Gestetner G060 User manual

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

G060/G570/G082
SERVICE MANUAL
RICOH GROUP COMPANIES

G570
SERVICE MANUAL
RICOH GROUP COMPANIES

G570
SERVICE MANUAL
RICOH GROUP COMPANIES

G060/G570/G082
SERVICE MANUAL
001159MIU

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.
A
ll 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 o
f
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.


2001 RICOH Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
p
rocesses and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
r
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual to
repair or modify Ricoh equipment risk persona
l
injury, damage to property or loss of warrant
y
p
rotection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G060 DSc38 2138 AH AP3800C SLP38c
G570 DSc38S 2138CMF AP3800CMF SLP38cS
G082 DSc38F 2138E AP3850C SLP38c DE
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*9/2001 Original Printing
1 2/2002 G570 Addition
2 6/2002 G082 Addition

SM i G060
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
1.1.4 POWER REQUIREMENTS.............................................................. 1-2
1.2 OPTIONAL UNIT COMBINATIONS.......................................................... 1-3
1.3 INSTALLATION FLOW CHART................................................................ 1-4
1.4 MACHINE INSTALLATION....................................................................... 1-5
1.5 OPTIONAL UNIT INSTALLATION............................................................ 1-7
1.5.1 LIST OF OPTIONS.......................................................................... 1-7
Note for Transporting the Machine....................................................... 1-7
1.5.2 PUNCH UNIT INSTALLATION ........................................................ 1-8
Accessory Check ................................................................................. 1-8
Installation Procedure .......................................................................... 1-9
PREVENTIVE MAINTENANCE
2 PREVENTIVE MAINTENANCE....................................................2-1
2.1 USER MAINTENANCE............................................................................. 2-1
2.2 SERVICE MAINTENANCE....................................................................... 2-3
REPLACEMENT AND ADJUSTMENT
3 REPLACEMENT AND ADJUSTMENT.........................................3-1
3.1 SPECIAL TOOLS ..................................................................................... 3-1
3.2 IMAGE ADJUSTMENT............................................................................. 3-2
3.2.1 REGISTRATION.............................................................................. 3-2
Image Area .......................................................................................... 3-2
Leading Edge....................................................................................... 3-2
Side to Side.......................................................................................... 3-2
Adjustment Standard............................................................................ 3-2
Paper Registration Standard................................................................ 3-2
1st side................................................................................................. 3-2
2nd side in duplex................................................................................ 3-2
Adjustment Procedure.......................................................................... 3-3
3.2.2 COLOR REGISTRATION ................................................................ 3-3
Line Position Adjustment...................................................................... 3-3
Adjustment for Line Speed of Fusing Unit............................................ 3-3
3.2.3 PRINTER GAMMA........................................................................... 3-4
Adjustment Overview........................................................................... 3-4
Adjustment Procedure.......................................................................... 3-4

