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SM

11-3

G049/G054

G

049/G

0

54

2. DETAILED SECTION DESCRIPTIONS

2.5 PAPER FEED

2.5.1 OVERVIEW G054

The built-in tray for the G032 can only hold A4/letter size. However, the G054 tray
can handle A4/letter or shorter.

The paper feed speed for the G049/G054 is the same as that of the G031/G032.
However, the feeding interval has been decreased in the G049/G054, allowing a
higher PPM.

2.10 PRINTER CONTROL BOARD

PCB LAYOUT

G049

Flash

ROM

DIP SW

ASIC

EEPROM

CPU

RAM

RAM

Centronics I/F

Option Bus (CN 2)

Option Bus (CN 3)

DIMM Slot

Control Panel

Engine I/F

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Summary of Contents for G031

Page 1: ...SERVICE MANUAL 000832MIU G031 G032 G049 G054 RICOH GROUP COMPANIES...

Page 2: ......

Page 3: ...SERVICE MANUAL G031 G032 G049 G054 RICOH GROUP COMPANIES...

Page 4: ......

Page 5: ...G031 G032 G049 G054 SERVICE MANUAL 000832MIU...

Page 6: ......

Page 7: ...RMISSION OF RICOH CORPORATION All product names domain names or product illustrations including desktop images used in this document are trademarks registered trademarks or the property of their respe...

Page 8: ......

Page 9: ...tion Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program Untrained and uncertified users utilizing information contained in...

Page 10: ......

Page 11: ...ANY GESTETNER RICOH SAVIN G031 P7020 AP2000 SLP20 G032 P7014 AP1400 SLP14 G049 P7021 AP2100 SLP21 G054 P7016 AP1600 SLP16 DOCUMENTATION HISTORY REV NO DATE COMMENTS 5 99 Original Printing 4 2000 G049...

Page 12: ......

Page 13: ...S 2 1 2 1 PRINTING 2 1 2 1 1 IMAGE DATA PATH 2 1 2 1 2 PRINTER CONTROL BOARD 2 2 2 1 3 IMAGE DATA PROCESSIING 2 3 2 1 4 HOST INTERFACE 2 4 2 2 LASER EXPOSURE 2 5 2 2 1 OVERVIEW 2 5 2 2 2 OPTICAL PATH...

Page 14: ...BOARD 2 47 2 10 1 PCB LAYOUT 2 47 2 10 2 DEVICES 2 48 INSTALLATION 3 INSTALLATION 3 1 3 1 INSTALLATION REQUIREMENTS 3 1 3 1 1 ENVIRONMENT 3 1 3 1 2 POWER REQUIREMENTS 3 1 3 2 PRINTER INSTALLATION 3 2...

Page 15: ...8 2 POWER UP DIAGNOSTIC MODE 4 25 4 8 3 DETAILED DIAGNOSTIC MODE 4 26 4 8 4 DIAGNOSTIC TEST DETAILS 4 27 4 9 FIRMWARE HISTORY 4 29 4 9 1 CONTROLLER FIRMWARE HISTORY G031 4 29 4 9 2 CONTROLLER FIRMWAR...

Page 16: ...6 25 6 6 2 MAIN MOTOR GEAR BOX REMOVAL 6 26 6 6 3 ENGINE CONTROL BOARD REPLACEMENT 6 27 6 6 4 PRINTER CONTROL BOARD REPLACEMENT 6 28 6 6 5 HIGH VOLTAGE SUPPLY BOARD 6 29 6 6 6 POWER SUPPLY UNIT REPLAC...

Page 17: ...REPLACEMENT 9 10 4 1 3 PAPER FEED MOTOR REPLACEMENT 9 11 4 1 4 PAPER FEED CLUTCH REMOVAL 9 12 4 1 5 PAPER FEED UNIT BOARD PAPER SIZE SWITCH REPLACEMENT 9 13 4 2 PAPER FEED UNIT OPTION FOR STINGER P4 9...

Page 18: ...INDICATIONS 10 16 4 2 NIB FIRMWARE MODIFICATION HISTORY 10 17 G049 G054 SERVICE MANUAL OVERALL INFORMATION 1 OVERALL MACHINE INFORMATION 11 1 1 1 SPECIFICATIONS 11 1 1 2 MACHINE CONFIGURATION 11 2 DET...

Page 19: ...ENDIX 4 1 2 2 SERVICE TOOL MENUS APPENDIX 5 1 2 3 STINGER SERVICE UTILITY SSU APPENDIX 7 1 3 USING AN IC CARD APPENDIX 8 1 3 1 PREPARING THE IC CARD APPENDIX 8 1 3 2 DOWNLOADING FROM THE IC CARD TO TH...

Page 20: ......

Page 21: ...he mechanical and electrical components because the printer starts making prints as soon as the warm up period is completed 5 The inside and the metal parts of the fusing unit become extremely hot whi...

Page 22: ...assis is not repairable in the field Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is r...

Page 23: ...031 G032 G049 G054 SERVICE MANUAL SERVICE PROCEDURES AND TABLES G031 G032 APPENDIX PREVENTIVE MAINTENANCE G031 G032 REPLACEMENT AND ADJUSTMENT G031 G032 TROUBLESHOOTING G031 G032 ENVELOPE FEEDER G913...

Page 24: ......

Page 25: ...OVERALL INFORMATION...

Page 26: ......

Page 27: ...4 LT SEF standard tray Resolution True 1 200 x 1 200 dpi available for PCL6 or PostScript 600 x 600 dpi 300 x 300 dpi simulated by doubling pixel width and height at 600 dpi resolution Printer Languag...

Page 28: ...velope Feeder Com 10 C6 DL Monarch Printing Paper Weight Paper tray 60 90 g m2 16 24 lb By pass 60 162 g m2 16 43 lb Power Source G031 120 V 60 Hz More than 8 0 A for North America 220 V 240 V 50 60 H...

Page 29: ...nal Envelope Feeder 60 envelopes Memory Standard 8 MB up to 40 MB with optional SIMM Toner Cartridge Information G031 G032 Pre set Toner Cartridge Commercial Toner Cartridge Pre set Toner Cartridge Co...

Page 30: ...anager Aficio Manager Operating Instructions G031 G032 22 27 29 Utility Software Optional Network Interface Board IP P2P IPXP2P MAP Bootpl NW setup NIB User s Manual Acrobat Reader Maintenance Kit Fus...

Page 31: ...Feed Unit Type 1400 G914 57 D Envelope Feeder Type 1400 G913 57 Internal Options E Network Interface Board Type 2000 G919 17 F RS232C Board Type 2000 G527 17 G Hard Disk Drive Type 2000 G690 17 H Memo...

Page 32: ...PAPER PATH G031 G032 1 6 SM 1 3 PAPER PATH G031 G032 G031V503 WMF G031V504 WMF Output Tray Paper Tray By pass Tray Output Tray Paper Tray By pass Tray...

Page 33: ...oller 5 By pass Feed Roller 6 By pass Tray 7 Registration Rollers G031 Relay Roller G032 8 Paper Feed Roller 9 Toner Cartridge 10 Paper Tray 11 Polygonal Mirror Motor 12 1st Mirror G031 F theta Lens G...

Page 34: ...Tray Paper Size Switch 10 Registration Sensor 11 By pass Tray Paper Sensor 12 Registration Clutch 13 Toner Near end Sensor 14 Tray Paper End Sensor 15 Fusing Thermistor 16 Tray Paper Near end Sensor 1...

Page 35: ...Solenoid 8 Toner Near end Sensor 9 Registration Sensor 10 By pass Tray Paper Sensor 11 Tray Paper End Sensor 12 Fusing Exit Sensor 13 Fusing Thermistor 14 Control Panel Board 15 Fusing Lamp 16 Thermo...

Page 36: ...PC interface print image processing operation panel and other controller options 25 21 Motors M1 Main Drives the main body components 6 5 M2 Polygonal Mirror Turns the polygonal mirror 24 20 M3 Exhau...

Page 37: ...ers 12 Solenoids SOL1 By pass Feed Starts paper feed from the by pass tray 8 7 SOL2 Tray Paper Feed G032 Starts paper feed from the paper tray 6 Lamps L1 Fusing Heats the hot roller 19 15 Thermistors...

Page 38: ...dark 2 LASER EXPOSURE The processed print image data from the engine control board ECB is transferred to the drum by a laser beam which forms an electrical latent image on the drum surface The areas...

Page 39: ...urrent depends on the resolution and the paper size This pulls the toner particles from the drum surface to the paper At the same time the paper is attracted to the transfer roller 5 PAPER SEPARATION...

Page 40: ...ECB The printer control board controls the control panel board The printer control board is also connected to the personal computer Video I F 5 V 24 V Sensors High Voltage Supply Board Motors Clutche...

