Gestetner G056 User manual

G056/G058/G073/G074
SERVICE MANUAL
001048MIU
RICOH GROUP COMPANIES

G056/G058/G073/G074
SERVICE MANUAL
RICOH GROUP COMPANIES
®
®

G056/G058/G073/G074
SERVICE MANUAL
001048MIU

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.
All product names, domain names or product illustrations, including desktop images,
used in this document are trademarks, registered trademarks or the property of their
respective companies.
They are used throughout this book in an informational or editorial fashion only and for
the benefit of such companies. No such use, or the use of any trade name, or web
site is intended to convey endorsement or other affiliation with Ricoh products.
2002RICOH Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
RICOH CORPORATION
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G056 P7026 Aficio
AP2600
SLP26
G058 P7026n Aficio
AP2600N
SLP26n
G073 P7126n Ricoh
AP2610N
AP2610N MLP26n
G074 P7126 Ricoh
AP2610
AP2610 MLP26
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*12/2000 Original Printing
13/2002G073/G074Addition

IIMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the copier and peripherals,
make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. Note that some components of the printer and the paper tray unit are
supplied with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check needs to be made with exterior covers
off or open while the main switch is turned on, keep hands away from
electrified or mechanically driven components.
5. The inside and the metal parts of the fusing unit become extremely hot while
the printer is operating. Be careful to avoid touching those components with
your bare hands.
HEALTH SAFETY CONDITIONS
Toner and developer are non-toxic, but if you get either of them in your eyes it
may cause temporary eye discomfort. Try to remove with eye drops or flush with
water as first aid. If unsuccessful, get medical attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
The printer and its peripherals must be installed and maintained by a customer
service representative who has completed the training course on those models.

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, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
LASER SAFETY
The enter for Devices and Radiological Health ( DRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified ustomer Engineer. The laser chassis is not
repairable in the field. ustomer engineers are therefore directed to return all
chassis and laser subsystems to the factory or service depot when replacement of
the optical subsystem is required.
!WARNING
Use of controls, or adjustment, or erformance of rocedures other than
those s ecified in this manual may result in hazardous radiation ex osure.
!WARNING
WARNING: Turn off the main switch before attem ting any of the
rocedures in the Laser Unit section. Laser beams can seriously damage
your eyes.
CAUTION MARKING:
G058R500.WMF

Trademarks
Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft
orporation in the United States and other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
P L® is a registered trademark of Hewlett-Packard ompany.
Ethernet® is a registered trademark of Xerox orporation.
PowerP ® is a registered trademark of International Business Machines
orporation.
Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights involved
with those marks.

SM i G056/G058/G073/G074
G056/G058
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.................................................1-1
1.1.4 POWER REQUIREMENTS ..............................................................1-2
1.2 MACHINE INSTALLATION .......................................................................1-2
1.3 OPTIONAL UNIT INSTALLATION.............................................................1-2
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE................................................... 2-1
2.1 USER MAINTENANCE .............................................................................2-1
2.2 SERVICE MAINTENANCE........................................................................2-2
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT........................................ 3-1
3.1 SPECIAL TOOLS ......................................................................................3-1
3.2 EXTERIOR COVERS ................................................................................3-2
3.3 LASER UNIT .............................................................................................3-3
3.3.1 CAUTION DECAL LOCATIONS.......................................................3-3
3.3.2 POLYGON MIRROR MOTOR ..........................................................3-4
3.3.3 LASER SYNCHRONIZATION DETECTOR......................................3-4
3.3.4 LASER UNIT ....................................................................................3-5
3.3.5 LASER DIODE UNIT ........................................................................3-7
Laser beam pitch adjustment................................................................3-8
3.4 TRANSFER ROLLER................................................................................3-9
3.5 TONER END SENSOR .............................................................................3-9
3.6 FUSING...................................................................................................3-10
3.6.1 FUSING UNIT.................................................................................3-10
3.6.2 HOT ROLLER AND FUSING LAMP...............................................3-11
3.6.3 THERMISTOR AND THERMOSTAT..............................................3-13
3.7 PAPER FEED..........................................................................................3-14
3.7.1 FEED ROLLER...............................................................................3-14
3.7.2 FRICTION PAD ..............................................................................3-14
3.8 BY-PASS TRAY ......................................................................................3-15
3.8.1 BY-PASS TRAY UNIT AND BY-PASS FEED ROLLER .................3-15
3.9 PRINTER CONTROLLER BOARD..........................................................3-16
3.10 ENGINE BOARD ...................................................................................3-16

