller transmits this drive power to the cleaning brush and the waste toner feeder. G108 6-26...

  • Page 183: Contact-Release Mechanism

    [f] on the camshaft. In this position, the cam stays in its lower position [e] and does not push up the cleaning unit release pin [d]. As a result, the cleaning unit stays in contact with the transfer belt. 6-27 G108...

  • Page 184: Waste Toner Agitator

    The waste toner agitator moves along the vertical waste toner path when the gear-shaft turns. The waste toner agitator agitates the waste toner in the vertical waste toner path. This process ensures that waste toner does not become blocked in the waste toner path. G108 6-28...

  • Page 185: Waste-Toner Collection Unit

    The drive power is transferred to the collection coil via the gears [E] located on the left end of the unit. NOTE: The gear [F] on the right end also routes drive power to the OPC-belt charge roller ( 6.4.1). 6-29 G108...

  • Page 186: Waste Toner Sensor

    When the waste toner bottle becomes almost full, the machine displays the message "Waste Toner is Almost Full.” From this point, the machine can make 200 developments. The machine will not print until the waste toner bottle is replaced after it has made the 200 developments. G108 6-30...

  • Page 187: Paper Tray Unit

    PAPER TRAY UNIT 6.7 PAPER TRAY UNIT 6.7.1 OVERVIEW G108D919.WMF 1. Transfer roller 4. Friction pad 2. Registration roller 5. Paper tray 3. Paper feed roller 6-31 G108...

  • Page 188: Paper Lift

    When you pull the paper tray out of the printer, the triangular rails [D] located on both sides push the levers [B], gradually down. Now the plate is at its lowermost position. And as described above, the hooks [C] hold the bottom plate in this position. G108 6-32...

  • Page 189: Paper Feed

    The friction pad [B] prevents the sheet below the topmost from also being fed. Drive The main motor drives the paper feed clutch ( 6.1.3). When activated, the paper feed clutch transfers the drive torque to the paper feed roller. 6-33 G108...

  • Page 190: Paper Size And Paper Tray Detection

    Not interrupted Interrupted DL/#10 Interrupted Not interrupted Not interrupted Interrupted Not interrupted Interrupted Not interrupted Interrupted Executive Interrupted Not interrupted Interrupted Interrupted Letter Interrupted Interrupted Not interrupted Interrupted Not interrupted Not interrupted Interrupted Interrupted Legal* * Optional legal-size tray G108 6-34...

  • Page 191: Sm G108

    NOTE: The optional paper tray unit does not have an OHP sensor. The paper tray unit cannot feed OHP sheets. Configuration Page and Utilities The Configuration Page (Menu > List/Test Print > Config. Page) shows the user settings in Paper Input. The utility software programs do not reference the OHP sensor. 6-35 G108...

  • Page 192: Ohp Sensor, User Setting, And Printer Driver

    • Simplex: OHP (= Printer driver) (= User setting) • Duplex: Glossy Not OHP Not OHP Not OHP Glossy Glossy Glossy No inconsistency Not OHP Not OHP Not OHP Not OHP No inconsistency (= Printer driver) (= User setting) G108 6-36...

  • Page 193: Paper End Sensor

    In this case, the feeler does not actuate (interrupt) the paper end sensor. When the paper is not in the tray, the bottom end of the feeler drops into an opening in the paper tray’s base [C]. In this case, the feeler actuates (interrupts) the paper end sensor. 6-37 G108...

  • Page 194: Paper Registration And Paper Transfer

    [C] which is located on the rear left corner of the printer. When the paper reaches the registration roller, the paper lifts the paper feeler. The left end of the feeler (interrupter) unblocks (de-actuates) the registration sensor. G108 6-38...

  • Page 195: Paper Transfer

    (activates) and the lobe of the cam pushes the transfer roller lever [A] back, which moves the transfer roller assembly away from the OPC belt. The transfer roller clutch receives its rotational torque from the main motor. G108D935.WMF 6-39 G108...

  • Page 196: Fusing Unit

    FUSING UNIT 6.9 FUSING UNIT 6.9.1 OVERVIEW G108D914.WMF 1. Pressure roller 6. Tension bolt 2. Pressure-roller sheet 7. Hot roller 3. Tension arm 8. Fusing thermostat 4. Fusing lamp 9. Fusing thermistor 5. Tension lever G108 6-40...