Page 41: ...ontrol Board This is the machine s main control board It controls the following functions IEEE 1284 parallel port Edge smoothing and toner saving Engine control board Control panel board Interfacing w...

Page 42: ...than 60 seconds 23 C 73 F Utilities Aficio Manager Dimensions mm W x D x H 450 x 420 x 270 mm with Std Tray adjusted for A4 450 x 555 x 270 mm with Std Tray adjusted for A3 360 x 420 x 270 mm with Std...

Page 43: ...DETAILED DESCRIPTIONS...

Page 44: ......

Page 45: ...l board generates the print image data and sends it with commands to the ECB Engine Control Board The printer control board contains the image processing ASIC ROCKY W The ROCKY W ASIC controls the ima...

Page 46: ...ROM A SIMM card can be installed for extra DRAM memory and a DIMM card can be connected for service purposes firmware upgrade The control board controls the following to produce the print image data...

Page 47: ...s Fig A shows the four possible pulse durations and Fig B shows how the laser pulse can be in one of three positions within the pixel Fig C shows an example of how edge smoothing is used Edge smoothin...

Page 48: ...ional Parallel Interface A 36 pin bi directional parallel interface connector female is used The bi directional parallel interface on the controller works in three modes Compatible Nibble and ECP mode...

Page 49: ...tor Speed rpm Data Frequency MHz 600 300 600 dpi printing 22478 22 22 0926 1 200 1 200 dpi printing 22478 22 44 1851 G032 Resolution dpi Modes Motor Speed rpm Data Frequency MHz 600 300 600 dpi printi...

Page 50: ...al Mirror B Cylindrical Lenses C LD Drive Board D Drum E LD Shutter F F Theta Mirror G BTL Barrel Toroidal Lens H 1st Mirror I F theta Lens J Laser Synchronization Detector K Shield Glass G031D506 WMF...

Page 51: ...polygonal mirror writes the pixels of the latent image on the drum The F theta mirror F ensures constant intervals between the pixels The BTL G corrects for irregularities in the polygonal mirror face...

Page 52: ...iode PD The PD is enclosed in the laser diode The PD passes an electrical current to the LD driver IC and this IC adjusts its output level to keep the laser diode output constant The laser diode power...

Page 53: ...here is a safety switch located at the front cover The switch is on the LD 24 V line Mechanical Laser Shutter When the toner cartridge is removed the laser shutter is released and this interrupts the...

Page 54: ...Roller B Cleaning Blade C OPC Drum D Transfer Roller E Transfer Blade F Development Roller G Mixing Blade H Toner Near end Sensor I Agitator The main motor drives the rollers in the toner cartridge T...

Page 55: ...er A and agitators D through a series of gears The main motor speed is controlled by the engine control board ECB When a new cartridge is installed the machine clears the near end condition if the ton...

Page 56: ...n the machine The high voltage supply board gives a negative dc voltage to the drum charge roller through the charge roller terminal B charge roller pressure spring C and the charge roller bushing D T...

Page 57: ...roller sleeve The doctor blade trims the toner to the desired thickness on the development roller sleeve The development roller does not contact the drum G There is a small gap between the toner on t...

Page 58: ...uired after the sensor is replaced Toner Supply The toner in the toner cartridge is mixed by the agitator s and mixing blade The toner near end sensor is not used to control toner supply When the mach...

Page 59: ...e toner remaining on the drum is scraped off by the cleaning blade and transferred to the collection area The mylar sheet B prevents the toner from dropping out of the cleaning unit The toner cartridg...

Page 60: ...ly keeps the transfer current constant The transfer current depends on the paper size For A3 11 x 17 paper in the G031 7 A is supplied and for A4 LT paper in the G032 6 A is supplied for 600 dpi resol...

Page 61: ...g run During transfer roller cleaning the high voltage supply unit supplies a negative cleaning bias to the transfer roller The negatively charged toner on the transfer roller is then transferred back...

Page 62: ...ion rollers D The paper tray has a friction pad E which allows only one sheet to feed at a time When the paper tray is closed after the paper is loaded the paper size actuator behind the paper size in...

Page 63: ...paper from the paper tray to the relay roller D Then the relay roller feeds the paper to the registration area The paper tray has a friction pad E which allows only one sheet to feed at a time This ma...

Page 64: ...5 Landscape A4 Landscape 71 4 x 101 2 Landscape 81 2 x 11 Landscape 81 2 x 11 Portrait A4 Portrait Long 81 2 x 13 Portrait 8 x 13 Portrait 81 4 x 13 Portrait 81 2 x 14 Portrait B4 Portrait A3 Portrait...

Page 65: ...ion pad C only allows the top sheet to feed Therefore during paper feed the top sheet of paper is separated from the stack and fed to the registration rollers D When the paper actuates the registratio...

Page 66: ...ge of paper sizes by using a user tool at the machine s operation panel Models Switch Location North America Europe Left Center Right 81 2 x 14 Portrait A5 Landscape On On On A4 Landscape A4 Landscape...

Page 67: ...tom Plate Lift The tray bottom plate is connected to the cassette arm A by the spring B When the cassette is put in the machine the slope of the guide block C on the machine lifts the cassette arm up...

Page 68: ...e paper stack to the correct height for paper feed This machine uses a feed roller and friction pad mechanism The friction pad F only allows the top sheet to feed to the relay roller I After one turn...

Page 69: ...ed paper to the registration roller D The by pass feed roller has two cams E and these cams release the by pass tray bottom plate to press the stack of paper against the by pass feed roller This machi...

Page 70: ...roller C starts to feed paper to the relay roller D The by pass feed roller cam E releases the by pass tray bottom plate to press the stack of paper against the by pass feed roller This machine uses a...

Page 71: ...lutch D turns off and the registration rollers stop turning However the tray paper feed roller clutch stays on for a bit longer This delay allows time for the paper to press against the registration r...

Page 72: ...relay roller B However this machine has no registration roller A certain time after the paper leading edge activates the registration sensor the CPU starts to write the latent image on the drum The r...

Page 73: ...fusing unit consists of the following parts 1 Pressure Roller Release Lever 2 Pressure Spring 3 Fusing Lamp 4 Fusing Thermistor 5 New Fusing Unit Detector G031 only 6 Hot Roller 7 Exit Roller 8 Fusing...

Page 74: ...ler A the fusing lamp B and the pressure roller The CPU monitors the hot roller temperature through the fusing thermistor C that is in contact with the hot roller surface The thermofuse D protects the...

Page 75: ...B by springs The hot roller strippers C separate the paper from the hot roller and direct it to the exit roller Then the exit roller feeds the paper to the paper tray 2 6 5 FUSING UNIT DRIVE RELEASE W...

Page 76: ...replacing the fusing unit clear the Replace Maintenance Kit status using the User Menu Maintenance PM Clear procedure There are two terminals A at the rear left side of the fusing unit Before install...

Page 77: ...the machine can start to print at any time The lamp stays on until the thermistor detects the standby temperature A Then the CPU maintains this temperature using on off control To start printing the...

Page 78: ...lb 195 C 195 C Normal paper 165 C 160 C 160 C 155 C Printing 1 200 dpi Thick paper 155 g m 41 lb 165 C 160 C After 26 seconds at 1 200 dpi using normal paper the temperature is reduced G032 Condition...

Page 79: ...in 3 C Over 3 C Over 3 C 100 60 60 60 0 Within 3 C 100 60 60 40 0 0 100 60 60 40 0 Within 3 C 100 60 60 40 0 Over 3 C 100 60 0 0 0 Ratio The proportion of time that the fusing lamp power is on 2 6 8 O...

Page 80: ...activates 15 minutes 30 minutes default 1 hour 2 hours 3 hours This feature is adjusted using the Job Control menu at the printer s operation panel NOTE When the machine is in energy saver mode the C...

Page 81: ...ver push the cover open levers at both sides of the front cover 2 7 2 FRONT COVER SAFETY SWITCH When the user opens the front cover the safety switch release lever A moves and the safety switch releas...

Page 82: ...e A the stopper B blocks the safety switch release lever C Therefore the front cover cannot be closed When the fusing unit is installed properly D the projection on the fusing unit E lifts up the stop...

Page 83: ...31 G032 Detailed Descriptions 2 8 ENGINE CONTROL BOARD 2 8 1 PCB LAYOUT CPU H8 3002 Engine I F C N 4 EPROM C N 6 C N 8 C N 1 0 CN3 C N 7 C N 9 Gate Array CN11 CN5 CN15 CN16 CN12 CN13 CN14 C N 2 EEPROM...

Page 84: ...Serial communication control for I F controller Laser printing control Power width modulation PWM timer LD driver sample hold function Pattern generation Fusing unit control timer Gate Array GAZELLE I...

