G065

SERVICE MANUAL
001269MIU
RICOH GROUP COMPANIES
 Š

SERVICE MANUAL
G065

RICOH GROUP COMPANIES

 G065
SERVICE MANUAL

001269MIU
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.

 2001 RICOH Corporation. All rights reserved.

 WARNING
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
 LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G065 P7145 2145 Aficio AP4510 MLP45

DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 12/2001 Original Printing
 G065
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 REQUIREMENTS ............................................. 1-2
1.1.4 POWER REQUIREMENTS.............................................................. 1-3
1.2 MACHINE INSTALLATION....................................................................... 1-3
1.3 OPTIONAL UNIT INSTALLATION............................................................ 1-3
1.4 SYMBOLS USED IN TEXT....................................................................... 1-3
1.5 LCT INSTALLATION (A683)..................................................................... 1-4
1.5.1 ACCESSORY CHECK ..................................................................... 1-4
1.5.2 INSTALLATION PROCEDURE........................................................ 1-5
1.6 BRIDGE UNIT INSTALLATION (B397)..................................................... 1-7
1.6.1 ACCESSORY CHECK ..................................................................... 1-7
1.6.2 INSTALLATION PROCEDURE........................................................ 1-8
1.7 1000-SHEET FINISHER INSTALLATION (A681)................................... 1-10
1.7.1 ACCESSORY CHECK ................................................................... 1-10
1.7.2 INSTALLATION PROCEDURE...................................................... 1-11
1.8 3000-SHEET FINISHER INSTALLATION (A697)................................... 1-14
1.8.1 ACCESSORY CHECK ................................................................... 1-14
1.8.2 INSTALLATION PROCEDURE...................................................... 1-15
1.9 PUNCH UNIT INSTALLATION (A812).................................................... 1-19
1.9.1 ACCESSORY CHECK ................................................................... 1-19
1.9.2 INSTALLATION PROCEDURE...................................................... 1-20
1.10 MAILBOX INSTALLATION (G909) ....................................................... 1-23
1.10.1 ACCESSORY CHECK ................................................................. 1-23
1.10.2 REQUIREMENT OPTIONS FOR MAIN MACHINE ..................... 1-23
1.10.3 INSTALLATION PROCEDURE.................................................... 1-24
1.11 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)....................... 1-27
1.11.1 ACCESSORY CHECK ................................................................. 1-27
1.11.2 INSTALLATION PROCEDURE.................................................... 1-28

PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE SCHEDULE............................... 2-1
2.1 PM TABLES.............................................................................................. 2-1
2.1.1 PM TABLES FOR THE PRINTER ................................................... 2-1
2.1.2 PM TABLES FOR OPTIONS ........................................................... 2-3

SM i G065
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT........................................ 3-1
3.1 GENERAL CAUTIONS ............................................................................. 3-1
3.1.1 LASER UNIT.................................................................................... 3-1
3.1.2 USED TONER ................................................................................. 3-1
3.2 SPECIAL TOOLS AND LUBRICANTS ..................................................... 3-2
3.2.1 SPECIAL TOOLS............................................................................. 3-2
3.2.2 LUBRICANTS .................................................................................. 3-2
3.2.3 SYMBOLS USED IN TEXT .............................................................. 3-2
3.3 FRONT DOOR.......................................................................................... 3-3
3.4 DUPLEX UNIT .......................................................................................... 3-3
3.5 UPPER RIGHT COVER............................................................................ 3-4
3.6 BY-PASS TRAY UNIT .............................................................................. 3-5
3.7 REAR COVERS........................................................................................ 3-6
3.7.1 REAR UPPER COVER.................................................................... 3-6
3.7.2 REAR LOWER COVER ................................................................... 3-6
3.8 LEFT COVERS......................................................................................... 3-7
3.8.1 LEFT UPPER COVER ..................................................................... 3-7
3.8.2 OPERATION PANEL ....................................................................... 3-8
3.8.3 PAPER OUTPUT TRAY .................................................................. 3-9
No Bridge Unit Installed ....................................................................... 3-9
Bridge Unit Installed ............................................................................. 3-9
3.9 LASER UNIT........................................................................................... 3-10
3.9.1 CAUTION DECAL LOCATIONS .................................................... 3-10
3.9.2 LASER UNIT.................................................................................. 3-11
3.9.3 POLYGON MIRROR MOTOR ....................................................... 3-12
3.9.4 LASER SYNCHRONIZATION DETECTOR ................................... 3-13
3.9.5 LD UNIT ......................................................................................... 3-13
Laser Beam Pitch Adjustment ............................................................ 3-14
3.10 PCDU.................................................................................................... 3-15
3.10.1 PHOTOCONDCUTOR CLEANING/DEVELOPMENT UNIT ........ 3-15
3.10.2 DRUM .......................................................................................... 3-16
3.10.3 PICK-OFF PAWLS....................................................................... 3-17
3.10.4 CHARGE ROLLER AND CLEANING ROLLER ........................... 3-18
3.10.5 DRUM CLEANING BLADE .......................................................... 3-19
3.10.6 ID SENSOR ................................................................................. 3-20
3.11 DEVELOPMENT................................................................................... 3-21
3.11.1 DEVELOPMENT UNIT ................................................................ 3-21
3.11.2 DEVELOPMENT FILTER............................................................. 3-22
3.11.3 DEVELOPMENT ROLLER........................................................... 3-23
3.11.4 DEVELOPER ............................................................................... 3-24
3.11.5 TD SENSOR ................................................................................ 3-26
3.12 TRANSFER UNIT ................................................................................. 3-27
3.12.1 TRANSFER BELT UNIT .............................................................. 3-27
3.12.2 TRANSFER BELT........................................................................ 3-28
3.12.3 CLEANING BLADE/TONER OVERFLOW SENSOR................... 3-29

G065 ii SM
 Transfer Belt Cleaning Blade ............................................................. 3-29
Toner Overflow Sensor ...................................................................... 3-29
3.13 PAPER FEED ....................................................................................... 3-30
3.13.1 PICK-UP, SEPARATION, AND FEED ROLLERS........................ 3-30
3.13.2 LOWER RIGHT COVER .............................................................. 3-31
3.13.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED
CLUTCHES ................................................................................. 3-32
3.13.4 UPPER PAPER FEED UNIT FOR TRAY 1.................................. 3-33
3.13.5 LOWER PAPER FEED UNIT FOR TRAY 2................................. 3-34
3.13.6 PAPER END/PAPER LIFT/RELAY SENSORS............................ 3-35
3.13.7 REGISTRATION SENSOR .......................................................... 3-36
3.13.8 TRAY LIFT MOTOR..................................................................... 3-38
3.13.9 FEED/DEVELOPMENT MOTOR ................................................. 3-39
3.14 FUSING ................................................................................................ 3-40
3.14.1 FUSING UNIT .............................................................................. 3-40
3.14.2 FUSING UNIT EXIT GUIDE......................................................... 3-41
3.14.3 HOT ROLLER STRIPPERS......................................................... 3-41
3.14.4 FUSING LAMPS .......................................................................... 3-42
Left Side............................................................................................. 3-42
Right Side .......................................................................................... 3-43
3.14.5 THERMISTORS AND THERMOSTATS ...................................... 3-44
3.14.6 HOT ROLLER/PRESSURE ROLLER .......................................... 3-45
3.15 BY-PASS TRAY.................................................................................... 3-47
3.15.1 COVER REPLACEMENT ............................................................ 3-47
3.15.2 BY-PASS FEED/PICK-UP ROLLER ............................................ 3-48
3.15.3 BY-PASS SEPARATION ROLLER REPLACEMENT .................. 3-49
3.15.4 PAPER END SENSOR/PICK-UP SOLENOID ............................. 3-50
3.15.5 PAPER SIZE SENSOR BOARD REPLACEMENT ...................... 3-51
3.15.6 BY-PASS TABLE REMOVAL....................................................... 3-52
3.15.7 PAPER FEED CLUTCH REPLACEMENT ................................... 3-53
3.16 DUPLEX UNIT ...................................................................................... 3-54
3.16.1 DUPLEX COVER REMOVAL ...................................................... 3-54
3.16.2 DUPLEX ENTRANCE SENSOR REPLACEMENT ...................... 3-55
3.16.3 DUPLEX EXIT SENSOR REPLACEMENT.................................. 3-56
3.17 DRIVE AREA ........................................................................................ 3-57
3.17.1 REGISTRATION/TRANSFER BELT CONTACT CLUTCHES ..... 3-57
3.17.2 MAIN MOTOR.............................................................................. 3-58
3.17.3 FUSING/EXIT MOTOR ................................................................ 3-59
3.17.4 FUSING/EXIT CLUTCH ............................................................... 3-60
3.17.5 TONER SUPPLY MOTOR ........................................................... 3-61
3.18 PRINTED CIRCUIT BOARDS .............................................................. 3-62
3.18.1 HIGH VOLTAGE POWER SUPPLY ............................................ 3-62
3.18.2 I/O BOARD .................................................................................. 3-63
3.18.3 BICU BOARD............................................................................... 3-64
3.18.4 PSU ............................................................................................. 3-64
3.19 HARD DISK/CONTROLLER BOARD ................................................... 3-65
To Format the HDD............................................................................ 3-65
3.20 PRINTING ADJUSTMENTS ................................................................. 3-66
3.21 PARALLELOGRAM IMAGE ADJUSTMENT......................................... 3-67

SM iii G065
TOUBLESHOOTING
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 ELECTRICAL COMPONENT DEFECTS................................................ 4-13
4.2.1 SENSORS ..................................................................................... 4-13
4.2.2 SWITCHES .................................................................................... 4-14
4.3 BLOWN FUSE CONDITIONS................................................................. 4-15
4.4 LEDS ...................................................................................................... 4-15
BICU .................................................................................................. 4-15
4.5 TEST POINTS ........................................................................................ 4-15
Controller Board ................................................................................. 4-15

SERVICE TABLES
5. SERVICE TABLES ...................................................................... 5-1
5.1 SERVICE PROGRAM MODE................................................................... 5-1
5.1.1 ENTERING AND LEAVING THE SERVICE PROGRAM MODE ..... 5-1
5.2 PRINTER CONTROLLER SERVICE MODE ............................................ 5-2
5.2.1 CONTROLLER SERVICE MODE MENUS ...................................... 5-2
5.2.2 BIT SWITCH PROGRAMMING ....................................................... 5-2
5.2.3 PRINTER CONTROLLER BIT SWITCH SETTINGS ....................... 5-3
5.3 PRINTER ENGINE SERVICE MODE ....................................................... 5-4
Leaving the SP Mode............................................................................. 5-5
5.3.1 SERVICE PROGRAM MODE TABLES ........................................... 5-6
1. Feed (SP1000-00) ............................................................................. 5-6
2. Drum (SP2000-00)........................................................................... 5-10
3. Process (SP3000-00)....................................................................... 5-20
4. HDD (SP4000-00)............................................................................ 5-21
5. Mode (SP5000-00)........................................................................... 5-21
6. Peripherals (SP6000-00) ................................................................. 5-25
7. Data Log (SP7000-00) ..................................................................... 5-26
5.3.2 TEST PATTERN PRINTING .......................................................... 5-29
Test Pattern Table: SP2902-03 Printing Test Patterns ...................... 5-30
5.3.3 INPUT CHECK............................................................................... 5-31
Table 1: By-pass Feed Table Paper Size........................................... 5-34
5.3.4 OUTPUT CHECK........................................................................... 5-35
SP5804 Output Check Table ............................................................. 5-36
5.3.5 MEMORY ALL CLEAR: SP5801.................................................... 5-37
5.3.6 SMC PRINT OUT LISTS: SP5990 ................................................. 5-38
5.4 SOFTWARE DOWNLOAD ..................................................................... 5-39
5.4.1 DOWNLOADING THE SOFTWARE .............................................. 5-39
5.4.2 POWER FAILURE DURING SOFTWARE DOWNLOAD............... 5-40
5.5 SELF-DIAGNOSTIC MODE.................................................................... 5-41
5.5.1 SELF-DIAGNOSTIC MODE AT POWER ON ................................ 5-41

G065 iv SM
 Self-Diagnostic Test Flow .................................................................. 5-41
5.5.2 DETAILED SELF-DIAGNOSTIC MODE ........................................ 5-42
5.6 DIP SWITCHES...................................................................................... 5-43
Controller: DIP SW2........................................................................... 5-43
I/O Board: DIP SW101 ....................................................................... 5-43

DETAILED DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS....................................... 6-1
6.1 OVERVIEW .............................................................................................. 6-1
6.1.1 COMPONENT LAYOUT .................................................................. 6-1
Paper Path ........................................................................................... 6-2
DRIVE LAYOUT................................................................................... 6-3
6.2 BOARD STRUCTURE .............................................................................. 6-4
6.2.1 BLOCK DIAGRAM ........................................................................... 6-4
6.2.2 CONTROLLER ................................................................................ 6-6
6.3 PRINTING PROCESS OVERVIEW .......................................................... 6-8
Drum Charge........................................................................................ 6-8
Laser Exposure .................................................................................... 6-8
Development ........................................................................................ 6-8
Image Transfer..................................................................................... 6-9
Separation............................................................................................ 6-9
ID Sensor ............................................................................................. 6-9
Cleaning............................................................................................... 6-9
Quenching............................................................................................ 6-9
6.4 LASER EXPOSURE ............................................................................... 6-10
6.4.1 OVERVIEW ................................................................................... 6-10
6.4.2 AUTO POWER CONTROL (APC) ................................................. 6-11
6.4.3 DUAL BEAM WRITING.................................................................. 6-12
6.4.4 LASER BEAM PITCH CHANGE MECHANISM ............................. 6-13
6.4.5 LD SAFETY SWITCHES ............................................................... 6-14
6.5 PHOTOCONDUCTOR UNIT (PCU)........................................................ 6-15
6.5.1 OVERVIEW ................................................................................... 6-15
6.5.2 DRIVE MECHANISM ..................................................................... 6-16
6.5.3 DRUM PAWLS............................................................................... 6-16
6.5.4 DRUM TONER SEALS .................................................................. 6-16
6.6 DRUM CHARGE..................................................................................... 6-17
6.6.1 OVERVIEW ................................................................................... 6-17
6.6.2 CHARGE ROLLER VOLTAGE CORRECTION ............................. 6-18
Correction for Environmental Conditions............................................ 6-18
Correction for Paper Width and Thickness (By-pass Tray only)......... 6-19
6.6.3 ID SENSOR PATTERN PRODUCTION TIMING ........................... 6-20
6.6.4 DRUM CHARGE ROLLER CLEANING ......................................... 6-21
6.7 DEVELOPMENT..................................................................................... 6-22
6.7.1 OVERVIEW ................................................................................... 6-22
DRIVE MECHANISM ......................................................................... 6-23
6.7.3 DEVELOPER MIXING ................................................................... 6-23
6.7.4 DEVELOPMENT BIAS................................................................... 6-24

SM v G065
 Mechanism......................................................................................... 6-24
Correction for Paper Width and Thickness (By-pass Tray only)......... 6-24
6.7.5 TONER SUPPLY ........................................................................... 6-25
Toner Bottle Replenishment Mechanism ........................................... 6-25
Toner Supply Mechanism .................................................................. 6-26
Toner Density Control ........................................................................ 6-26
Sensor Control Mode ......................................................................... 6-27
Image Pixel Count Mode.................................................................... 6-27
6.7.6 TONER NEAR END/END DETECTION......................................... 6-28
Standard Method................................................................................ 6-28
Adjustable Near-end Warning Method ............................................... 6-28
6.7.7 TONER END RECOVERY............................................................. 6-29
6.7.8 TONER SUPPLY WITH ABNORMAL SENSORS.......................... 6-29
6.8 DRUM CLEANING AND TONER RECYCLING...................................... 6-30
6.8.1 DRUM CLEANING......................................................................... 6-30
6.8.2 TONER RECYCLING .................................................................... 6-30
6.9 PAPER FEED ......................................................................................... 6-31
6.9.1 OVERVIEW ................................................................................... 6-31
6.9.2 PAPER FEED DRIVE .................................................................... 6-32
6.9.3 PICK-UP/SEPARATION ROLLER RELEASE................................ 6-32
6.9.4 PAPER LIFT .................................................................................. 6-33
6.9.5 PAPER END DETECTION............................................................. 6-34
6.9.6 PAPER REGISTRATION............................................................... 6-34
6.9.7 PAPER SIZE DETECTION ............................................................ 6-35
6.9.8 PAPER HEIGHT DETECTION....................................................... 6-36
6.10 BY-PASS TRAY.................................................................................... 6-37
6.10.1 OVERVIEW ................................................................................. 6-37
6.10.2 BY-PASS TRAY OPERATION..................................................... 6-38
6.10.3 BY-PASS PAPER SIZE DETECTION.......................................... 6-39
6.11 DUPLEX UNIT ...................................................................................... 6-40
6.11.1 OVERVIEW ................................................................................. 6-40
6.11.2 DUPLEX DRIVE LAYOUT ........................................................... 6-41
6.11.3 DUPLEX BASIC OPERATION..................................................... 6-42
Larger than A4 Lengthwise/LT Lengthwise (SEF).............................. 6-42
Up to A4 Lengthwise/LT Lengthwise (SEF) ....................................... 6-42
6.11.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM...................... 6-43
Feed-in............................................................................................... 6-43
Inversion and Exit............................................................................... 6-43
6.12 IMAGE TRANSFER AND PAPER SEPARATION ................................ 6-44
6.12.1 OVERVIEW ................................................................................. 6-44
6.12.2 BELT DRIVE MECHANISM ......................................................... 6-45
6.12.3 TRANSFER BELT UNIT CONTACT MECHANISM ..................... 6-45
6.12.4 IMAGE TRANSFER AND PAPER SEPARATION
MECHANISM ............................................................................... 6-46
6.12.5 TRANSFER BELT CHARGE ....................................................... 6-47
Mechanism......................................................................................... 6-47
Correction for Paper Width and Thickness......................................... 6-48
Transfer Currents to Leading Edge and Image Areas........................ 6-49
6.12.6 TRANSFER BELT CLEANING MECHANISM.............................. 6-50

G065 vi SM
 6.13 IMAGE FUSING AND PAPER EXIT ..................................................... 6-51
6.13.1 OVERVIEW ................................................................................. 6-51
6.13.2 FUSING DRIVE ........................................................................... 6-52
6.13.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM .................... 6-52
6.13.4 EXIT GUIDE PLATE AND DE-CURLER ROLLERS .................... 6-53
6.13.5 PRESSURE ROLLER.................................................................. 6-53
6.13.6 CLEANING MECHANISM............................................................ 6-53
6.13.7 FUSING TEMPERATURE CONTROL......................................... 6-54
Temperature Control .......................................................................... 6-54
Fusing Idling Temperature ................................................................. 6-55
6.13.8 OVERHEAT PROTECTION......................................................... 6-55
6.14 ENERGY SAVER MODE...................................................................... 6-56

BRIDGE UNIT B397

1. OVERALL MACHINE INFORMATION ........................................ 7-1
1.1 SPECIFICATIONS .................................................................................... 7-1
1.2 MECHANICAL COMPONENT LAYOUT................................................... 7-2
1.3 ELECTRICAL COMPONENT LAYOUT .................................................... 7-3
1.4 ELECTRICAL COMPONENT DESCRIPTION .......................................... 7-3
1.5 DRIVE LAYOUT ....................................................................................... 7-4

2. DETAILED DESCRIPTION.......................................................... 7-5

2.1 JUNCTION GATE MECHANISM .............................................................. 7-5

3. REPLACEMENT AND ADJUSTMENT........................................ 7-6

3.1 EXIT SENSOR REPLACEMENT.............................................................. 7-6

SPECIFICATIONS
8. SPECIFICATIONS....................................................................... 8-1
1. GENERAL SPECIFICATIONS.................................................................... 8-1
2. SUPPORTED PAPER SIZES ..................................................................... 8-2
3. SOFTWARE ACCESSORIES..................................................................... 8-3
3.1 PRINTER DRIVERS ........................................................................... 8-3
3.2 UTILITY SOFTWARE ......................................................................... 8-3
. MACHINE CONFIGURATION ...................................................................... 8-4
4.1 SYSTEM COMPONENTS .................................................................. 8-4
4.2 INSTALLABLE OPTION TABLE ......................................................... 8-5
5. OPTIONS.................................................................................................... 8-6
5.1 BRIDGE UNIT..................................................................................... 8-6
5.2 1000-SHEET FINISHER ..................................................................... 8-6
5.3 3000-SHEET FINISHER ..................................................................... 8-7
5.4 LARGE CAPACITY TRAY (LCT) ........................................................ 8-8
5.5 MAILBOX............................................................................................ 8-8
5.6 PAPER TRAY UNIT............................................................................ 8-8

SM vii G065
 !IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
1. Before disassembling or assembling parts of the printer and peripherals,
make sure that the printer power cord is unplugged.
2. The wall outlet should be near the printer and easily accessible.
3. 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 has 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 by
accident, 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

1. The printer and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on
those models.
2. The NVRAM on the system control board has a lithium battery which can
explode if replaced incorrectly. Replace the NVRAM only with an identical
one. The manufacturer recommends replacing the entire NVRAM. Do not
recharge or burn this battery. Used NVRAM must be handled in accordance
with local regulations.

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.
4. When keeping used lithium batteries in order to dispose of them later, do not
put more than 100 batteries per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
LASER SAFETY
The Center for Devices and Radiological Health (CDRH) prohibits the repair of
laser-based optical units in the field. The optical housing unit can only be repaired
in a factory or at a location with the requisite equipment. The laser subsystem is
replaceable in the field by a qualified Customer Engineer. The laser chassis 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 required.

!WARNING
Use of controls, or adjustment, or performance of procedures other than
those specified in this manual may result in hazardous radiation exposure.

!WARNING
WARNING: Turn off the main switch before attempting any of the
procedures in the Laser Unit section. Laser beams can seriously damage
your eyes.

Caution Labels

G065RLW.WMF

LASER-3.WMF

LASER-1.WMF
Lithium Batteries (Memory Back-up)

!CAUTION
The danger of explosion exists if a battery of this type is incorrectly
replaced. Replace only with the same or an equivalent type recommended
by the manufacturer. Discard used batteries in accordance with the
manufacturer’s instructions.

Warning Concerning Copyright

Many documents are copyrighted. Such documents may not be reproduced by
copying or in any other form without the express permission of the copyright holder.

Conventions in this Manual

This manual uses several symbols and some simple abbreviations.

Symbol What it means

☛ Refer to section number
! See Core Tech Manual for details
" Screw
# Connector
$ E-ring
% C-ring
HP Home Position
T/S Transfer/Separation

The following notations are used in text to describe the direction of paper feed:
lengthwise and sideways. The annotations “SEF” and “LEF” denote “Short Edge
Feed” and “Long Edge Feed’. (The arrows indicate the direction of paper feed.)

Lengthwise (SEF) Sideways (LEF)

INSTALLATION G065

POSITION 1
TAB
PREVENTIVE MAINTENANCE G065

POSITION 2
TAB
REPLACEMENT AND ADJUSTMENT G065

POSITION 3
TAB
TROUBLESHOOTING G065

POSITION 4
TAB
SERVICE TABLES G065

POSITION 5
TAB
DETAILED DESCRIPTIONS G065
POSITION 6
TAB

BRIDGE UNIT B397

POSITION 7
TAB

SPECIFICATIONS G065
POSITION 8
TAB
INSTALLATION
 INSTALLATION REQUIREMENTS

1. INSTALLATION

Installation
1.1 INSTALLATION REQUIREMENTS
1.1.1 ENVIRONMENT

1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)

2. Humidity Range: 15 % to 80 % RH
3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight).
4. Ventilation: 3 times/hr/person
5. Avoid areas which are exposed to sudden temperature changes. This includes:
1) Areas directly exposed to cool air from an air conditioner.
2) Areas directly exposed to heat from a heater.
6. Do not place the machine in an area where it will be exposed to corrosive
gases.
7. Do not install the machine at any location over 2,500 m (8,125 ft.) above sea
level.
8. Place the machine on a strong and level base. (Inclination on any side should
be no more than 5 mm.)
9. Do not place the machine where it may be subjected to strong vibrations.

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2") of level
Right to left: Within 5 mm (0.2") of level

SM 1-1 G065
INSTALLATION REQUIREMENTS

1.1.3 MACHINE SPACE REQUIREMENTS

Place the printer near the power source, providing clearance as shown:

C
A: In Front: > 75 cm (29.6")
B: Left: > 10 cm (4")
C: To Rear: > 10 cm (4")
D: Right: > 45 cm (17.8")
B D

A
G065I000.WMF

630 mm (24.8")

540 mm (21.3") 360 mm (14.2")

530 mm (20.9") 625 mm (24.6")

G065I001.WMF G065I002.WMF

970 mm (38.2")

625 mm (24.6")
720 mm (28.4")
600 mm (23.6")
1320 mm (52")
G065I003.WMF

The 75 centimeters recommended for the space at the front is for pulling out the
paper tray only. If an operator stands in front of the printer, more space is required.

G065 1-2 SM
 MACHINE INSTALLATION

1.1.4 POWER REQUIREMENTS

Installation
!CAUTION
1. Make sure the plug is firmly inserted in the outlet.
2. Connect the printer to an independent power source. Avoid connecting
the printer to a power supply shared with another machine.
3. Always ground the machine.

1. Input voltage level: 120 V, 60 Hz: More than 12 A

220 V ~ 240 V, 50 Hz/60 Hz: More than 8 A
2. Permissible voltage fluctuation: ±10%
3. Do not set anything on the power cord.

1.2 MACHINE INSTALLATION

Refer to the Operating Instructions for details.

1.3 OPTIONAL UNIT INSTALLATION

The following options are available for this machine. Refer to the Operating
Instructions for how to install these options.
• PTU (Paper Tray Unit)
• 64/128/256 MB DIMMs
• HDD (Hard Disk)
• IEEE 1394

1.4 SYMBOLS USED IN TEXT

Screw: ! Connector: "

SM 1-3 G065
LCT INSTALLATION (A683)

1.5 LCT INSTALLATION (A683)

1.5.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Joint Pin ................................................................................. 2
2. Stepped Screw - M3x18......................................................... 4
3. Magnet Cover ........................................................................ 1
4. NECR (-17, -27 machines)..................................................... 1
5. Installation Procedure ............................................................ 1

G065 1-4 SM
 LCT INSTALLATION (A683)

1.1.2 INSTALLATION PROCEDURE

Installation
A683I501.WMF

[C]

[B]
A683I604.WMF
A683I500.WMF
[A]

!CAUTION
Switch off the main machine and unplug its power cord before starting the
following procedure.

NOTE: The Paper Tray Unit (G520) must be installed before installing the LCT.
1. Unpack the LCT and remove the tapes.
2. Open the right cover [A] of the paper tray unit.
3. Open the lower right cover [B] and cut the holding band [C].
NOTE: When cutting the holding band, the upper part of the band should be
cut as shown. Otherwise, paper jams may occur.
4. Remove the right lower cover.

SM 1-5 G065
LCT INSTALLATION (A683)

[A]
[E]

[B] [D] [C] A683I503.WMF

5. Install the joint pins [A].

6. Push the release lever [B] and slide the LCT to the right (front view).
7. Hang the LCT [C] on the joint pins, then secure the brackets [D] (! x 4).
8. Return the LCT to the previous position and connect the LCT cable [E].
9. Open the LCT cover and load the paper.
10. Turn on the ac switch and check the LCT operation.