  • Page 197: Drive

    Releasing the pressure may be necessary to remove jammed paper from the fusing unit. 6.9.4 FUSING PROCESS The hot roller and the pressure roller are approximately 150°C (302°F) during the fusing process. The pressure between these two rollers is approximately 300 N (Newtons) 6-41 G108...

  • Page 198: Temperature Control

    The fusing lamp goes off if either one of the two fusing thermostats “breaks” the electrical circuit. Note: Items 1 and 2 above are on two individual (separate) electrical circuits. See next page for: TS, TA and TPS descriptions. G108 6-42...

  • Page 199: Temperature

    • TPS: The fusing thermostats “break” (open) the electrical circuit to the fusing lamp, fusing is disabled, and the printer will not print. Energy Saver Mode While the printer is in energy saver mode, the fusing lamp is off. 6-43 G108...

  • Page 200: Paper Exit Unit

    Should the paper stack in the paper exit tray become too high, the left end of the feeler (interrupter) unblocks (de- actuates) the paper overflow sensor and a message is displayed. G108 6-44...

  • Page 201: Controller

    Program ROM 24 MB SD card slots NVRAM 32 KB Not expandable Printer language RPCS, PCL5c, PS3 (PDF) Emulation None Hard disk Standard: None Optional: 10 GB Network Interface Standard: IEEE 1284, USB 2.0, Ethernet Optional: IEEE 802.11b, Bluetooth 6-45 G108...

  • Page 202: Board Layout

    SD card slot 1 SDRAM (128 MB) 10 SD card slot 2 IEEE 1284 port 11 IDE I/F 12 BCU I/F ASIC (Piccolo) 13 ASIC (Horn) Ethernet I/F 14 NVRAM DIP switch 15 I/F for an optional board USB 2.0 port G108 6-46...

  • Page 203: Controller Functions

    “Auto Continue” (Menu > System > Auto Continue) is disabled (Off). When Auto Continue is enabled (Immediate/1 minute/5 minutes/10 minutes/15 minutes), the controller will start the job again automatically, after one minute, five minutes, 10 minutes, or 15 minutes. 6-47 G108...

  • Page 204: Black Over Print

    As a result of this over-print, even if the line position of the black toner is not correct, the undesirable white line (void area) will not be present when transferred to the paper and fused. G108 6-48...

  • Page 205: Network Data Protection Unit

    SSL) or the use of a third-party CA certificate. Secured printing via SSL can only be utilized when printing via IPP. SmartDeviceMonitor is the recommended utility to use when printing IPP. Supported Network Interface The NDPU supports these network interfaces: Ethernet, IEEE 1394, and IEEE 802.11b. 6-49 G108...

  • Page 206: Ethernet Board

    Operating Standard Interface, is a framework upon which networking standards are arranged. It is commonly diagramed as a layered pyramid with the physical layer, Layer 1, on the bottom of the pyramid, and layer 7, the application layer, at the top. G108 6-50...

  • Page 207: Ethernet

    Ethernet interface unit. The table lists the indications of these LEDs. G108D951.WMF Function Status On: 100 Mbps mode Orange [A] Indicates the operation mode Off: 10 Mbps mode On: Link Safe Green [B] Indicates the link status Off: Link Fail 6-51 G108...

  • Page 208: Usb 2.0

    Type B supports two types of connectors– Type A and Type B. Type A is used on G108D965.WMF G108D966.WMF the host device, such as a computer. Type B is used for the peripheral device, such as a printer. G108 6-52...

  • Page 209: Pin Assignment

    Transfer Rate (SP5-844-001) adjusts the transfer rate of the USB port. You can specify Auto Change or Full Speed (12 Mbps). If Auto Change frequently causes transfer errors, you should try specifying Full Speed as a possible solution to this issue. 6-53 G108...

  • Page 210: Ieee 802.11B (Wireless Lan)

    TCP/IP, Apple Talk, NetBEUI, IPX/SPX Bandwidth: 2.4 GHz (divided over 14 channels, 2400 to 2497 MHz for each channel) LED Indicators Description LED 1 (Green) Link Status Linked No Link LED 2 (Orange) Power Distribution Power On Power Off G108 6-54...

  • Page 211: Transmission Modes

    This arrangement is usually used in complex topologies. However the current low cost of good quality access points makes this the choice of smaller installations as well. Each node uses the same Service Set ID (SSID) as the access point’s to communicate. G108D958.WMF 6-55 G108...

  • Page 212: Security Features

    You can specify WEP keys from Web Device Monitor or via Telnet. MAC Address When infrastructure mode is used, MAC addresses can be also used to manage access. NOTE: Some types of access points do not support MAC addresses. G108 6-56...