G056/G058/G073/G074 ii SM
3.11 MAIN MOTOR .......................................................................................3-17
3.12 SOLENOIDS AND CLUTCHES.............................................................3-17
3.13 POWER SUPPLY UNIT AND HIGH VOLTAGE SUPPLY BOARD .......3-18
3.14 IMAGE ADJUSTMENT..........................................................................3-19
3.14.1 REGISTRATION ADJUSTMENT..................................................3-19
3.14.2 PARALLELOGRAM IMAGE ADJUSTMENT ................................3-19
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................ 4-1
4.1 SERVICE CALL CONDITIONS .................................................................4-1
4.1.1 SUMMARY .......................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS .............................................................4-2
4.2 CONTROLLER ERROR ............................................................................4-4
4.3 ELECTRICAL COMPONENT DEFECTS ..................................................4-6
4.3.1 SENSORS ........................................................................................4-6
4.3.2 SWITCHES.......................................................................................4-6
4.4 BLOWN FUSE CONDITIONS ...................................................................4-7
4.5 LEDS .........................................................................................................4-7
SERVICE TABLES
5. SERVICE TABLES...................................................................... 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...........5-1
Entering the Service Mode....................................................................5-1
Accessing the Required Program .........................................................5-1
Inputting a Value or Setting for a Service Program ...............................5-2
Exiting Service Mode ............................................................................5-2
5.2 PRINTER CONTROLLER SERVICE MODE .............................................5-3
5.2.1 SERVICE MODE MENU (‘1. SERVICE MENU’)..............................5-3
5.2.2 BIT SWITCH PROGRAMMING ........................................................5-3
5.3 PRINTER ENGINE SERVICE MODE........................................................5-4
5.3.1 SERVICE MODE TABLE (‘2. ENGINE MAINTE’) ............................5-4
Memory Clear .......................................................................................5-8
5.3.2 INPUT CHECK TABLE ...................................................................5-10
Table 1: Paper Size Switch (Main Unit) ..............................................5-11
Table 2: Paper Size Switch (optional paper tray)................................5-12
Table 3: Paper Height Sensor (standard cassette) .............................5-12
Table 4: Paper Height Sensor (optional paper tray)............................5-12
5.3.3 OUTPUT CHECK TABLE ...............................................................5-13
5.4 FIRMWARE UPDATE PROCEDURE......................................................5-14
5.4.1 CONTROLLER/NIB/ENGINE FIRMWARE UPDATE......................5-14
5.4.2 ERROR RECOVERY......................................................................5-15
Controller ............................................................................................5-15
NIB/Engine Board ...............................................................................5-15