G065 1-6 SM
 BRIDGE UNIT INSTALLATION (B397)

1.6 BRIDGE UNIT INSTALLATION (B397)

Installation
1.6.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Stepped Screw ...................................................................... 2
2. Connector Cover.................................................................... 1
3. Exit Mylar ............................................................................... 2
4. Installation Procedure ............................................................ 1

SM 1-7 G065
BRIDGE UNIT INSTALLATION (B397)

1.1.2 INSTALLATION PROCEDURE

[A]

[B]

[E]

B397I401.WMF

[F]
B397I407.WMF
[C]

[D] B397I500.WMF

!CAUTION
Switch off the main machine and unplug its power cord before starting the
following procedure.

1. Unpack the bridge unit [A] and remove all tapes and shipping retainers.
2. Remove the inner tray [B].
3. On the side of the machine, remove the three small covers [C].
If the optional external output tray (A825) will be installed (instead of a
finisher), do Step 4.
4. Remove the two small covers [D].
5. Remove the cover [E] (! x 1)
6. Remove the cap [F].
7. Remove the paper height sensor (! x 2, " x 1)

G065 1-8 SM
 BRIDGE UNIT INSTALLATION (B397)

[A]

Installation
[E]
B397I402.WMF [B]

[D]

[C]
B397I444.WMF

8. If an optional finisher is to be installed, attach two mylars [A] to the bridge unit.
9. Remove the cover [B].
10. Install the bridge unit [C] (! x 2).
11. Connect the bridge unit I/F harnesses [D] (" x 2).
12. Install the connector cover [E].
13. Turn on the main switch and check the bridge unit operation (make sure that
there are no paper jams).

SM 1-9 G065
1000-SHEET FINISHER INSTALLATION (A681)

1.7 1000-SHEET FINISHER INSTALLATION (A681)

1.7.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Front Stand ............................................................................ 1
2. Rear Stand............................................................................. 1
3. Knob Screw ........................................................................... 1
4. Screw - M4x12....................................................................... 6
5. NECR (-17 machine) ............................................................. 1
6. Installation Procedure ............................................................ 1
7. Screw - M4x10....................................................................... 1
8. Tray ....................................................................................... 1
9. Snap ring ............................................................................... 1

G065 1-10 SM
 1000-SHEET FINISHER INSTALLATION (A681)

1.1.2 INSTALLATION PROCEDURE

Installation
A681I701.WMF

A681I702.WMF

!CAUTION
Switch off the main machine and unplug its power cord before starting the
following procedure.

NOTE: The bridge unit (B397) and paper tray unit (G520) must be installed before
installing this finisher.
If the mailbox (G909) will be installed, first install the mailbox, then the
bridge unit for the mailbox (G912), and finally install the finisher.
1. Unpack the finisher and remove the tapes and retainers.

SM 1-11 G065
1000-SHEET FINISHER INSTALLATION (A681)

[A]

[C]

[B] A681I704.WMF

[D]

[E]
A681I705.WMF

2. Fasten [A] (! x 2) loosely.

3. Hang the front stand [B] and rear stand [C] on the screws installed in step 2.
4. To secure the front and rear stands tighten [A] (! x 2) and secure the stands
(! x 4).
5. At the front, use handle [D] to pull out the stapler unit.
6. Remove the locking lever [E] (! x 1).
7. Align the finisher on the stands, and lock it in place by pushing the locking
lever.
8. Secure the locking lever (! x 1) and push the stapler unit into the finisher.

G065 1-12 SM
 1000-SHEET FINISHER INSTALLATION (A681)

Installation
[F]

[C]
[A]

[D]

A681I706.WMF

[E] [B]

9. Secure the finisher [A] (! x 1).

10. Adjust the securing knobs [B] under the front and rear stands until the finisher
is perpendicular to the floor.
11. Install the shift tray [C] (snap ring x 1).
NOTE: Make sure that the three pegs [D] fit into the slots [E] properly.
12. Connect the finisher cable [F] to the main machine.
13. Turn on the main power switch and check the finisher operation.

SM 1-13 G065
3000-SHEET FINISHER INSTALLATION (A697)

1.8 3000-SHEET FINISHER INSTALLATION (A697)

1.8.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Front joint bracket .................................................................. 1
2. Rear joint bracket................................................................... 1
3. Entrance guide plate.............................................................. 1
4. Shift tray................................................................................. 1
5. Shift tray guide....................................................................... 1
6. Staple position decal.............................................................. 1
7. Screw - M3x6......................................................................... 2
8. Screw - M4x14....................................................................... 4
9. Screw - M3x8......................................................................... 4
10. Cushion ................................................................................. 1
11. Upper grounding plate ........................................................... 1
12. Lower grounding plate ........................................................... 2
13. NECR (-17 machine) ............................................................. 1
14. Installation procedure ............................................................ 1

G065 1-14 SM
 3000-SHEET FINISHER INSTALLATION (A697)

1.1.2 INSTALLATION PROCEDURE

Installation
A697I506.WMF

A697I507.WMF

!CAUTION
Unplug the main machine power cord before starting the following
procedure.

NOTE: The bridge unit (B397) and paper tray unit (G520) must be installed before
installing this finisher.
If the mailbox (G909) will be installed, first install the mailbox, then the
bridge unit for the mailbox (G912), and finally install the finisher.
1. Unpack the finisher and remove the tapes.

SM 1-15 G065
3000-SHEET FINISHER INSTALLATION (A697)

[B]

[A]

[C]

A697I558.WMF

2. Install the front joint bracket [A] and rear joint bracket [B] (! x 2 ea.).
3. Peel off the backing of the double-sided tape that is attached to the lower
grounding plate [C].
4. Attach one lower grounding plate to the center position of the paper tray unit as
shown.

G065 1-16 SM
 3000-SHEET FINISHER INSTALLATION (A697)

Installation
[B]

[A]

[C]

A697I559.WMF

5. Attach the cushion [A] at the position [B].

6. Install the entrance guide plate [C] (! x 2).

SM 1-17 G065
3000-SHEET FINISHER INSTALLATION (A697)

[C]

A697I534.WMF

[G]

[D]

[B]
[A]

[F] [E]

A697I550.WMF

7. If the customer requires the punch unit, install it now, before attaching the
finisher to the machine. See ‘Punch Unit Installation’.
8. Open the front door of the finisher, and remove the screw [A] that secures the
locking lever [B]. Then pull the locking lever.
9. Align the finisher on the joint brackets, and lock it in place by pushing the
locking lever.
NOTE: 1) Before securing the locking lever, make sure that the top edges of
the finisher and the copier are parallel from front to rear as shown
[C].
2) Secure the locking lever (! x 1) and close the front door.
10. Install the shift tray guide [D] on the shift tray. If the customer does not wish to
install it on the shift tray, store it at the location [E].
NOTE: The shift tray guide helps to properly stack exiting paper. However, it
reduces the capacity of the shift tray by 50, from 3,000 to 2,950.
11. Install the shift tray [F] (! x 4).
12. Connect the finisher cable [G] to the main machine.
13. Turn on the main power switch and check the finisher operation.

G065 1-18 SM
 PUNCH UNIT INSTALLATION (A812)

1.9 PUNCH UNIT INSTALLATION (A812)

Installation
1.9.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Spacer - 2 mm ....................................................................... 1
2. Spacer - 1 mm ....................................................................... 2
3. Stepped screw - Short ........................................................... 1
4. Stepped screw - Long............................................................ 1
5. Punch unit knob ..................................................................... 1
6. Spring .................................................................................... 1
7. Harness - Long ...................................................................... 1
8. Harness - Short...................................................................... 1
9. Hopper................................................................................... 1
10. Punch position decal.............................................................. 1
11. Tapping screw - M4x10.......................................................... 2
12. Screw with flat washer - M4x6 ............................................... 1
13. NECR..................................................................................... 1

SM 1-19 G065
PUNCH UNIT INSTALLATION (A812)

1.1.2 INSTALLATION PROCEDURE

[A]

[D]

[B]

A812I761.WMF

[C]

A812I763.WMF

!CAUTION
Unplug the copier power cord and remove the 3,000-sheet finisher from the
copier before starting the following procedure.

1. Unpack the punch unit and remove the shipping retainers [A] (! x 4) and [B] (!
x 1).
2. Open the front door and remove the hopper cover [C] (! x 2).
3. Remove the finisher rear cover (! x 2) and remove the transport guide plate
[D] (! x 4).

G065 1-20 SM
 PUNCH UNIT INSTALLATION (A812)

Installation
[A]
[B]
A812I510.WMF

[D]

[C]

A812I765.WMF

4. Install the spacer [A] (thickness = 2 mm).

NOTE: There are three spacers in the accessory box. Do not lose the other
two spacers (1-mm) because they are used for adjusting the punch
hole position.
5. Install the punch unit [B] and secure it with a long stepped screw [C].
6. Install the punch unit knob [D] (! x 1).
7. Secure the rear of the punch unit (! x 2).

SM 1-21 G065
PUNCH UNIT INSTALLATION (A812)

[B]
[E]
[A] [C]
A812I767.WMF

[D]
A812I511.WMF

[F]

A812I512.WMF

8. Install the sensor bracket [A] (! x 1, spring x1).

9. Connect the harnesses [B].
NOTE: 1) The harness binders [C] must not be between the harness clamps [D].
2) The harness binder [E] must be positioned to the left of the harness
clamp.
10. When a three-punch-hole unit is installed: Turn on switch 1 of DIP SW 100
on the finisher control board.
11. Slide the hopper [F] into the finisher.
12. Reassemble the finisher and attach the 3000-sheet finisher to the copier, then
check the punch unit function.

G065 1-22 SM
 MAILBOX INSTALLATION (G909)

1.10 MAILBOX INSTALLATION (G909)

Installation
1.10.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Front joint bracket .................................................................. 1
2. Rear joint bracket................................................................... 1
3. Exit guide mylar ..................................................................... 1
4. Proof tray attachment ............................................................ 1
5. Upper grounding plate ........................................................... 1
6. Lower grounding plate ........................................................... 2
7. Cushion ................................................................................. 1
8. Tapping screw - M4x14.......................................................... 4
9. Bin decals .............................................................................. 1
10. Installation procedure ............................................................ 1

1.1.2 REQUIREMENT OPTIONS FOR MAIN MACHINE

When the mailbox is going to be installed on this printer, the following options must
be installed first.
• Bridge unit type 450 (B397)
• Paper tray unit - PS430 (G520)

SM 1-23 G065
MAILBOX INSTALLATION (G909)

1.1.3 INSTALLATION PROCEDURE

G909I500.WMF

[B]
[A]

[C]
G909I559.WMF

!CAUTION
Unplug the main machine power cord before starting the following
procedure.

NOTE: If a finisher will be installed, first install this mailbox, then the bridge unit for
the mailbox (G912), and finally install the finisher.
1. Unpack the finisher and remove the pieces of tape.
2. Attach the front joint bracket [A] and rear joint bracket [B] to the main machine
(! x 2 ea.).
3. Peel off the backing of the double-sided tape that is attached to the lower
grounding plate [C].
4. Attach one lower grounding plate to the center of the bottom edge of the paper
tray unit as shown.

G065 1-24 SM
 MAILBOX INSTALLATION (G909)

Installation
[B]

[A]

[C]

[D] [E]
G909I550.WMF

5. Attach the cushion [A] to the position [B].

6. Open the front cover [C] of the mailbox, and remove the screw [D] that secures
the locking lever [E]. Then pull the locking lever.

SM 1-25 G065
MAILBOX INSTALLATION (G909)

[B]

[A] [C]

G909I503.WMF

G909I552.WMF

7. Align the mailbox on the joint brackets, and lock it in place by pushing the
locking lever [A].
8. Secure the locking lever (! x 1) and close the front door.
9. Connect the mailbox cable [B] to the main machine.
10. Peel off the backing of the double-sided tape that is attached to the proof tray
attachment [C].
11. Install the proof tray attachment on the proof tray.
12. Turn on the main switch and check the mailbox operation.

G065 1-26 SM
 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

1.11 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

Installation
1.11.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box against the following
list:

Description Q’ty
1. Guide plate bracket ............................................................... 1
2. Cable..................................................................................... 1
3. Cover switch.......................................................................... 1
4. Grounding bracket................................................................. 1
5. Finisher shielding plate.......................................................... 1
6. Screw - M4x8 ........................................................................ 9
7. Screw - M4x4 ........................................................................ 4
8. Screw - M3x6 ........................................................................ 2

SM 1-27 G065
BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

1.11.2 INSTALLATION PROCEDURE

[A]

[D]

[A] [E]
[B]
G912I506.WMF

[C]
G909I508.WMF

!CAUTION
Unplug the main machine power cord before starting the following
procedure.

NOTE: The bridge unit for the mailbox must be installed when both the mailbox
and a finisher will be installed. Install the mailbox first, then this bridge unit,
and finally the finisher
1. Unpack the bridge unit and remove the shipping retainers [A].
NOTE: Do not remove the protective sheet [B] at this time.
2. Remove the mailbox if it has been installed.
3. Remove the rear cover [C] of the mailbox (! x 8).
4. Remove the proof tray unit [D] (! x 6, " x 1).
5. Remove the cover [E].

G065 1-28 SM
 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

Installation
[B]

[C]

[A]
G912I503.WMF

[F]
[D]

G912I504.WMF

[E]

G912I505.WMF
[D]

6. Open the left front cover [A] of the mailbox, and remove the inner plate [B] (! x
3).
7. Install the guide plate bracket [C] (! x 4 - M4x4).
8. Route the cable [D] and clamp it as shown.
9. Connect the cover switch [E] to the cable then install the cover switch (! x 2 -
M4x8).
10. Remove the paper guide plate [F] (! x 2).

SM 1-29 G065
BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

[B]

[A] [C]

G912I501.WMF
[D]

[F]

[E]
G912I507.WMF

[H]

[G]

[H]
G912I508.WMF

11. Pull up the tab [A] of the protective sheet.

NOTE: 1) Do not remove the protective sheet at this time.
2) Make sure that all mylars are held between the two folded halves of
the protective sheet.
12. Turn over the bridge unit [B] and insert the protective sheet [C] into the gap [D]
between the paper guides, then put the bridge unit on the mailbox [E].
NOTE: When holding the bridge unit, do not touch the timing belt. Otherwise
the timing belt may come off the gear.
13. Remove the tape [F] for the protective sheet.
14. Open the upper paper guide [G] then pull out the protective sheet [H].
NOTE: Check that all mylars are set into the gap between the paper guides.

G065 1-30 SM
 BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

Installation
[C] [B]

[E] [B]
[A]

[D]
[C]
[B]
G912I509.WMF
[B]

G912I513.WMF

[G]

[F]
G912I510.WMF

15. Secure the bridge unit [A] (! x 4 - M4x8).

16. Route the cables [B] through the openings [C].
17. Route the solenoid harness [D] through the opening [E].
18. Connect the cables to the solenoid and sensors and clamp the cable as shown.
19. Reinstall the rear cover and proof tray unit.
20. Install the mailbox on the main machine (refer to the Mailbox Installation
procedure for more detail).
If installing the 3000-sheet finisher (A697), do steps 21 to 25.
21. Install the front joint bracket [F] and rear joint bracket [G] which are contained in
the finisher’s accessory box.

SM 1-31 G065
BRIDGE UNIT FOR MAILBOX INSTALLATION (G912)

[B]

G912I502.WMF
[A]

[C]

G912I512.WMF

22. Remove the seal [A].

23. Attach the grounding bracket [B] (! x 3 - M4x8).
24. Attach the shielding plate [C] to the finisher (! x 2 - M3x8).
25. Attach the finisher to the mailbox (refer to the finisher installation procedure).
26. Turn on the main switch of the main machine and check the bridge unit
operation. (Select a print mode that uses the finisher.)

G065 1-32 SM
PREVENTIVE MAINTANENCE
 PM TABLES

2. PREVENTIVE MAINTENANCE SCHEDULE

2.1 PM TABLES
2.1.1 PM TABLES FOR THE PRINTER
Two maintenance kits are provided for customers.

Maintenance
Preventive
NAME CONTENTS
Maintenance Kit Type 4510A PCDU (Photo Conductor Cleaning/Development Unit)
Maintenance Kit Type 4510B Fusing Unit and Transfer Unit

Components marked with an asterisk (*) should be inspected, serviced, and

replaced without the maintenance kits.
NOTE: Amounts mentioned as the PM interval indicate the number of prints.
Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect
EM 150K 300K 450K NOTE
PCDU
DRUM (OPC) AREA
Charge Roller* R R R
Cleaning Roller* R R R
Quenching Lamp C Dry cloth
Pick-off Pawls* R R R
Spurs C C C Dry cloth or alcohol
ID Sensor Perform SP3001-02 after
C C C
blower brush cleaning.

CLEANING UNIT
Drum Cleaning Blade* R R R
Cleaning Entrance Seal Blower brush, replace if
C C C
required.
Side Seal I I I

DEVELOPMENT
Development Drive Gears I I I Replace every 5 PM (750 K)
Development Filter* R R R
Developer* I R I
Entrance Seal I I I
Side Seal I I I
Development Roller C C C Dry cloth

SM 2-1 G065
PM TABLES

EM 150K 300K 450K NOTE

PAPER FEED
Registration Roller C C C C Water or alcohol.
Paper Feed Roller* I R R R Check counter value for each
Separation Roller* I R R R (SP7204). If ≥ 150 K, replace
Pick-up Roller* I R R R roller. After replacing the roller,
Paper Feed Roller do SP7816 to reset counter.
I R R R
(By-pass feed table)*
Separation Roller
I R R R
(By-pass feed table)*
Pick-up Roller
I R R R
(By-pass feed table)
Paper Feed Guides C C C Water or alcohol.
Relay Rollers C C C Water or alcohol.
Bottom Plate Pad C C C Water or alcohol.
Bottom Plate Pad Water or alcohol.
C C C
(By-pass feed)
Registration Sensor C C C Blower brush
Paper Feed Roller Gear Silicone Grease G-501.*
L L L
(By-pass feed)

DUPLEX UNIT
Upper Transport Roller C C C Water or alcohol.
Lower Transport Roller C C C Water or alcohol.

TRANSFER BELT UNIT

Transfer Belt* C R R R Dry cloth
Transfer Belt Cleaning
R R R
Blade*
Transfer Belt Rollers C C C Dry cloth
Entrance Seal C C C Dry cloth
Transfer Entrance Guide C C C C Dry cloth
Used Toner Tank I C C C Empty the tank.

FUSING UNIT/PAPER EXIT

Fusing Entrance and Exit Water or alcohol.
C C C
Guide Plates
Hot Roller* R R R
Pressure Roller* R R R
Fusing Thermistors* R R R
Cleaning Roller C C C Water or alcohol.
Cleaning Roller Bushings L L L Grease: Barrierta JFE 55/2
Hot Roller Strippers* C R C Water or alcohol.
Paper Exit Guide Ribs C C C Water or alcohol.
Exit Sensor C C C Blower brush

DRIVE
Drive Belts I Replace if necessary

G065 2-2 SM
 PM TABLES

2.1.2 PM TABLES FOR OPTIONS

NOTE: Amounts mentioned as the PM interval indicate the number of prints.
Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect
EM 150K 300K 450K NOTE
PAPER TRAY UNIT G520

Maintenance
Preventive
Paper Feed Rollers R R R Check counter with SP7204. If
Pick-up Rollers R R R ≥ 150 K, replace roller. After
Separation Rollers replacing the roller, do SP7816
R R R to reset counter.
Relay Rollers C C C Dry or damp cloth
Bottom Plate Pad C C C Dry or damp cloth

EM 150K 300K 450K NOTE

LCT A683
Paper Feed Roller Check counter with SP7204. If
≥ 150 K, replace roller. After
R R R
replacing the roller, do SP7816
to reset counter.
Pick-up Roller* R R R
Separation Roller* R R R
Bottom Plate Pad C C C Dry or damp cloth

EM 150K 300K 450K NOTE

1000-SHEET/3000-SHEET FINISHER
Rollers C Water or alcohol.
Brush Roller (A681) I I I I Replace if required.
Discharge Brush C C C C Dry cloth
Sensors C Blower brush
Jogger Fences I I I I Replace if required.
Punch Waste Hopper I I I I Empty hopper.

* Note: Lubricate the paper feed clutch

gear [A] with Silicone Grease [A]
G501 every P.M.

G065P500.WMF

SM 2-3 G065
REPLACEMENT AND ADJUSTMENT
 GENERAL CAUTIONS

3. REPLACEMENT AND ADJUSTMENT

3.1 GENERAL CAUTIONS
!CAUTION
To avoid damage to the transfer belt, drum, or development unit when it is
removed or re-installed, never turn off either power switch while electrical
components are active.

!CAUTION
Turn off the main power switch and unplug the machine before attempting

Replacement
any of the procedures in this section.

Adjustment
and
3.1.1 LASER UNIT

1. Do not loosen the screws that secure the LD drive board to the laser diode
casing. Doing so would throw the LD unit out of adjustment.
2. Do not adjust the variable resistors on the LD unit, as they are adjusted in the
factory.
3. The polygon mirror and F-theta lenses are very sensitive to dust. Do not open
the optical housing unit.
4. Do not touch the glass surface of the polygon mirror motor unit with bare
hands.
5. After replacing the LD unit, do the laser beam pitch adjustment. Otherwise, an
SC condition will be generated.

3.1.2 USED TONER

1. Dispose of used toner in accordance with local regulations. Never throw toner
into an open flame, for toner dust may ignite.

SM 3-1 G065
SPECIAL TOOLS AND LUBRICANTS

3.2 SPECIAL TOOLS AND LUBRICANTS

3.2.1 SPECIAL TOOLS
Part Number Description Q’ty
A2309003 Adjustment Cam – Laser Unit 1
A2309004 Positioning Pin – Laser Unit 1
A2309352 Flash Memory Card – 4MB 1
A2309351 Case – Flash Memory Card 1
G0219350 Parallel Loopback Connector 1

3.2.2 LUBRICANTS
Part Number Description Q’ty
A2579300 Grease Barrierta S552R 1
52039501 Silicone Grease G-501 1

3.2.3 SYMBOLS USED IN TEXT

Screw: ! Connector: " C-clamp (snap ring): # E-clamp: $

G065 3-2 SM
 FRONT DOOR

3.3 FRONT DOOR

[A]

Replacement

Adjustment
and
[B]
G065R951.WMF

1. Open front door.

2. Front door. Left pin [A], right pin [B].

3.4 DUPLEX UNIT

[A]
[C]
[B]

[D]

G065R003.WMF

1. Connector cover [A] (! x 1)

2. Duplex connectors [B] (" x 2)
3. Duplex support arm [C] (# x 1)
4. Duplex unit [D]
NOTE: Grip the duplex unit with both hands, slowly rotate it towards you and
then lift up.

SM 3-3 G065
UPPER RIGHT COVER

3.5 UPPER RIGHT COVER

[C]
[B]

[A]
G065R945.WMF

NOTE: Work carefully to avoid damaging the development roller.

1. Duplex unit (☛ 3.4)
2. Transfer belt unit (☛ 3.12.1)
3. Metal support arm [A] (! x 1)
4. Band support arm [B] (loop fastener)
5. Connector [C] (" x 1)
6. Upper right cover (# x 1, bushing x 1)

G065 3-4 SM
 BY-PASS TRAY UNIT

3.6 BY-PASS TRAY UNIT

[B]

[C]

Replacement

Adjustment
and
[D]

[A]
G065R952.WMF

Use this procedure to remove the complete by-pass tray unit from the machine. If
you wish to remove only the table, or some of the components of this unit, ☛ 3.15.
1. Duplex unit (☛ 3.4)
2. Left cover [A] (! x 1)
3. Right cover [B] (! x 1)
4. Connectors [C] (" x 2)
5. By-pass unit [D] (! x 4)
NOTE: After removing the screws, lift to unhook the by-pass tray unit from the
frame of the machine.

SM 3-5 G065
REAR COVERS

3.7 REAR COVERS

3.7.1 REAR UPPER COVER

[B]

[A]

G065R953.WMF

1. Left corner cover [A] (! x 2)

2. Rear upper cover [B] (! x 2)

3.7.2 REAR LOWER COVER

[A]
G065R954.WMF

1. Rear lower cover [A] (! x 4)

G065 3-6 SM
 LEFT COVERS

3.8 LEFT COVERS

3.8.1 LEFT UPPER COVER

Replacement

Adjustment
and
[A]

[B]

G065R955.WMF

1. Rear left corner cover [A] (! x 2)

2. Left upper cover [B] (! x 4)

SM 3-7 G065
LEFT COVERS

3.1.2 OPERATION PANEL

[A]

[D]

[B]

[C]
G065R919.WMF

!WARNING
The fusing unit below the cover is hot. Allow the machine to cool for a few
minutes before you begin the procedure.

1. Fusing unit cover [A] (caps x 2, ! x 2)

NOTE: Insert the tip of a screwdriver into the slot to release the plastic hook
and lift. Exert very little pressure to avoid breaking the hooks.
2. After removing the screws, slide cover [B] forward to remove it.
NOTE: Before re-installing the cover, open the duplex unit and carefully insert
the brackets on the bottom of the cover into the slots [C].
3. Operation panel [D] (! x 2, " x 2)
NOTE: Turn over the fusing unit cover and pull off the operation panel to
expose the connector.

G065 3-8 SM
 LEFT COVERS

3.1.3 PAPER OUTPUT TRAY

[B]
[A]

Replacement
[C]

Adjustment
[D]

and
G065R920.WMF

[E]
G065R921.WMF

No Bridge Unit Installed

1. Sub copy tray [A]
2. Paper sensor ass’y [B] (! x 2)
3. Cover [C] (! x 1)
4. Paper output tray [D] (! x 3)
5. If the duct on the bottom of the paper output tray base hangs up on the vertical
support [E] below, reach under and pull the duct up over the support.

Bridge Unit Installed

1. Bridge unit [A] (! x 2, " x 2)
2. Paper output tray [B] (! x 3)
3. If the duct on the bottom of the paper output tray base hangs up on the vertical
support [E] below, reach under and pull the duct up over the support.

SM 3-9 G065
LASER UNIT

3.9 LASER UNIT

!WARNING
Turn off the main power switch and unplug the machine before attempting
any of the procedures in this section. Laser beams can seriously damage
your eyes.

3.9.1 CAUTION DECAL LOCATIONS

Two caution decals are located in the laser section as shown below. (See the next
page for removal instructions.)

G060R951.WMF

LASER-3.WMF

LASER-1.WMF

G065RLW.WMF

G065 3-10 SM
 LASER UNIT

3.1.2 LASER UNIT

[C] [A]

[B]

[D]

Replacement
[F]

Adjustment
and
[B]
G065R211.WMF

[G]

[E] G065R962.WMF

!WARNING
Turn off the main power switch and unplug the machine before attempting
this procedure. Laser beams can seriously damage your eyes.

1. Open the front door and raise the toner bottle holder handle [A].
2. Front door (pins [B] x 2)
3. Inner cover [C] (! x 2, " x 2)
4. Shield glass [D]
5. Shield plate [E] (! x 2)
6. Laser unit connectors [F] (" x 5, " x 1 flat cable)
NOTE: Hold the LD board securely when disconnecting connectors.
7. Laser unit [G] (! x 2)
NOTE: When sliding out the laser unit, do not hold the LD board. Hold the
laser unit casing.

SM 3-11 G065
LASER UNIT

3.1.3 POLYGON MIRROR MOTOR

[A]

[B]

G065R994.WMF

G065R201.WMF

1. Laser unit (☛ 3.9.2)

2. Laser unit cover [A] (! x 4, 2 hooks)
3. Polygon mirror motor [B] (! x 4, " x 1)
4. After replacing the motor, do the image adjustment. (☛ 3.20)

G065 3-12 SM
 LASER UNIT

3.1.4 LASER SYNCHRONIZATION DETECTOR

Replacement

Adjustment
[A]

and
G065R206.WMF

1. Laser unit (☛ 3.9.2)

2. Laser synchronization detector [A] (! x 1, " x 1).

3.1.5 LD UNIT

[A]
G065R513.WMF

1. Laser unit (☛ 3.9.2)

2. LD unit [A] (! x 3, " x 1)
NOTE: To avoid damaging the LD board, hold it securely when disconnecting
the connectors. Hold the laser unit casing.
3. After replacing the LD board, perform SP2109 to adjust the laser beam pitch
(described on the next page).