  • Page 213: Troubleshooting

    To avoid interference with neighboring channels, it is recommended that you change the channel by three. For example, if channel 11 (default) is currently used, try using channel 8. 25MHz 25MHz Channel 2,412 2,437 2,462 G108D967.WMF 6-57 G108...

  • Page 214: Communication Status

    If the communication condition is not good, try the following: • Move the printer closer to the access point. • Check for anything that might interfere with wireless communication. • If the problem is not solved, try changing the channel. G108 6-58...

  • Page 215: Bluetooth

    (IRDA). Bluetooth nodes do not require any special settings. Standard: Bluetooth 1.1 (Bluetooth Special Interest Group) Data transfer: 1 Mbps Bandwidth: 2.4 GHz Frequency Hopping Spread Spectrum (FHSS) 6.15.2 BLOCK DIAGRAM Interface Board PCMCIA Bluetooth Card Bus PCMCIA Card Controller Controller Board G108D968.WMF 6-59 G108...

  • Page 216: Communication

    By doing so, the nodes on one Piconet avoid interference with other nodes on other Piconets located on the same LAN even if they use the same radio band. Channel 1 Channel 2 Channel 3 Time G108D969.WMF G108 6-60...

  • Page 217: Profiles

    A computer can communicate with a node when the node sends the PIN code. PIN codes are 4-digit numbers. The G108 uses the last four digits of its serial number as the PIN code. You cannot change the PIN code.

  • Page 219: Specifications

    SPECIFICATIONS...

  • Page 221: General Specifications

    Min. 104.8 mm x 210 mm Supported Paper Sizes) Paper Weight: Standard tray: 60 ∼ 210 g/m (16 lb.~ 55 lb.) Optional paper feed unit: 60 ∼ 105 g/m (16 lb. ~ 28 lb.) Output Paper 250 sheets (face down) Capacity: G108...
  • Page 222 482 x 525 x 436 mm With PFU and duplex unit: 482 x 525 x 591 mm Weight: Printer: 31.5 kg PFU: 5.8 kg Duplex unit: 5.3 kg Environmental Energy star tier 2 specifications Standard: Safety Standard: UL 1950/1995 Third Edition G108...

  • Page 223: Supported Paper Sizes

    The paper size is selected manually North America (Menu > Paper Input > Tray 1/2 Paper Size). Europe The paper size is not detected; but the paper SEF: Short edge feed can be used. LEF: Long edge feed The paper size is not usable. G108...

  • Page 224: Software Accessories

    • SmartDeviceMonitor for Client Helps users to manage their own print status on the network. For more information about SmartDeviceMonitor for Client, see SmartDeviceMonitor for Client Help. • USB Printing Support Provides USB connection to Windows 98 SE/Windows Me. G108...

  • Page 225: Machine Configuration

    SPECIFICATIONS 4. MACHINE CONFIGURATION G108V901.WMF Unit EDP Code Diagram Remarks Printer G108 Duplex unit AD460 G390 Paper tray unit Type 1000 G389 Legal paper cassette Type 1000 G391 For U.S. model only G108...
  • Page 226 G332 Hard disk drive Type 2600 G575 Network data protection unit Stored on an SD card G394 Type A IEEE 802.11b interface unit G682 Type D Cannot install both at the same time. Bluetooth interface unit Type G377 2238 G108...

  • Page 227: Paper Tray Unit

    Dimensions (W x D x H): Duplex unit only: 345 mm x 185 mm x 406.2 mm With the printer: 480 mm x 522 mm x 440 mm Weight Duplex unit only: Approx. 5.3 kg With the printer: Approx. 35.8 kg G108...
  • Page 229 G389 PAPER FEED UNIT TYPE 1000...
  • Page 231 PAPER FEED UNIT G389 TABLE OF CONTENTS 1. REPLACEMENT AND ADJUSTMENT ..........1 1.1 EXTERIOR COVERS..................1 1.1.1 TOP COVER AND SENSOR COVER ..........1 1.1.2 BOTTOM BASE AND REAR COVER ..........2 1.1.3 RIGHT COVER ..................4 1.1.4 LEFT COVER ..................4 1.2 FEED ROLLER AND SEPARATOR PAD .............

  • Page 233: Read This First

    Read This First Safety and Symbols Replacement Procedure Safety Turn off the main power switch and unplug the machine before beginning any of the replacement procedures in this manual. Symbols Used in this Manual This manual uses the following symbols. : See or Refer to : Screws : Connector...