Page 85: ...SRAM EEPROM Motors Clutches Fan Motor Clutch Sensors Optional Paper Feed Unit Sync Detector LD Drive Board Regulator Driver Driver Laser Diode Fusing Unit Printer Control Board Sensors High Voltage Su...

Page 86: ...Registration Sensor By pass Paper End Sensor 1st Tray Paper End Sensor Paper Near end Sensor 1st Tray Paper Size Sensor Toner Near end Sensor Fusing Unit LD Drive Board Laser Synch Detector Polygon Mo...

Page 87: ...ygon motor on off and rotation speed control Detects the polygon motor lock condition Signal from the laser synchronization detector The detector is built into the LD drive board in the G032 CN8 9 Sig...

Page 88: ...inting request CN1 B8 CBSY I Enables communication from the controller CN1 B9 CCLK I Synchronization clock for serial communication from the controller CN1 B10 CMD I Serial command from the controller...

Page 89: ...3 GND CN8 4 5V CN8 5 SNDCK O 2nd PFU motor lock CN8 6 XSNDFD O 2nd PFU motor on CN8 7 XSNDCL O 2nd PFU paper end clutch on CN8 8 SPSEN I 2nd PFU paper feed sensor CN8 9 EPEND I 2nd PFU paper end dete...

Page 90: ...CN15 1 N C CN15 2 N C CN15 3 CVFB I Transfer roller bias feedback signal CN15 4 TCCFB I Transfer roller bias feedback current CN15 5 MCVFB I Charge voltage feedback signal CN15 6 BIUFB I Development b...

Page 91: ...RAM CPU ASIC Centronics I F DIP S W Option Bus CN2 EEPROM Engine I F Flash ROM Flash ROM DIMM SLOT Option Bus CN3 SIMM Connector Control Panel G031D538 WMF CPU ASIC Centronics I F DIP S W Flash ROM E...

Page 92: ...EPROM 2 KB NVRAM Centronics I F Bi directional parallel interface standardized by IEEE1284 G031 2 slots RS232C Ethernet 100 Base Tx 10 Base T Hard disk drive IC Card adapter for up dating controller f...

Page 93: ...INSTALLATION...

Page 94: ......

Page 95: ...ere it will be exposed to corrosive gases 8 Do not install the machine at any location over 2 000 m 6 500 ft above sea level 9 Place the machine on a strong and level base Inclination on any side shou...

Page 96: ...Instructions 3 4 ENVELOPE FEEDER INSTALLATION See the Installing the Envelope Feeder section in the Operating Instructions 3 5 HARD DISK INSTALLATION See the Hard Disk Installation sheet that comes wi...

Page 97: ...illustration 1 Plug in the power cord and turn on the main switch Then Ready is displayed 2 Press the Menu key to enter the Main Menu 3 Press the Arrow key to select List Print 4 Press the Enter key...

Page 98: ...Toner Saving On System Copies 1 Jam Recovery On I O Timeout 30 seconds Energy Saver 30 minutes Auto Continue Off Page Protect On PCL Menu Orientation Portrait Form Length 60 Font Source Internal Font...

Page 99: ...iguration page shows the size of the hard disk For the NIB confirm that Network Card F printed on the configuration page shows the type of network card For the PCL version of the printer control board...

Page 100: ...elow 3 8 3 PRINTING THE NETWORK INTERFACE BOARD CONFIGURATION SHEET NOTE The NIB configuration sheet will be printed out once just after turning on for the first time when the NIB is installed 1 Insta...

Page 101: ...SERVICE TABLES AND PROCEDURES...

Page 102: ......

Page 103: ...ns most of the field procedures and is covered in section 4 2 IC Card Boot Service Mode Most of these features are covered in the Appendix which describes procedures that are mainly for use in the ser...

Page 104: ...the service mode all LEDs are lit 3 Use the arrow keys to scroll through the menu listing To select an item press the Enter key Then the sub menu will appear 4 To return to the 1st level menu press th...

Page 105: ...SERVICE PROGRAM MODE SM 4 3 G031 G032 Service Tables and Procedures 4 2 2 SERVICE PROGRAM MODE MENU TREE The following diagram shows the service mode menu tree G031M500 WMF...

Page 106: ...lowest level using the Up Down arrow keys To go back to a higher level press the Escape key Inputting a Value or Setting for a Service Program 1 Enter the required program mode as explained above NOT...

Page 107: ...Log Tray 3 G031 Side to side Registration Feed from Paper Tray 3 Optional Paper Feed Unit Use the V W keys to increase or decrease See Replacement and Adjustment Print Registration Adjustments for de...

Page 108: ...error log counters To view the log and counters press the Enter key then press the Escape key Counter Clear Error Log Counter Error Log Counter Reset To clear the log and counters press the Enter key...

Page 109: ...the check The menu will go back to level 2 when the Escape key is pressed Note 1 OK NG are not displayed 2 To prevent mechanical or electrical damage do not keep an electrical component on for a long...

Page 110: ...erial number is stored in the NVRAM on the controller board 2 The printer ID is checked during font downloading 3 Store the same number when the NVRAM is cleared with the IC card boot menu 4 The produ...

Page 111: ...0 DLTR 1 4 Tray 3 1 0 FREE 2 4 Transition Normal Density Light 2 Total Print Count 1 Unit 1 page Motor Work Time 0 Unit 5000 sec Paper Feed Roller Counter 0 Unit 5000 sec Transfer Roller Counter 0 Un...

Page 112: ...ust never be changed regardless of the printer control board serial number After clearing the NVRAM or replacing the NVRAM the original number must be stored again using Serial Number in service progr...

Page 113: ...input them afterwards F Tray paper status This shows the paper size and amount of paper remaining The remaining paper is showed in 2 steps for the 1st tray or 4 steps for the 2nd and 3rd trays 0 4 me...

Page 114: ...an be cleared using counter clear in the service program mode menu J Diagnostic Error Logging The ten latest errors are logged The log is stored in the NVRAM and can be cleared by Diag clear in the se...

Page 115: ...d In this case the printer ID does not need to be restored When the NVRAM is cleared or changed because of a hardware problem the original printer ID must be restored Restoring the Printer ID The prin...

Page 116: ...laced earlier the serial number on the new board must not be used for the Printer ID 4 Then the cursor shifts to the right 5 To store the number in the display press the Enter key 6 The display goes b...

Page 117: ...the printer off 2 Turn on DIP SW 1 on the printer control board 3 Plug the IC card into the IC card adapter then connect it to the option bus connector NOTE The G031 has two option bus connectors The...

Page 118: ...lowest level using the Up Down arrow keys 3 To go back to a higher level press the Escape key TOTAL PATTERN 2 x 2 FLAG SHIP FOX PATTERN B L A N K REAL 1 200 dpi REGISTRATION ADJUSTMENT FREE SIZE E E P...

Page 119: ...wnload firmware to a DIMM card from a PC through a parallel cable Copy to DIMM See the appendix for details Download firmware to an IC card from a PC through a parallel cable Copy to CARD See the appe...

Page 120: ...controller Transfer current settings Product name plug and play Image density Controller serial number Motor work time Diagnostic error logging Paper feed roller counter Controller firmware version Tr...

Page 121: ...on the IC card in advance either using SwapBox or the service tool menu This is also covered in the appendix The service tool menu allows firmware to be copied from a PC through a parallel cable to an...

Page 122: ...aration IC card containing new firmware IC card adapter Connecting the IC Card G031 ASIC RAM RAM RAM RAM RAM RAM SIMM Connector DIMM Slot Font ROM Flash ROM Flash ROM DIP SW Control Panel I F Centroni...

Page 123: ...n bus connector NOTE G031 has two option bus connectors Only the connector on the left side can be used for downloading 4 Turn on the printer The printer will boot from the firmware in the IC card NOT...

Page 124: ...rn the printer on and enter the service program mode 11 Print the log print and check the controller firmware version 12 Return to the user mode NOTE There are two ways to go back to the user mode fro...

Page 125: ...ITY TRAY LOCKING PAPER SIZE THICK PAPER PRINT QUALITY EDGE SMOOTHING RESOLUTION IMAGE DENSITY TONER SAVING S Y S T E M COPIES I O TIMEOUT ENERGY SAVER AUTO CONTINUE PAGE PROTECT P C L M E N U ORIENTAT...

Page 126: ...m the ECB board This test pattern does not use the printer control board This test helps to find whether the problem is caused by the ECB or the printer control board The location of TB1 is as shown b...

Page 127: ...during this test the test is proceeding without problems If the Power LED does not blink during the test it means that a fatal error has occurred If the machine detects an error the machine displays...

Page 128: ...ror the machine displays the error code e g 0101 on the operation panel turns off the Power LED blinks the Error LED and stops the test If an error occurs during the test press the Escape key and the...