G060 ii SM
3.3 EXTERIOR COVERS ............................................................................... 3-5
3.3.1 REAR COVER AND UPPER REAR COVER................................... 3-5
3.3.2 PAPER EXIT TRAY......................................................................... 3-5
3.3.3 UPPER RIGHT COVER................................................................... 3-5
3.3.4 FRONT COVER............................................................................... 3-6
3.3.5 LEFT COVER AND REAR LEFT COVER ....................................... 3-6
3.3.6 UPPER LEFT COVER AND OPERATION PANEL.......................... 3-7
3.4 LASER OPTICS........................................................................................ 3-8
3.4.1 CAUTION DECAL LOCATIONS...................................................... 3-8
3.4.2 LASER OPTICS HOUSING UNIT.................................................... 3-9
Adjustments after Replacing the Laser Optics Housing Unit.............. 3-11
3.4.3 POLYGON MIRROR MOTOR ....................................................... 3-12
3.4.4 LASER SYNCHRONIZING DETECTOR BOARDS ....................... 3-12
3.5 PCU AND DEVELOPMENT UNIT.......................................................... 3-13
3.6 PAPER FEED......................................................................................... 3-14
3.6.1 PICK-UP, FEED, AND SEPARATION ROLLERS.......................... 3-14
Tray 1 and Tray 2............................................................................... 3-14
By-pass Tray...................................................................................... 3-14
3.6.2 PAPER WIDTH DETECTION BOARD........................................... 3-15
3.6.3 VERTICAL TRANSPORT SENSOR.............................................. 3-15
3.6.4 RIGHT DOOR UNIT....................................................................... 3-16
3.6.5 REGISTRATION SENSOR AND RELAY SENSOR....................... 3-17
3.6.6 PAPER FEED CLUTCHES............................................................ 3-17
3.6.7 BY-PASS FEED CLUTCH ............................................................. 3-18
3.6.8 TRAY LIFT MOTOR....................................................................... 3-18
3.7 TRANSFER AND PAPER TRANSPORT UNIT ...................................... 3-19
3.7.1 TRANSFER UNIT.......................................................................... 3-19
3.7.2 TRANSFER BELT CLEANING UNIT............................................. 3-21
3.7.3 CLEANING BLADE AND CLEANING ROLLER............................. 3-22
3.7.4 TRANSFER BELT.......................................................................... 3-23
3.7.5 OTHERS........................................................................................ 3-27
Front Plate ......................................................................................... 3-27
Grounding Spring............................................................................... 3-27
Drive Gear and Left Drive Roller........................................................ 3-27
3.8 FUSING.................................................................................................. 3-28
3.8.1 FUSING UNIT................................................................................ 3-28
3.8.2 OIL SUPPLY UNIT......................................................................... 3-29
3.8.3 UPPER COVER............................................................................. 3-29
3.8.4 FUSING BELT UNIT...................................................................... 3-30
3.8.5 PRESSURE ROLLER.................................................................... 3-33
3.8.6 PAPER EXIT.................................................................................. 3-35
3.9 ELECTRICAL COMPONENTS............................................................... 3-36
3.9.1 MOVING THE CONTROLLER BOX OUT OF THE WAY .............. 3-36
3.9.2 MOVING THE HIGH VOLTAGE SUPPLY UNIT -
C, B OUT OF THE WAY................................................................ 3-36
3.9.3 CONTROLLER AND BCU............................................................. 3-37
3.9.4 NVRAM REPLACEMENT PROCEDURE...................................... 3-38
NVRAM for BCU ................................................................................ 3-38
NVRAM for Controller ........................................................................ 3-38

SM iii G060
NVRAMs for both BCU and Controller ................................................3-38
3.9.5 REMOVING THE HIGH VOLTAGE SUPPLY BOARD - C, B .........3-39
3.9.6 PSU ................................................................................................3-39
3.10 DRIVE UNIT ..........................................................................................3-40
3.10.1 REGISTRATION CLUTCH ...........................................................3-40
DEVELOPMENT CLUTCHES ............................................................3-41
3.10.3 DEVELOPMENT DRIVE MOTOR - CMY .....................................3-43
3.10.4 DRUM DRIVE MOTOR - CMY AND
DRUM DRIVE MOTOR - K...........................................................3-44
DEVELOPMENT DRIVE MOTOR - K .................................................3-45
TROUBLESHOOTING
4 TROUBLESHOOTING .................................................................. 4-1
4.1 PROCESS CONTROL ERROR CONDITIONS .........................................4-1
4.1.1 DEVELOPER INITIALIZATION RESULT .........................................4-1
4.1.2 PROCESS CONTROL SELF-CHECK RESULT...............................4-3
4.1.3 LINE POSITION ADJUSTMENT RESULT .......................................4-4
4.2 SERVICE CALL CONDITIONS .................................................................4-7
4.2.1 SUMMARY .......................................................................................4-7
SC Classification...................................................................................4-7
4.3 SC TABLE .................................................................................................4-9
4.4 TROUBLESHOOTING GUIDE ................................................................4-35
4.4.1 IMAGE QUALITY............................................................................4-35
4.4.2 COLOR SHIFT ...............................................................................4-39
Adjustment Standard: Max. 200 µm...................................................4-41
Preparation .........................................................................................4-41
How to measure the gap between color lines .....................................4-46
4.4.3 COLOR SHIFT AFTER TRANSFER UNIT REPLACEMENT .........4-48
Check the color shift level ...................................................................4-48
Fusing/ Registration Roller Speed Adjustment ...................................4-48
SP mode (sub-scan registration) reset................................................4-48
Transfer belt aging..............................................................................4-48
Fusing roller speed adjustment...........................................................4-49
Registration roller speed adjustment (for color mode) ........................4-49
Line position fine adjustment for sub-scan..........................................4-49
Registration roller speed adjustment (For B&W mode).......................4-50
4.5 ELECTRICAL COMPONENT DEFECTS ................................................4-51
4.5.1 SENSORS ......................................................................................4-51
4.6 BLOWN FUSE CONDITIONS .................................................................4-52
4.7 LEDS (BCU) ............................................................................................4-52
SERVICE TABLES
5 SERVICE TABLES........................................................................ 5-1
5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...........5-1
Rev. 09/2003