  • Page 235: Replacement And Adjustment

    Exterior Covers 1. REPLACEMENT AND ADJUSTMENT 1.1 EXTERIOR COVERS Turn the power off and disconnect the printer before you remove parts of the printer. Symbols: : See or refer to, : Screw, : Connector, : Clip ring, : E ring 1.1.1 TOP COVER AND SENSOR COVER When you reassemble, attach the top cover before you close the paper tray.

  • Page 236: Bottom Base And Rear Cover

    Exterior Covers Sensor cover [D] 1.1.2 BOTTOM BASE AND REAR COVER Remove the printer from the paper feed unit. Tray Three screws on the bottom base [A] Do not remove the stud shafts [C] at this time. If you remove the stud shafts, the bottom base becomes loose.
  • Page 237 Exterior Covers Top cover ( "Top Cover and Sensor Cover") Clutch assembly ( "Paper Feed Clutch") Ground plate [B] ( x 1) Stud shafts [C] Bottom base [D] Rear cover [E] ( x 2) G389...

  • Page 238: Right Cover

    Exterior Covers 1.1.3 RIGHT COVER Rear cover ( "Bottom Base and Rear Cover") Right cover [A] ( x 2) 1.1.4 LEFT COVER Rear cover ( "Bottom Base and Rear Cover") Left cover [A] ( x 2) G389...

  • Page 239: Feed Roller And Separator Pad

    Feed Roller and Separator Pad 1.2 FEED ROLLER AND SEPARATOR PAD 1.2.1 FEED ROLLER Tray Gear [A] ( x 1) Bushing [B] ( x 1) Bushing [C] ( x 1) Feed roller (with the shaft) [D] G389...
  • Page 240 Feed Roller and Separator Pad Roller support [E] ( x 1) Feed roller [F] Necessary Setting After replacing the feed roller, reset the PM counter for this part (see the service manual for the main body). G389...

  • Page 241: Separator Pad

    Feed Roller and Separator Pad 1.2.2 SEPARATOR PAD Feed roller (with the shaft) ( "Feed Roller") Separator pad [A] Necessary Setting After replacing the feed roller, reset the PM counter for this part (see the service manual for the main body). G389...

  • Page 242: Sensors

    Sensors 1.3 SENSORS 1.3.1 PAPER END SENSOR Sensor cover ( "Covers – Top Cover and Sensor Cover") Sensor [A] ( x 1) 1.3.2 PAPER END FEELER AND LINK LEVER Sensor cover ( "Covers – Top Cover and Sensor Cover") Tray Stopper [A] Link lever [B] G389...

  • Page 243: Paper Size Sensor

    Sensors Paper end feeler [C] Reassembling Attach the link lever. Attach the stopper. Close the tray. Attach the paper end feeler. Attach the sensor cover. 1.3.3 PAPER SIZE SENSOR Tray [A] Sensor cover (with the sensor) [B] ( x 1) G389...
  • Page 244 Sensors Paper size sensor [C] ( x 2, x 2) G389...

  • Page 245: Paper Feed Clutch

    Paper Feed Clutch 1.4 PAPER FEED CLUTCH Top cover ( ‘Covers’) Clutch assembly [A] ( x 1, x 2) Bushing [B] ( x 1) G389...
  • Page 246 Paper Feed Clutch Gear [C] ( x 1) Bushing [D] Clutch shaft [E] ( x 2) Paper feed clutch [F] G389...

  • Page 247: Relay Gears

    Relay Gears 1.5 RELAY GEARS Clutch assembly ( "Paper Feed Clutch") Relay gears [A] ( x 2) Reassembling Make sure that you attach the spring [B] to the relay gear bracket and the clutch assembly bracket. G389...

  • Page 248: Details

    Paper Size and Paper Tray Detection 2. DETAILS 2.1 PAPER SIZE AND PAPER TRAY DETECTION There is a printed circuit board [B] at the rear end of the right paper-tray rail. There are four photosensors on this PCB. The three photosensors on the front side [E] [F] [G] are the paper size sensors.
  • Page 249 Paper Size and Paper Tray Detection Paper Size Sensor Paper Tray Sensor Paper Size Interrupted Interrupted Not interrupted Interrupted Executive Not interrupted Interrupted Not interrupted Interrupted Letter Interrupted Not interrupted Not interrupted Interrupted G389...