SM 3-13 G065
LASER UNIT

Laser Beam Pitch Adjustment

After replacing the LD board, do the laser beam pitch adjustment. There are two
procedures: one for 400 dpi, and one for 600 dpi. These use the following SPs.

SP2110 Test Mode Dpi (0: 400 dpi, 8: 600 dpi)

SP2109-01 LD Beam Pitch Adjustment – 400 dpi
SP2109-02 LD Beam Pitch Adjustment – 600 dpi
SP2109-03 LD Beam Pitch Adjustment – 400 dpi Initial Setting
SP2109-04 LD Beam Pitch Adjustment – 600 dpi Initial Setting

NOTE: If you do not have an SMC Report for reference, print the SMC Report so
you can look up and match the SP numbers below with the correct name.
1. Set SP2110 to 0 (for 400 dpi), or to 8 (for 600 dpi).
2. Execute SP2109-08 to reset all the beam pitch data.
3. For SP2109-01 input 144.
NOTE: The entry “144” is only a starting reference value that will allow the
machine to operate. It is only a starting point for adjustment.
4. Execute SP2109-03.
5. Print the test pattern onto A3 (11" x 17") paper using SP2902-03 no.15. (☛ 5
Service Tables, 5.1.2 Test Pattern Printing (SP2902).
6. On the test pattern write 144, the value of SP2109-01.
7. Change the value of SP2109-01 and then print another test pattern, repeating
steps 2 to 6. Print about 5 patterns with different values for SP2109-01 (e.g. 48,
96, 192, 240).
8. Check these test patterns. If the laser beam pitch is not correct, the image
looks like a black vertical stripe pattern (see the diagrams below).
NOTE: For example, if the pattern made with the value 192 has fewer obvious
stripes than the other printouts, the correct value is near 192.
9. Fine adjustment: Do steps 2 to 6 to adjust the laser beam pitch position until
thin lines are of uniform thickness (no stripes should appear on the printout).
NOTE: In step 3, input a value estimated to be correct (e.g., if 192 was the
closest, try 182), then do steps 4 and 5, then if necessary go back to
step 2 and try another value.
10. After adjusting the laser beam pitch for 400 dpi, adjust it for 600 dpi, using the
same procedure as for 400 dpi (use the SP modes for 600 dpi). Laser beam
pitch for 600 dpi should be 24 ~ 48 more than for 400 dpi.

Adjustment not complete Adjustment complete

G065R552.WMF G065R553.WMF
G065 3-14 SM
 PCDU

3.10 PCDU
3.10.1 PHOTOCONDCUTOR CLEANING/DEVELOPMENT UNIT

[B]

[A]
[C]

Replacement

Adjustment
and
G065R905.WMF

[C]

[D]

[E] G065R906.WMF

1. Open the front door.

2. Lower the by-pass tray, open the duplex unit, and open the transfer unit right
cover.
3. Release the PCDU lock [A].
4. Hold the PCDU by the handle [B] and pull out slowly.
5. Remove the screws [C] (! x 3).
6. Pull the PCU horizontally then up [D] to separate it from the development unit
[E].
7. Cover the drum with a clean sheet of paper to protect it from exposure to light.
Assembly
1. With the PCU slightly offset, set it on top of the development unit, then carefully
slide it horizontally to ensure that the end of the toner supply shutter at the
toner supply port opens.
2. Check the exposed spring on the back of the PCDU.
• If the spring is spread open, the supply port is open.
• If the spring is not open, the supply port is shut. Slide the PCU back and
engage it correctly.
NOTE: If the supply port remains closed, no toner will reach the drum.

SM 3-15 G065
PCDU

3.10.2 DRUM

[C]

[B]

[A] G065R907.WMF

G065R908.WMF

[D] [E] G065R304.WMF

1. PCDU (☛ 3.10.1)
CAUTION: Never touch the drum surface with bare hands.
2. Remove the toner cap [A] and use it to cover the toner port [B].
3. Turn the PCU upside down and remove the lower cover [C] (! x 2, pawls x 3)
4. Press at ➀ to release the charge roller [D], release the charge roller ➁, press
the drum [E] to the front, and then remove the drum ➂.
5. SP adjustments.
Charge Roller Bias Adjustment Set to the standard value
2001-01 to ensure carrier is not
attracted to the drum.
ID Sensor Initial Setting 3001-02 Initializes the ID sensor.
Image Transfer Current – Image Face 2301 01 Set to the default
Image Transfer Current – Image Back 2301 02 settings.
Image Transfer Current – Lead Edge Face 2301 03
Image Transfer Current – Image Face By-pass 2301 04

G065 3-16 SM
 PCDU

3.10.3 PICK-OFF PAWLS

[A]

Replacement

Adjustment
and
[B]

G065R305.WMF

1. Remove the drum. (☛ 3.10.2)

2. Pawl assembly [A]
3. Pick-off pawl [B] (spring x 1, spur x 1)
Pick-off pawl position adjustment
If the pick-off pawl has marked the drum with a line, adjust the position by:
• Changing the spur position.
• Changing the pick-off pawl assembly position

SM 3-17 G065
PCDU

3.10.4 CHARGE ROLLER AND CLEANING ROLLER

[B]

[C] [A]

[D]

G065R500.WMF

1. Remove the drum. (☛ 3.10.2)

2. Two snap rings [A] (# x 2)
3. Charge roller holder [B]
4. Charge roller [C]
NOTE: Do not touch the charge roller.
5. Cleaning roller [D].
6. SP Adjustment:
Charge Roller Bias Adjustment Set to the standard value
(–1,480 V) to ensure
2001-01
carrier is not attracted to
the drum.
Image Transfer Current - Image Face 2301 01 Set to the default
Image Transfer Current - Image Back 2301 02 settings.
Image Transfer Current - Lead Edge Face 2301 03
Image Transfer Current - Image Face By-pass 2301 04

G065 3-18 SM
 PCDU

3.10.5 DRUM CLEANING BLADE

[A]

Replacement

Adjustment
and
G065R307.WMF

1. Remove the drum. (☛ 3.10.2)

2. Remove the charge roller. (☛ 3.10.4)
3. Remove the drum cleaning blade [A] (! x 2).

SM 3-19 G065
PCDU

3.10.6 ID SENSOR

[A]

[B]

G065R991.WMF

[C]

1. PCDU (☛ 3.10.1)
2. Fusing unit (☛ 3.14.1)
3. Development unit (☛ 3.11.1)
4. PCDU rail [A] (! x 2, " x 1)
5. ID sensor bracket [B] (! x 1, " x 1)
6. ID sensor [C] (! x 1)
7. Perform the ID sensor initial setting with SP3001-2 (☛ 5. Service Tables)

G065 3-20 SM
 DEVELOPMENT

3.11 DEVELOPMENT
3.11.1 DEVELOPMENT UNIT

[A]

Replacement

Adjustment
and
[B]

G065R202.WMF

1. PCDU. (☛ 3.10.1)
NOTE: Spread paper on a clean flat surface that is free of pins, paper clips,
staples, screws or any other metal objects.
2. Separate the PCU [A] and development unit [B] (! x 3).
3. Set the development unit on the spread paper, and cover the exposed drum
with a clean piece of paper.
4. SP adjustment if you are temporarily installing a used development unit for test
purposes:
Vref Manual Set SP2220 Set TD Sensor reference voltage to 4.0 V.
TD Sensor Manual Setting SP2802-01 Adjusts TD sensor output.
(☛ 5. Service Tables)

SM 3-21 G065
DEVELOPMENT

3.1.2 DEVELOPMENT FILTER

[A]

[B]

G065R909.WMF

1. Development unit (☛ 3.11.1)

2. Upper development cover [A] (# x 2)
3. Development filter [B].
NOTE: Make sure that the surface with the red mark is facing up.

G065 3-22 SM
 DEVELOPMENT

3.1.3 DEVELOPMENT ROLLER

[C]
[A]

[B]

Replacement

Adjustment
and
G065R910.WMF

1. Development unit (☛ 3.11.2)

2. Upper development cover (☛ 3.11.2)
3. Gear [A] (# x 1)
4. Joint bracket [B]
5. Development roller [C] (! x 2)
NOTE: 1) Work carefully to avoid scratching or nicking the development roller.
2) Make sure that the part is grounded correctly.

SM 3-23 G065
DEVELOPMENT

3.1.4 DEVELOPER

[B]

[A]
G065R404.WMF

[D]

[C]

G065R405.WMF

1. Development unit (☛ 3.11.1)

2. Remove the development roller (☛ 3.11.3)
3. Tip out the old developer [A]
4. Turn drive gear [B] to ensure that no developer remains in the unit or on the
developer roller.
NOTE: Dispose of the used developer in accordance with local regulations.
Work carefully to avoid scratching or nicking the development roller.
5. Pour approximately 1/3 of the developer [C] evenly along the length of the
development unit.
6. Rotate the drive gear [D] to work the developer into the unit. Repeat [C] and [D]
until all toner is in the unit and level with the edges.

G065 3-24 SM
 DEVELOPMENT

Replacement

Adjustment
[A]

and
G065R518.WMF

7. Reassemble the development unit

8. Cover the toner entrance hole [A] with a piece of paper.
9. Install the development unit in the machine.
10. Turn on the main power switch, make sure that the machine has warmed up,
then perform the TD sensor initial setting using SP2801.
NOTE: When performing this setting, cover the toner entrance hole with a
piece of paper. This prevents used toner falling from the PCU into the
development unit during the TD sensor initial setting and interfering
with the Vref setting (toner density reference voltage).
11. After performing the TD sensor initial setting, remove the sheet [A] from the
development unit.

SM 3-25 G065
DEVELOPMENT

3.1.5 TD SENSOR

[A]

G065R975.WMF

1. Remove the development unit (☛ 3.11.1)

2. Empty all developer from the development unit (☛ 3.11.4)
3. TD sensor [A] (! x 1)
NOTE: The TD sensor is attached to the casing with double-sided tape. Pry it
off with the flat head of a screwdriver. Use fresh double-sided tape to
re-attach the sensor.
4. Pour new developer into the development unit and perform the TD sensor initial
setting using SP2801.
NOTE: When performing the TD sensor initial setting, cover the toner entrance
hole with a piece of paper (☛ 3.11.4).

G065 3-26 SM
 TRANSFER UNIT

3.12 TRANSFER UNIT

3.12.1 TRANSFER BELT UNIT

[A]

Replacement

Adjustment
and
[B]
G065R501.WMF

G065R522.WMF

NOTE: To avoid exposing the PCU drum to strong light, cover it with paper if the
right cover will be open for a long period.
1. Lower the by-pass tray, open the duplex unit, and open the right cover.
2. Transfer unit [A] (1 hook)
3. Transfer belt [B] (springs x 2, 1 hook)
NOTE: Avoid touching the transfer belt surface.

SM 3-27 G065
TRANSFER UNIT

3.12.2 TRANSFER BELT

[B]

[E] [A]

[C]

[D]

G065R524.WMF
[B]

1. Remove the transfer belt unit. (☛ 3.12.1)

2. Belt drive gear [A]
3. Set screws [B] (! x 2)
4. Lay on a flat, clean surface and fold the unit to release the tension on the belt
[C].
5. Transfer belt [D]
NOTE: 1) Avoid touching the transfer belt surface.
2) Before installing the new transfer belt, clean all the rollers and shafts
with alcohol to prevent the belt from slipping.
3) When reinstalling the transfer belt, make sure that the belt is under the
pin [E].
4) To avoid damaging the transfer belt during installation, manually turn the
rollers and make sure that the new transfer belt is not running over the
edges of any of the rollers.

G065 3-28 SM
 TRANSFER UNIT

3.12.3 CLEANING BLADE/TONER OVERFLOW SENSOR

[B]

[A]

Replacement

Adjustment
and
G065R911.WMF

Transfer Belt Cleaning Blade

1. Transfer belt unit. (☛ 3.12.1)
2. Transfer belt. (☛ 3.12.2)
3. Transfer belt cleaning blade [A] (! x 3)
NOTE: Avoid touching the edge of the new blade. Check the new blade for
dust or damage.

Toner Overflow Sensor

1. Transfer belt unit. (☛ 3.12.1)
2. Transfer belt. (☛ 3.12.2)
3. Transfer belt cleaning blade [A] (! x 3)
4. Turn over the transfer unit and empty the used toner in the transfer unit.
5. Toner overflow sensor [B] (! x 1, " x 3)

SM 3-29 G065
TRANSFER UNIT

NOTE: Re-install the color-coded wires in the correct order.

R: Red, P: Purple, B: Blue

G065 3-30 SM
 PAPER FEED

3.13 PAPER FEED

3.13.1 PICK-UP, SEPARATION, AND FEED ROLLERS

[B]

Replacement

Adjustment
and
[A] [C]
G065R918.WMF

1. Paper tray
2. Pick-up roller [A]
3. Feed roller [B] (# x 1)
4. Separation roller [C] (# x 1)
NOTE: Do not touch the roller surface with bare hands. After installing the new
rollers, do SP7816 for the appropriate paper tray.

SM 3-31 G065
PAPER FEED

3.13.2 LOWER RIGHT COVER

[A]

[B]

G065R904.WMF

1. Duplex unit (☛ 3.4)

2. By-pass tray (☛ 3.6)
3. LCT (if installed)
4. Lower right cover [A] (! x 5)
5. Vertical transport cover [B]
NOTE: Push the cover completely to the left and then press in on the right tab
to release the peg from the hole.

G065 3-32 SM
 PAPER FEED

3.13.3 RELAY/UPPER PAPER FEED AND LOWER PAPER FEED

CLUTCHES

[D]
[E]

Replacement

Adjustment
[A]

and
[F]

[C]

G065R973.WMF
[B]

1. Rear lower cover (☛ 3.7.2)

2. First paper feed clutch bracket [A] (! x 2, bushing x 1)
3. Second paper feed clutch bracket [B] (! x 2, bushing x 1)
4. Drive bracket [C] (! x 1, spring x 1, bearing x 1)
5. Relay clutch [D] (" x 1)
6. Upper paper feed clutch [E] (" x 1)
7. Lower paper feed clutch [F] (" x 1)

SM 3-33 G065
PAPER FEED

3.13.4 UPPER PAPER FEED UNIT FOR TRAY 1

[B]

[B]

[A]
[B]
G065R900.WMF

[C]

G065R941.WMF

1. Upper paper tray

2. Right lower cover (☛ 3.13.2)
3. Upper right cover (☛ 3.5)
4. Upper paper feed clutch [A] (☛ 3.13.3)
5. 3 relay gears [B]
6. Upper paper feed unit [C] (! x 2, " x 1)

G065 3-34 SM
 PAPER FEED

3.13.5 LOWER PAPER FEED UNIT FOR TRAY 2

Replacement

Adjustment
and
G065R974.WMF [A]
[B]

[C]
[E]

[D] G065R943.WMF

1. Lower the paper trays

2. Lower right cover (☛ 3.13.2)
3. Lower paper feed clutch [A] (☛ 3.13.3)
4. Relay gears [B] (x 3)
5. Cover [C] (! x 2)
6. Gear [D] (x 1)
7. Lower paper feed unit [E] (! x 2, " x 1)

SM 3-35 G065
PAPER FEED

3.13.6 PAPER END/PAPER LIFT/RELAY SENSORS

[A] [B]
[C]

[D]

G065R944.WMF

1. Appropriate paper feed unit (☛ 3.13.4, 3.13.5)

2. Paper lift sensor [A] (" x 1)
3. Paper end sensor [B] (" x 1)
4. Relay sensor bracket [C] (! x 1, " x 1)
5. Relay sensor [D]

G065 3-36 SM
 PAPER FEED

3.13.7 REGISTRATION SENSOR

[D]
[C]

[F]
[B]

[A]

Replacement
G065R992.WMF

Adjustment
[G]
[I]

and
[E]

G065R922.WMF

[J]
[H]

G065R993.WMF

1. Front door (☛ 3.3• )

2. Rear upper cover (☛ 3.7.1)
3. Right door and transfer belt unit (☛ 3.5, 3.12.1)
4. PCU (☛ 3.10.1)
5. Development unit (☛ 3.12.1)
6. Inner cover [A] (! x 2)
7. Front registration holder [B] (! x 1)
8. Front registration roller gear [C] ($ x 1)
9. Registration roller bushing [D] (spring x 1)
10. High voltage power supply board [E] (! x 3, " x 6)
11. Three flywheels [F] (! x 3)
12. Right rear cover [G] (! x 3)
13. Right cover switch bracket [H] (! x 1)
14. Rear registration holder [I] (! x 1)
15. Registration roller bushing [J] ($ x 1, spring x 1)

SM 3-37 G065
PAPER FEED

[B]

[A]
G065R934.WMF

[C]
[D]
[E] G065R935.WMF

16. Guide plate [A] and registration roller [B] (spring x 1, # x 1)

17. Registration guide plate [C] (! x 2, " x 1)
18. Sensor bracket [D] (! x 1)
19. Registration sensor [E] (! x 1, " x 1)

G065 3-38 SM
 PAPER FEED

3.1.8 TRAY LIFT MOTOR

[A]

Replacement

Adjustment
and
[C]

G065R964.WMF
[B]

1. Rear lower cover (☛ 3.7.2)

2. Bracket [A] (! x 2)
3. Motor control board [B] (! x 2, " x 13)
4. Tray lift motor [C] (! x 2)

SM 3-39 G065
PAPER FEED

3.1.9 FEED/DEVELOPMENT MOTOR

[B]

[A]

[C] G065R982.WMF

1. Rear lower cover (! x 4) (☛3.7.2)

2. Rear upper cover (! x 4) (☛3.7.1)
3. Tray lift motor (☛ 3.13.8)
4. Support [A] (! x 2, harnesses x 2)
5. Timing belt [B] (Raise arm to release tension on belt.)
6. Feed/development motor [C] (! x 3, " x 2)

G065 3-40 SM
 FUSING

3.14 FUSING
3.14.1 FUSING UNIT

!CAUTION
Allow the unit to cool before doing the following procedure.

[B]

Replacement

Adjustment
and
[C]

[A]

G065R901.WMF

1. Open the front door, duplex unit, and right door.

2. Set screw [A] (! x 1)
3. Fusing unit release lever [B]
4. Slide out the fusing unit [C]
NOTE: After removing the fusing unit, close the right cover.

SM 3-41 G065
FUSING

3.1.2 FUSING UNIT EXIT GUIDE

[A]

G065R912.WMF

1. Fusing unit (☛ 3.14.1)

2. Exit guide [A]
NOTE: Press the guide to the left and then press on the right end to release
the peg from the hole.

3.1.3 HOT ROLLER STRIPPERS

[A]

[B]

G065R913.WMF

1. Fusing unit (☛ 3.14.1)

2. Fusing unit cover [A] (! x 4)
NOTE: Note the positioning of the step screws (x 2) and set screws (x 2).
3. Hot roller strippers [B] (x 7), springs (x 7)

G065 3-42 SM
 FUSING

3.1.4 FUSING LAMPS

[B]

Replacement

Adjustment
and
[C]

[A]
G065R914.WMF

[E]

[D]

G065R915.WMF

1. Fusing unit (☛ 3.14.1)

2. Fusing unit cover (☛ • 3.14.3)
3. Fusing entrance guide [A] (! x 2)
4. Lower cover [B] (! x 1)

Left Side
5. Two terminals [C] (! x 2)
6. Center fusing lamp lead [D] (3 clamps)
7. Bracket [E] (! x 1)

SM 3-43 G065
FUSING

[C] [D]

[A]

[B]
G065R607.WMF

Right Side
1. Two terminals [A] (! x 2)
2. Spring [B]
3. Connector bracket [C] (! x 2)
4. Bracket [D] (! x 2)
NOTE: To avoid breaking the fusing lamps, handle them with care. Avoid
touching the lamps with your fingers. Note the top/bottom positioning of
the fusing lamps as you remove them. The sizes of the holes in the
holder match the sizes of the ends of the 650 W lamp (red) and 550 W
lamp (brown).
5. Remove both fusing lamps.

G065 3-44 SM
 FUSING

3.1.5 THERMISTORS AND THERMOSTATS

[B]

Replacement

Adjustment
[A]

and
G065R917.WMF

1. Fusing unit (☛ 3.14.1)

2. Fusing upper and lower cover (☛ 3.14.3, 3.14.4)
3. Center thermistor [A] (! x 1, " x 1, holder x 1)
4. End thermistor [B] (! x 1, " x 1, holder x 1)
CAUTION: The thermistors are thinly coated and extremely fragile. Handle with
care to avoid damaging them. They should be replaced every 150K.
5. Center thermostat [C] (! x 2)
6. End thermostat [D] (! x 2)

SM 3-45 G065
FUSING

3.1.6 HOT ROLLER/PRESSURE ROLLER

[C]

[A]

[B] G065R902.WMF

1. Fusing unit (☛ 3.14.1)

2. Fusing upper and lower cover (☛ 3.14.3, 3.14.4)
3. Fusing lamp. (☛ 3.14.4)
4. Springs x 2 [A] (both sides)
5. Arms x 2 [B] (both sides)
6. Pawl bracket [C] (! x 4)

G065 3-46 SM
 FUSING

[D]
[B]
[A]

[E]
[C]

Replacement

Adjustment
[B]

and
[F]
[G]

G065R903.WMF

7. Hot roller [A]

CAUTION: The hot roller is easily damaged. Always handle it carefully.
8. C-rings x 2 [B] (both ends)
9. Drive gear [C]
10. Bushings x 2 [D] (both ends)
11. Pressure roller [E]
12. Fusing knob [F] (! x 1)
13. Bushings x 2 [G] (both ends)
NOTE: 1) Before installing the new hot roller, peel off 3 cm (1 inch) from both
ends of the protective sheet on the new roller.
2) Never touch the surface of the rollers.
3) Work carefully to avoid damaging the surface of the hot roller.
4) The standard pressure roller spring position is the upper position.
5) When reinstalling the hot roller assembly and pressure roller
assembly, make sure that the flange position of the bushings is as
shown.

SM 3-47 G065
BY-PASS TRAY

3.15 BY-PASS TRAY

3.15.1 COVER REPLACEMENT

[D]

[A]

[C]
[B]

1. Rear cover [A] (! x 1)

2. Front cover [B] (! x 1)
3. Hinge cover [C] (! x 1)
4. Upper cover [D] (! x 2)
5. Close duplex unit and pull out upper cover.

G065 3-48 SM
 BY-PASS TRAY

3.15.2 BY-PASS FEED/PICK-UP ROLLER

[C]

[B]

[A]

Replacement

Adjustment
and
G065R541.WMF

1. Upper cover (☛ 3.15.1)

2. Lift up paper end feeler [A] to lock feeler in position.
NOTE: Before reinstalling the upper cover, return the paper end feeler to its
original position.
3. Replace the paper feed roller [B] (# x 1)
4. Replace the pick-up roller [C].
NOTE: Do not touch the roller surface with bare hands. After installing the new
rollers, do SP7816 for the bypass tray.

SM 3-49 G065
BY-PASS TRAY

3.1.3 BY-PASS SEPARATION ROLLER REPLACEMENT

[A]

G065R542.WMF

1. Close the by-pass table.

2. Remove the separation roller [A] from the bottom (# x 1)
NOTE: Do not touch the roller surface with bare hands. After installing the new
rollers, do SP7816 for the bypass tray.

G065 3-50 SM
 BY-PASS TRAY

3.1.4 PAPER END SENSOR/PICK-UP SOLENOID

[C]

[A]
[B]

Replacement

Adjustment
and
G065R543.WMF

1. Upper cover (☛ 3.15.1)

2. Lift paper end feeler [A].
NOTE: Before reinstalling the upper cover, return the paper end feeler to its
original position.
3. Paper end sensor [B] (" x 1).
4. Pick-up solenoid [C] (! x 1, " x 1, spring x 1)

SM 3-51 G065
BY-PASS TRAY

3.1.5 PAPER SIZE SENSOR BOARD REPLACEMENT

[C]

[B]

[A] G065R544.WMF

1. Hook [A]
2. Paper tray [B] (" x 1).
3. Size sensor board [C].
NOTE: To avoid breaking the hook of the paper size sensor board, handle it
carefully during removal.

G065 3-52 SM
 BY-PASS TRAY

3.1.6 BY-PASS TABLE REMOVAL

[A]

[B]

Replacement

Adjustment
and
[C]

G065R505.WMF

Note: To remove the entire by-pass tray unit, and not just the table, ☛ 3.6
1. Hinge cover (☛ 3.15.1)
2. Harness [A] (" x 1).
3. Screws [B] (! x 2)
4. By-pass table [C].
CAUTION: To relieve pressure on the spring during removal, depress it as shown
in the illustration.

SM 3-53 G065
BY-PASS TRAY

3.1.7 PAPER FEED CLUTCH REPLACEMENT

[A]

G065R546.WMF
[C]

[B]

G065R547.WMF

1. By-pass tray
2. Paper feed unit [A] (! x 2, " x 1)
3. Rear bracket [B] (! x 3, clip x 1, bushing x 1)
4. Paper feed clutch [C] (" x 1)

G065 3-54 SM
 DUPLEX UNIT

3.16 DUPLEX UNIT

3.16.1 DUPLEX COVER REMOVAL

[A]

Replacement

Adjustment
and
G065R101.WMF

1. Duplex unit cover [A] (! x 4)

SM 3-55 G065
DUPLEX UNIT

3.16.2 DUPLEX ENTRANCE SENSOR REPLACEMENT

[A]
[B]

G065R102.WMF

1. Duplex unit cover (☛ 3.16.1)

2. Sensor holder [A] (! x 1)
3. Entrance sensor [B] (" x 1)

G065 3-56 SM
 DUPLEX UNIT

3.1.3 DUPLEX EXIT SENSOR REPLACEMENT

[A]

[B]

Replacement

Adjustment
and
G065R103.WMF

1. Duplex unit (☛3.4)

2. Sensor bracket [A] (! x 1)
3. Exit sensor [B] (" x 1)

SM 3-57 G065
DRIVE AREA

3.17 DRIVE AREA

3.17.1 REGISTRATION/TRANSFER BELT CONTACT CLUTCHES

[A]

[B]

G065R965.WMF

[D]

[C] G065R923.WMF

1. Rear upper cover (! x 2)

2. High voltage supply board [A] (" x 6, ! x 6)
NOTE: Make sure that you re-connect the wires in
the correct order.
They are labeled 1 → 2 → B → C
3. Flywheels [B] (! x 3)
4. Registration clutch [C] ($ x 1, " x 1)
5. Transfer belt contact clutch [D] (" x 2, ! x 2) G065R502.WMF

G065 3-58 SM
 DRIVE AREA

3.1.2 MAIN MOTOR

Replacement
[A]

Adjustment
and
[D]

[C]

[B] G065R924.WMF

1. Rear upper cover, high voltage power supply, flywheels (☛ 3.17.1)

2. Remove the main cooling fan [A] (! x 2).
3. Timing belt [B] x 1
4. Bracket [C] (! x 2)
5. Main motor [D] (" x 2, ! x 3)

SM 3-59 G065
DRIVE AREA

3.1.3 FUSING/EXIT MOTOR

[A]

G065R925.WMF
[B] [C]

[D]
G065R926.WMF

[E]
G065R927.WMF

1. Rear upper cover (☛3.7.1)

2. Fusing unit cover (☛3.8.2) (Do not disconnect.)
3. Paper output tray (☛3.8.3)
4. Harnesses [A] (x 3)
5. Connector bracket [B] (! x 1, harness x 1)
6. Main fan [C] (! x 1, " x 1)
7. Motor bracket [D] (! x 1)
8. Fusing/exit motor [E] (! x 5)

G065 3-60 SM
 DRIVE AREA

3.1.4 FUSING/EXIT CLUTCH

Replacement

Adjustment
[A]

and
G065R928.WMF

[C]
[B]
G065R929.WMF

1. Rear upper cover (☛3.7.1)

2. Fusing unit fan (harnesses x 2, ! x 2, " x 1) (☛3.17.3)
NOTE: You may need to loosen the screws of the right upper cover to see the
right screw of the fan bracket.
3. HVPS (High Voltage Power Supply) (! x3) (Do not remove connectors.)
(☛3.17.1)
4. Flywheels (! x 3) (☛3.17.1)
5. Transfer belt contact clutch [A] (! x 2, " x 2)
6. Fusing/exit clutch brackets [B] (! x 3)
7. Fusing/exit clutch [C] (" x 1)

SM 3-61 G065
DRIVE AREA

3.1.5 TONER SUPPLY MOTOR

[C]

[B]
[D]

[A]

G065R971.WMF

[E]

[F]

G065R972.WMF

1. Open the front door.

2. Raise holder handle [A].
3. Push the holder lever [B] to the right.
4. Stopper [C]
5. Toner bottle holder and bottle [D]
6. Motor harness [E] (clamps x 2)
7. Toner supply motor [F] (hooks x 2, " x 1)
NOTE: Press in on both sides of the motor to release it.