G060 iv SM
Entering the Service Mode................................................................... 5-1
Accessing the Required Program......................................................... 5-2
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 REMARKS....................................................................................... 5-3
Display on the Control Panel Screen ................................................... 5-3
Others.................................................................................................. 5-4
5.2.2 SERVICE MODE MENU (“1. SERVICE”) ........................................ 5-5
5.2.3 BIT SWITCH PROGRAMMING ....................................................... 5-6
5.3 PRINTER ENGINE SERVICE MODE....................................................... 5-7
5.3.1 SERVICE MODE TABLE (“2. ENGINE”).......................................... 5-7
SP1-XXX (Feed) .................................................................................. 5-7
SP2-XXX (Drum)................................................................................ 5-13
SP3-XXX (Process)............................................................................ 5-23
SP5-XXX (Mode)................................................................................ 5-30
SP6-XXX (Peripherals) ...................................................................... 5-38
SP7-XXX (Data Log).......................................................................... 5-39
5.3.2 INPUT CHECK TABLE.................................................................. 5-47
Table 1: Paper Height Sensor............................................................ 5-49
Table 2: Paper Size Switch (Tray 2)................................................... 5-49
Table 3: Paper Size (By-pass Table) ................................................. 5-49
5.3.3 OUTPUT CHECK TABLE .............................................................. 5-50
5.3.4 TEST PATTERN (SP5-997)........................................................... 5-54
5.4 FIRMWARE UPDATE PROCEDURE..................................................... 5-55
5.4.1 TYPE OF FIRMWARE................................................................... 5-55
5.4.2 ERROR RECOVERY..................................................................... 5-55
Engine Firmware/Controller NIB Firmware......................................... 5-55
Controller System Firmware:.............................................................. 5-55
5.4.3 CONTROLLER/ENGINE FIRMWARE UPGRADE......................... 5-56
5.5 CONTROLLER SELF-DIAGNOSTICS.................................................... 5-57
5.5.1 OVERVIEW ................................................................................... 5-57
5.5.2 DETAILED SELF-DIAGNOSTICS.................................................. 5-58
5.6 USER PROGRAM MODE....................................................................... 5-59
5.7 DIP SWITCHES...................................................................................... 5-60
Controller Board................................................................................. 5-60
DETAILED SECTION DESCRIPTIONS
6 DETAILED SECTION DESCRIPTIONS........................................6-1
6.1 OVERVIEW .............................................................................................. 6-1
6.1.1 COMPONENT LAYOUT .................................................................. 6-1
6.1.2 PAPER PATH.................................................................................. 6-2
6.1.3 DRIVE LAYOUT............................................................................... 6-3
6.1.4 BOARD STRUCTURE..................................................................... 6-4
Overview.............................................................................................. 6-4
Descriptions ......................................................................................... 6-5
6.1.5 PRINTING PROCESS..................................................................... 6-6