Page 129: ...timer of the ASIC NVRAM Tests the NVRAM ASIC P1284 Tests the parallel interface IEEE1284 ASIC Engine I F Tests the engine control board I F of the ASIC Font ROM Tests the font ROM ASIC PVDMA Tests the...

Page 130: ...onnector for the RS232C Interface STROBE DATA1 DATA2 DATA3 DATA4 DATA5 DATA6 DATA7 DATA8 ACK BUSY PE SELECT CAN NC GND GND DIAG GND GND IPRIME FAULT NC NC NC SELECIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1...

Page 131: ...isplaying Tray x add paper Aficio Manager displays Paper out G0315915 K August 1999 Production 2 03 The Font Download function has been added The paper size signal from AS400 cannot be recognized prop...

Page 132: ...dpi When the print job starts while displaying Tray x add paper Aficio Manager displays Paper out G0325915 K August 1999 Production 2 03 The Font Download function has been added The paper size signal...

Page 133: ...PREVENTIVE MAINTENANCE...

Page 134: ......

Page 135: ...PM clear in the user s maintenance menu is required to reset the display This is not needed for the G031 because the G031 automatically resets the display when it detects the new fusing unit Symbol ke...

Page 136: ......

Page 137: ...REPLACEMENT AND ADJUSTMENT...

Page 138: ......

Page 139: ...he outside then remove the left cover C 1 screw 4 Slightly shift the right cover D towards the rear then remove it 1 screw G032 NOTE Before removing the exterior covers remove the printer from the pap...

Page 140: ...cover 3 Remove the operation panel A 2 screws and 1 connector 4 Remove the lock lever B 5 Remove the cable cover C 1 screw 6 Release the shutter arm D as shown 7 Remove the clamp G031 1 screw or cabl...

Page 141: ...t and Adjustment 6 1 3 CONTROL BOARD COVER REMOVAL 1 Remove the top left and right covers Refer to Exterior Cover Removal section 6 1 1 2 Remove the shielding plate A 5 screws G031 only 3 Remove the c...

Page 142: ...oving the fusing unit because it could be very hot 1 Turn off the main switch 2 Open the front cover 3 Release the levers A as shown 4 Replace the fusing unit B 5 Perform the PM clear except after ins...

Page 143: ...ENT 1 Remove the fusing unit Refer to Fusing Unit Replacement section 6 2 1 2 Remove the fusing cover A 2 screws 3 Remove the fusing exit sensor B 4 Remove the bracket C and the spring D G031 has two...

Page 144: ...lamp with your bare hands 8 Replace the hot roller C 1 C ring D and 1 gear E NOTE 1 Be careful not to scratch the hot roller with the stripper pawls 2 Do not touch the hot roller with your bare hands...

Page 145: ...e the exit guide plate A 2 screws 3 G031 only Remove the entrance guide B 3 screws 4 Remove the pressure arms C 5 Remove the bushings D 6 Replace the pressure roller E NOTE 1 When re installing the pr...

Page 146: ...SING THERMOFUSE REPLACEMENT 1 Remove the hot roller Refer to Hot Roller and Fusing Lamp Replacement section 6 2 2 2 Remove the two screw covers A 230 V machine only 1 screw each 3 Replace the fusing t...

Page 147: ...ment section 6 2 2 2 Remove the two screw covers A 230 V machine only 1 screw each 3 Remove the screw B securing the thermistor 4 Remove the two cable covers C 1 screw each NOTE When re installing the...

Page 148: ...10 SM 6 3 TRANSFER ROLLER 6 3 1 TRANSFER ROLLER REPLACEMENT 1 Open the front cover 2 Open the transfer roller cover A 3 Replace the transfer roller B NOTE Do not touch the transfer roller with your b...

Page 149: ...EMOVAL G031 1 Open the by pass tray A 2 While lifting the hooks B lower the by pass tray and remove it as shown C G032 1 Open the by pass tray D 2 Draw out the paper cassette 3 While moving the hooks...

Page 150: ...ght cover Refer to Exterior Cover Removal section 6 1 1 2 While releasing the hook A remove the by pass feed roller cover B as shown NOTE Remove the by pass feed roller cover carefully it is attached...

Page 151: ...lling the by pass feed solenoid make sure that the projection B on the by pass feed clutch C touches the underside of the bracket D 5 While unhooking the hook E from the by pass feed clutch remove the...

Page 152: ...ling the by pass feed roller cover make sure that the sensor C and connector D are connected together and attached to the frame as shown 3 While unhooking the hooks E remove the by pass feed roller F...

Page 153: ...placement and Adjustment 6 4 3 PAPER FEED ROLLER REPLACEMENT G031 1 Draw out the paper cassette 2 While releasing the spring mechanism A remove the paper feed roller B NOTE Do not touch the paper feed...

Page 154: ...APER FEED G031 G032 6 16 SM G032 1 Draw out the paper cassette 2 While releasing the hook A remove the paper feed roller B NOTE Do not touch the paper feed roller with your bare hands G031R521 WMF B A...

Page 155: ...R REPLACEMENT G032 ONLY 1 Remove the by pass feed roller cover Refer to By pass Feed Roller Replacement section 6 4 2 2 While unhooking the hooks A pull the shaft B out to the right 3 Replace the rela...

Page 156: ...w out the paper cassette 2 Remove the paper from the paper tray Turn the tray upside down and place it on a flat surface 3 While unhooking the hooks A remove the friction pad B as shown NOTE Be sure t...

Page 157: ...the control board cover Refer to Control Board Cover Removal section 6 1 3 2 Remove the paper feed roller Refer to Paper Feed Roller Replacement section 6 4 3 3 While unhooking the hook A pull the sh...

Page 158: ...main switch and unplug the machine before attempting any of the procedures in this section Laser beams can seriously damage your eyes 6 5 1 CAUTION DECAL LOCATIONS Caution decals are located in the l...

Page 159: ...Remove the laser unit A 4 screws and 3 connectors G031 or 2 connector G032 NOTE 1 Disconnect connectors B and C first When connector D is accessible disconnect it 2 When removing or re installing the...

Page 160: ...ment section 6 5 1 2 Replace the LD unit A by removing the screws B as shown NOTE Do not touch VR101 C and VR102 D because they are adjusted in the factory before shipment Laser Synchronization Detect...

Page 161: ...n doing the following steps take care not to damage the mirror surface with the tip of the screwdriver 1 Remove the top cover Refer to Exterior Cover Removal section 6 1 1 2 Remove the laser unit top...

Page 162: ...d 1 connector NOTE Do not touch VR101 on the LD unit because it is adjusted in the factory before shipment Polygonal Mirror Motor NOTE When doing the following steps take care not to damage the mirror...

Page 163: ...6 6 OTHERS 6 6 1 TONER NEAR END SENSOR REPLACEMENT 1 Remove the control board cover Refer to Control Board Cover Removal section 6 1 3 2 Remove the toner cassette 3 Replace the toner near end sensor...

Page 164: ...A 3 screws and 1 connector Gear Box 1 Remove the control board cover Refer to Control Board Cover Removal section 6 1 3 2 Remove the by pass feed clutch B Refer to By pass Feed Roller Replacement sec...

Page 165: ...must not be lit or blinking It there is some data in the buffer wait until all data has been printed NOTE Before replacing the engine board print out the print log see Service Program Mode Print Log i...

Page 166: ...e buffer wait until all data has been printed NOTE Before replacing the controller board print out the configuration page User Menu List Print Config Page and the print log see Service Program Mode Pr...

Page 167: ...chronization Detector Replacement section 6 5 3 for G031 or LD Unit Polygonal Mirror Motor Replacement section 6 5 5 for G032 3 Remove the engine control board Refer to Engine Control Board Replacemen...

Page 168: ...D unit Refer to LD Unit Laser Synchronization Detector Replacement section 6 5 3 for G031 or LD Unit Polygonal Mirror Motor Replacement section 6 5 5 for G032 3 Remove the printer control board Refer...

Page 169: ...key and Escape key together to enter the service mode Use the arrow key until PRINT LOG appears 2 Print out the print log from the desired paper feed tray and check the margin at all four sides Adjust...

Page 170: ......

Page 171: ...TROUBLESHOOTING...

Page 172: ......

Page 173: ...ze Memory Overflow Memory Overflow Print Overrun Print Overrun Hard Disk Error Error SC 2600 Network Interface Board Error Error SC 2700 RS232C Board Error Error SC 2900 Memory Unit SIMM Error Error S...

Page 174: ...cartridge correctly If the image density gets too light replace the toner cartridge NOTE This machine only has a toner near end sensor There is no toner end sensor Fusing Unit Installation Error Messa...

Page 175: ...n into tray XX or the by pass tray and print automatically If not check that the paper size setting in the tray is correct NOTE 1 When Auto Select is specified for the paper source using the printer d...

Page 176: ...the printer If you do not want to lose any of the transferred data set the Page Protect feature to On before printing the job If you cannot clear this message simplify the print job NOTE Make sure to...