G065 3-62 SM
 PRINTED CIRCUIT BOARDS

3.18 PRINTED CIRCUIT BOARDS

3.18.1 HIGH VOLTAGE POWER SUPPLY

Replacement

Adjustment
and
[A]

G065R965.WMF

1. Rear upper cover (☛ 3.7.1)

2. High voltage power supply [A] (! x 3, " x 6)

SM 3-63 G065
PRINTED CIRCUIT BOARDS

3.1.2 I/O BOARD

[A]

G065R930.WMF

[B]

G065R968.WMF

1. Rear upper cover (☛ 3.7.1)

2. Expansion box [A] (! x 5, " x 1)
3. I/O board [B] (! x 2, " x all)
NOTE: Make sure that the DIP switch settings on the new board are the same
as those on the old board.

G065 3-64 SM
 PRINTED CIRCUIT BOARDS

3.1.3 BICU BOARD

Replacement

Adjustment
[A]

and
G065R931.WMF

1. I/O board (☛ 3.18.2)

2. BICU board [A] (! x 4, " x all)

3.1.4 PSU

[A]

G065R970.WMF

1. Left upper cover (☛ 3.8.1)

2. PSU [A] (! x 5, " x all)

SM 3-65 G065
HARD DISK/CONTROLLER BOARD

3.19 HARD DISK/CONTROLLER BOARD

[B]

[C]

[A]
G065R933.WMF
G065R932.WMF

1. Left rear corner cover (☛ 3.8.1)

2. Expansion spacer [A] (! x 2)
3. HDD unit bracket [B] (" x 2)
4. HDD unit [C] (! x4)
NOTE: Work carefully to avoid dropping or hitting the HDD.

To Format the HDD

The first time the machine is powered on with the new HDD installed, a message
prompts you to format the hard disk.
1. Press (Menu).
2. Press &' to display “Maintenance” and then press #(Enter).
3. Press &' to display “HDD Format”, and then press #(Enter).
4. Press #(Enter).
HDD Format
Press # to Start

5. Press #(Enter).
Completed
Restart Printer

6. Switch the printer off and on.

G065 3-66 SM
 PRINTING ADJUSTMENTS

3.20 PRINTING ADJUSTMENTS

Perform the appropriate adjustments after replacing any of the following items:
• Polygon mirror motor
• Paper side fence
• Memory all clear
• Rollers and gears
• Paper feed unit
For details about how to perform the adjustments, refer to the Operating
Instructions. See ‘Maintenance Menu’ in Section 6 (‘Making Printer Settings with
the Operation Panel’) of the Operating Instructions (Printer Reference).

Replacement

Adjustment
and

SM 3-67 G065
PARALLELOGRAM IMAGE ADJUSTMENT

3.21 PARALLELOGRAM IMAGE ADJUSTMENT

Do the following procedure if a parallelogram prints while adjusting the printing
registration or printing margin using a trimming area pattern.
The following procedure should be done after adjusting the side-to-side registration
for each paper tray station.

[C]
[B]

[D]

[A]

[E]

G065R207.WMF

G065R515.WMF

Use SP2902 03 No. 11 (Printing Test Pattern: Belt Pattern Trimming Area) to
determine whether a parallelogram image appears. If the parallelogram pattern
appears, perform the following procedure.
1. Laser unit [A]
2. Bracket [B] (! x 2)
3. Install adjustment cam [C] (P/N: A2309003)
4. Secure positioning pin [D] (P/N: A2309004) with the two screws removed with
the bracket [B]. Do not tighten the screws at this time.
5. To adjust the position of the laser unit [E]
1) Adjust the laser unit position by turning the adjustment cam. (See the
illustration above.)
2) Tighten the adjustment bracket.
3) Print the trimming area pattern to check the image. If the results are not
satisfactory, repeat steps 5-1) to 5-3).

G065 3-68 SM
TROUBLESHOOTING
 SERVICE CALL CONDITIONS

4. TROUBLESHOOTING
CAUTION
To avoid damaging the hard disk or memory, never turn off the main power
switch when the Data In LED is lit or flashing.

4.1 SERVICE CALL CONDITIONS

4.1.1 SUMMARY
There are 4 levels of service call conditions.

Level Definition Reset Procedure

To prevent damage to the machine, the main Enter SP mode, execute
machine cannot be operated until the SC has SP5810, then exit the SP mode.
A
been reset by a service representative (see the
note below).
If the SC was caused by incorrect sensor Turn the operation switch and
B detection, the SC can be reset by powering the main power switch off and on.
main power switch off and on.

shooting
Trouble-
The main machine can be operated as usual, Turn the operation switch off
C
excluding the unit related to the service call. and on.
The SC history is updated. The machine can be The SC will not be displayed.
D
operated as usual. Only the SC history is updated.

NOTE: 1) If there is problem with one of the electrical circuit boards, before
replacing the board, first disconnect then reconnect the connectors to
see if this solves the problem.
2) If the problem concerns a motor lock, first check the mechanical load on
the component before replacing motors or sensors.

SM 4-1 G065
SERVICE CALL CONDITIONS

4.1.2 SC CODE DESCRIPTIONS

SC Level Symptom Possible Cause
CHARGE ROLLER
302 C Charge roller current leak • Charge roller damaged
A charge roller current leak signal • High voltage supply board
was detected. defective
• PCU harness defective or
disconnected
304 C Charge roller current correction error • ID sensor defective
The charge roller bias correction is
performed twice even if the
maximum charge roller bias (–2kV) is
applied to the roller.
EXPOSURE UNIT
320 C Polygon motor error • Harness at the polygon mirror
The polygon motor does not reach motor disconnected or defective
the ready state (it does not reach • Polygon motor or polygon motor
operating speed within 25 seconds driver defective
after the polygon motor on signal, or • Polygon motor drive pulse not
the lock signal is still activated for output correctly
more than 2 seconds after the • LOCK signal could not be
polygon motor off signal). detected
321 C F-GATE error (no laser writing • BICU board defective
signal) • PCI harness between the
The laser writing signal (F-GATE) controller board and the BICU
does not go LOW for more than 30 defective or disconnected
seconds after the paper reaches the
registration sensor.
322 C 1st laser synchronization error • Poor harness connection between
The LD1 synchronization signal the laser synchronization detector
cannot be detected by the main scan board and the LD unit.
synchronization detector board even • Laser synchronization detector
after the laser diodes are activated. board out of position and angle of
reflection not correct
• Laser synchronization detector
board defective
• LD unit defective
323 C LD (Laser Diode) drive current too • LD unit defective (not enough
high power, due to aging)
The LD drive board applies more • Poor connection between the LD
than 110 mA to the LD. unit and the BICU board
• BICU defective
326 C 2nd laser synchronization error • Poor connection between the laser
The LD2 synchronization signal synchronization detector board
cannot be detected by the main scan and the LD unit.
synchronization detector board even • Laser synchronization detector
after the laser diodes are activated. board out of position
• Laser synchronization detector
board defective
• LD unit defective

G065 4-2 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

327 B LD unit H.P. error 1 • H.P. sensor/harness defective
The LD unit H.P. sensor does not • LD unit home position sensor
detect the on condition when the LD defective
unit moves to its home position. • LD positioning motor harness
defective
• LD unit movement blocked
because of incorrect connector
routing
328 B LD unit H.P. error 2 • H.P. sensor/harness defective
The LD unit H.P. sensor does not • LD positioning/harness motor
detect an off condition when the LD defective
unit moves from its home position. • LD unit movement blocked
because of incorrect connector
routing
329 B LD unit beam pitch adjusted • After initialization of the SP
incorrectly modes, SP2109-03 or SP2109-04
The LD unit H.P. sensor does not was not executed.
detect the ON condition while • The harness is blocking the LD
changing the LD unit position to drive (PCB), preventing
correct the LD position or to adjust adjustment of the pitch
the dpi.

shooting
Trouble-
ID SENSOR
350 C ID sensor pattern test error • ID sensor defective
One of the following ID sensor output • ID sensor connector defective
voltages was detected twice • Poor ID sensor connector
consecutively when checking the ID connection
sensor pattern. • I/O board (IOB) defective
Vsp ≥ 2.5 V • High voltage supply board
Vsg ≤ 2.5 V defective
Vsp = 0 V • ID sensor dirty
• Defect at ID sensor pattern writing
area of the drum
351 C ID sensor Vsg test error • ID sensor defective
When ID sensor checks the drum • ID sensor connector defective
surface, VSG = 0, or PWM = 0 • Poor ID sensor connection
• I/O board (IOB) defective
• Scanning system defective
• High voltage supply board
defective
• ID sensor dirty
• Defect at the ID sensor pattern
writing area of the drum
352 C ID sensor edge detect pattern error • ID sensor defective
At 800 ms intervals, the value of the • ID sensor connector defective
ID sensor edge pattern voltage was • Poor ID sensor connector
not 2.5 V for 2 consecutive attempts. connection
• I/O board (IOB) defective
• High voltage supply board
defective
• Dirty ID sensor
• Defect at the ID sensor pattern
writing area of the drum

SM 4-3 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

353 C LED current abnormal at initialization • ID sensor defective
during ID sensor adjustment • ID sensor harness defective
At ID sensor initialization, one of the • ID sensor connector defective
following is detected: • Poor ID sensor connection
At PWM = 255, VSG < 4.0 V • I/O board (IOB) defective
At PWM = 0, VSG ≥ 4.0 V • Exposure system defective
• High voltage supply board
defective
• Dirty ID sensor
354 C ID sensor adjustment timeout error • ID sensor defective
VSG out of the adjustment target • ID sensor harness defective
range (4.0 ± 0.2 V) within 20 s at VSG • ID sensor connector defective
initialization. • I/O board (IOB) defective
• Exposure system defective
• Poor ID sensor connector
connection
• High voltage supply board
defective
• Dirty ID sensor
DEVELOPMENT UNIT
390 C TD sensor error: Test value • TD sensor defective
abnormal • TD sensor not connected or
TD sensor output voltage is less than connector damaged
0.5 V or more than 4.8 V after 10 • Poor connection between the TD
consecutive times during printing. sensor and the I/O board (IOB)
• I/O board (IOB) defective
• Toner supply defective
391 C TD sensor error: Auto adjust error • TD sensor abnormal
At initialization of the TD sensor, • TD sensor disconnected
VT < 1.8 V or VT > 4.8 V. • Poor TD sensor connection
• I/O board (IOB) defective
• Toner supply defective
395 C Development bias abnormal • High voltage supply board
A development bias leak signal is defective
detected. High voltage output to the • Poor connection at the
development unit exceeded the development bias terminal
upper limit (65%) for 60 ms. • Poor connection at the high
voltage supply board
TRANSFER UNIT
401 C Transfer roller bias output abnormal • High voltage supply board
A transfer roller current leak signal is defective
detected. • Poor cable connection or defective
cable
• Transfer connector defective
402 C Transfer roller open error • High voltage supply board
The transfer roller current feedback defective
signal is not detected. • Transfer connector cable defective
• Transfer connector defective
• Poor PCU connection

G065 4-4 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

403 C Transfer belt H.P. abnormal • Main motor/drive malfunction
H.P. is not detected after the T/S • Transfer belt contact clutch
clutch is switched on twice. defective
• Transfer belt position sensor
defective
• Harness disconnected
405 C Transfer belt position abnormal • Main motor/drive malfunction
The transfer belt does not separate • Transfer belt position sensor
from the drum during ID sensor defective
pattern checking. • Poor transfer belt position sensor
connection
• Transfer belt contact clutch
defective
MAIN DRIVE
440 C Main motor abnormal • Too much load on the drive
(1) During motor rotation before the mechanism
start of printing, the H.P. of the T/S • Main motor defective
clutch is detected, the main motor
lock signal (PLL) goes low, and 5
retries are not successful, resulting in
an internal lock. (2) A main motor

shooting
Trouble-
lock signal is not detected within 2
seconds after the main motor turns
on.
442 C PCU new unit detection error • New unit detection sensor
After the main motor turns on, the defective.
PCU new unit detection sensor • PCU defective
remains on for 2 or more seconds.
450 Feed/Development motor abnormal • Feed/development motor defective
(1) During motor rotation before the
start of printing, the motor lock signal
(PLL Lock) goes low, 5 retries are
not successful, resulting in an
internal lock.
(2) A motor lock signal is not
detected within 2 s after the main
motor turns on.
490 C Exhaust fan motor lock • Too much load on the drive
An exhaust fan motor lock signal is mechanism
detected within 5 seconds after the • Exhaust fan motor defective or a
exhaust fan motor turns on. loose object is interfering with the
fan
• Poor fan motor connector
connection

492 C Cooling fan motor lock • Too much load on the drive
A cooling fan motor lock signal is mechanism
detected within 5 seconds after the • Cooling fan motor defective or a
cooling fan motor turns on. loose object is interfering with the
fan
• Poor fan motor connector
connection

SM 4-5 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

PAPER FEED
501 C 1st tray lift malfunction • Lift motor malfunction or
Paper height sensor does not disconnected
activate after the tray lift motor is on • Height sensor abnormal, or
for 10 s. If the main power switch is connector loose
turned on when the paper is already • Loose paper or object between the
at feed height, the paper height tray and motor
position is detected again, and the • Pick-up arm malfunction
paper height sensor should de-
activate within 5 s after the paper
bottom plate starts to drop. If it does
not deactivate within 5 s after 4
consecutive attempts, a message
prompts the user to reset Tray 1.
After two attempts to release the
error by re-setting the paper tray,
then this SC is issued.
502 C 2nd tray lift malfunction • Lift motor abnormal or
Paper height sensor does not disconnected
activate after the tray lift motor is on • Height sensor defective or
for 10 s. If the main power switch is disconnected
turned on when the paper is already • Loose paper or object between the
at feed height, the paper height tray and motor
position is detected again, and the • Pick-up arm malfunction
paper height sensor should de-
activate within 5 s after the paper
bottom plate starts to drop. If it does
not deactivate within 5 s after 4
consecutive attempts, a message
prompts the user to reset Tray 1.
After two attempts to release the
error by re-setting the paper tray,
then this SC is issued.
503 C 3rd tray lift malfunction (optional • Tray lift motor defective or
paper tray unit) disconnected
Paper height sensor does not • Height sensor defective or
activate after the tray lift motor is on disconnected
for 13 s. If the main power switch is
on when the paper is already at the
feed height, the paper height position
is detected again, and the paper
height sensor should de-activate
within 5 s after the paper bottom
plate starts to drop. If it does not
deactivate within 5 s after four
consecutive attempts, the tray lift
motor halts. After two attempts to re-
set the paper tray, this SC is issued
and tray control halts.

G065 4-6 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

504 C 4th tray lift malfunction (optional • Tray lift motor defective or
paper tray unit) disconnected
Paper height sensor does not activate • Height sensor defective or
after the tray lift motor is on for 13 s. If disconnected
the main power switch is on when the
paper is already at the feed height, the
paper height position is detected
again, and the paper height sensor
should de-activate within 5 s after the
paper bottom plate starts to drop. If it
does not deactivate within 5 s after
four consecutive attempts, the tray lift
motor halts. After two attempts to re-
set the paper tray, this SC is issued
and tray control halts.
506 C Paper tray unit main motor lock • Paper tray unit main motor
(optional paper tray) defective
A main motor lock signal is detected • Paper tray unit main motor
for more than 50 ms during rotation. connection loose
• Too much load on the drive
mechanism

shooting
Trouble-
507 C LCT main motor lock (optional LCT) • LCT main motor defective
A main motor lock signal is detected • Paper tray unit main motor
for more than 50 ms during rotation. connection loose
• Too much load on the drive
mechanism
510 C LCT tray malfunction • LCT lift motor defective or
• LCT lift sensor does not activate disconnected.
within 18 seconds after the LCT lift • Upper limit sensor defective or
motor turns on. disconnected
• After paper end, LCT lift sensor • Pick-up solenoid defective or
does not activate within 4 s after 4 disconnected
consecutive attempts. • Paper end sensor defective
• After lowering, tray motor does not
switch off within 5 s.
520 C Fusing/Exit • Too much load on the drive
A Fusing/Exit motor lock signal is mechanism
detected within 2 seconds after the • Fusing/Exit motor defective
Fusing/Exit motor turns on.
FUSING UNIT
NOTE: When an SC error is issued for the fusing system (SC54x), the printer cannot be released
from the SC status by cycling the machine off and on. The service technician must
execute SP5810 to restore the printer to normal operation.
541 A Fusing thermistor open • Fusing thermistor disconnected
• The fusing temperature detected • Fusing thermistor connector
by the thermistor was below 7°C defective
(44.6°F) for 5 seconds • Fusing thermistor damaged or
• 2 seconds after reaching 45°C warped
(113°F) the temperature does not • Fusing temperature signal –15%
reach an additional 15oC (59°F) less than the standard input
after checking twice. voltage

SM 4-7 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

542 A Fusing temperature warm-up error • Fusing lamp defective
• Fusing temperature does not • Poor fusing unit connector
reach fusing standby temperature • Thermistor warped or broken
of 45°C (113°F) within 14 s at • Thermostat has tripped
main power on or closing the front • BICU defective
cover. • Power supply board defective
• 20 seconds after reaching 50°C
the fusing roller does not reach
warm-up temperature.
543 A Fusing overheat error (software • Power supply unit defective
detection) • I/O board (IOB) defective
Fusing temperature of over 230°C • BICU defective
(446°F) is detected for 5 s by the • Fusing thermistor defective
fusing thermistors at center or either
end of the fusing roller.
544 A Fusing overheat error (hardware • Power supply unit defective
circuit detection) • I/O board (IOB) defective
Dual-monitor circuitry of the BICU • BICU defective
detects an extremely high • Fusing thermistor defective
temperature of 240°C (464°F) and
trips the relay circuit off.
545 A Fusing lamp remains on • Thermistor out of position.
After reaching warm-up temperature
with main motor on, the end fusing
lamp remains on at full power for 15
s, or the center fusing lamp remains
on at full power for 10s
546 A Fusing ready temperature unstable • Thermistor connection loose
After reaching warm-up temperature, • Fusing unit connector loose
temperature fluctuations of 50°C
(122°F) within 1 s occur 2 times or
more.
547 B Zero cross signal malfunction • Power supply board defective
The applied power supply ac • Noise on the ac power line
frequency detection is over 66 Hz or
below 45 Hz, and the zero cross
signals are not detected within 500
ms after the main power on.
548 A Fusing unit installation error • Fusing unit is not installed, or is
The machine cannot detect the installed incorrectly
fusing unit when the front cover and • Fusing unit connection loose
right cover are closed.
COMMUNICATION AND CONTROL
620 C Communication timeout error • Serial line connecting BICU and
between BICU and finisher or finisher unstable
mailbox • External noise
The BICU does not receive a • BICU board and finisher main
response after 3 attempts within 100 board connection defective or
ms to send data to the finisher or loose
mailbox. • Finisher main board defective
• BICU board defective

G065 4-8 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

621 C Communication timeout error • Serial line connecting BICU and
between BICU and finisher or finisher unstable
mailbox • External noise
A break (low) signal is received from
the finisher or the mailbox.
623 C Communication timeout error • Serial line connecting BICU and
between BICU and paper tray unit paper tray unit unstable
The BICU does not receive a • External noise
response after 3 attempts within 100 • BICU board and paper tray main
ms to send data to the paper tray board connection defective or
unit. loose
• Paper tray main board defective
• BICU board defective
624 C Communication break error between • Serial line connecting BICU and
BICU and paper tray unit paper tray unit unstable
The BICU cannot communicate with • External noise
the paper tray unit because it has • BICU board and LCT main board
received a break signal. connection defective or loose
• Optional paper feed unit interface
board defective
• BICU board defective

shooting
Trouble-
626 C Communication timeout error • Serial line connecting BICU and
between BICU and LCT LCT unit unstable
The BICU does not receive a • External noise
response after 3 attempts within 100 • BICU board and LCT main board
ms to send data to the LCT. connection defective or loose
• LCT interface board defective
• BICU board defective
627 C Communication break error between • Serial line connecting BICU and
BICU and LCT LCT unit unstable
The BICU cannot communicate with • External noise
the LCT unit because it has received • BICU board and LCT main board
a break signal. connection defective or loose
• LCT interface board defective
• BICU board defective
640 D BICU control data transfer sumcheck • Controller board defective
error • External noise
A sampling of control data sent from • BICU board defective
the BICU to the controller reveals a
sumcheck error. Only the logging
count is performed.
641 D BICU control data transfer abnormal • Controller board defective
Data send from BICU to controller • External noise
failed after 3 attempts. • BICU board defective
670 C Engine response error • BICU defective
After powering on the machine, a • Controller board defective
response is not received from the
engine within the specified time.
690 A GAVD block I2C bus error • I2C bus on BICU defective
An error is detected in the GAVD
communication I2C control register of
the GABIC2.

SM 4-9 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

691 A GAVD FCI block I2C bus error • I2C bus on BICU defective
An error is detected in the FCI
communication I2C control register of
the GABIC2.
692 A CDIC GAVD block I2C bus error • I2C bus on BICU defective
An error is detected in the CDIC
communication I2C control register of
the GABIC2.
722 B Finisher jogger motor error • Jogger H.P. sensor defective
The finisher jogger H.P. sensor does • Jogger motor defective
not return to the home position, or
move out of the home position, within
the specified time.
724 B Finisher staple hammer motor error • Staple jam
Stapling not complete within 600 ms • Stapler overload caused by trying
after the staple hammer motor turns to staple too many sheets
on. • Staple hammer motor defective
725 B Finisher stack feed-out motor error • Stack feed-out H.P. sensor
The stack feed-out belt H.P. sensor defective
does not activate within the specified • Stack feed-out motor overload
time after the stack feed-out motor • Stack feed-out motor defective
turns on.
726 B Finisher shift tray 1 lift motor error • Shift motor defective or
• Tray shift does not finish within the overloaded
specified time after the shift motor • Shift tray lift motor defective or
turns on overloaded
• Stack height sensor does not
activate within the specified time
after the shift tray lift motor turns
on.
727 B Finisher stapler rotation motor error • Stapler rotation motor defective or
The H.P. sensor does not switch on overloaded
or off within the specified time, i.e. • Stapler rotation motor connection
stapler rotation does not finish within loose or connector defective
the specified time after the staple
rotation motor turns on, or the stapler
does not return to its H.P. within the
specified time after stapling finishes.
729 B Finisher punch motor error • Punch motor defective or
After the punch motor turns on, the overloaded
punch H.P. sensor does not activate • Punch H.P. sensor defective
within the specified time. • Punch motor connection loose or
connector defective

G065 4-10 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

730 B Finisher stapler positioning motor • Stapler positioning motor defective
error or overloaded
The stapler H.P. sensor does not • Stapler H.P. sensor defective
switch on or off within the specified • Stapler positioning motor
time, i.e. after the stapler motor turns connection loose or connector
on, the stapler does not return to its defective
H.P. within the specified time, or the
stapler H.P. sensor does not activate
within the specified time after the
stapler motor turns on.
731 B Finisher exit guide open/close motor • Finisher exit guide open/close
error motor defective
After the finisher exit guide • Open/close sensor defective
open/close motor is turned on, the
open/close sensor does not activate
within the specified time.
732 C Finisher upper tray shift motor error • Upper tray shift motor defective or
The upper tray shift motor does not overloaded
stop within the specified time. • Upper tray shift sensor defective
733 C Finisher lower tray lift motor error • Lower tray lift motor defective or
The stack height sensor does not overloaded

shooting
Trouble-
activate within the specified time, i.e. • Upper stack height sensor
the lower tray lift motor does not defective
stop. • Lower tray lower limit sensor
defective
734 C Finisher lower tray shift motor error • Lower tray shift motor defective or
The lower tray shift sensor does not overloaded
activate with the specified time, i.e. • Lower tray shift sensor defective
the lower tray shift motor driving the
lower tray does not stop.
800 B Startup without video output end • Controller board defective
error
Video transfer to the engine is
started, but the engine did not issue
the video transmission end
command within the specified time.
818 B Watchdog error • Controller board defective
The CPU does not access the • Software malfunction –download
watchdog register within the controller firmware again
specified time.
819 B Kernel mismatch error • Software application error
Software bug
822 B Self-Diagnostic Error: HDD • HDD defective
The hard disk drive returned an error • HDD connector defective
during the self-diagnostic test. • Controller board defective
823 B Self-diagnostic Error: NIB • Network interface board defective
The network interface board returned • Controller board defective
an error during the self-diagnostic
test.

SM 4-11 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

829 B Self-diagnostic Error: Optional RAM • RAM DIMM defective
The optional RAM returned an error • Controller board defective
during the self-diagnostic test.
835 B Self-Diagnostic Error: Parallel • Loopback connector not detected
Interface • IEEE1284 connector defective
Loopback test error. • Controller board defective
836 B Self-diagnostic Error: Resident Font • Controller board defective
ROM
The resident font ROM returned an
error during the self-diagnostic test.
850 B Network I/F Abnormal • NIB defective
NIB interface error. • Controller board defective
851 B IEEE 1394 I/F Abnormal • IEEE1384 interface board
IEEE1394 interface error defective
• Controller board defective
860 C No HDD detection at main power on • Cable between controller board
and HDD loose or defective
Hard disk is not detected. • HDD power connector loose or
defective
• HDD defective
• Controller board defective
861 C No HDD detection when recovering • Cable between controller board
from Energy Saver Mode and HDD loose or defective
• HDD power connector loose or
Hard disk is not detected. defective
• HDD defective
• Controller board defective
862 A Maximum number of bad sectors • Defective HDD
detected on HDD
101 bad sectors have been detected,
i.e. SC863 has occurred 101 times,
which is the maximum allowable
number.
863 B Bad sector • Damaged data (potentially
HDD sector data cannot be read defective HDD).
correctly.
864 B HDD data CRC error • Abnormal data transfer when
HDD reports CRC error during HDD reading from the HDD.
operation.
865 B HDD access error • HDD defective
HDD error detected other than
SC863 and SC864.
CONTROLLER
820 B Self-Diagnostic Error: CPU • Controller board defective
The central processing unit returned • Software defective
an error during the self-diagnostic
test.