SM iii G056/G058/G073/G074
5.5 POWER-ON SELF TEST ........................................................................5-16
5.6 OTHER TESTS .......................................................................................5-16
5.7 USER PROGRAM MODE .......................................................................5-17
5.8 DIP SWITCHES.......................................................................................5-18
Controller Board..................................................................................5-18
Engine Board ......................................................................................5-18
5.9 FIRMWARE HISTORY ............................................................................5-19
5.9.1 G056/G058 ENGINE FIRMWARE MODIFICATION HISTORY ......5-19
5.9.2 G056/G058 NIB FIRMWARE MODIFICATION HISTORY..............5-20
5.9.3 G056/G058 CONTROLLER FIRMWARE HISTORY ......................5-23
DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ...............................................................................................6-1
6.1.1 MECHANICAL COMPONENT LAYOUT...........................................6-1
6.1.2 PAPER PATH...................................................................................6-2
6.2 BOARD STRUCTURE...............................................................................6-3
6.2.1 OVERVIEW ......................................................................................6-3
6.2.2 DESCRIPTIONS...............................................................................6-4
6.2.3 CONTROLLER BOARD ...................................................................6-5
6.3 PRINTING PROCESS...............................................................................6-6
6.3.1 OVERVIEW ......................................................................................6-6
6.3.2 LASER EXPOSURE .........................................................................6-7
Overview...............................................................................................6-7
Automatic Power Control (APC) ...........................................................6-8
LD Safety Mechanisms .........................................................................6-9
6.3.3 CARTRIDGE OVERVIEW ..............................................................6-10
6.3.4 DRUM CHARGE.............................................................................6-10
6.3.5 DEVELOPMENT.............................................................................6-11
Overview.............................................................................................6-11
Toner Supply ......................................................................................6-11
Development Unit ...............................................................................6-11
Toner Density Control .........................................................................6-12
Development Bias...............................................................................6-12
Toner End Detection ...........................................................................6-13
6.3.6 IMAGE TRANSFER AND PAPER SEPARATION ..........................6-14
Overview.............................................................................................6-14
Transfer Roller Cleaning .....................................................................6-14
6.3.7 CLEANING .....................................................................................6-15
6.3.8 QUENCHING..................................................................................6-15
6.3.9 ID CHIP ..........................................................................................6-16
6.4 PAPER FEED..........................................................................................6-17
6.4.1 OVERVIEW ....................................................................................6-17
Paper Tray ..........................................................................................6-17
By-pass Tray.......................................................................................6-17
6.4.2 PAPER TRAY.................................................................................6-18
Tray Extension....................................................................................6-18
Rev. 12/2002

G056/G058/G073/G074 iv SM
Paper Lift ............................................................................................6-18
Paper Feed and Registration ..............................................................6-19
Paper Size Detection ..........................................................................6-20
Paper End/Paper Near-end Detection ................................................6-20
6.4.3 BY-PASS TRAY..............................................................................6-21
6.5 IMAGE FUSING AND PAPER EXIT........................................................6-22
6.5.1 OVERVIEW ....................................................................................6-22
6.5.2 FUSING DRIVE ..............................................................................6-22
6.5.3 FUSING ENTRANCE GUIDE SHIFT..............................................6-23
6.5.4 PRESSURE ROLLER.....................................................................6-23
6.5.5 NEW FUSING UNIT DETECTION..................................................6-24
6.5.6 FUSING TEMPERATURE CONTROL............................................6-25
6.5.7 PAPER EXIT ..................................................................................6-26
6.5.8 ENERGY SAVER MODE................................................................6-27
Entering Energy Saver Mode..............................................................6-27
Leaving Energy Saver Mode...............................................................6-27
6.6 CONTROLLER FUNCTIONS ..................................................................6-28
6.6.1 METER-CHARGE MODE...............................................................6-28
Meter-charge Counter Display ............................................................6-28
PM Warning Display ...........................................................................6-28
6.6.2 SAMPLE PRINT .............................................................................6-28
6.6.3 LOCKED PRINT .............................................................................6-29
6.6.4 PAPER SOURCE SELECTION......................................................6-29
Tray Priority (Auto Tray Select)...........................................................6-29
Tray Lock ............................................................................................6-29
Manual Tray Select.............................................................................6-29
6.6.5 AUTO CONTINUE..........................................................................6-30
Auto Tray Select .................................................................................6-30
Manual Tray Select.............................................................................6-30
6.6.6 PAPER OUTPUT TRAY .................................................................6-31
Output Tray Selected..........................................................................6-31
Auto Tray Switching............................................................................6-31
6.7 NIB ..........................................................................................................6-32
6.7.1 BLOCK DIAGRAM..........................................................................6-32
6.7.2 LED INDICATORS..........................................................................6-32
6.8 IEEE1394 INTERFACE ...........................................................................6-33
6.8.1 SPECIFICATIONS..........................................................................6-33
Hardware Specification .......................................................................6-33
System Requirements.........................................................................6-33
6.8.2 IEEE1394 .......................................................................................6-33
6.8.3 BLOCK DIAGRAM..........................................................................6-34
6.8.4 PIN ASSIGNMENT.........................................................................6-34
6.8.5 REMARKS ABOUT THIS INTERFACE KIT....................................6-35
6.8.6 TROUBLESHOOTING NOTES ......................................................6-35