Page 177: ...s main switch off and on Then try to do the print job again NOTE If you remove the memory unit you might not be able to print a job that contains large or complex data Right Optional Board Error Mess...

Page 178: ...e machine is repaired SC302 High Voltage Power Supply Error Definition A charge roller current leak signal is detected A transfer roller current leak signal is detected A development bias leak signal...

Page 179: ...on Possible Causes Too much load on the drive mechanism Main motor defective SC542 Fusing Temperature Warm up Error Definition The fusing temperature does not reach 80 C within 60 seconds after the ma...

Page 180: ...e machine is in energy saver mode Possible causes Fusing thermistor defective Power supply unit defective SC998 Fusing Unit Mismatch Definition The fusing unit for a different area is installed in the...

Page 181: ...2104 ASIC timer error Printer Control Board defective NVRAM 08 SC2105 NVRAM check error Printer Control Board defective ASIC P1284 parallel port 09 Not tested during power up diagnostics ASIC Engine I...

Page 182: ...int exception AA Fetch unsupported command AB Co processor exception AC Overflow exception AD Trap command exception AF Floating point operation exception B7 Watch exception B8 Data access or fetch wi...

Page 183: ...ions 0404 Error during the bus error check with load or storing instructions 0405 Error during the system call check with SYSCALL instructions 0406 Error during the break point check with BREAK instru...

Page 184: ...702 VR4300 interrupt request error 0703 Interrupt check error 0704 Interrupt mask error ASIC Timer 0705 Timer frequency error Printer Control Board defective Device Code Description Possible Cause 080...

Page 185: ...6 Interrupt request error of the ASIC when the SELECT signal goes high 0917 Interrupt request error of the VR4300 when the SELECT signal goes high 0918 Interrupt start error of the VR4300 when the SEL...

Page 186: ...nterrupt request error of the VR4300 during command reception 0A07 Interrupt start error of the VR4300 during command reception Engine I F 0A08 Interrupt masking error during command reception Printer...

Page 187: ...rrupt request error of the VR4300 in HDD mode 1204 Interrupt start error of the VR4300 in HDD mode 1205 HDD interrupt masking error 1206 HDD register error 1207 HDD buffer RAM error 1208 HDD ECC error...

Page 188: ...32C mode 1405 Empty interrupt masking error of the in RS232C mode 1406 DSR error 1407 Command timeout error RS232C 1408 Loopback error Optional RS232C defective Printer Control Board defective Device...

Page 189: ...End message appears even if there is paper in the by pass tray Open A paper jam at the registration roller when a print is made Registration S5 3 2 ECB Shorted The Paper Jam message appears even if t...

Page 190: ......

Page 191: ...ENVELOPE FEEDER G913...

Page 192: ......

Page 193: ...opes 72 90 g m 19 24 lb Size W x D x H G031 450 mm x 552 mm x 91 mm 17 7 x 21 7 x 3 6 G032 360 mm x 421 mm x 119 mm 14 2 x 16 6 x 4 7 Weight G031 2 5 kg G032 1 6 kg 1 2 MECHANICAL COMPONENT LAYOUT Thi...

Page 194: ...PAPER LIFT G031 G032 8 2 SM 2 DETAILED SECTION DESCRIPTIONS 2 1 PAPER LIFT Refer to the paper feed section in the service manual for the main body...

Page 195: ...PAPER LIFT SM 8 3 G031 G032 Envelope Feeder G913 3 INSTALLATION See the Installing the Envelope Feeder in section 2 Installing Options of the operating instructions...

Page 196: ...4 SM 4 REPLACEMENT AND ADJUSTMENT 4 1 FRICTION PAD REPLACEMENT 1 Draw out the envelope feeder 2 While unhooking hooks A replace the friction pad B as shown NOTE Make sure to unhook the hooks or the h...

Page 197: ...PAPER FEED UNIT G914 G915...

Page 198: ......

Page 199: ...eight 60 90 g m2 16 24 lb Dimensions W x D x H 450 mm x 528 8 mm x 125 mm Tray Capacity 500 sheets Weight Less than 5 7 kg 13 lb 1 1 2 G032 PAPER FEED UNIT G914 57 Copy Paper Size Maximum A4 8 5 x 11...

Page 200: ...MECHANICAL COMPONENT LAYOUT G031 G032 9 2 SM 1 2 MECHANICAL COMPONENT LAYOUT G031 G032 1 Paper Feed Roller 2 Friction Pad G914V500 WMF G914V501 WMF 1 2 1 2...

Page 201: ...OUT G031 G032 1 Paper Feed Unit Board 2 Paper Feed Motor 3 PFU Paper Feed Clutch 4 PFU Paper Size Switch 5 PFU Paper Feed Sensor 6 PFU Paper End Sensor 7 PFU Paper Near end Sensor 8 PFU Paper Near end...

Page 202: ...nd Sensor Informs the CPU when there is no paper in the tray 6 S3 S4 PFU Paper Near end Sensor Informs the CPU of the estimated remaining paper amount there are 4 signal patterns 7 8 S5 PFU Cassette S...

Page 203: ...uns out of paper the actuator A of the paper end sensor drops into the cutout in the tray bottom plate and this activates the paper end sensor 2 4 PAPER NEAR END DETECTION When the paper in the paper...

Page 204: ...motor drives the PFU paper feed clutch gear A and the drive roller gear B through several gears The paper feed unit uses a feed roller and friction pad mechanism The friction pad only allows the top s...

Page 205: ...G914 G915 The PFU paper feed clutch turns on at the same time as the paper feed motor starts The paper actuates the PFU paper feed sensor A and the drive roller feeds the paper to the registration rol...

Page 206: ...PAPER FEED G031 G032 9 8 SM 3 INSTALLATION See the Paper Feed Unit Installation sheet that comes with the Operating Instructions...

Page 207: ...G032 Paper Feed Unit G914 G915 4 REPLACEMENT AND ADJUSTMENT 4 1 PAPER FEED UNIT OPTION FOR G031 4 1 1 PAPER FEED ASSEMBLY REMOVAL 1 Remove the top cover A 7 screws 2 Remove the paper feed assembly B...

Page 208: ...31 G031 G032 9 10 SM 4 1 2 DRIVE ROLLER REPLACEMENT 1 Remove the paper feed assembly Refer to Paper Feed Assembly Removal 2 Replace the drive roller A 2 snap rings Do not touch the drive roller with y...

Page 209: ...ION FOR G031 SM 9 11 G031 G032 Paper Feed Unit G914 G915 4 1 3 PAPER FEED MOTOR REPLACEMENT 1 Remove the paper feed assembly Refer to Paper Feed Assembly Removal 2 Replace the paper feed motor A 2 scr...

Page 210: ...paper feed assembly Refer to Paper Feed Assembly Removal 2 Remove the paper feed roller Refer to Paper Feed Roller Replacement in the service manual for the main body 3 While unhooking the hooks A pu...

Page 211: ...SIZE SWITCH REPLACEMENT Paper Feed Unit Board 1 Remove the top cover Refer to Paper Feed Assembly Removal 2 Replace the paper feed unit board A 1 screw and 8 connectors Paper Size Switch 1 Remove the...

Page 212: ...FEED ROLLER PAPER FEED CLUTCH REPLACEMENT 1 Draw out the paper cassette 2 Remove the snap ring A 3 Release the lever B as shown 4 Lower the shaft C then remove the paper feed clutch D 5 Replace the p...

Page 213: ...IVE ROLLER REPLACEMENT 1 Draw out the paper cassette 2 Remove the snap ring A 3 While releasing the lever B remove the paper drive roller assembly C 4 Replace the paper drive roller bushing D gear E a...

Page 214: ...aw out the paper cassette 2 Remove the relay roller cover A 4 hooks 3 Remove the two springs B and two bushings C 4 Replace the relay roller D Friction Pad 1 Draw out the paper cassette 2 Replace the...

Page 215: ...the paper drive roller assembly Refer to Paper Drive Roller Replacement 3 Remove the cover A 1 screw 4 Remove the two grounding plates B 1 screw each 5 Remove the paper feed motor assembly C 6 Replace...

Page 216: ......

Page 217: ...NETWORK INTERFACE BOARD G919 TYPE 2000...

Page 218: ......

Page 219: ...pport IP and IPX SNMP support of MIB 2 and proprietary NIC MIB SNMP support of standard MIB and proprietary printer MIBs on compatible printers Required Cable STP Shielded Twisted Pair cable Category...

Page 220: ...exadecimal number The upper 6 digits are always 0040AF and the lower 6 digits are unique to each board 2 1 2 STATUS SHEET By default the NIB network interface board prints a status sheet every time af...