G065 4-12 SM
 SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

821 B Self-Diagnostic Error: ASIC • Controller board defective

The ASIC returns an error during the

self-diagnostic test at power on
because the ASIC and CPU timer
interrupts were compared and
determined to be out of range.
824 B Self-diagnostic Error: NVRAM • NVRAM damaged or abnormal
The resident non-volatile RAM • Backup battery has discharged
returns an error during the self- • NVRAM socket damaged
diagnostic test at power on.
827 B Self-diagnostic Error: RAM • Memory malfunction
The resident RAM returned a verify
error during the self-diagnostic test at
power on.
828 B Self-diagnostic Error: ROM • Controller board defective
The resident read-only memory • Firmware defective
returned an error during the self-
diagnostic test at power on.

shooting
Trouble-
OTHER
900 B Electronic total count error • NVRAM defective
• The value of the total count has
already exceeded its limit
(9,999,999)
• During counting, a defect was
detected at the mechanical
counter.
951 C F-GATE error at write request • Software defective
After the IPU receives an F-GATE • BICU defective
signal, it receives another F-GATE
signal (software timeout error)
954 B Printer setting error • Software defective
The IPU does not respond with the
settings required to start printer
image processing.
955 C Memory setting error • Software defective
The IPU does not respond with the
settings required to start memory
image processing.
966 No ready signal from the polygon • Defective polygon mirror motor
motor.
At the start of printing, no ready
signal is received for the polygon
motor from the LD unit.
984 B Print image data transfer error • Controller board defective
The image transfer from the • BICU defective
controller to the engine via the PCI • Connectors between BICU and
bus does not end within 15 s after controller loose or defective
startup.

SM 4-13 G065
SERVICE CALL CONDITIONS

SC Level Symptom Possible Cause

986 C Software write parameter setting • Software defective
error
An unstable area at the storage
destination in the settings table is set
NULL for the parameter received by
the write module.
990 B Software performance error • Software defective
The software attempted to perform • Internal parameter incorrect
an unexpected operation. • Insufficient working memory
• When this SC occurs, the file
name, address, and data will be
stored in NVRAM. Note the above
data and the situation in which this
SC occurs. Report this information
to the technical control center.
991 D Software continuity error • Software bug
The software attempted to perform • Internal parameter incorrect
and unexpected operation. Unlike • Insufficient working memory
SC990, continuity of the software is
the problem.

G065 4-14 SM
 ELECTRICAL COMPONENT DEFECTS

4.2 ELECTRICAL COMPONENT DEFECTS

4.2.1 SENSORS
Component
CN Condition Symptom
(Symbol)
LD Unit Home SC328 is displayed when the laser beam
Open
Position (S6) 220-2 pitch is changed.
(IOB) SC327 is displayed when the laser beam
Shorted
pitch is changed.
Toner Density (TD) The Add Toner indicator blinks even if there
Open
(S7) 205-5 is toner in the development unit.
(IOB) SC390 is displayed.
Shorted
Paper Exit (S8) The Paper Jam indicator lights whenever a
Open
203-B2 print is made.
(IOB) The Paper Jam indicator lights even if there is
Shorted
no paper.
Registration (S9) The Paper Jam indicator lights even if there is
Open
207-B2 no paper.
(IOB) The Paper Jam indicator lights whenever a
Shorted
print is made.

shooting
Trouble-
Image Density (ID) 219-5 Open SC352 is displayed after printing.
(S10) (IOB) Shorted SC350 is displayed after printing.
Upper Paper Add Paper is displayed even if there is paper.
Height (S11) 235-2 Open If this condition occurred four times, SC501
(PFB) will be displayed.
Shorted SC501 is displayed.
Lower Paper Add Paper is displayed even if there is paper.
Height (S12) 236-2 Open If this condition occurred four times, SC502
(PFB) will be displayed.
Shorted SC502 is displayed.
Upper Paper End The Paper End indicator lights even if paper
Open
(S13) 235-8 is placed in the upper paper tray.
(PFB) The Paper End indicator does not light even if
Shorted
there is no paper in the upper paper tray.
Lower Paper End The Paper End indicator lights even if paper
Open
(S14) 236-8 is placed in the lower paper tray.
(PFB) The Paper End indicator does not light even if
Shorted
there is no paper in the lower paper tray.
Upper Relay (S15) The Paper Jam indicator lights whenever a
Open
235-5 print is made.
(PFB) The Paper Jam indicator lights even if there is
Shorted
no paper.
Lower Relay (S16) The Paper Jam indicator lights whenever a
Open
236-5 print is made.
(PFB) The Paper Jam indicator lights even if there is
Shorted
no paper.
Transfer Belt 203-A10 Open No symptom
Position (S17 (IOB) Shorted SC403 is displayed

SM 4-15 G065
ELECTRICAL COMPONENT DEFECTS

4.2.2 SWITCHES
Component
CN Condition Symptom
(Symbol)
Right Lower Cover “Doors/Covers Open” is displayed even if the
Open
(SW1) 232-3 right lower cover is closed.
(PFB) LCD goes blank when the lower cover is
Shorted
opened.
Main (SW3) 102-1~4 Open The machine does not turn on.
(PSU) The machine does not turn off.
Shorted
107-1
Front Cover Safety “Doors/Covers Open” is displayed even if the
Open
(SW4) 107-1 front cover is closed.
(PSU) “Doors/Covers” Open is not displayed even if
Shorted
the front cover is opened.

G065 4-16 SM
 BLOWN FUSE CONDITIONS

4.3 BLOWN FUSE CONDITIONS

Rating
Fuse Symptom at power on
115 V 210 ~ 230 V
Power Supply Board
FU1 6.3 A/125 V 6.3 A/250 V “Doors/Covers Open” is displayed
FU2 6.3 A/125 V 6.3 A/250 V “Doors/Covers Open” for the finisher is displayed
FU3 6.3 A/125 V 4 A/250 V Paper end condition
FU4 6.3 A/125 V 6.3 A/250 V SC121 is displayed
FU5 6.3 A/125 V 6.3 A/250 V SC302, or SC403, or SC405 displayed
FU101 15 A/125 V — No response
FU102 10 A/12 5V 5 A/250 V No response
FU103 2 A/125 V 1 A/250 V Normal operation (optional heaters do not work)

4.4 LEDS
BICU
Number Monitored Signal
Monitors whether the program is working normally or not. The LED blinks in
LED101

shooting
Trouble-
normal conditions.
LED102 Flashes during program downloading.

4.5 TEST POINTS

Controller Board
No. Monitored Signal
TP1 GND
TP2 —
TP3 GND
TP4 —
TP5 —
TP6 GND
TP7 +3.3 VCG
TP8 DB0 RXD
TP9 DB0 TXD
TP10 GND
TP11 +5 VE
TP12 GND
TP13 +5 V
TP14 +5 VE
TP15 GND
TP16 R.FGATE
TP17 W.FGATE
TP18 +2.5 V
TP19 +1.65 VCP
TP20 +3.3 V

SM 4-17 G065
SERVICE TABLES
 SERVICE PROGRAM MODE

5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE
!CAUTION
Before entering the service menu, make sure that the Data In lamp is off. If
the Data In lamp is lit or flashing, wait for it to go off. It will remain on until
the current print job has completed.

5.1.1 ENTERING AND LEAVING THE SERVICE PROGRAM MODE

Europe North America

G065S902.WMF

Service
Tables
1. To set the printer in the service mode:
If the printer is off, press and hold down !(Online) and (Escape) then switch
the printer on.
Release the buttons when you see “1. Service” in the LCD.
-or-
If the printer is on, press and hold down ! and " for over 5 seconds and
release.
Press #(Enter). You will see “1. Service” in the LCD. The printer is in the
service mode.
2. Press ! or " to display the menu titles.
1.Service Controller service settings. (☛ 5.2)
2.Engine Engine service settings. (☛ 5.3)
3.End Leave the SP mode and return to normal operation.

3. With the item that you want to open displayed in the LCD, press #(Enter).
4. Press ! or " to display all the menus on the same level, then press #(Enter)
to open the submenus.
5. Press (Escape) to the highest level, ! or " to display “3.End” then press
#(Enter).

SM 5-1 G065
PRINTER CONTROLLER SERVICE MODE

5.2 PRINTER CONTROLLER SERVICE MODE

5.2.1 CONTROLLER SERVICE MODE MENUS
The controller service mode menu (1.Service) is the first item on the menu.

Item What It Does

Bit Switch Adjusts the bit switch settings.
Clear Setting Initializes the settings for the “System” menu of the user mode.
Print Summary Prints a summary of all the controller settings.
Display Version Displays the current version number of the controller firmware.

5.2.2 BIT SWITCH PROGRAMMING

1. Enter the SP mode, select “1.Service”, and press #(Enter) twice.

SP1001-001
Bit Switch 1 Set

2. Press ! or " to select the bit switch setting to change.

SP1001-002
Bit Switch 2 Set

3. Press #(Enter).
Sw#2 00000000
bit0 _

4. Select the “0” or “1” for each position. The leftmost digit is 7 and the rightmost
is 0.
• Press ! or " to move the cursor to the right or left to position the it at the
digit to change.
• Press #(Enter) then press ! or " to toggle the digit between “1” and “0”.
• With the digit for entry displayed on the second line, press #(Enter). The
selected digit is entered into the position above.
• Repeat this procedure to set all the digits.
5. When you are finished, press (Escape) to return to the previous level. The
new settings for the bit switch are now stored.

G065 5-2 SM
 Rev. 10/2003 PRINTER CONTROLLER SERVICE MODE

5.2.3 PRINTER CONTROLLER BIT SWITCH SETTINGS

Position: 7 6 5 4 3 2 1 0
Display: 0 0 0 0 0 0 0 0

Bit Switch 1 Default

0 0
1 0
2 1
3 0
Do not change.
4 0
5 0
6 0
7 0
Bit Switch 2
0 0
1 0 Do not change.
2 0
⇒ 3
4
0
0
PDL Sniffing. See PUB(C)-051 for details.

5 0
Do not change.
6 0
7 0
Bit Switch 3
⇒ 0 0 PS Fonts Download. See PUB(C)-045 for details.
1 0

Service
Tables
2 0
3 0
4 0 Do not change.
5 0
6 0
7 0
Bit Switch 4
0 0
1 0
2 0
3 0
Do not change.
4 0
5 0
6 0
7 0

SM 5-3 G065
PRINTER ENGINE SERVICE MODE

5.3 PRINTER ENGINE SERVICE MODE

The Printer Engine Service mode is used to check electrical data, change modes,
and adjust values.

Here is a quick summary of how to enter and use the Printer Engine Service mode
to change the settings listed in the Service Program Mode Tables. (☛ 5.3.1)
1. Press ! and " together, hold down for over 5 seconds, release and then press
#(Enter).
2. Press ! or " to display “2.Engine”.
3. Press #(Enter).
4. Press " or ! to display the SP code groups.
1. Feed SP1000
2. Drum SP2000
3. Process SP3000
4. HDD SP4000
5. Mode SP5000
6. Periphs SP6000
7. Data Log SP7000

5. Press ! or " to select the group, and then press #(Enter).

NOTE: The 2-line display is rotational. If you press ! with “1.Feed” displayed,
the display will jump to “7.Data Log”, the last selection. Similarly, if you
press ! with “7.Data Log” displayed, the display will jump to “1.Feed”,
the first selection.
6. While referring to the Service Program Mode Tables, press ! or " to select the
SP that you want to change, and then press #(Enter).
NOTE: If you see > or >> to the right of a selection name, this means a menu
sublevel exists.
7. Follow one of the procedures below to change a setting.
• To change a single-digit number setting:
Press #(Enter). A number replaces the cursor.
Press ! or " to increase or decrease the number.
Press #(Enter). The number selected on the 2nd line replaces the number
above.
Press (Escape) to return to the previous level.

G065 5-4 SM
 PRINTER ENGINE SERVICE MODE

• To change a multiple-digit number setting

Press ! or " to move the cursor to the digit that you want to change.
Press #(Enter). A number replaces the cursor.
Press ! or " to increase or decrease the number.
Press #(Enter). The number selected on the 2nd line replaces the number
above.
Repeat the procedure to enter numbers for the other digits.
Press #(Escape) to return to the previous level.

• To select an item from a list

The current selection is marked with a large asterisk (*).
Press ! or " to display on the 2nd line the item to select.
With the item that you want to select displayed on the second line, press
#(Enter). The selected item is marked with an asterisk.
Press #(Escape) to return to the previous level.

Leaving the SP Mode

1. When you are finished with SP selection, press (Escape) until you see
“2.Engine”.
2. Press " to display “3.End”.
3. Press #(Enter) to display “Offline”.
4. Press !(On Line) to set the printer online.

Service
Tables
NOTE: Powering the printer off and on leaves the SP mode, and returns the
printer online in normal operation mode.

SM 5-5 G065
PRINTER ENGINE SERVICE MODE

5.3.1 SERVICE PROGRAM MODE TABLES

Service Table Key
Notation What it means
[range / default / step] Example: [–9 ~ +9 / +3.0 / 0.1 mm step]. The setting can be
adjusted in the range ±9, value reset to +3.0 after an NVRAM reset,
and the value can be changed in 0.1 mm steps with each key press.
italics Comments added for reference.
* Value stored in NVRAM. After a RAM reset, this default value
(factory setting) is restored.
DFU Denotes “Design or Factory Use”. Do not change this value.
Japan only The feature or item is for Japan only. Do not change this value.
(S) Sideways feed direction (LEF)
(L) Lengthwise feed direction (SEF)

1. Feed (SP1000-00)
SP1 Mode Number Function and [Setting]
1001* Sub-Scan Registration Adjusts the printing leading edge registration
Adjustment using the trimming area pattern (SP2902-03,
No.11).
[+9 ~ –9 / 3.0 / 0.1 mm]
Use #(Enter) to toggle between ± before
entering the value.
Specification: 3 ±2 mm
1002* Side-to-Side Registration Adjusts the printing side-to-side (main scan)
registration. Changing this setting adjusts the
printing starting position. These settings should
be adjusted after the optical unit or laser
synchronization detection board is replaced.
Reduce the value to move the image closer to
the operation panel side of the machine.
01 Tray 1 [–9 ~ +9/ +3.0 mm / 0.1 mm step]
02 Tray 2
03 Tray 3 [–9 ~ +9/ +2.0 mm / 0.1 mm/step]
04 Tray 4
05 Duplex Tray [–9 ~ +9/ +0.0 mm / 0.1 mm/step]
06 By-pass Tray [–9 ~ +9/ +3.0 mm / 0.1 mm/step]
07 LCT [–9 ~ +9/ +1.5 mm / 0.1 mm/step]
1003* Registration Buckle Adjustment
01 Paper Feed Trays, LCT Adjusts the relay clutch timing at registration.
02 Duplex Tray Relay clutch timing determines the amount of
03 By-pass Tray paper buckle at registration. (A “+” setting
04 Tray 1 causes more buckling.)
05 By-pass Thick [–9 ~ +9 / +0.0 mm (1 mm for 1st Tray Feed) /
0.1 mm step]

G065 5-6 SM
 PRINTER ENGINE SERVICE MODE

SP1 Mode Number Function and [Setting]

1012* Exit Junction Solenoid Timing Adjusts the operation timing of the solenoids at
the entrance and exit of the paper exit section to
accommodate the increased speed of the duplex
unit.
This SP has been added to compensate for the
increased operation speed of the duplex unit for
this machine. Increase the value if the leading
edges are jamming. Decrease the value if
trailing edges are bending at the entrance.
1 Exit Junction Start Solenoid [200 ~ 450 / 370 / 10 ms]
2 Exit Junction End Solenoid [200 ~ 450 / 370 / 10 ms]
1103* Fusing Idling Switches hot roller idling on/off. When on (1), the
hot roller will rotate until enough time has
elapsed so the hot roller can reach optimum
temperature to ensure even heat on the hot
roller.
01 0:Off 1:On In a cold environment, switch on and then set
the idling time with SP1103-02 to ensure the
quality of the first prints.
[0 ~ 1 / 0 / 1 step]
0: No rotation
1: Rotation
Switch on if fusing on the 1st and 2nd prints is
incomplete (this may occur if the room is cold.)
02 Fusing Idling Interval (s) Sets the idling time before the machine starts to
print.
[0 ~ 60 sec. / 30 sec. / 1 sec.]
SP1103 01 must be set on before this setting

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can be performed.
1104* 01 Fusing Temperature Selects the fusing temperature control mode.
Control [0~1 / 0 / 1 step]
0: Enables the On/Off Control method with the
thermistor and CPU.
1: Enables the Phase Control method.
Generally, phase control is used only if the
customer has a slightly unstable power
supply. Selecting phase control could cause
and increase in electrical noise or cause the
controller to emit a low pitch noise.
The machine must be cycled off and on to
enable this setting after it is changed.
1105* Fusing Temperature Adjustment
Allows adjustment of the hot roller temperature at the center and ends of the roller
for the quality or thickness of the paper. The hot roller in this machine has two fusing
lamps: one heats the center of the roller, and the other heats both ends. Each fusing
lamp can be adjusted separately.
Use SP1105-03, 04 to adjust for feeding standard paper from the by-pass tray, and
use SP1105-07, 08 to adjust for feeding thick paper from the by-pass tray.
01 Center (Roller Center) [120°C ~ 200°C / 180°°C / 1°C step]
02 Ends (Roller Ends) [120°C ~ 200°C / 185°°C / 1°C step]
03 Center (By-pass) [120°C ~ 220°C / 190°°C / 1°C step]

SM 5-7 G065
PRINTER ENGINE SERVICE MODE

SP1 Mode Number Function and [Setting]

1105* 04 Ends (By-pass) [120°C ~ 220°C / 190°°C / 1°C step]
05 Center (Reload) Adjusts the temperature for re-heating the center
of the hot roller:
Reload Temp. = Fusing. Temp – SP Value
[0°C ~ 60°C / 30°°C / 1°C step]
When the fusing temperature exceeds this
setting, the machine can operate.
Do not set a reload temperature (Spec. Temp –
SP Value) higher than the SP1105-02 setting.
06 Ends (Reload) Adjusts the temperature for re-heating the ends
of the hot roller:
Reload Temp. = Fusing. Temp – SP Value
[0°C ~ 60°C / 30°°C / 1°C step]
When the fusing temperature exceeds this
setting, the machine can operate.
Do not set a reload temperature (Spec. Temp –
SP Value) higher than the SP1105-02 setting.
07 Roller Center (By-pass) Adjusts the temperature of the center of the hot
Thick Paper roller for feeding thick paper with the by-pass
tray.
[120°C ~ 220°C / 200°°C / 1°C step]
08 Roller Ends (By-pass) Adjusts the temperature of the ends of the hot
Thick Paper roller for feeding thick paper with the by-pass
tray.
[120°C ~ 220°C / 200°°C / 1°C step]
09 Roller Center (Thick Paper) Adjusts the temperature for re-heating the center
of the hot roller for feeding thick paper:
Reload Temp. = Fusing. Temp – SP Value
[0°C ~ 60°°C / 5°°C / 1°C step]
When the fusing temperature exceeds this
setting, the machine can operate.
Do not set a reload temperature (Spec. Temp –
SP Value) higher than the SP1105-02 setting.
10 Roller Ends (Thick Paper) Adjusts the temperature for re-heating the ends
of the hot roller for feeding thick paper:
Reload Temp. = Fusing. Temp – SP Value
[0°C ~ 60°C / 5°°C / 1°C step]
When the fusing temperature exceeds this
setting, the machine can operate.
Do not set a reload temperature (Spec. Temp –
SP Value) higher than the SP1105-02 setting.
1106 Temperature Display
Sets the temperature display to show the fusing temperature (monitored by
thermistors) for the center or ends of the hot roller, or the temperature of the I/O
Board at power on.
01 Roller Center Monitors and displays temperature (°C) of the
hot roller center.
02 Roller Ends Monitors and displays temperature (°C) of the
hot roller ends.
03 I/O Temp. Monitors and displays the temperature (°C) of
the I/O board at power on.

G065 5-8 SM
 PRINTER ENGINE SERVICE MODE

SP1 Mode Number Function and [Setting]

1109* 01 Fusing Nip Band Check DFU
1111* 01 Switchback Timing Adjusts the reverse timing of paper in the duplex
unit (stopping the rotation of the reverse roller
after the trailing edge of the paper passes the
duplex entrance sensor).
[+5 ~ –5 / 0 mm / 1 mm step]
Adjust the timing if paper frequently jams at the
inverter gate in the duplex unit.

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Tables

SM 5-9 G065
PRINTER ENGINE SERVICE MODE

2. Drum (SP2000-00)
SP2 Mode Number Function and [Setting]
2001* Charge Roller Bias Adjustment
01 Image Pattern Adjusts the voltage applied to the charge roller
for the image area to maintain a charge of –800
V on the OPC drum surface.
[–1,000 ~ –2,000 / –1,480 V / 10 V step]
02 ID Sensor Pattern Adjusts the voltage applied to the charge roller
when making the ID sensor pattern (for charge
roller voltage correction). The actual charge
roller voltage is this value plus the value of
SP2001-01.
[0 ~ 700 / 200 V / 10 V step]
The default is adjusted automatically based on
the number of prints.
00 K ~ 10 K: 200 V
10 K ~ 50 K: 230 V
50 K ~ 150 K: 340 V
2005* Charge Roller Voltage
01 Correction 1 Adjusts the lower threshold value for the charge
roller correction. DFU
When the value of VSP/VSG is greater than this
value, the charge roller voltage increases by 30
V (e.g., from –1,480 to –1,510).
[0.1 ~ 1.0 / 0.85 / 0.05 step]
02 Correction 2 Adjusts the upper threshold value for the charge
roller correction. DFU
When the value of VSP/VSG is greater than this
value, the charge roller voltage decreases by 30
V (absolute value).
[0.1 ~ 1.0 / 0.9 / 0.05 step]
03 Adjustment 1 Adjusts the lower limit value for charge roller
voltage correction. DFU
[–1,000 ~ –2,000 / 1,480 V / 10 V step]
04 Adjustment 2 Adjusts the upper limit value for charge roller
voltage correction. DFU
[–1,000 ~ –2,000 / 2,000 V / 10 V step]
05 Step Adjusts the correction voltage adjustment step
size. DFU
[0 ~ 100 V / 30 V / 10 V step]
2101* Printing Erase Margin Adjusts the leading edge (top), trailing edge
(bottom), left, and right margins.
01 Leading Edge [0 ~ 9.0 / 3 / 0.1 mm step]
02 Trailing Edge Specification: ±2 mm
03 Right Edge [0 ~ 9.0 / 2 / 0.1 mm step]
04 Left Edge Specification: ±1.5 mm
05 Trailing Edge – Back side Adjusts the trailing edge erase margin on the
reverse side of duplex prints.
[0 ~ 9.0 / 1.2 / 0.1 mm step]
Recommended: 2 ±1.5 mm

G065 5-10 SM
 PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2101* 06 Back Side – Right Adjusts the right side erase margin in the
reverse side of duplex prints.
[0 ~ 9.0 / 0.3 / 0.1 mm step]
Recommend: 2 ±1.5 mm
07 Back Side – Left Adjusts the left side erase margin in the reverse
side of duplex prints.
[0 ~ 9.0 / 0.3 / 0.1 mm step]
Recommended: 2 +2.5/–1.5 mm
2103* LD Power Adjust Adjusts the intensity of the laser for the printer.
The printer and fax settings can be adjusted
separately.DFU
01 LD1 Print Control (–55 ~ +64 / –20 /1 LSB step)
02 LD2 Print Control Approx. 50/128 = 0.4%
03 LD1 Printer (–55 ~ +64 / –5 /1 LSB step)
04 LD2 Printer Approx. 50/128 = 0.4%
05 LD1 Adjustment Start/End DFU
06 LD2 Adjustment Start/End DFU
2109* LD Beam Pitch Adjustment
Adjusts the beam gap for the dual beam system. After replacing the LD unit or
replacing or clearing the NVRAM, use this SP mode to adjust the laser beam pitch.
This adjustment is performed by specifying the number of pulses to the stepper
motor that will adjust the angle of rotation of the LD unit from the home position.
01 400 dpi Adjusts the laser beam pitch value for 400 dpi
resolution.
400 dpi: [8 ~ 262 / 144 / 1 pulse step]
After replacing the LD unit or replacing or
clearing NVRAM, use this SP and SP2109-03 to
adjust the laser beam pitch.

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02 600 dpi Adjusts the laser beam pitch value for 600 dpi
resolution.
600 dpi: [28 ~ 284 / 168 / 1 pulse step]
After replacing the LD unit or replacing or
clearing NVRAM, use this SP and SP2109-04 to
adjust the laser beam pitch.
03 400 dpi Initial Setting Initializes the laser beam pitch for 400 dpi using
the value for SP2109-01.
After entering a value for SP2109-1, this SP
must be executed.
04 600 dpi Initial Setting Initializes the laser beam pitch for 600 dpi using
the value for SP2109-02.
After entering a value for SP2109-02, this SP
must be executed.
05 Auto Interval Set Sets the interval for automatic laser beam pitch
adjustment.
[0 ~ 65,535 / 10,000 / 1 step]
When the number of times that the resolution
has been changed reaches this value, the laser
unit position is automatically corrected.

SM 5-11 G065
PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2109* 06 LD Unit Position Displays the current LD unit position (number of
pulses from home position). If this is different
from the value of SP2109-01 or SP2109-02, LD
unit positioning has failed.
07 Pitch Change Count Displays how many times the LD unit position
has been changed (how many times the
resolution has changed.)
When the laser beam pitch adjustment is done,
this counter is reset to zero.
08 Beam Pitch Data Reset Resets the values of SP2109-06 and SP2109-
07.
After replacing the LD unit, this SP mode must
be performed. See section 3.9.5.
2110 01 Test Mode dpi Sets the scanning resolution (dpi).
[See below / 8 / 0 ~ 18]
Range 0: 400 x 400 dpi
1: 391 x 406 dpi
2: 406 x 391 dpi
4: 300 x 300 dpi
8: 600 x 600 dpi
15: 439 x 430 dpi
16: 476 x 476 dpi
17: 483 x 465 dpi
18: 465 x 483 dpi
2112 01 Polygon Motor Off Timer Input the time that the polygon motor is to switch
off after the printer has remained idle for the
specified time and entered the standby mode.
If set to zero, the polygon motor never switches
off in standby mode. However, if the machine
enters the energy saver mode, the polygon
motor will ignore the zero setting and switch
itself off.
[0~60 s / 10 s / 5 s step]
2201* Development Bias
01 Image Development Bias Adjusts the development bias for printing.
Use as a temporary measure to correct faint
images printed with an aging drum.
[–200 ~ –700 / 540 V / 10 V step]
02 ID Sensor Pattern Adjusts the development bias for the ID sensor
pattern for VSP (ID sensor output after reading
the ID sensor pattern).
[–200 ~ –700 / 380 V / 10 V step]
2207 01 Forced Toner Supply Forces the toner bottle to supply toner at 1-
second intervals for up to 30 seconds. To start,
press #(Enter).

G065 5-12 SM
 PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2208* 01 Toner Supply Mode Selects the toner mode.
0: Sensor control
1: Image pixel count.
If you select 1, set SP2209-02 to its default
value. Use image pixel count mode only as a
temporary measure if the ID or TD sensor is
defective and a replacement is not available.

2209* Toner Supply Rate Adjusts the toner supply rate.