  • Page 250: Paper Lift

    Paper Lift 2.2 PAPER LIFT A spring [H] and a white bar are below the bottom plate [G]. The white bar has a spring [A] and two hooks [D]. These hooks hold the bottom plate. The white bar moves to the two sides.

  • Page 251: Paper Feed

    Paper Feed 2.3 PAPER FEED The paper feed unit does not have a motor. The main motor of the printer drives the topmost gear [A] in the clutch assembly. The clutch [B] sends drive power to the paper feed roller [C] when it is set on.

  • Page 252: Paper End Detection

    Paper End Detection 2.4 PAPER END DETECTION 2.4.1 PAPER END SENSOR A paper end sensor [A] and a feeler [C] are on the top cover [D]. The feeler stays on the topmost paper in the paper tray. When the paper tray is empty, the feeler falls into the opening [E] in the bottom plate.

  • Page 253: Link Lever

    Paper End Detection 2.4.2 LINK LEVER Function A link lever is on the top cover. This link lever lifts the feeler of the paper end sensor when the paper tray is out of the paper feed unit. The link lever lets the feeler fall down when the paper tray is in the paper feed unit.
  • Page 255 G390 DUPLEX UNIT...
  • Page 257 DUPLEX UNIT G390 TABLE OF CONTENTS 1. REPLACEMENT AND ADJUSTMENT ..........1 1.1 EXTERIOR COVER ..................1 1.2 PAPER GUIDE ..................... 3 1.2.1 REAR GUIDE ..................3 1.2.2 LOWER GUIDE ................... 3 1.2.3 TOP GUIDE..................4 1.2.4 UPPER GUIDE ..................5 1.3 SCREW BASE....................

  • Page 259: Replacement And Adjustment

    EXTERIOR COVER 1. REPLACEMENT AND ADJUSTMENT  CAUTION Turn off the main power switch and disconnect all cabling, including the A.C. cord, from the printer before you remove any parts. Keys:  : Screw  : Connector : See or refer to ...
  • Page 260 EXTERIOR COVER 4. Top cover [A] ( x 2, 2 hooks [B]) G390R903.WMF 5. Release the supports [C][D]. 6. Release the hinge [E]. 7. Rear cover [F] G390R904.WMF G390...

  • Page 261: Paper Guide

    PAPER GUIDE 1.2 PAPER GUIDE 1.2.1 REAR GUIDE 1. Left cover, right cover 1.1) 2. Gear [A] 3. Timing belts [B][C] 4. Spacer [D] 5. Bushing [E] 6. Bushing [F] 7. Inverting roller [G] 8. Rear guide [H] G390R906.WMF 1.2.2 LOWER GUIDE 1.

  • Page 262: Top Guide

    PAPER GUIDE 3. Timing belt ( x 1) [B] 4. Gear [C] 5. Bushing [D] 6. Bushing [E] ( x 1) 7. Exit roller [F] 8. Lower guide [G] ( x 2) G390R907.WMF 1.2.3 TOP GUIDE 1. Left cover, right cover, top cover 1.1) 2.

  • Page 263: Upper Guide

    SCREW BASE 1.2.4 UPPER GUIDE 1. Top guide ( 1.2.3) 2. Entrance roller ( 1.6.1) 3. Upper guide [A] ( x 2) G390R920.WMF 1.3 SCREW BASE 1. Open the rear cover [A]. 2. Open the rear guide [B]. 3. Attachment screws [C][D] ( x 1 for each) G390R921.WMF G390...

  • Page 264: Controller Board

    CONTROLLER BOARD 1.4 CONTROLLER BOARD 1. Left cover ( 1.1) 2. Controller board [A] (All 's,  x 2) G390R905.WMF 1.5 DRIVE PATH 1.5.1 MOTOR 1. Right cover ( 1.1) 2. Transport motor [A] ( x 1,  x 2) 3.

  • Page 265: Gears And Timing Belts

    DRIVE PATH 1.5.2 GEARS AND TIMING BELTS 1. Feed motor, exit motor ( 1.5.1) 2. Spacer [A] ( x 1) 3. Two timing belts [B][C] 4. Gear [D] 5. Timing belt [E] 6. Spacer [F] 7. Bushing [G] 8. Gear [H] 9.

  • Page 266: Roller

    ROLLER 1.6 ROLLER 1.6.1 ENTRANCE ROLLER 1. Left cover, right cover, top cover ( 1.1) 2. Timing belt x 1, gear x 1 1.5.2) 3. Bushing [A] 4. Bushing [B] ( x 1) 5. Entrance roller [C] G390R919.WMF 1.6.2 UPPER TRANSPORT ROLLER 1.