Page 221: ...Explorer 3 02 or later or any version of Netscape Navigator The World Wide Web Publishing service must be stopped before starting the MAP utility on the Windows NT server desktop 2 The NetWare Setup...

Page 222: ...e print jobs No Yes Yes DHCP Parameters Enable DHCP Default Yes Yes The NIB obtains IP parameters from a DHCP server No IP parameters must be specified manually No Yes No IP Address in NVRAM Default Y...

Page 223: ...the NIB cannot receive any print jobs because the jobs are sent to the previously assigned IP address There are two solutions for this problem The first one is simply enable the IP Address in NVRAM p...

Page 224: ...inting software can also be used in networks where servers are present however often the server printer services are utilized instead Server based priint services offer centralized printing management...

Page 225: ...soft IPX SPX SPX compatible protocol stack on Windows 9x or Windows NT4 0 and a Web browser Microsoft Internet Explorer 3 02 or later or any version of Netscape Navigator NDS Network Use the NetWare S...

Page 226: ...etwork interface board and the NIB cover 4 screws Then change the FACT jumper setting as shown above 2 Install the network interface board and turn on the machine 3 The green LED flashes 3 times then...

Page 227: ...to unzip the file to a temporary directory on a host computer Two types of utility software FlashUP and FTPDL are provided as ZIP files with this document Use the FlashUP utility for Novell server ba...

Page 228: ...0 98 13 46 00 _SETUP 1 5 984 04 29 96 08 25 22 _SETUP DLL 156 070 11 10 98 13 45 52 _SETUP LIB 5 11 10 98 13 46 00 DISK1 ID 686 11 06 98 08 54 26 Readme txt 44 608 07 24 96 04 00 00 SETUP EXE 33 11 10...

Page 229: ...oose a new firmware file and click OK 4 Choose a network interface card or multiple cards from the unit names listed in the dialog box then click OK The update will start 5 If you do not see the desir...

Page 230: ...finished CAUTION Do not turn off the machine until after it prints a status sheet after automatic re initialization Otherwise the new firmware may not be programmed to the flash ROM successfully Recov...

Page 231: ...07 95 20 22 40 _ISDEL EXE 668 293 12 21 98 16 52 20 _SETUP 1 5 984 04 29 96 08 25 22 _SETUP DLL 156 374 12 21 98 16 52 06 _SETUP LIB 5 12 21 98 16 52 20 DISK1 ID 1 146 12 21 98 16 50 54 Readme txt 44...

Page 232: ...032 10 14 SM Firmware Update Procedure 1 Start the FTPDL utility 2 Choose FIle Download 3 Choose a new firmware file and click OK 4 Enter the IP address of the network interface card in which you wish...

Page 233: ...ter the firmware has been downloaded click OK to finish 8 The Print Server Card then updates its flash ROM The machine will print a status report after the flash ROM update has finished CAUTION Do not...

Page 234: ...r The NIB detected a bad RAM chip during initialization Turn the machine off and on If the NIB detects the same error again replace the NIB Blinks for 10 s then goes off Blinks Initialization Error Th...

Page 235: ...queue after printing from VAX system has been fixed The countermeasure for NIB 450e has been included in NIB type 2000 4 IP fragmentation problem with token ring Ethernet converter has been fixed 5 I...

Page 236: ...test path Rst576c upd Sept 02 Production 5 76c Note 1 IPP printing Only G049 and G054 support this feature not supported by G031 G032 Windows 2000 or Windows 98 ME allow IPP printing IPP client progra...

Page 237: ...G049 G054 SERVICE MANUAL...

Page 238: ......

Page 239: ...ower Source G049 120 V 60 Hz More than 6 6 A for North America 220 240 V 50 60 Hz More than 3 5 A for Europe G054 120 V 60 Hz More than 4 7 A for North America 220 240 V 50 60 Hz More than 2 4 A for E...

Page 240: ...PPD Files 3 Font manager 4 Aficio Manager 5 Operating Instructions G049 G054 22 27 6 Port Navi 1 2 MACHINE CONFIGURATION Internal Options No Item Machine Code H Printer Feature Expander Type 185 32MB...

Page 241: ...54 tray can handle A4 letter or shorter The paper feed speed for the G049 G054 is the same as that of the G031 G032 However the feeding interval has been decreased in the G049 G054 allowing a higher P...

Page 242: ...G049 G054 11 4 SM G054 Flash ROM DIP SW ASIC EEPROM CPU RAM RAM Centronics I F Option Bus CN 2 DIMM Slot Control Panel Engine I F...

Page 243: ...9 2 slots RS232C Ethernet 100 Base Tx 10 Base T Hard disk drive IC Card adapter for up dating controller firmware CN 3 G054 1 slot RS232C Ethernet 100 base Tx 10 Base T Hard disk drive IC Card adapter...

Page 244: ...ORY G054 ENGINE FIRMWARE MODIFICATION HISTORY DESCRIPTION OF MODIFICATION FIRMWARE LEVEL SERIAL NUMBER FIRMWARE VERSION First Mass Production G0305157B 1st mass Production 1 00 To meet EMI standard th...

Page 245: ...Word 2000 PCLXL 1200dpi images created by WordArt are not printed correctly PS fonts download to HDD slowly G0495910 B Jan 2001 Production 1 29 Printing stalls when using the PS driver under Windows...

Page 246: ...the by pass tray is selected by driver the paper size selected by driver is available regardless of the paper size set by the operation panel Dip SW 4 On The print is available only when the paper si...

Page 247: ...sionally referred to as the Stinger This reference will be seen in computer screen captures and in various documentation throughout this section The Stinger P3 G031 and the Stinger P4 G032 NOTE The Ap...

Page 248: ......

Page 249: ...IC card plugged into a G031 or G032 printer via a parallel cable using either the DOS copy b command or the Stinger downloading utility Then the IC card is taken to the customer s premises and downloa...

Page 250: ...mware from a PC to a DIMM plugged into a G032 or G032 printer via a parallel cable using either the DOS copy b command or the Stinger downloading utility Then the IC card is taken to the customer s pr...

Page 251: ...download firmware from a PC to the printer a byte swapping operation must be performed on the released firmware To do this use the Byte Swap button of the SSU Stinger Service Utility program This crea...

Page 252: ...SERVICE TOOLS G031 G032 A 4 SM 1 2 SERVICE TOOLS 1 2 1 OPERATION PANEL The locations of the keys on the operation panel are shown below G031X504 WMF G031X506 WMF...

Page 253: ...owing features Menu Function Update controller firmware using an IC card Update Firmware For details see this appendix and Downloading New Controller Software in section 4 of the service manual Downlo...

Page 254: ...Free Size Print 2 x 2 pattern on free size paper Header Attach Print with header dpi 600 dpi 1 200 dpi real 1 200 dpi Paper Thick Normal Special sheet Tray CS S standard cassette CS 1 second tray CS 2...

Page 255: ...ice menu Copy to CARD This is the same as in the IC card boot service menu DIMM to Memory Downloads from a DIMM card plugged into the printer into the flash memory 1 2 3 STINGER SERVICE UTILITY SSU To...

Page 256: ...rmware file on a PC Use the Byte Swap button in the Stinger Service Utility 2 Copy this file from the PC to an IC card plugged into a G031 or G032 printer via a parallel cable The computer must be con...

Page 257: ...e eg P3card rom from the file list 4 Enter the destination file name eg P3carddwn rom NOTE Any destination file name can be used However the recommended file name is XXXdwm rom Using a standard naming...

Page 258: ...nnector on the printer control board NOTE G031 has two option bus connectors The left side connector is used for the downloading Do not turn DIP SW 1 on or the printer will boot from the IC card 3 Tur...

Page 259: ...NDIX Second prepare the PC 6 Start the utility click stinger exe or the SSU icon The downloading utility window is opened 7 Click the Download button in the Stinger utility window The download window...

Page 260: ...ndows utility When the downloading is finished a message is displayed on the printer 10 Turn the printer off then on and enter the service program mode 11 Print the log print and check the controller...

Page 261: ...USING AN IC CARD SM A 13 G031 G032 APPENDIX 1 3 2 DOWNLOADING FROM THE IC CARD TO THE PRINTER This is explained in Downloading New Controller Software in section 4 of the service manual Rev 04 2000...

Page 262: ...a parallel cable The computer must be connected to the printer with a parallel cable Use either the Stinger Service Utility for use with Windows systems or MS DOS use the copy b command NOTE When usin...

Page 263: ...using MS DOS Any firmware already included on the DIMM card will be overwritten Stinger Service Utility First prepare the printer 1 Turn off the printer 2 Change DIP SW1 to ON on the printer control...

Page 264: ...ey then the Form Feed key Second prepare the PC 8 Start the utility click stinger exe or the SSU icon The downloading utility window is opened 9 Click the Download button in the Stinger utility window...