01 Toner Rate Sets the amount of toner supplied every second
by the toner supply motor.
Increasing this value reduces the toner supply
clutch on time. Use a lower value if the user
tends to make lots of prints that have a high
proportion of black.
[10 ~ 800 mg/s / 60 mg/s / 5 mg steps]
02 Toner Rate Displays the toner supply correction coefficient
(Supply Correction Data) (K). It can also be used to adjust K, but the value
is changed again when VT (VTD, the output of
the TD sensor) is measured for the next print.
The toner supply rate depends on the amount of
toner in the toner bottle. This change is
corrected using this coefficient. This SP can be
used to check the toner supply condition. The
lower the value of K, the lower the toner density.
[0.25 ~ 3.0 / 3.0 / 0.25 steps]
2210* 01 Pattern Interval (ID Sensor) Sets the interval between ID sensor pattern
prints for toner control. This setting allows
adjustment for customers who do not make

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many prints daily. Selecting zero cancels
creation of the ID sensor pattern.
[0 ~ 200 / 10 / 1 print step]
The ID sensor reads the sensor pattern and
outputs this reading as Vsp and sends it to the
CPU where it is used to calculate Vref (Vsp/Vsg
= Vref).
If the total count exceeds 10 during a print job,
for example “15”, the pattern is created and read
at completion of the print job.

SM 5-13 G065
PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2210* 02 Large Job Sets the interval between ID sensor pattern
prints with the halftone pattern added. The ID
sensor reads the halftone pattern and outputs it
as Vsm to the CPU. The Vsm value is used in
the calculation Vsm/Vsg to adjust the power to
the LD.
[2 ~ 999 / 200 / 1 print step]
This SP executes at 200 prints (or at the
adjusted count) regardless of whether the print
job has completed. This method of adjusting the
power output and the amount of light emitted by
the LD ensures standard quality images by
ensuring that prints do not become faint, slows
the deterioration of the OPC drum over time, and
reduces scatter.
2213* 01 Toner End Count Selects the number of prints that can be printed
once the copier has detected the toner near-end
condition.
[0 ~ 2 / 0 / 1 step]
0: 90 prints
1: No prints
2: 10 prints
Select 1 or 2 if the customer normally makes
prints of high density.
2220* 01 Vref Manual Set Allows manual adjustment of Vref, the targeted
voltage for the TD sensor.
[1.0 ~ 5.0 V / 4.0 V / 0.01 V step]
Change this value after replacing the development unit with another unit that
contains toner.
1. Check the value of SP2220 in the machine containing the test unit and the
machine that you are going to move it to.
2. Install the test development unit, and then input the VREF for this unit into
SP2220.
3. After the test, put back the old development unit, and change SP2220 back to the
original value.
2223* 01 Vt Previous Copy Displays the TD sensor output voltage for the
immediately previous print.
02 Vt Previous 10 Averaged Displays the average of the most recent TD
sensor outputs (from the previous 10 prints).
03 Vt Change Rate Displays the rate of change in the TD sensor
output.
04 Vt Gain Displays the GAIN value used to calculate the
on time for the toner supply motor.
05 Image Pixel Count Displays the image pixel count.
2301* Transfer Current Adjustment Adjusts the current applied to the transfer belt
during printing the 5 phases listed below.
01 Image Face Printing the first side of the paper (image area).
(1st Side of Paper) If the user uses thicker paper, the current may
have to be increased to ensure sufficient transfer
of toner.
[20 ~ 100 µA / 45 / 1 µA step]

G065 5-14 SM
 PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2301* 02 Image Back Printing the second side of the paper (image
(2nd Side of Paper) area) during duplex printing.
[20 ~ 100 µA / 45 / 1 µA step]
03 Leading Edge. Face Printing at leading edge of the paper.
Increase the current to separate the paper from
the drum properly in high humidity and high
temperature conditions.
[20 ~ 100 µA / 45 / 1 µA step]
04 Image Face By-pass Printing from the by-pass tray (image area).
(By-pass Feed) If the user normally feeds thicker paper from the
bypass tray, use a higher setting.
[20 ~ 100 µA / 45 / 1 µA step]
05 Leading Face By-pass Printing at the leading edge of paper fed from
(Leading Edge By-pass the by-pass tray.
Feed) Increase the current to separate the paper from
the drum properly in high humidity and high
temperature conditions.
[20 ~ 100 µA / 60 / 1 µA step]
2309* Transfer Current Correction
01 a (Paper Lower Width) Adjusts the lower paper width threshold for the
transfer current, charge voltage, and
development bias corrections. DFU
Use this SP when an image problem (e.g.,
insufficient toner transfer) occurs with a small
width paper. If the paper width is smaller than
this value, the transfer current will be multiplied
by the factor in SP2309-03 (paper tray) or
SP2309-05 (by-pass).

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[0 ~ 297 / 150 / 1 mm step]
02 b (Paper Upper Width) Adjusts the upper paper width threshold for the
transfer current, charge voltage, and
development bias corrections. DFU
As for SP2309-01, but the factors are in
SP2309-04 (paper tray) and SP2309-06 (by-
pass).
[0 ~ 297 / 216 / 1 mm step]
03 Alpha (Tray) Adjusts the transfer current correction coefficient
used if the paper width is less than the setting of
SP2309-01. DFU
[1.0 ~ 3 / 1.2 / 0.1 mm step]
04 Beta (Tray) Adjusts the transfer current correction coefficient
used if the paper width is less than the setting of
SP2309-02. DFU
[1.0 ~ 3 / 1.2 / 0.1 mm step]
05 Gamma (By-pass) Adjusts the transfer current correction coefficient
used if the paper width is less than the setting of
SP2309-01. DFU
[1.0 ~ 3 / 1.5 / 0.1 mm step]
06 Delta (By-pass) Adjusts the transfer current correction coefficient
used if the paper width is less than the setting of
SP2309-02. DFU
[1.0 ~ 3 / 1.5 / 0.1 mm step]

SM 5-15 G065
PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2801* TD Sensor Initial Setting Performs the TD sensor initial setting. This SP
mode controls the voltage applied to the TD
sensor to make the TD sensor output about 4.0
V. Press #(Enter) to start. After execution the TD
sensor output voltage is displayed.
Use this mode only after installing the machine,
changing the TD sensor, or adding new
developer.
2802* TD Sensor Manual Setting Allows you to adjust the TD sensor output VT
manually for the initial, maximum, and minimum
settings.
01 Initial Vt Adjusts the TD sensor output (VT).
Change this value after replacing the
development unit with another one that already
contains toner.
For example, when using a development unit
from another machine for test purposes. To
adjust VT, use a similar procedure as for
SP2220.
[1.0 ~ 5.00 V / 4.78 V / 0.02 V step]
02 Vt Max Adjusts the maximum value for SP2802-01.
[1.0 ~ 5.00 V / 4.78 V / 0.02 V step]
03 Vt Min Adjusts the minimum value for SP2802-01.
[1.0 ~ 5.00 V / 1.0 V / 0.02 V step]
2805 01 Initialize Process Control Initializes all the process control settings.
Setting
2902 03 Test Pattern (Printing) Prints the printer test patterns. Select the
number of the test pattern that you want to print.
(☛ 5.3.2)
[0~38 / 0 / 1 step]
This SP mode is useful for finding whether the
LDB (Laser Diode Board) or the BICU is
defective. If the printout is not satisfactory, the
LDB is defective.
2909 02 Print Main Scan Adjusts the magnification in the main scan
Magnification – Printer direction when printing from a personal
computer.
[–2.0 ~ +2.0 / 0 / 1% step]
2911 Transfer Current Timing Adjusts the transfer current timing for the three
items below.
01 La (On Timing) On timing at leading edge.
[–30 ~ +30 / 0 mm / 1 mm step]
02 Lb (Off Timing) Transfer current switch timing. This determines
when the leading edge stops and the image area
current begins (☛ SP2301).
[0 ~ +30 / 10 mm / 1 mm step]
03 Lc (Off Timing) Transfer current timing (e.g. –5 mm) is 5 mm
after the trailing edge.
[–30 ~ +30 / – 5 mm / 1 mm step]

G065 5-16 SM
 PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2912 01 Drum Reverse Rotation Adjusts the time the drum and belt are reversed
Interval in order to prevent paper dust and toner from
collecting at the blade. DFU
[0 ~ 10 /3 / 1 step]
Example 1: If you enter 3, then:
3/2 = 2 (rounded up) x 10 + 10 = 30 ms
Example 2: If you enter 10, then:
10/2 = 5 x 10 + 10 = 60. However, the limit is 50
ms so in this case, 60 ms is reduced to 50 ms.
2913* 01 Test Pattern Density Sets the print density for the patterns printed
with SP2902-03. DFU
[0 ~ 15 / 15 / 1 ]
2914* Process Control Setting Adjusts the charge roller voltage for the following
items.
01 C alpha Adjusts the charge roller voltage used when
paper with a small width is fed from the by-pass
tray. The paper width below which the correction
starts depends on the value of SP2309-01.
Use this SP when an image problem (such as
white spots at the center of black dots or breaks
in thin black lines) occurs when paper with a
small width is fed from the by-pass feed tray.
[0 ~ 400 / 150 / 10 V step]
02 C beta Adjusts the charge roller voltage used when
paper with a small width is fed from the by-pass
tray. The paper width below which the correction
starts depends on the value of SP2309-02.
Use this SP when an image problem

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(☛ SP2914-01) occurs when paper with a small
width is fed from the by-pass feed tray.
[0 ~ 400 / 0 / 10 V step]
03 B gamma Adjusts the development bias used when paper
with a small width is fed from the by-pass tray.
The paper width below which the correction
starts depends on the value of SP2309-01.
Use this SP when an image problem
(☛ SP2914-01) occurs when paper with a small
width is fed from the by-pass feed tray.
[0 ~ 300 / 200 / 10 V step]
04 B delta Adjusts the development bias used when paper
with a small width is fed from the by-pass tray.
The paper width below which the correction
starts depends on the value of SP2309-02.
Use this SP when an image problem
(☛ SP2914-01) occurs when paper with a small
width is fed from the by-pass feed tray.
[0 ~ 300 / 50 / 10 V step]
2920 01 LD Off Check Used to confirm that the laser diode shuts off
when the cover is opened. DFU
2960* 01 Toner Overflow Sensor Selects whether the toner overflow sensor is
activated or not.
0 = No, 1 = Yes

SM 5-17 G065
PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2964* 01 Transfer Cleaning Blade Applies a pattern of toner to the transfer belt at a
Forming defined interval between sheets on the transfer
belt in order to reduce friction between the belt
surface and the cleaning blade.
[0 ~ 30 / 3 / 1 sheet]
Under conditions of high temperature and high
humidity, the density control feature may reduce
the amount of toner, which also reduces the
amount of toner on the surface of the transfer
belt. With less toner on the belt, the friction
between the belt and the blade increases, and
could cause the blade to bend or scour the
surface of the belt.
2971 01 Toner Full Count Counter that confirms that the contact of the
waste toner full sensor is operating normally.
Execution of SP5801 initializes this value by
setting it to 0. DFU
2972* Grayscale Limit Controls the halftone density level to prevent
deterioration of the OPC. The halftone density is
detected by the ID sensor, and the machine
adjusts the intensity of the LD beam according to
the upper/lower limit setting.
01 Upper Limit Defines the upper limit for grayscale control.
A larger value allows a wider range of halftones
at the pale end of the scale. If the image
contains pale areas with fuzzy borders
surrounded by dark areas, reduce this value to
make the borders clearer.
[0 ~ 100 / 85 / 1 step]
02 Lower Limit Defines the lower limit for grayscale control.
A smaller value allows a wider range of
halftones at the dark end of the scale.
[0 ~ 100 / 65 / 1 step]
2973* 01 Grayscale Check Interval Determines how often (number of copies in the
copy cycle) the grayscale (intermediate halftone)
pattern is written on the drum and read by the ID
sensor. After the specified number of copies has
been exceeded, when the copy job ends, the
machine adds the intermediate halftone pattern
to the ID sensor pattern, reads it and outputs as
the value Vsm. The reading for Vsm is used to
calculate Vsm/Vsg, then this value is used to
adjust the LD power output.
[0 ~ 1,000 / 100 / 10 step]
The intermediate halftone pattern is also read
and the LD power adjusted when the machine
front door is opened and closed.
2974* 01 Image Density Adjustment Adjusts image density. Changing this setting
adjusts development bias and ID sensor output
voltage that in turn raises or lowers image
density.
[1 ~ 5 / 3 / 1 step]

G065 5-18 SM
 PRINTER ENGINE SERVICE MODE

SP2 Mode Number Function and [Setting]

2975 01 Toner End Time Sets a time limit for issuing the toner near end
warning on the operation panel. The time may
need to be shortened for customers who run
especially large print jobs to ensure earlier
warning of the toner near end condition.
[0 ~ 2,000 / 0 / 10 s step]
0: Normal end detection (90 sheets after near-
end detected – SP2213)
Setting for 1300 s allows about 26 K prints at 5%
coverage starting with a new cartridge, before
the toner near-end warning is issued.
2976 01 Toner Bottle On Count Displays the total ON time of the toner supply
motor, calculated from when the toner bottle was
replaced. Use this to check that the toner end
count when using SP2975 is working properly.
[0 ~ 2,000,000 / 0 / 1 ms Step]
When SP2975 is set to any value other than “0”,
this value is displayed when it matches the
setting set for SP2975. When SP2975 is set to
“0”, SP2976 is disabled. SP2976 is automatically
set to zero by toner end recovery.
2980* 01 Charge Counter Sets the number of pages to print after toner and
carrier initialization before the charge input is
increased to compensate for deterioration over
time in the polarity of the carrier.
[1 ~ 1,000K / 0 / 1 step]
The strength in the polarity of the carrier in the
toner will eventually decrease and cause lower
charge output. Setting the charge output to

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Tables
increase after a specified number of prints can
compensate for this effect.

SM 5-19 G065
PRINTER ENGINE SERVICE MODE

3. Process (SP3000-00)
SP3 Mode Number Function and [Setting]
3001* ID Sensor Initial Setting
01 ID Sensor PWM Setting Allows you to reset the PWM (Pulse Width
Modulation) of the ID sensor LED to avoid a
service call error after clearing NVRAM or
replacing the NVRAM.
[0 ~ 255 / 100 / 1 step]
The PWM data is stored by executing SP3001-
02.
02 ID Sensor Initialization Executes the ID sensor initial setting. ID sensor
output for the bare drum (VSG) is adjusted
automatically to 4.0 ±0.2 V.
Press # to start. Perform this setting after
replacing or cleaning the ID sensor, replacing
the drum, or clearing NVRAM.
3103* ID Sensor Output Display Displays the current Vsg, Vsp, Vsdp, and
grayscale control in the range 0 V ~ 5.00 V.
Press #(Enter), press !" to select the item to
display, then press #(Enter).
This SPs are for display only; you cannot adjust
the settings.
01 Vsg Vsg is the ID sensor output after reading the
bare drum surface.
Normal display: 4±0.5 V
SC350 (ID Sensor Pattern Test Error) is issued if
this reading is abnormal.
02 Vsp Vsp is the ID sensor output after reading the ID
sensor pattern:
Normal display: 0.1 ~ 0.3
SC351 (ID Sensor Vsg Test Error) is issued if
this reading is abnormal.
03 Vsdp Vsdp is the ID sensor output immediately after
Vsp output when the charge potential drops.
This reading is used for design purposes to
determine the development characteristics. DFU
Normal display: 3.4 ~ 4.0
SC352 (ID Sensor Edge Detect Pattern Error) is
issued if this reading is abnormal.
04 Vsm/Vsg Vsm is the ID sensor output after reading the
intermediate halftone pattern (grayscale) portion
of the ID sensor pattern.
Normal display: 65% ~ 85% (SP2972)
The addition of the intermediate halftone pattern
to the ID sensor pattern is a new feature. Vsm is
used (Vsm/Vsg) to determine the power level
adjustment of the LD. The LD power level is
adjusted automatically to ensure the quality of
images, slow deterioration of the OPC over time,
and reduce scatter.

G065 5-20 SM
 PRINTER ENGINE SERVICE MODE

4. HDD (SP4000-00)
SP4 Mode Number Function and [Setting]
4911 01 Format HDD Formats the hard disk. After execution, you must
cycle the machine off and on with the power
switch.

5. Mode (SP5000-00)
SP5 Mode Number Function and [Setting]
5024* 01 mm/inch Display Selects the unit of measurement.
After selection, turn the main power switch off
and on.
0: mm, 1: inch
5104* 01 A3/DLT Double Count Specifies whether the counter is doubled for
A3/DLT.
0: No, 1: Yes
If 1 is selected, the total counter and the current
user code counter count up twice when A3 or
DLT paper is used.
5129 01 F Paper Selection Three selections are available for F-size paper.
[0 ~2 / 0 / 1 step]
0: Foolscap 8" x 13" Lengthways (SEF)
1: Foolscap 81/2" x 13" Lengthways (SEF)
2: Folio 81/4" x 13" Lengthways (SEF)
5131* 01 Paper Size Type Selection Selects the paper size type for printing..
[0~2 / DIP SW setting / 1 step]

Service
Tables
0: Japan
1: North America
2: Europe
After changing the setting, turn the copier off and
on. If the paper size of the archive files stored on
the HDD is different, abnormal prints could
result.
5501 03 PCU Count Sets the timing of the display warning for
replacing the PCU. When printing reaches this
total, the replace PCU warning is issued.
[40 ~ 150 / 150 / 10K step]
Using the default setting, when the number of
prints reaches 150,000 (150 x 1,000) the
warning is issued with the PM Counter Display
(SP7803).
5801* Memory Clear Resets all correction data for process control
and all software counters, and returns all modes
and adjustments to their default values. (☛
5.3.5)
Use this SP only after replacing the NVRAM, or
after the printer has malfunctioned due to a
damaged NVRAM.

SM 5-21 G065
PRINTER ENGINE SERVICE MODE

SP5 Mode Number Function and [Setting]

5802* Printer Free Run Performs a free run. The printer prints the
number of blank prints requested for testing.
[0 ~ 1 /0 / 1 step]
0: Free run mode off.
1: Free run mode on.
5803* Input Check Displays the signals received from sensors and
switches. (☛ 5.3.3)
5804* Output Check Turns on the electrical components individually
for test purposes. (☛ 5.3.4)
5807* Option Connection Check Checks the connectors to the optional peripheral
02 Bank devices. Execution will return either a “1” or “0”:
03 LCT 0: Device not connected correctly.
04 Finisher 1: Device connected correctly.
5810 SC Clear When an SC error is issued for the fusing
system (SC54x), the printer cannot be released
from the SC status by cycling the machine off
and on. The service technician must execute
SP5810 to restore the printer to normal
operation.
5811* 01 Machine Serial Number Used to input the machine serial number (limit:
11 digits). This is normally done at the factory.
DFU
5812 02 Service Fax Number Enter the telephone number of the service
representative. The fax number is printed
automatically when a service call error occurs.
The number entry is limited to 20 digits,
including hyphens.
5828* 25 Network Software Switch Sets the information for the software used on the
network.
[00000000h ~ FFFFFFFh / 00000000h / 1 hex]
27 Network SYSLOG Server Sets the address for the Syslog Server.
Address Setting [00000000h ~ FFFFFFFFh / 7F000001h / 1 step]
7F000001h (127.0.0.1)
28 Network Time Server Sets the time server address.
Address Setting [00000000h / 00000000h / 1 step]
30 Network Direct Port Number Sets the port number for TCP direct printing.
Setting [1024 ~ 65535 / 9100 / 1 step]
32 Network IPX Address Setting Sets the IPX address used by NetWare on the
(NetWare) network. (Allowed entry: 12 numerics)
34 Network Software Switch Sets the NetWare software information used by
Setting (NetWare) the network.
[0000h ~ FFFFh / 0003h / 1 hex]
36 Network AppleTalk Module Sets the mode for the operation of AppleTalk on
Setting the network with multiple protocols.
2: EtherTalk Phase2
37 Network NetNo Setting Sets NetNo information using AppleTalk on a
(AppleTalk) network using multiple protocols. (Range: 12
characters)
38 Network Object Name Sets the object AppleTalk object name for a
Setting (AppleTalk) network using multiple protocols.

G065 5-22 SM
 PRINTER ENGINE SERVICE MODE

SP5 Mode Number Function and [Setting]

5828* 47 Network Job Analysis Sets the Centronics job analysis timeout for the
Timeout Setting (Centronics) network.
[0 ~ 4,200 s / 3 s / 1 sec. step]
48 Network Job Timeout Setting Sets the Centronics job timeout for the network.
(Centronics) [0 ~ 4,200 s / 0 s / 1 sec. step]
49 Network Noise Cancel Sets the noise cancel level for the network.
Setting (Centronics) [4 ~ 7 / 4 / 1 clock per step]
50 Network 1284 Compatibility Switches Centronics IEEE1284 compatibility
Setting (Centronics) on/off for the network.
0: Disabled, 1: Enabled
Selecting “0” disables bi-directional data
transmission.
51 Network Data Transfer Sets the Centronics transfer speed for the
Speed Setting (Centronics) network.
0: Slow, 1: Fast
If you select “0” there will be a 120 µs delay from
the STP signal to the data transfer. (With 1:
FAST there is no delay.)
52 Network ECP Setting Switches the ECP setting for Centronics off/on.
(Centronics) 0: Disabled, 1: Enabled
With “1” selected, SP5828-50 must be enabled
for 1284 mode compatibility.
53 Network Transmission Selects the Ethernet transmission speed.
Speed Setting [0x00 ~ 0x03 / 0x00 / 0x01 step]
Bit 1 Bit 2 Speed
0 0 Auto Sense
0 1 10Base-T

Service
Tables
1 0 100Base-T
1 1 Auto
66 Start Time Job Spool Clear When the printer is powered off, spooled print
jobs on the hard disk remain there until the next
time the printer is powered on. This setting
determines whether to print spooled jobs from
the previous printing session the next time the
printer is powered on.
[0 ~ 1 / 1 / 1 step]
0: Job clear. Clears spooled jobs on the hard
disk when the printer is switched on.
1: Print jobs. Prints spooled jobs on the hard
disk when the printer is powered on.
5839 07 IEEE1394 IEEE 1394 settings.
08 BCR Mode
09 1394a Check for IRM
10 Unique ID Enumeration
11 Force Logout
12 Exclusive Login
13 Maximum Initiator Number
for Login

SM 5-23 G065
PRINTER ENGINE SERVICE MODE

SP5 Mode Number Function and [Setting]

5907* 01 Plug & Play Sets the brand name and the production name
for Windows Plug & Play. This information is
stored in NVRAM. If the NVRAM is defective or
has been replaced, these names should be
registered again.
To set the plug and play model name, enter the
model number, and then press #(Enter).
5915 01 Mechanical Counter Checks whether the mechanical counter inside
Detection the inner cover is connected or not.
Display:
0: Not detected
1: Detected
2: Unknown
5930 Meter Charge This is a total count system for the PCU, fusing
unit, etc. When this setting is set, the PCU
replace time status is not issued from the
engine. However, the internal copy count
continues to function.
5958 Feed Clutch Timing Adjusts the clutch timing to optimize the intervals
between fed sheets to reduce jams in the feed
unit. DFU
[35 ~ 57.5 / 42.5 / 2.5mm step]
5970 Debug Serial Output DFU
5990 SMC Printouts DFU
1 All (Data List) Prints all of the system parameter lists for the
2 SP (Mode Data List) item selected.
4 Provisionally
5 Diagnosis Report
7 NIB Summary

G065 5-24 SM
 PRINTER ENGINE SERVICE MODE

6. Peripherals (SP6000-00)
SP6 Mode Number Function and [Setting]
6105* 01 Staple Adjustment Adjusts the staple position in the main scan
direction when using the 3000-sheet finisher.
[–3.5 ~ +3.5 / 0 / 0.5 mm step]
A larger value shifts the staple toward the edge
of the paper.
6113* Punch Position Adjustment Adjusts the punch hole position.
[–7.5 ~ +7.5 / 0 / 0.5 mm steps]
A larger value shifts the holes toward the edge
of the paper.
01 2 Hole 2-hole punches for Japan, North America,
Europe, and 4-hole punches for Northern
Europe.
02 3 Hole 3-hole punches for North America, and 4-hole
punches for Europe.

Service
Tables

SM 5-25 G065
PRINTER ENGINE SERVICE MODE

7. Data Log (SP7000-00)

SP7 Mode Number Function and [Setting]
7001* 01 Main Motor Operation Time The number of prints and drive time for drum
revolutions can be obtained by counting the
main motor revolution time. If the amount of the
time required for the drum to revolve to print 1
copy increases, this data combined with the
number of prints can be used to analyze
problems and could be useful for future product
development.
Display: 00000000 ~ 99999999 min.
7003* 01 Total Counter Select a number to display the total print count
04 Counter for the selected item.
05 Others
7007 Charge Counter Displays the count total for the selected item.
01 Duplex Count
02 A3/DLT Count
03 Staple Count
7101* Print Count Displays the total number of prints by paper size.
005 A4 H (Sideways)
006 A5 H (Sideways)
014 B5 H (Sideways)
038 LT H (Sideways)
044 HLT H (Sideways)
132 A3 V (Lengthwise)
133 A4 V (Lengthwise)
134 A5 V (Lengthwise)
141 B4 V (Lengthwise)
142 B5 V (Lengthwise)
160 DLT V (Lengthwise)
164 LG V (Lengthwise)
166 LT V (Lengthwise)
172 HLT V (Lengthwise)
255 Others
7204* Tray Print Count Displays the total number of sheets fed from
each paper feed tray.
01 Paper Tray 1 Printer
02 Paper Tray 2 Printer
03 Paper Tray 3 Paper Tray Unit (Option)
04 Paper Tray 4 Paper Tray Unit (Option)
05 LCT Large Capacity Tray (Option)
06 By-pass Copier
7206* 01 Staple Counter – Normal Displays the total number of staples fired.
Staple
7209* 01 Punch Counter Displays the total times the punch has fired.
7401* 01 Total SC Count Displays the total number of service calls that
have occurred. Display range: 0000 ~ 9999
7502* 01 Jam Count Total Displays the total number of copy jams.
Display range: 0000 ~ 9999

G065 5-26 SM
 PRINTER ENGINE SERVICE MODE

SP7 Mode Number Function and [Setting]

7504* Jam Count by Location Displays the total number of copy jams by
location.
Display range: 0000 ~ 9999
A “Paper Late” error occurs when the paper fails
to activate the sensor at the precise time. A
“Paper Lag” paper jam occurs when the paper
remains at the sensor for longer than the
prescribed time.