  • Page 267: Lower Transport Roller

    INTERLOCK SAFETY SWITCHES 1.6.3 LOWER TRANSPORT ROLLER 1. Left cover, right cover, top cover 1.1) 2. Timing belt x 1, gear x 1, bushing 1.5.2) 3. Bushing [B] ( x 1) 4. Lower transport roller [C] 1.6.4 INVERTING ROLLER G390R922.WMF 1.2.1 1.6.5 EXIT ROLLER 1.2.2...

  • Page 268: Sensor

    SENSOR 1.8 SENSOR 1.8.1 PAPER SENSOR 2 1. Rear cover ( 1.1) 2. Sensor bracket (with the sensor) [A] ( x 1) 3. Paper sensor 2 [B] ( x 1) G390R912.WMF 1.8.2 PAPER SENSOR 1 1. Remove the duplex unit from the printer.

  • Page 269: Paper Gate Solenoid

    PAPER GATE SOLENOID 1.9 PAPER GATE SOLENOID G390R914.WMF 1. Left cover ( 1.1) 2. Paper gate solenoid [A] ( x 2) Reassembling Make sure that the solenoid correctly engages with the lever [B]. G390...

  • Page 270: Stopper

    STOPPER 1.10 STOPPER G390R916.WMF 1. Make sure that the screws [A] inside the rear paper guide [B] are correctly attached. NOTE: The duplex unit is unstable and unsafe if these screws are not correctly attached. 2. Release the bolt [C] from the printer. NOTE: The screw will not come off the stopper.

  • Page 271: Detailed Section Descriptions

    COMPONENT LAYOUT AND PAPER PATH 2. DETAILED SECTION DESCRIPTIONS 2.1 COMPONENT LAYOUT AND PAPER PATH G390D901.WMF 1. Paper gate (of the printer) 6. Lower transport roller 2. Entrance roller 7. Inverting roller 3. Upper transport roller 8. Paper sensor 2 4.

  • Page 272: Drive Layout

    DRIVE LAYOUT 2.2 DRIVE LAYOUT G390D902.WMF 1. Entrance roller gear 5. Inverting roller gear 2. Upper transport roller gear 6. Inverting motor 3. Relay gear 7. Lower transport roller gear 4. Transport motor 8. Exit roller gear G390...

  • Page 273: Duplex Printing Process

    DUPLEX PRINTING PROCESS 2.3 DUPLEX PRINTING PROCESS Overview of the duplex printing procedure: 1. The printer prints the second side of the first sheet. 2. The paper gate solenoid then energizes to actuate (open) the paper gate [A] ( 2.4). The leading edge of the first sheet [B] then enters the duplex unit.

  • Page 274: Paper Gate Control

    PAPER GATE CONTROL 2.4 PAPER GATE CONTROL Solenoid and Lever The paper gate solenoid [C] controls the motion of the lever [B]. The spring [A] lifts the lever when the solenoid is de-energized (off). The solenoid pulls down the lever when the solenoid is energized (on).

  • Page 275: Paper Transport

    PAPER TRANSPORT 2.5 PAPER TRANSPORT G390D905.WMF Overview There are two motors on the right side of the duplex unit, the transport motor [F], and the inverting motor [g]. These two motors drive five separate rollers. NOTE: The rollers and paper path shown with uppercase letters are mostly related to the transport roller.

  • Page 276: Safety Switches

    SAFETY SWITCHES 2.6 SAFETY SWITCHES The duplex unit utilizes two interlock safety switches. There is one on the left side and one on the right side of the unit. These switches de-actuate (and electrically open) when you open the rear cover of the duplex unit. The printer stops printing when either one of the two safety switches are de- actuated (open).

  • Page 277: Troubleshooting

    LOOSE CONNECTION 3. TROUBLESHOOTING 3.1 LOOSE CONNECTION The table below lists some possible symptoms that can be caused by loose connections on the duplex controller board. Symptom Possible Cause The operation panel shows that the printer One of the following connectors is not connected: CN101, CN103, CN108, CN109.

  • Page 278: Paper Jam

    PAPER JAM 3.2 PAPER JAM The table below lists some possible symptoms for paper jams. Symptom Possible Cause The paper stops after it has been fed The duplex unit is incorrectly installed. The halfway into the duplex unit. screws behind the rear paper guide [A] are not fastened ( Option Setup Guide).

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