Page 265: ...APPENDIX 10 The download window is displayed 11 Click the Reference key and select the firmware file that you wish to download eg P3carddwn rom NOTE Only a byte swapped file can be used for the downl...

Page 266: ...message is displayed on the printer 13 Turn the printer off then on and enter the service mode 14 Print the log print and check the controller firmware version 15 Turn the printer off and then on to...

Page 267: ...ess the Form Feed key Then downloading starts 7 This message shows that downloading has finished successfully 8 Turn off the printer 9 Detach the DIMM card 10 Turn the printer on again and enter the s...

Page 268: ...lel cable The computer must be connected to the printer with a parallel cable Use either the Stinger Service Utility for use with Windows systems or MS DOS use the copy b command NOTE When using the W...

Page 269: ...list 3 Enter the destination file name eg P3carddwn rom NOTE Any destination file name can be used However the recommended file name is XXXdwn rom Using a standard naming system such as this will pre...

Page 270: ...more minutes During this period the printer display is as shown C copy b download file name eg XXXdwn rom prn Enter The C prompt returns 7 When the download is finished the printer s display is as sho...

Page 271: ...Menu key together to enter the service tool menu 3 Use the arrow keys to select Download 4 Press the Enter key then press the Form Feed key Second prepare the PC 5 Start the utility click stinger exe...

Page 272: ...nload button in the Stinger utility window 7 The download window is displayed 8 Click the Reference key and select the firmware file that you wish to download eg P3carddwn rom NOTE Only a byte swapped...

Page 273: ...ad is finished the printer display is as shown 10 Turn the printer off then on and enter the service mode 11 Print the log print and check the controller firmware version 12 Return to the user mode NO...

Page 274: ...ta to lpt1 and tit tries to send the data to lpt2 However SSU cannot open lpt2 The default printer must be connected to lpt1 Countermeasure Connect the port of the default printer to lpt1 use the port...

Page 275: ...TECHNICAL SERVICE BULLETINS...

Page 276: ...onfigured to only poll printers with a valid IP address by either checking or unchecking the To Be Monitored checkbox in the Aficio Manager Net Vision Client Window SOURCES AFFECTED Currently all vers...

Page 277: ...ate your Parts Catalogs with the following information G031 REFERENCE PART NUMBER OLD DESCRIPTION NEW DESCRIPTION QTY PAGE ITEM G0291417 Control Panel LT Control Panel US 1 7 13 G0291427 Control Panel...

Page 278: ...hines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN...

Page 279: ...using the toner cartridge initially supplied with the machine 2 The noise occurs when the Cleaning Blade flips Since the Cleaning Blade is located between the Charge Roller and the Drum the Charge Rol...

Page 280: ...UAL INSERT GENERAL The Service Manual pages listed below must be replaced with the pages supplied Each bulletin package contains 1 set of replacement pages PAGES The revised areas have been highlighte...

Page 281: ...ERVIEW 4 25 4 8 2 POWER UP DIAGNOSTIC MODE 4 25 4 8 3 DETAILED DIAGNOSTIC MODE 4 26 4 8 4 DIAGNOSTIC TEST DETAILS 4 27 4 9 ROM HISTORY 4 29 4 9 1 ROM HISTORY G031 4 29 4 9 2 ROM HISTORY G032 4 29 PREV...

Page 282: ...6 6 2 MAIN MOTOR GEAR BOX REMOVAL 6 26 6 6 3 ENGINE CONTROL BOARD REPLACEMENT 6 27 6 6 4 PRINTER CONTROL BOARD REPLACEMENT 6 28 6 6 5 HIGH VOLTAGE SUPPLY BOARD 6 29 6 6 6 POWER SUPPLY UNIT REPLACEMENT...

Page 283: ...od Item Corrected HDD and Serial Port functions have been added Phase 2 2 01 G Jun 99 Prod Initial Production 1 05 E 1st Production 4 9 2 ROM HISTORY G032 Description P N G0325915 Version Production I...

Page 284: ...Serial Numbers listed below will have the new style Gear C3 installed during production MODEL NAME SERIAL NUMBER Gestetner P7020 P0190700001 Gestetner P7014 P029080001 Ricoh AP200 P0190700001 Ricoh AP...

Page 285: ...MODEL NAME SERIAL NUMBER Gestetner P7020 P0190800001 Ricoh AP200 P0190800001 Savin SLP20 P0190800001 Continued TURN GUIDE To increase the reliability for paper feeding the Turn Guide for the right sid...

Page 286: ...OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT b...

Page 287: ...to the prior models the only differences are detailed bold and underlined in the update package The materials should only be used by those technicians who are already certified on the G049 G054 printe...

Page 288: ...TION 10 9 3 2 2 FLASHUP UTILITY FOR NOVELL IPX NETWORKS 10 10 3 2 3 FTPDL UTILITY FOR TCP IP NETWORKS 10 13 4 TROUBLESHOOTING 10 16 4 1 LED INDICATIONS 10 16 G049 G054 SERVICE MANUAL OVERALL INFORMATI...

Page 289: ...velope Feeder Com 10 C6 DL Monarch Printing Paper Weight Paper tray 60 90 g m2 16 24 lb By pass 60 162 g m2 16 43 lb Power Source G031 120 V 60 Hz More than 8 0 A for North America 220 V 240 V 50 60 H...

Page 290: ...G049 G054 SERVICE MANUAL...

Page 291: ...ower Source G049 120 V 60 Hz More than 6 6 A for North America 220 240 V 50 60 Hz More than 3 5 A for Europe G054 120 V 60 Hz More than 4 7 A for North America 220 240 V 50 60 Hz More than 2 4 A for E...

Page 292: ...PPD Files 3 Font manager 4 Aficio Manager 5 Operating Instructions G049 G054 22 27 6 Port Navi 1 2 MACHINE CONFIGURATION Internal Options No Item Machine Code H Printer Feature Expander Type 185 32MB...

Page 293: ...54 tray can handle A4 letter or shorter The paper feed speed for the G049 G054 is the same as that of the G031 G032 However the feeding interval has been decreased in the G049 G054 allowing a higher P...

Page 294: ...G049 G054 11 4 SM G054 Flash ROM DIP SW ASIC EEPROM CPU RAM RAM Centronics I F Option Bus CN 2 DIMM Slot Control Panel Engine I F...

Page 295: ...it DRAM 2 EEPROM 2 KB NVRAM Centronics I F Bi directional parallel interface standardized by IEEE 1284 Option I F G049 2 slots RS232C Ethernet 100 Base Tx 10 Base T Hard disk drive IC Card adapter for...

Page 296: ...download firmware from a PC to the printer a byte swapping operation must be performed on the released firmware To do this use the Byte Swap button of the SSU Stinger Service Utility program This crea...

Page 297: ...USING AN IC CARD SM A 13 G031 G032 APPENDIX 1 3 2 DOWNLOADING FROM THE IC CARD TO THE PRINTER This is explained in Downloading New Controller Software in section 4 of the service manual Rev 04 2000...

Page 298: ...message is displayed on the printer 13 Turn the printer off then on and enter the service mode 14 Print the log print and check the controller firmware version 15 Turn the printer off and then on to...

Page 299: ...on Panel Harness 1 0 7 14 G0293863 G0293967 Discharge Brush 1 0 7 24 Denotes that this item was incorrectly numbered as item 23 and should have been item 24 UPDATE 2 G032 only REFERENCE OLD PART NO NE...

Page 300: ...NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as...

Page 301: ...0 SLP14 SLP21 SLP16 SAVIN SLP20 SLP14 SLP21 SLP16 SUBJECT PARTS CATALOG UPDATES GENERAL The following parts updates are being issued for all G031 G032 G049 G054 Parts Catalogs UPDATE 1 G031 only REFER...

Page 302: ...een modified The hollow areas of the gear have been eliminated and are now solid The additional weight of the Gear will reduce jitter Also the old style support shaft for Gear C3 was mounted on the ol...

Page 303: ...an be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OL...

Page 304: ...ANUAL INSERT GENERAL The Service Manual pages listed below must be replaced with the pages supplied Each bulletin package contains 1 set of replacement pages PAGES The revised areas have been highligh...

Page 305: ......

Page 306: ...r Aficio Manager displays Paper out G0315915 K August 1999 Production 2 03 4 9 2 G032 FIRMWARE MODIFICATION HISTORY G031 PRINTER FIRMWARE MODIFICATION HISTORY DESCRIPTION OF MODIFICATION FIRMWARE LEVE...

Page 307: ...nt will be described in this bulletin The G049 information is placed into the G031 portion of the Parts Catalog and the G054 information is placed into the G032 portion of the Parts Catalog The follow...

Page 308: ...l Panel US G054 1 7 9 G0301421 Control Panel EU G054 1 7 9 G0301258 Guide Transport G054 2 7 36 Denotes new item number G054 only Page 9 REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM G0302663 Paper...