Paper Late Paper Lag

Error
Error No. Error No.
01 Power on
03 Tray 1 Misfeed
04 Tray 2 Misfeed
05 Tray 3 Misfeed
06 Tray 4 Misfeed
07 57 LCT Tray Sensor
08 58 Relay Sensor 1
09 59 Relay Sensor 2
10 60 Relay Sensor 3
61 Relay Sensor 4
13 63 Registration Sensor
14 64 Fusing Exit Sensor
Exit/Entrance
16 66
Sensor
Relay Sensor 1
17 67
(option)
Relay Sensor 2
18 68
(option)
Duplex Entrance
19 69

Service
Tables
Sensor
23 73 Duplex Exit Sensor
24 74 1-Bin Tray Sensor
25 Finisher Entrance
26 Finisher Proof Tray
27 Finisher Shift Tray
28 Finisher Staple Tray
29 Finisher Tray
Mailbox Entrance
30
Sensor
Mailbox Proof
31
Sensor
Mailbox Relay
32
Sensor
33 Mailbox Exit Sensor
Booklet Finisher
35-41
(Japan Only)

SM 5-27 G065
PRINTER ENGINE SERVICE MODE

SP7 Mode Number Function and [Setting]

7506* Jam Count by Copy Size Displays the total number of copy jams by paper
05 A4 H (Sideways) size.
06 A5 H (Sideways)
14 B5 H (Sideways)
38 LT H (Sideways)
44 HLT H (Sideways)
132 A3 V (Lengthwise)
133 A4 V (Lengthwise)
134 A5 V (Lengthwise)
141 B4 V (Lengthwise)
142 B5 V (Lengthwise)
160 DLT V (Lengthwise)
164 LG V (Lengthwise)
166 LT V (Lengthwise)
172 HLT V (Lengthwise)
255 Other
7803* 02 PM Counter Display Displays the PM counter since the last PM and
resets the counter for PCU replacement to zero.
When the count exceeds the setting for SP5501-
03, the PCU count warning for replacement is
displayed.
7807 SC/Jam Counter Reset Resets the SC and jam counters. To reset, press
#(Enter).
7808 Counter Reset Resets all counters excluding SP7003-***, 7006-
***, 7007-***. Press #(Enter) to reset.
7816 Print Counter Reset Resets the total copy count by paper tray. To
01 Tray 1 reset, press #(Enter).
02 Tray 2 Use these SP modes when replacing the pick-
03 Tray 3 up, feed, and separation rollers.
04 Tray 4
05 LCT
06 By-pass
7832 Self-Diagnosis Result Display Displays the results of self-diagnostic testing.
When there are no errors, 00/00 is displayed. If
an error occurred, the display will show the SC
number.
7910 ROM Number Acquires the ROM section number and records
01 System it, and prints the number in the SMC Report.
02 Engine The ROM section number is not displayed on
07 Finisher the operation panel. This SP appears only in the
09 Bank SMC report.
10 LCT
11 Print Post

G065 5-28 SM
 PRINTER ENGINE SERVICE MODE

5.1.2 TEST PATTERN PRINTING

Enter the SP mode and select SP2902.
1. Press !" together (5s), release, then press #(Enter).
System Ver.1.00
1. Service

2. Press "
System Ver. 1.00
2. Engine

3. Press #(Enter).
<Engine>
1. Feed

4. Press ".
<Engine>
2. Drum

5. Press #(Enter).
SP2001>>
Charge Roll Bias

6. Press " to display “Test Pattern”

SP2902
Print T Pattern

7. Press #(Enter).

Service
Tables
00
_

8. Press !" together (5s), release, then press #(Enter).

01
_

9. Press (Escape) twice then print an SMC Report. (☛ 5.3.6)

10. Repeat this procedure to print as many test prints as needed.

NOTE: 1) After you enter a Print Test Pattern number, when you execute the SMC
Report print procedure, the test pattern prints, not the SMC Report.
2) The machine will remain in this mode until you leave the Service Mode,
or switch the printer off an on.
3) After leaving the re-entering the Service Mode, or after cycling the
machine off an on, the SMC Report feature is restored to normal
operation.

SM 5-29 G065
PRINTER ENGINE SERVICE MODE

Test Pattern Table: SP2902-03 Printing Test Patterns

No. Test Pattern
00 None
01 Vertical Line (1-dot)
02 Horizontal Line (1-dot)
03 Vertical Line (2-dot)
04 Horizontal Line (2 dot)
05 Grid Pattern (1-dot)
06 Grid Pattern (1-dot pair)
07 (not used)
08 (not used)
09 Full Dot Pattern
10 Black band
11 Trimming Area
12 Trimming Area (2-dot)
13 Argyle Pattern
14 Argyle Pattern (2-dot_)
15 Hound’s Tooth Check (2-dot Horizontal)
16 Checked Flag Pattern
17 Point Black Pattern
18 Black Band (Vertical)
19 Independent Pattern (4-dot)
20 Horizontal Line (1-dot) (Reversed LD1, LD2)
21 Grid Pattern (1-dot) (Reversed LD1, LD2)
22 Grid Pattern (1-dot pair) (Reversed LD1, LD2)
23 Independent Pattern (1-dot) (Reversed LD1, LD2)
24 3 Grayscale
25 Grayscale (Horizontal)
26 Grayscale (Vertical)
27 Grayscale (Vertical/Horizontal)
28 Grayscale (Grid)
29 Grayscale (Horizontal Extension)
30 Grayscale (Vertical Extension)
31 Grayscale (Horizontal Margin)
32 Grayscale (Vertical Margin)
33 Grayscale (Vertical/Horizontal Margin)
34 Grayscale (Horizontal Extension Margin)
35 Grayscale (Vertical Extension Margin)
36 White Pattern
37 Grid (1-dot pair) (OR Outside Data 1)
38 Trimming Area (OR Outside Data)

G065 5-30 SM
 PRINTER ENGINE SERVICE MODE

5.1.3 INPUT CHECK

Enter the SP mode and select SP5803.
1. Press !" together (5s), release, then press #(Enter).
System Ver.1.00
1. Service

2. Press ".
System Ver. 1.00
2. Engine

3. Press #(Enter).
<Engine>
1. Feed

4. Press " to display “5. Mode”.

<Engine>
5. Mode

5. Press #(Enter).
SP5024
mm/inch Display

6. Press ! to display “Input Check”.

SP5803 >>
Input Check

7. Press #(Enter).

Service
Tables
SP5803-001
Paper Feed 1

8. Press ! or " to select the item to check.

SP5803-013
Full Exit Tray 2

9. Press #(Enter). Refer to the table on the next page.

Full Exit Tray 2
(7)00001010(0)

SM 5-31 G065
PRINTER ENGINE SERVICE MODE

Reading
Number Bit Description
0 1
7 Fusing Exit Sensor Activated Deactivated
6 Paper Height Sensor 2 Activated Deactivated
5 Paper Height Sensor 1 Activated Deactivated
SP5803-001
4 Not used — —
Paper Feed 1
(Upper Tray) 3 Paper Size Sensor 4 Activated Deactivated
2 Paper Size Sensor 3 Activated Deactivated
1 Paper Size Sensor 2 Activated Deactivated
0 Paper Size Sensor 1 Activated Deactivated
7 Duplex Unit Set Sensor Unit set Unit not set
6 Paper Height Sensor 2 Activated Deactivated
5 Paper Height Sensor 1 Activated Deactivated
SP5803-002
4 Not used — —
Paper Feed 2
(Lower Tray) 3 Paper Size Sensor 4 Activated Deactivated
2 Paper Size Sensor 3 Activated Deactivated
1 Paper Size Sensor 2 Activated Deactivated
0 Paper Size Sensor 1 Activated Deactivated
7 Zero Cross Signal Detected Not detected
Transfer Belt Position
6 Not present Present
Sensor
5 Exhaust Fan Lock Signal Not locked Locked
SP5803-003
4 Cooling Fan Lock Signal Not locked Locked
Regist/Others
3 Main Motor Lock Signal Not locked Locked
2 Toner Overflow Sensor Tank not full Tank full
1 Cover Open Cover closed Cover opened
0 Registration Sensor Paper detected Paper not detected
7 Duplex reverse path door Closed Open
6 Paper End Sensor Paper detected Paper not detected
5 Not used — —
Paper Size Sensor 4,
4 Activated Deactivated
By-pass
SP5803-004 Paper Size Sensor 3,
By-pass Feed 3 Activated Deactivated
By-pass
Paper Size Sensor 2,
2 Activated Deactivated
By-pass
Paper Size Sensor 1,
1 Activated Deactivated
By-pass
0 Unit Set Signal Yes No
7 Not used Yes No
6 Unit Set Signal Connected Not connected
5 Paper Sensor Paper detected Paper not detected
4 Relay Sensor Paper detected Paper not detected
SP5803-005 3 Exit Sensor Paper detected Paper not detected
Relay Unit Left Cover Switch Switch pressed
(Bridge Unit) 2 Switch not pressed
(cover closed)
Middle Cover Switch Switch pressed
1 Switch not pressed
(cover closed)
Right Cover Switch Switch pressed
0 Switch not pressed
(cover closed)

G065 5-32 SM
 PRINTER ENGINE SERVICE MODE

Reading
Number Bit Description
0 1
7 Feed Motor Lock No Yes
6 F-Gate Signal Active Not active
5 Height Sensor Feed height Not feed height
SP5803-006
4 Paper Exit Sensor Paper detected Paper not detected
Unit Set
(Detection) 3 Fusing Unit Detected Not detected
2 Total Counter Not detected Detected
1 Key Counter Detected Not detected
0 Key Card Present Detected Not detected
7 Front cover/open closed Open Closed
6 Vertical feed path Clear Not clear
2nd Tray Lift Sensor Paper not at upper Paper at upper limit
5
limit
SP5803-007 1st Tray Lift Sensor Paper not at upper Paper at upper limit
4
Paper End limit
3 Lower Relay Sensor Paper detected Paper not detected
2 Upper Relay Sensor Paper detected Paper not detected
1 Lower Paper End Sensor Paper not detected Paper detected
0 Upper Paper End Sensor Paper not detected Paper detected
7 Dip Switch - 8 On Off
6 Dip Switch - 7 On Off
5 Dip Switch - 6 On Off
SP5803-008 4 Dip Switch - 5 On Off
DIP Switch 3 Dip Switch - 4 On Off
2 Dip Switch - 3 On Off
1 Dip Switch - 2 On Off

Service
Tables
0 Dip Switch - 1 On Off
7 Not used
6 Right cover open/closed Closed Open
5 1-Bin Unit Set Detected Not detected
SP5803-009 4 LD, H.P. sensor Positioned Not positioned
Duplex Unit 3 Exit Sensor (Jam) Paper detected Paper not detected
2 Entrance Sensor (Jam) Paper detected Paper not detected
1 Paper End Sensor Paper detected Paper not detected
0 Duplex Unit Switch Cover closed Cover open
7 Tray 4: Bit 1
8 Tray 4: Bit 0 Bit 1 Bit 2 Capacity
5 Tray 3: Bit 1 1 1 Full
SP5803-010 1 0 50% or more
4 Tray 3: Bit 0
Remainder of 0 1 10% or more
Feed Tray-1 3 Tray 2: Bit 1
0 0 Out, or tray not set
2 Tray 2: Bit 0
1 Tray 1: Bit 1
0 Tray 1: Bit 0

SM 5-33 G065
PRINTER ENGINE SERVICE MODE

Reading
Number Bit Description
0 1
7 By-pass Yes/No
6 Not used Bit 2 Bit 1 Bit 0 Capacity
5 Not used 1 1 1 Full
SP5803-011 1 0 0 80% or more
4 Not used
Remainder of 0 1 1 50% or more
Feed Tray 2 3 Not used
0 1 0 30% or more
2 LCT: Bit 2
0 0 0 10% or more
1 LCT: Bit 1
0 LCT: Bit 0
7 Mailbox: Bin 9 Not full or no tray Full
6 Mailbox: Bin 8 Not full or no tray Full
5 Not used — —
SP5803-012 4 Not used Not full or no tray Full
Full Exit Tray 1 3 Finisher: Shift Tray Not full or no tray Full
2 Not used — —
1 1-Bin Exit Not full or no tray Full
0 Machine Exit Not full or no tray Full
7 Mailbox: Bin 7 Not full or no tray Full
6 Mailbox: Bin 6 Not full or no tray Full
5 Mailbox: Bin 5 Not full or no tray Full
SP5803-013 4 Mailbox: Bin 4 Not full or no tray Full
Full Exit Tray 2 3 Mailbox: Bin 3 Not full or no tray Full
2 Mailbox: Bin 2 Not full or no tray Full
1 Mailbox: Bin 1 Not full or no tray Full
0 Mailbox: Proof Tray Not full or no tray Full

Table 1: By-pass Feed Table Paper Size

Number. Bit 4 Bit 3 Bit 2 Bit 1 Paper Width
1 1 1 1 Post Card
1 1 1 0 B6 lengthwise
1 1 0 1 B5 lengthwise
1 1 0 0 A5 lengthwise/5.5"
4: By-pass
1 0 1 1 B4 lengthwise
1 0 0 1 A4 lengthwise/8.5"/8"
0 1 1 1 A3 lengthwise
0 0 1 1 11" x 17"

G065 5-34 SM
 PRINTER ENGINE SERVICE MODE

5.1.4 OUTPUT CHECK

NOTE: Motors keep turning in this mode regardless of upper or lower limit sensor
signals. To prevent mechanical or electrical damage, do not keep an
electrical component on for a long time.
Enter the SP mode and select SP5804.
1. Press !" together (5s), release, then press #(Enter).
System Ver.1.00
1. Service

2. Press ".
System Ver. 1.00
2. Engine

3. Press #(Enter).
<Engine>
1. Feed

4. Press " to display “5. Mode”.

<Engine>
5. Mode

5. Press #(Enter).
SP5024
mm/inch Display
6. Press ! repeatedly to display “Output Check”.

Service
SP5804 >>

Tables
Output Check

7. Press #(Enter).
SP5804-001
1st.PaperFeedCl.

8. Press ! or " to display the item to check.

SP5804-027
Fuser Exit Motor

9. Press #(Enter).
<Fuser Exit Motor>

10. Press #(Enter) to switch the component on, then press #(Enter) to switch it off.
Fuser Exit Motor
Fuser Exit Motor

11. Press (Escape) then repeat Steps 8 to 11 to check other items.

12. When you are finished press (Escape) until you see “2.Engine” then select
“3.End”.

SM 5-35 G065
PRINTER ENGINE SERVICE MODE

SP5804 Output Check Table

No. Description No. Description
1 1st Paper Feed CL 43 ~ 44 Not used
2 2nd Paper Feed CL 45 Duplex Junction Gate SOL
3 3rd Paper Feed CL (PTU) 46 Not used
4 4th Paper Feed CL (PTU) 47 Relay Junction Gate SOL
5 By-pass Feed CL 48 ~ 49 Not used
6 LCT Paper Feed CL 50 Tray Junction Gate SOL
7 ~ 10 Not used 51 Stapler Junction Gate SOL
11 1st. Paper Tray (Lift Motor) 52 Positioning Roller SOL (Finishers)
12 2nd. Paper Tray (Lift Motor) 53 ~ 54 Not used
13 By-pass Pick-up SOL 55 Polygon Motor
14 LCT Pick-up SOL 56 Toner Supply Motor
15 ~ 16 Not used 57 Transfer Belt CL
17 Transport Motor 1 (Finisher) 58 ~ 61 Not used
18 Transport Motor 2 (Finisher) 62 Quenching Lamp
19 Exit Motor 1 (Finisher) 63 Charge Bias
20 Staple Motor 1 (Finisher) 64 ~ 66 Not used
21 Punch Motor 1 (Finisher) 67 Development Bias
22 ~ 24 Not used 68 Not used
25 LCT Motor 69 Transfer Belt (Bias)
26 Bank Motor (PTU) 70 ID Sensor LED
27 Fusing/Exit Motor 71 ~ 74 Not used
28 Main Motor 75 Exhaust Fan Motor
29 Duplex Transport (Motor) 76 Cooling Fan Motor (High Speed)
30 Duplex Inverter Motor – Rev. 77 Cooling Fan Motor (Low Speed)
31 Duplex Inverter Motor – Fwd 78 Bridge Unit Fan Motor
32 Development Motor 79 ~ 84 Not used
33 ~ 34 Not used 85 Total Counter
35 Bank Relay CL 86 ~ 91 Not used
36 Relay CL 92 Shift Lift Motor (Finisher)
37 Fusing/Exit CL 93 Jogger Motor (Finisher)
38 LCT Relay CL 94 Stapler Unit Motor (Finisher)
39 Registration CL 95 Stack Feed Out Motor (Finisher)
40 Development CL 96 Shift Motor (Finisher)
Exit Junction Gate SOL Stapler Rotation Motor (Finisher)
41 97
(Upper Unit)
Duplex Junction Gate SOL Not used
42 98 ~ 99
(Lower Unit)

G065 5-36 SM
 PRINTER ENGINE SERVICE MODE

5.1.5 MEMORY ALL CLEAR: SP5801

Executing Memory All Clear resets all the settings stored in the NVRAM to their
default settings except the following:

SP7003-1: Electrical total counter value

SP5811-1: Machine serial number
SP5907: Plug & Play Brand Name and Production Name Setting

1. Press ! and " together, hold down for over 5 seconds, release and then
press #(Enter).
2. Press ! or " to display “2.Engine”.
3. Press #(Enter).
4. Press " or ! to display “5.Mode” then press #(Enter).
5. Press " or ! to display “Memory Clear” then press #(Enter).
6. With “Clear All” displayed, press #(Enter), then press #(Enter) again to execute.
<Clear All>
Result=OK

Here is a summary of all the settings.

No. Item Function

01 Clear All Initializes all items below.
Clear Engine Initializes all registration settings for engine adjustments and
02
processing settings.

Service
Tables
Clear SCS Initializes default system settings and ROM update
03
information.
Clear Printer Initializes the printer defaults, the printer SP Bit SW, and
08
printer CSS counter.
Clear NCS Initializes the system defaults and interface settings (IP
11 addresses also), SmartNetMonitor for Admin., Web Status
Monitor settings, and the TELNET settings.

7. After clearing all settings make sure that you perform the following settings:
• Do the laser beam pitch adjustment (SP2109). See section 3.9.5.
• Referring to the SMC Report, re-enter any values, which had been changed
from their factory settings.
• Execute SP3001-2 (ID Sensor Initial Setting).

SM 5-37 G065
PRINTER ENGINE SERVICE MODE

5.1.6 SMC PRINT OUT LISTS: SP5990

1. Enter the SP Engine Mode.

<Engine>
1.Feed

2. Press ! or " until you see “5.Mode”.

<Engine>
5.Mode

3. Press #(Enter).
SP5024
mm/inch Display

4. Press ! to select SP5990.

SP5990 >>
SMC Printout

5. Press #(Enter).
SP5990-001
All Group

6. Press ! or " to select what to print.

1 All Group All reports
2 SP Mode SMC Report for SP codes
4 Logging Data SP Codes for SP7000-00 only.
5 Provisionally Self-Diagnosis Report.
7 NIB Summary Network Configuration Report

7. For example, to print the SP Mode list, press ! or " to display SP Mode and
press #(Enter).
<SP Mode>
Execute?

8. Press #(Enter).
<SP Mode>
Processing

9. The report prints.

10. Repeat from Step 6 to print another report.

G065 5-38 SM
 SOFTWARE DOWNLOAD

5.4 SOFTWARE DOWNLOAD

5.4.1 DOWNLOADING THE SOFTWARE
Before downloading the software, please note:
• If you are downloading the Engine software for the BICU, 1 card is required.
• If you are downloading the Controller software, 2 cards are required.
• Follow the basic procedure described below to install the software for either the
Engine or the Controller.

1. Turn off the main power switch.

2. Remove the IC card [A] cover.
3. Insert the IC card [B] containing the software
to download into the card slot of the
controller.
[A]
4. Turn on the main power.
Onboard Sys. 1/2

5. Press #(Enter). An asterisk appears in the [B]

LCD. G065S900.WMF

6. Press " to display “Update Data”, then press

#(Enter) to start writing the data from the card to the printer.
7. Monitor the downloading status on the operation panel. While downloading is in

Service
Tables
progress, the LCD will display some dashes, slowly replaced by asterisks
(***-----) moving left to right.

!CAUTION
Never switch off the power while downloading. Switching off the power
while the new software is being downloading will damage the boot files in
the controller.

After confirming that downloading is completed, the LCD displays:

Updated
Power Off/On

8. Turn off the main power and remove the IC card.

9. If you are installing the software for the Engine (BICU), go to the next step.
If you are installing the software for the Controller, you must repeat the
procedure for the second card.
10. After all the software has been downloaded, turn the main power on and
confirm that the new software loads and that the machine starts normally.

SM 5-39 G065
SOFTWARE DOWNLOAD

5.1.2 POWER FAILURE DURING SOFTWARE DOWNLOAD

If a power failure occurs before downloading is completed, you will not be able to
continue downloading with the Controller cards or the Engine card using the
operation panel.

1. If a power failure occurs before downloading, leave the card inserted in the slot
and set the power switch to off.
2. If you were downloading from either Controller card, on the Controller Board set
DIP Switch 1 to ON.
-or-
If you were downloading from the Engine card, on the I/O Board set DIP Switch
8 to ON.
3. After restoring the power supply to the printer, switch it on.
4. The downloading will complete but nothing will be displayed on the operation
panel until downloading has completed.
5. When the display returns to normal, switch the printer off.
6. If you were downloading from either Controller card, on the Controller Board
reset DIP Switch 1 to OFF.
-or-
If you were downloading from the Engine card, on the I/O Board reset DIP
Switch 8 to OFF.
7. Switch on the printer to confirm normal operation.

G065 5-40 SM
 SELF-DIAGNOSTIC MODE

5.5 SELF-DIAGNOSTIC MODE

5.5.1 SELF-DIAGNOSTIC MODE AT POWER ON
As soon as the main machine is powered on, the controller waits for the initial
settings of the copy engine to take effect and then starts an independent self-
diagnostic test program. The self-diagnostic test follows the path of the flow chart
shown below and checks the CPU, memory, HDD, and so on. An SC code is
displayed in the touch panel if the self-diagnostic program detects any malfunction
or abnormal condition.

Self-Diagnostic Test Flow

Power On

* Checks only the area used by

RAM Check* the self-diagnostic test. Detailed Self-Diagnosis

NG: SC820 ROM Device NG: SC828

CPU Check
CRC Check

ASIC Check NG: SC821 Resident NG: SC829

RAM Total
Area Check
Resident RAM NG: SC827
Connection Optional
Check RAM Total
Area Check

Optional RAM NG: SC829

Connection NVRAM

Service
Check

Tables
Total Area
Check
Clock NG: SC838
Generator
Check HDD Check

IEEE1284
NV-RAM NG: SC824
Check Loop-back
Check

Font ROM
Header Font ROM
Check CRC Check

Network Detailed Self-

Interface Diag. End
Check

Allocation
Check

YES
Detailed Self-
Diag. Mode?

NO

Self-Diag. End

G065S903.WMF

SM 5-41 G065
SELF-DIAGNOSTIC MODE

5.5.2 DETAILED SELF-DIAGNOSTIC MODE

In addition to the self-diagnostic test initiated every time the main machine is
powered on, you can set the machine in a more detailed diagnostic mode manually
in order to test other components or conditions that are not tested during self-
diagnosis after power on.
The following device is required in order to put the printer in the detailed self-
diagnosis mode.

No. Name
G0219350 Parallel Loopback Connector

Follow this procedure to execute detailed self-diagnosis.

1. Switch off the printer.
2. Press and hold down the !(On line) and #(Enter) buttons together, then switch
on the printer.
3. Release the buttons when you see:
DIAGNOSE
0100

4. The number will change automatically as the self-diagnostic test runs. After
about 30 seconds, the initial display returns and a self-diagnostic report prints.
A report like the one below is printed every time a detailed self-diagnostic test
is executed, whether errors were detected or not.

MODEL NAME XXXX

Serial No Firmware P/# : ACP82XXXX [1/1]

Self-Diagnosis Report Firmware Version: 0.38 Fri Sep 7 05:45:18 2001

[System Construction]
Kernel Version : NetBSD 1.3.3 (HAKONE_RAM) #11: Sep 4 11:18:48 JST 2001
C P U S y s t e m B u sClock : 124.0 MHz CPU Pipeline Clock : 248.0 MHz
Board Type : 12 A S I C Version : 1128608306
RTC Existence : existence R A M Capacity : 67:108864 MB
HDD Existence : existence HDD Model :

[Total Counter ]
0001000

[Error List ]
SCCODE ( E R R O RC O D E ) SC CODE (ERROR CODE) SC CODE (ERROR CODE) SC CODE ( E R R O R CODE)

SC835 (1120)

G065S901.WMF

G065 5-42 SM
 DIP SWITCHES

5.6 DIP SWITCHES

Controller: DIP SW2
DIP SW No. ON OFF
1 IC Card Boot System ROM Boot
2
3 Keep at “OFF”
4

I/O Board: DIP SW101

DIP SW No. Function ON OFF
1 Not used. Off (Do not change)
Jam Detection Off On
2
(see Note)
3 SC Generation Disabled Enabled
4 Not used OFF (Do not change)
5 Not used OFF (Do not change)
6 Destination OFF Japan ON North America OFF Europe ON Not used
7 OFF OFF ON ON
Software Software download from IC card Normal position.
8
Download for the engine.

NOTE: Disabling jam detection is effective only for the main machine (not for the
options).

Service
Tables

SM 5-43 G065
DETAILED DESCRIPTIONS
 OVERVIEW

6. DETAILED SECTION DESCRIPTIONS

6.1 OVERVIEW
6.1.1 COMPONENT LAYOUT

1 2 3 4 5
6
7
8
9
32 10
11
31
12
30 13
14
29

15
16
17
18
19
20
21
28 27 26 25 24 23 22
G065D022.WMF

1. Exit Roller 17. By-pass Paper End Sensor

Descriptions
2. Paper Exit Sensor 18. By-pass Paper Feed Roller
Detailed
3. Hot Roller 19. By-pass Separation Roller
4. Entrance Sensor 20. Upper Relay Roller
5. Inverter Gate 21. Feed Roller
6. Inverter Roller 22. Separation Roller
7. Pressure Roller 23. Pick-up Roller
8. Transfer Belt Cleaning Blade 24. Bottom Plate
9. Upper Transport Roller 25. Development Unit
10. Transfer Belt 26. Charge Roller
11. OPC Drum 27. Fθ Mirror
12. Registration Roller 28. Barrel Toroidal Lens (BTL)
13. Lower Transport Roller 29. Polygonal Mirror Motor
14. Duplex Exit Sensor 30. Laser Unit
15. By-pass Tray 31. Toner Bottle Holder
16. By-pass Pick-up Roller 32. Exit Junction Gate

SM 6-1 G065
 OVERVIEW

Paper Path

8 6 7 1

9 5
10 G065D551.WMF

1. Interchange unit
2. Duplex unit
3. By-pass tray
4. Large capacity tray (LCT)
5. Paper tray unit
6. Bridge unit
7. 1-bin shift tray
8. Mailbox bridge unit
9. Mailbox
10. Finisher

G065 6-2 SM
 OVERVIEW

6.1.2 DRIVE LAYOUT

10 9

PCU Drive
1
Fusing

2 8

7
3
6

5
Development

Transfer
4 G065D002.WMF

1. Transfer Belt Contact Clutch 6. Paper Feed/Development Motor

2. Registration Clutch 7. Development Clutch

Descriptions
3. Upper Paper Feed Clutch 8. Main Motor Detailed
4. Lower Paper Feed Clutch 9. Fusing/Exit Motor
5. Relay Clutch 10. Fusing/Exit Clutch

In this machine, the development unit is provided with its own motor, separate from
the main motor.

SM 6-3 G065
 BOARD STRUCTURE

6.2 BOARD STRUCTURE

6.2.1 BLOCK DIAGRAM

LDB

Controller
BICU
Mother Board

Operation Panel

xxx SOL
PSU

CL
PFCB

HVPS M

CL CL CL M

IOB CL

DUPLEX
CL

M CL

Fan
M
M M
Fan Fan CL PTU
M

LCT

G065D998.WMF

This machine employs the GW (Grand Workware) architecture, which allows the
printer to be expanded by installing simple modular components (ROM DIMMs) on
the controller board.
Here is a brief summary of the boards and their functions. For more details, refer to
the Point-to-Point diagram and list of components supplied with the printer.

BICU (Base Engine and Image Control Unit)

Controls all machine functions both directly and through other control boards.

LDB (Laser Diode Board)

Powers the laser diode. Output level is controlled to compensate for changes in
temperature and humidity to maintain constant light intensity.

Controller (CB)
Controls memory and all peripheral devices. The Controller Board is equipped with
slots to accommodate the following interfaces: HDD, PCMCIA, NIB, IEEE1284,
IEEE1394.