Page 309: ...C ROCKY_Z G054 1 19 1 G0545900 Oscillator Video G054 1 19 3 G054 only Page 23 REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM G0305125 Engine Control Board 120V G054 1 23 G0305130 Engine Control Board...

Page 310: ...nto the G032 portion of the Parts Catalog The following parts updates are being issued for all G031 G032 G049 G054 Parts Catalogs UPDATE 1 G049 only Page 7 REFERENCE PART NUMBER DESCRIPTION QTY PAGE I...

Page 311: ...9 G0301421 Control Panel EU G054 1 7 9 G0546601 Sheet Control Panel G054 NRG 1 7 35 G0301258 Guide Transport G054 2 7 36 Denotes new item number G054 only Page 9 REFERENCE PART NUMBER DESCRIPTION QTY...

Page 312: ...ASIC ROCKY_Z G054 1 19 1 G0545900 Oscillator Video G054 1 19 3 G054 only Page 23 REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM G0305125 Engine Control Board 120V G054 1 23 G0305130 Engine Control B...

Page 313: ...CABLE MODEL GESTETNER P7020 P7014 GESTETNER P7020 P7014 GESTETNER P7020 P7014 GESTETNER P7020 P7014 RICOH AP2000 AP1400 RICOH AP2000 AP1400 RICOH AP2000 AP1400 RICOH AP2000 AP1400 SAVIN SLP20 SLP14 SA...

Page 314: ...ted on the Configuration sheet correctly G0315915 L Prod Discontinued 2 05 4 9 2 G032 FIRMWARE MODIFICATION HISTORY G032 PRINTER FIRMWARE MODIFICATION HISTORY DESCRIPTION OF MODIFICATION FIRMWARE LEVE...

Page 315: ...being issued for all G031 G049 Parts Catalogs REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM G0292752 Spring Clutch 1Kgf 1 0 0 15 2 G0292765 Spring Clutch 1 5Kgf 0 1 0 15 2 Continued...

Page 316: ...90600001 Savin SLP21 From First Production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OL...

Page 317: ...AP2100 AP1600 RICOH AP2000 AP1400 AP2100 AP1600 RICOH AP2000 AP1400 AP2100 AP1600 RICOH AP2000 AP1400 AP2100 AP1600 SAVIN SLP20 SLP14 SLP21 SLP16 SAVIN SLP20 SLP14 SLP21 SLP16 SAVIN SLP20 SLP14 SLP21...

Page 318: ...2 3 FTPDL UTILITY FOR TCP IP NETWORKS 10 13 4 TROUBLESHOOTING 10 16 4 1 LED INDICATIONS 10 16 4 2 NIB FIRMWARE MODIFICATION HISTORY 10 17 G049 G054 SERVICE MANUAL OVERALL INFORMATION 1 OVERALL MACHINE...

Page 319: ...stem has been fixed The countermeasure for NIB 450e has been included in NIB type 2000 4 IP fragmentation problem with token ring Ethernet converter has been fixed 5 It is possible to fix network spee...

Page 320: ...dition Power on Within 2 minutes After 2 minutes Ready to print old 170 170 Ready to print new 600dpi 164 164 1200dpi 135 135 Standby mode old 175 165 Standby mode new 600dpi 164 173 133 173 1200dpi 1...

Page 321: ...elected by Dip SW 4 Dip SW 4 Off Default When the by pass tray is selected by driver the paper size selected by driver is available regardless of the paper size set by the operation panel Dip SW 4 On...

Page 322: ...tioning Roller Positioning Roller G049 1 7 30 G0293950 Transfer Roller Transfer Roller G049 1 7 31 H3063179 Transfer Spacer Bushing 2 7 44 DENOTES NEW ITEM NUMBER G031 G049 only REFERENCE PART NUMBER...

Page 323: ...1 Savin SLP14 Service parts only Savin SLP16 P2900400001 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can...

Page 324: ...n of additional bulletins SERVICE MANUAL GENERAL The Service Manual pages listed below must be replaced with the pages supplied Each bulletin package contains 1 set of replacement pages PAGES The revi...

Page 325: ...8 2 POWER UP DIAGNOSTIC MODE 4 25 4 8 3 DETAILED DIAGNOSTIC MODE 4 26 4 8 4 DIAGNOSTIC TEST DETAILS 4 27 4 9 FIRMWARE HISTORY 4 29 4 9 1 CONTROLLER FIRMWARE HISTORY G031 4 29 4 9 2 CONTROLLER FIRMWAR...

Page 326: ...INDICATIONS 10 16 4 2 NIB FIRMWARE MODIFICATION HISTORY 10 17 G049 G054 SERVICE MANUAL OVERALL INFORMATION 1 OVERALL MACHINE INFORMATION 11 1 1 1 SPECIFICATIONS 11 1 1 2 MACHINE CONFIGURATION 11 2 DET...

Page 327: ...isplaying Tray x add paper Aficio Manager displays Paper out G0315915 K August 1999 Production 2 03 The Font Download function has been added The paper size signal from AS400 cannot be recognized prop...

Page 328: ...dpi When the print job starts while displaying Tray x add paper Aficio Manager displays Paper out G0325915 K August 1999 Production 2 03 The Font Download function has been added The paper size signal...

Page 329: ...9 2 slots RS232C Ethernet 100 Base Tx 10 Base T Hard disk drive IC Card adapter for up dating controller firmware CN 3 G054 1 slot RS232C Ethernet 100 base Tx 10 Base T Hard disk drive IC Card adapter...

Page 330: ...ORY G054 ENGINE FIRMWARE MODIFICATION HISTORY DESCRIPTION OF MODIFICATION FIRMWARE LEVEL SERIAL NUMBER FIRMWARE VERSION First Mass Production G0305157B 1st mass Production 1 00 To meet EMI standard th...

Page 331: ...Word 2000 PCLXL 1200dpi images created by WordArt are not printed correctly PS fonts download to HDD slowly G0495910 B Jan 2001 Production 1 29 Printing stalls when using the PS driver under Windows...

Page 332: ...the by pass tray is selected by driver the paper size selected by driver is available regardless of the paper size set by the operation panel Dip SW 4 On The print is available only when the paper si...

Page 333: ...ERT Note This copy is intended as a master original for reproduction of additional bulletins SERVICE MANUAL GENERAL The Service Manual pages listed below must be replaced with the pages supplied Each...

Page 334: ...queue after printing from VAX system has been fixed The countermeasure for NIB 450e has been included in NIB type 2000 4 IP fragmentation problem with token ring Ethernet converter has been fixed 5 I...

Page 335: ...test path Rst576c upd Sept 02 Production 5 76c Note 1 IPP printing Only G049 and G054 support this feature not supported by G031 G032 Windows 2000 or Windows 98 ME allow IPP printing IPP client progra...

Page 336: ...LICABLE MODEL GESTETNER P7020 P7014 P7021 P7016 LANIER N A RICOH AP2000 AP1400 AP2100 AP1600 SAVIN SLP20 SLP14 SLP21 SLP16 SUBJECT PAPER CASSETTE ASS Y GENERAL The following parts have been changed to...

Page 337: ...e it is necessary to install them together as a set NOTE 3 The diameter of the holder on the paper cassette has been increased from 4 mm to 6mm NOTE 4 The diameter of the opening on the base plate ass...

Page 338: ...and direct cross cable connection are possible however if using LAN connection it is best to chose an environment with low network traffic 2 Uninstall the firmware currently installed If the FTPDL fi...

Page 339: ...tely If the NIB status sheet printing has been activated please wait until this sheet is printed out Be sure to print a NIB status sheet before and after upgrading the NIB 6 Enable TCP IP for the targ...

Page 340: ...machine will begin downloading the UPD or UPP file This will take approximately 3 minutes during which time the panel will show how much has been completed 13 After the UPD or UPP file download has be...

Page 341: ...he NIB This is printed on the NIB status page If it is not recovery cannot be performed using this tool and the NIB will need to be reprogrammed by the manufacturer NetSilicon 5 Select the NIB and cli...

Page 342: ...connection are possible however if using LAN connection it is best to chose an environment with low network traffic 2 Uninstall the firmware currently installed If the FTPDL file is present skip to st...

Page 343: ...tely If the NIB status sheet printing has been activated please wait until this sheet is printed out Be sure to print a NIB status sheet before and after upgrading the NIB 6 Enable TCP IP for the targ...

Page 344: ...machine will begin downloading the UPD or UPP file This will take approximately 3 minutes during which time the panel will show how much has been completed 13 After the UPD or UPP file download has be...

Page 345: ...he NIB This is printed on the NIB status page If it is not recovery cannot be performed using this tool and the NIB will need to be reprogrammed by the manufacturer NetSilicon 5 Select the NIB and cli...

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