G065 6-4 SM
 BOARD STRUCTURE

Mother Board
Interfaces the BICU and Controller. The operation panel connects directly to the
Mother Board.

Operation Panel
Controls the LCD user interface and button controls.

PSU (Power Supply Unit)

Provides dc power to the system and ac power to the fusing lamp.

HVPS (High Voltage Power Supply)

Supplies high voltage to the drum charge roller, development roller, and transfer
belt.

IOB (Input/Output Board)

Controls the mechanical parts of the printer (excluding the paper feed section), and
the fusing lamp power. Specifically, the IOB controls:
• All main drive sensors, motors, and solenoids.
• PWM (Pulse Width Modulation) of the HVPS.
• Serial interfaces of all peripherals.
• Fusing.

PFCB (Paper Feed Control Board)

Controls the mechanical parts of all paper feed sections.

Duplex
Provides the system interface for all electronic components, i.e. sensors, switches,
motors, and solenoids for the attached duplex unit.

Descriptions
Detailed

SM 6-5 G065
 BOARD STRUCTURE

6.2.2 CONTROLLER

OPTION
OPTION OPTION OPTION

3.5" HDD RAM

100Base-TX
IEEE1284 IC Card ROM More than (64/128/ IEEE1394
10Base-T
10 GB 256 MB)

IEEE1284 Network IC Card ROM DIMM HDD RAM DIMM PCI

I/F I/F I/F I/F I/F I/F I/F

System Resident
Font ROM NVRAM
Flash ROM SDRAM CELLO CPU
(4MB) (32 kB)
(12 MB) (64 MB)

CONTROLLER
Engine I/F

OPERATION
MOTHER BOARD
PANEL

BICU

G065D999.WMF

The controller employs GW (Grand Workware) architecture that allows the

controller board to control the engine and printer applications.
The following software can be downloaded from the Controller IC Card.
• Controller (Including System OS, MIB, PJL, RPCS, PostScript3 and PCL6)
• BICU (engine control)
For details about how to download software from an IC card, see “Software
Download” in “5. Service Tables”.

G065 6-6 SM
 BOARD STRUCTURE

1. CPU. Employs RM7000A-300. Clock frequency: 300 MHz.

2. ASIC: CELLO. Uses a dedicated chip developed for use with GW architecture.
These components perform CPU and I/F control and also control: memory,
local bus, interrupts, PCI bus, video data, HDD, network, operation panel, and
IEEE1284.
3. SDRAM. Comprises a 64 MB RAM chip, expandable with a 64 MB or 128 MB
or 256 MB SDRAM.
4. System Flash ROM. Provided with an 12 MB Flash ROM for the system OS,
MIB, PJL, RPCS, PostScript3 and PCL6.
5. NVRAM. 32 KB of NVRAM are provided for the system. The NVRAM stores
many settings, including OS system log information settings, calendar settings,
current system settings, all printer settings, and network settings. The NVRAM
also employs an RTC (Real Time Clock) for time management.
6. HDD. A 3.5" HDD (more than 10 GB) can be connected using an IDE I/F. The
hard disk is partitioned as shown in the table below.
Area Size Usage Remarks
File System 1 500 MB Font download, form registration. Remain after power off/on.
File System 2 500 MB Job spool area. Erased at power off.
Image TMP1 Collation, sample print and Erased at power off.
2000 MB
locked print.
Image TMP2 Collation Erased at power off.
500 MB

Image TMP3 Collation and locked print. Erased after power off.
500 MB

Job Log 10 MB Job log. Remain after power off/on.

Descriptions
Detailed

SM 6-7 G065
 PRINTING PROCESS OVERVIEW

6.3 PRINTING PROCESS OVERVIEW

[F]

[G]
[H]
[E]

[A]

[D]
[B]

[C]

G065D111.WMF

Drum Charge
The charge roller [A] gives a negative charge to the organic photoconductive
(OPC) drum. The charge remains on the surface of the drum because the OPC
layer has a high electrical resistance in the dark.

Laser Exposure
The image data is projected onto the drum by two laser beams [B], which form an
electrostatic latent image on the drum surface. The amount of charge remaining as
a latent image on the drum depends on the laser beam intensity, controlled by the
BICU.

Development
The magnetic developer brush on the development roller [C] contacts the latent
image on the drum. Toner particles are electrostatically attracted to the areas of the
drum surface where the laser reduced the negative charge on the drum.

G065 6-8 SM
 PRINTING PROCESS OVERVIEW

Image Transfer
Paper is fed into the area between the drum surface and the transfer belt [D] at the
proper time to align it with the image on the drum. The transfer bias roller applies a
high positive charge to the reverse side of the paper through the transfer belt. This
positive charge pulls the toner particles from the drum surface onto the paper while
the paper is electrostatically attracted to the transfer belt.

Separation
Paper separates from the drum as a result of the electrical attraction between the
paper and the transfer belt. Pick-off pawls [E] help separate the paper from the
drum.

ID Sensor
The ID sensor [F] measures the reflectivity of the pattern formed by the laser on the
surface of the drum. This output signal is used for toner supply control and also
measures the drum surface reflectivity, which is used for charge roller voltage
control.

Cleaning
The drum cleaning blade [G] removes any toner remaining on the drum surface
after the image is transferred to the paper.

Quenching
Finally, the light from the quenching lamp [H] electrically neutralizes the charge on
the drum surface.

Descriptions
Detailed

SM 6-9 G065
 LASER EXPOSURE

6.4 LASER EXPOSURE

6.4.1 OVERVIEW

6 7 8

9
1 G065D541.WMF

1. LD unit 6. Laser synchronization detector

2. Cylindrical lens 7. BTL (Barrel Toroidal Lens)
3. Polygonal mirror 8. F-theta mirror
4. Shield glass 9. Toner shield glass
5. Mirror
This machine uses two laser diodes to produce electrostatic images on an OPC
drum. The laser diode unit converts image data from the BICU board into laser
pulses, and the optical components direct these pulses to the drum. To produce a
high quality image, these are 256 gradations for the laser power.
The output path from the laser diode to the drum is shown above. The LD unit
outputs two laser beams to the polygon mirror through the cylindrical lens and the
shield glass.
Each surface of the polygon mirror reflects two full main scan lines. The laser
beams go to the F-theta mirror, mirror, and BTL (barrel toroidal lens). Then these
laser beams go to the drum through the toner shield glass. The laser
synchronization detector determines the main scan starting position.
NOTE: The front door and upper right door (transfer door) are equipped with safety
switches that automatically shut down the laser unit when either door is
opened.

G065 6-10 SM
 LASER EXPOSURE

6.4.2 AUTO POWER CONTROL (APC)

The LD board drives the laser diode. Even if a constant electric current is applied to
the laser diode, the intensity of the output light changes with the temperature. The
intensity of the output decreases as the temperature increases.
In order to keep the output level constant, the LD board monitors the electrical
current passing through the photodiode (PD). Then it increases or decreases the
current to the laser diode as necessary, comparing it with the reference level. This
auto power control is done just after the machine is turned on and during printing
while the laser diode is active.
The reference levels are adjusted on the production line. Do not touch the variable
resistors on the LD b oard in the field.

Descriptions
Detailed

SM 6-11 G065
 LASER EXPOSURE

6.4.3 DUAL BEAM WRITING

This LD unit employs two laser [C]
diodes [A] (LD) and [B] (L2). Each [B]
face of the polygon mirror writes two [D]
main scan lines, and twelve main
[E]
scans are produced when the
polygon mirror rotates once. This
reduces polygon motor rotation
speed, reduces noise generated by
the polygon motor, and reduces the
frequency of the image data clock.
[A]
The two laser beams follow the path:
collimating lenses [C] → prism [D] →
polygon mirror [E]

G065D203.WMF

2 mm

P1
P2

P1: 400 dpi

P2: 600 dpi

G065D204.WMF

The two laser beams arrive on the drum surface about 2 mm apart in the main
scan direction and about 0.06 mm apart (at 400 dpi) in the sub scan direction. The
two-mm difference in the main scan direction allows the machine to detect the laser
synchronization signal for each beam.

G065 6-12 SM
 LASER EXPOSURE

6.4.4 LASER BEAM PITCH CHANGE MECHANISM

[D]

[B]

[C]

[A]

G065D543.WMF

When the LD positioning motor [A] turns, the metal block [B] in contact with the LD
unit housing [C] moves up and down and changes the position of L2 (L1 does not
move).
Both LD unit positions are at fixed distances from the LD unit home position sensor
[D].

Descriptions
Usually, the LD unit moves directly to the proper position. However, when the Detailed
number of times that the resolution has changed reaches the value of SP2109 07
(Pitch Change Count), the LD unit moves to the home position, and this re-
calibrates the LD unit positioning mechanism.

SM 6-13 G065
 LASER EXPOSURE

6.4.5 LD SAFETY SWITCHES

BICU LDDR Upper Right

Cover Switch
CN312-1 CN402-4 +5V CN403-1

LD5V CN403-3

LD2 Front Cover

CN301-10

LD1
Safety Switch
CN109-8

PSU +5V

G065D505.WMF

To ensure personal safety and to prevent the laser beam from inadvertently
switching on during servicing, power to the laser diode is switched off when the
front cover or upper right cover is opened. Four safety switches are installed in
series on the LD5 V line from the power supply unit (PSU) via the BICU board.

G065 6-14 SM
 PHOTOCONDUCTOR UNIT (PCU)

6.5 PHOTOCONDUCTOR UNIT (PCU)

6.5.1 OVERVIEW

9 1 2 3

4
8

5
7

G065D301.WMF

1. Toner Collection Coil 6. Transfer Entrance Guide

2. Toner Collection Plate 7. Charge Roller
3. Spur 8. Brush Roller

Descriptions
4. Pick off Pawl 9. Cleaning Blade Detailed
5. OPC Drum (φ60 mm)

SM 6-15 G065
 PHOTOCONDUCTOR UNIT (PCU)

6.5.2 DRIVE MECHANISM

The drive from the main motor [A] is [A]
transmitted to the drum [B] through a [C]
series of gears, a timing belt [C], and
the drum drive shaft [D].
The main motor has a drive
controller, which outputs a motor lock
signal when the rotation speed is out [E]
of the specified range. The flywheel [D]
[E] on the end of the drum drive shaft
stabilizes the rotation speed (this [B]
prevents banding and jitter on
copies). G065D302.WMF

6.5.3 DRUM PAWLS

The pick-off pawls [A], mounted in
the holders [B] on the drum and in
contact with the drum, strip paper
from the drum if it has not yet
separated. The gears [C] are
removable, and the positions of the [A]
holders can be adjusted.

[C]
[B] G065D305.WMF

6.5.4 DRUM TONER SEALS

Seals have been added to the
structure of the PCU (photoconductor
unit) to further prevent toner leakage.

G065D992.WMF

G065 6-16 SM
 DRUM CHARGE

6.6 DRUM CHARGE

6.6.1 OVERVIEW

[F] [D] [E]

[C]

[A]

[B]
G065D525.WMF

This machine uses a drum charge roller to charge the drum.

The drum charge roller [A] contacts the surface of the drum [B] to give it a negative
charge. The high voltage supply board [C] supplies a negative dc voltage to the
drum charge roller through the charge roller terminal [D], bias plate [E], and the
rear roller bushing [F] to give the drum surface a negative charge of –950V.

Descriptions
Detailed

SM 6-17 G065
 DRUM CHARGE

6.6.2 CHARGE ROLLER VOLTAGE CORRECTION

Correction for Environmental Conditions

3 cm 3 cm

ID Sensor Pattern 3 cm

Sub Scan Direction

Charge Voltage –1480V

On
Laser Diode
Off

Drum Potential –950V

–540V
Development Bias –550V

–380V
–150V
ID Sensor Output Vsg (4.00V)
Vsdp (3.50V)

Vsp (0.31V)

t
G065D506.WMF

The voltage transferred from roller to drum could vary with the temperature and
humidity around the drum charge roller. The lower the temperature or humidity, the
higher the applied voltage required.
The ID sensor measures the effects of ambient conditions, and any small change
in drum potential caused by changes in temperature/humidity is reflected in the
amount of toner transferred to the drum.
This measurement is done immediately after the ID sensor pattern for toner density
control. After creating ID sensor pattern [A], another pattern [B] is made. To do this,
the LD switches off, the charge roller voltage drops, and the drum potential is
reduced to –600 V. At the same time, development bias returns to –550 V. The
drum potential is now slightly higher than the development bias, so only a very
small amount of toner transfers to the drum. The ID sensor measures the density of
pattern [B], and Vsdp, the output voltage, is compared with Vsg which was read
from the bare drum at the same time.

G065 6-18 SM
 DRUM CHARGE

Correction for Paper Width and Thickness (By-pass Tray only)

The by-pass tray can be used for non-standard paper narrower than sizes
accepted by the paper trays. Thicker paper, OHP sheets, etc. can also be loaded in
the by-pass tray but adjustments must be performed with the SP modes listed
below in order to avoid jams and quality problems.

SP Mode SP Name
SP2001-01 Charge Roller Bias Adjustment Default: –1,480 V
SP2309-01 Paper Lower Width [a] Width limit. Default: 150 mm
SP2309-02 Paper Upper Width [b] Width limit. Default: 216 mm
SP2914-01 Cα Adjust 10 V/step. Default: +150 V
SP2914-02 Cβ Adjust 10 V/step. Default: 0

The way that these SP modes are used is shown below.

SP2309-01 SP2309-02
0 mm Default: 150 mm Default: 216 mm 297 mm

Voltage: Voltage: Voltage:

SP2001-01 + SP2914-01 SP2001-01 + SP2914-02 SP2001-01
Default: –1,480 + 150 Default: –1,480 + 0 Default: –1,480

For example, with the default settings, if the paper width fed from the by-pass tray
is 100 mm, the charge roller voltage will be –1,480 + 150 V.

Descriptions
Detailed

SM 6-19 G065
 DRUM CHARGE

6.6.3 ID SENSOR PATTERN PRODUCTION TIMING

At certain times, an ID sensor pattern is created on the drum. The ID sensor reads
the sensor pattern and outputs this reading as Vsp and sends it to the CPU where
it is used to calculate Vref (Vsp/Vsg = Vref).
These times are as follows:
Every time the system is powered up
After every 10 prints
• This number of prints can be adjusted with SP2210-01 (Pattern Interval – ID
Sensor).
• When the number of prints exceeds 10 during a print job, the ID sensor pattern is
not created and read until after the print job completes.
After every 100 prints
• This number of prints can be adjusted with SP2973-01.
• When the number of prints exceeds 100 during a print job, the ID sensor pattern
is not created and read until after the print job completes.
• At this time, a halftone pattern is added to the standard ID sensor pattern. The
reading from this pattern, Vsm, is used with Vsg (Vsm/Vsg) to calculate the value
to be used to determine the amount of LD (laser diode) power adjustment
required. This method improves consistent greyscale reproduction, slows the
deterioration of the OPC drum, and reduces scatter.
After every 200 prints
• The halftone pattern is added to the standard ID sensor pattern every 200 prints.
This interval can be changed with SP2210-02 (Large Job).
• When 200 prints is reached, even if in the middle of a job, the ID sensor pattern
will be made. For example, if the job contains 1,100 sheets, the ID sensor
patterns will be made every 200 sheets, and at the end of the job.
When the front door of the machine is opened and closed
• The halftone pattern is added to the standard ID sensor pattern at this time also.

The following SP codes are also used for grayscale control. Refer to the SP code
table for full details.
SP Code Name What It Does
Grayscale Copy Interval Check Determines how often the halftone pattern
2973-01 is added to the standard ID sensor pattern.
Default setting: 100
Grayscale Upper Limit Sets the upper limit for LD adjustment
2972-01
based on the Vsm/Vsg calculation.
Grayscale Lower Limit Sets the lower limit for LD adjustment
2972-02
based on the Vsm/Vsg calculation.
Vsm/Vsg (Immediate Grayscale Displays value used to determine the LD
3103-04 Post-Pattern Output) power adjustment (Normally, Vsm/Vsg =
65% ~ 85%)

G065 6-20 SM
 DRUM CHARGE

6.6.4 DRUM CHARGE ROLLER CLEANING

[B]

[A]

G065D901.WMF

The drum charge roller [A], always in contact with the drum, get dirty easily, so the
brush roller [B] also remains in contact with the charge roller to clean it.

Descriptions
Detailed

SM 6-21 G065
 DEVELOPMENT

6.7 DEVELOPMENT
6.7.1 OVERVIEW

6
1

4 G065D401.WMF

1. Drum 5. Mixing Auger

2. Development Roller 6. Development Filter
3. Paddle Roller 7. Doctor Blade
4. TD Sensor

G065 6-22 SM
 DEVELOPMENT

6.7.2 DRIVE MECHANISM

The feed/development motor [A]
drives the development roller [B] [A]
through the gears and the paddle
roller gear [C].
The drive shaft engages and
disengages the paddle roller gear [B]
when the development unit is
inserted into and removed from the
machine.
NOTE: The development drive [C]
gears are helical gears,
quieter than normal gears.

G065D402.WMF

6.7.3 DEVELOPER MIXING

" [C]
[B]
!
[C]

" #
[A]
"
[D] $

Descriptions
Detailed

$
G065D403.WMF

The dual mixing roller consists of the outer paddle [A] and the inner auger [B].
The outer paddle moves developer to the front ! and supplies it to the
development roller. Developer that spills off by the doctor blade " passes through
the holes [C] in the outer paddle, and is transported to the rear # by the inner
auger.
While the dual mixing roller is moving the developer, some developer also passes
back to the development unit through the holes in the bottom of the paddle roller
$. New toner from the toner bottle and recycled toner from the toner collection coil
both enter the development unit at [D].

SM 6-23 G065
 DEVELOPMENT

6.1.4 DEVELOPMENT BIAS

Mechanism
Black areas of the latent image are at a
low negative charge (about -150 V) and
white areas are at a high negative [A]
charge (about –950 V). [D]
To attract negatively charged toner to
[B]
the black areas of the latent image on
the drum, the high voltage supply board
[A] applies a bias of –540 volts to the
development roller throughout the image
[C]
development process. The bias is
applied to the development roller shaft
[B] through the bias terminal spring [C]
G065D404.WMF
and bias terminal [D].
The development bias voltage (–540 V)
can be adjusted with SP2201 (Development Bias).

Correction for Paper Width and Thickness (By-pass Tray only)

The by-pass tray can be used for non-standard paper narrow than sizes accepted
by the paper trays. Thicker paper, OHP sheets, etc. can also be loaded in the by-
pass tray but adjustments must be performed with the SP modes listed below in
order to avoid jams and misfeeds.

SP Mode SP Name
SP2201-01 Development Bias Default: -540 V
SP2309-01 Paper Lower Width [a] Width limit. Default: 150 mm
SP2309-02 Paper Upper Width [b] Width limit. Default: 216 mm
SP2914-03 Process Control Setting (Bγ) Adjust 10 V/step. Default 210 V
SP2914-04 Process Control Setting (Bδ) Adjust 10 V/step. Default 50 V

The way that these SP modes are used is shown below.

SP2309-01 SP2309-02
0 mm Default: 150 mm Default: 216 mm 297 mm

Voltage: Voltage: Voltage:

SP2201-01 + SP2914-03 SP2201-01 + SP2914-04 SP2201-01
Default: –540 + 200 Default: –540 + 50 Default: –540

For example, with the default settings, if the paper width fed from the by-pass tray
is 200 mm, the development bias voltage will be –540 + 50 V.

G065 6-24 SM
 DEVELOPMENT

6.1.5 TONER SUPPLY

Toner Bottle Replenishment Mechanism

[F]
[H]
[G]

[D] [C]

[E]

[A]
[B]
G065D504.WMF

When the toner bottle is installed in the bottle holder [A], pin [B] slides up the side
of the PCU [C], pulling out the toner shutter [D]. When the toner bottle holder lever
[E] is returned to its original position, the cap [F] pulls away and is kept in place by
the chuck [G].

Descriptions
The toner bottle holder lever [E] cannot be lowered when a toner bottle is not Detailed
installed in the holder. This prevents toner falling out of the holder unit as a result
of lowering the handle with no toner bottle installed.
The toner bottle has a spiral groove [H], which rotates the bottle to move toner to
the development unit. When the bottle holder unit is pulled out, the chuck [G]
releases the toner bottle cap and the toner shutter [D] closes and blocks the
opening.

SM 6-25 G065
 DEVELOPMENT

Toner Supply Mechanism

The toner supply motor [A] rotates the [A]
toner bottle [B] and the mylar blades
[C] (see below).
[B]

G065D545.WMF

[C]
Toner falls into the toner bottle holder,
and the toner supply mylar blades [C]
transfer the toner to slit [D]. Installing
the PCU opens the shutter [E].
The toner falls into the development
unit through the slit.

[D] [E] G065D509.WMF

Toner Density Control

There are two modes for controlling and maintaining constant toner supply: sensor
control (both direct and indirect) and image pixel count control. The mode can be
changed with SP2208-01 (Toner Supply Mode).
NOTE: The factory setting is sensor control mode; image pixel count mode should
only be used temporarily until a defective TD or ID sensor can be replaced.

G065 6-26 SM
 DEVELOPMENT

Sensor Control Mode

In the sensor control mode, the amount of toner required to print the page is
calculated by the CPU; it adds up the image data value of each pixel and converts
the sum to a value between 0 and 255. (255 would mean a completely black page.)
The machine must vary toner supply for each print in order to maintain the correct
amount of toner in the developer and to account for changes in drum reflectivity
due to changes in temperature and humidity. The CPU uses data from the TD
sensor and ID sensor to determine whether or not the toner supply motor should be
switched on and to calculate how long it should remain on in order to supply more
toner to the mixture in the development unit.

TD Sensor
When new developer of standard toner concentration is installed, namely 20 g of
toner per 500 g of developer (4.0% by weight), the TD sensor must be set to its
initial setting of 4.0 V with SP2801. This initial setting is used as the toner supply
reference voltage or Vref. For every print cycle, the TD sensor directly checks the
toner density in the developer mixture, and after 10 copies these 10 readings are
averaged and this value becomes TD sensor output voltage Vt(10).
The machine compares Vt(10) with Vref. If Vt(10) is greater than Vref, the toner
concentration in the development unit judged to be low. When Vt(10) is detected to
be greater than Vref 20 times, then this indicates that the toner concentration is
consistently low, Vref is incremented by 0.1 V, and the conditions are checked
again. The result of this check determines the value of K, the toner supply rate
coefficient, which is one of the factors that is used in the toner supply motor on-
time calculation.

ID Sensor
In addition to comparing Vt(10) from the TD sensor and Vref, after every 10 copies
the ID sensor, located at the lower right area of the drum, checks both the
reflectivity (Vsg) and the pattern on the drum (Vsp), created by the laser diodes
and charge roller. If the reflected light is too strong, this indicates that toner is low

Descriptions
and toner is added to the development unit. (The frequency of these checks can be Detailed
adjusted with SP2210; see section 6.8.3. for full details.)

Image Pixel Count Mode

This mode should only be used only as a temporary measure while waiting for
replacement parts, such as a TD sensor. This mode controls the toner supply
amount using the same method for determining the toner bottle motor on time.
However, the values that were in effect when the toner density control mode was
changed over to image pixel count mode with SP2208-01 (Toner Supply Mode)
remain in effect and cannot be changed.

SM 6-27 G065
 DEVELOPMENT

6.1.6 TONER NEAR END/END DETECTION

Standard Method
The toner near-end condition is detected based on the Vt(10) output from the TD
sensor. If the difference between Vref (toner supply reference voltage) and Vt (10)
is less than or equal to –0.45, then toner concentration is judged be very low and K
(the toner supply coefficient) is set to 0.25, the machine enters the toner near end
condition and the machine switches on the toner supply motor.
If a difference greater than –0.45 is detected, then toner concentration is judged as
low but the machine does another test by comparing Vref and Vt (10). If the
machine determines that Vt (10) is greater than Vref 40 times, the toner supply
motor switches on and remains on for twice the time that Vt (10) was greater than
Vref. If the toner concentration is still low, then the machine enters the toner near
end condition.
The final toner end is detected using the ID sensor. If the ID sensor detects that the
ID sensor pattern is very light (Vsp drops below 2.0 V), then the sensor triggers the
toner end condition.
If Vsp is less than 2.0 V, the density of the ID sensor pattern is very light, so the
machine detects the toner end condition. However, if Vsp remains higher than 2.0
V but 90 copies have been made after toner near end was determined, the
machine enters the toner end condition.
NOTE: The number of copies between toner near-end and toner end can be
changed with SP2213. The default is 90 copies.

Adjustable Near-end Warning Method

By storing a value in SP2975, a near-end warning can be set up to appear on the
LCD when the toner supply motor has rotated for a certain amount of time from
after a new toner cartridge was installed. This allows the user to be prepared much
earlier than just 90 prints to change the cartridge. Refer to the SP table for more.

G065 6-28 SM
 DEVELOPMENT

6.1.7 TONER END RECOVERY

If the front door is opened and then closed while a toner near end/end condition
exists, the machine will attempt to recover. When the front door is closed, the toner
supply motor turns on to supply toner. The machine checks the TD sensor output 2
seconds after the main motor turns on (Vtp), and the sensor is checked again
every 1 second (Vtp1)
The machine detects the toner concentration using Vref, Vt (10), Vtp, and Vtp1. If
the toner concentration is still too low, the toner supply motor remains on for
another 10 seconds while the machine checks Vt. If toner concentration is judged
to be at the standard level, then the toner near end/end condition is cancelled and
K (toner supply coefficient) is reset. If toner concentration has not reached the
standard level, the toner supply motor rotates continuously until it does (maximum
motor on time is 16 seconds) and then it will switch off.

6.1.8 TONER SUPPLY WITH ABNORMAL SENSORS

The TD sensor is checked every print. If the readings from the TD sensor become
abnormal during a print job, the machine holds the GAIN factor constant (GAIN is
normally calculated from TD sensor readings) to allow toner supply to vary with
only pixel count for the rest of the print job. Then at the end of the print job, an SC
code is generated and the machine must be repaired.
The ID sensor is checked every 10 copies (see section 6.8.3 for full details on ID
sensor pattern intervals). If readings become abnormal, an SC code is generated
and the machine must be repaired. If this happens during a print job, Vref is not
changed, the print job is allowed to finish, and then the SC code is generated.
If spare parts are not available, the technician can use SP2208-1 to temporarily put
the machine in image pixel count mode. (☛ 5. Service Tables)

Descriptions
Detailed

SM 6-29 G065
 DRUM CLEANING AND TONER RECYCLING

6.8 DRUM CLEANING AND TONER RECYCLING

6.8.1 DRUM CLEANING
This machine employs a counter blade
system. After the image is transferred [D]
[A] [E]
to paper, a cleaning blade [A] removes
any toner remaining on the drum. The
toner collection coil [B] carries scraped
off toner to the toner collection plate
[C].
The collar [D] on the cleaning blade
bracket contacts the outer rim of cam
gear [E], which moves the cleaning
blade side to side. This side-to-side
movement disperses accumulated [C]
toner to prevent early blade edge wear
at one location. [B]
G065D902.WMF
The drum reverses about 5 mm after
every print job to remove particles on
the edge of the cleaning blade.

6.8.2 TONER RECYCLING

[A]
Toner collected by the toner collection
coil [A] is transported to the opening [B].
This toner falls into the development
unit with new toner coming from the
toner bottle. The paddle roller [C] mixes
the collected toner with the new toner.
NOTE: A screen filter [D] has been
added to strain out paper dust
and other foreign matter.

[D]

[C]
[B] G065D509.WMF

G065 6-30 SM
 PAPER FEED

6.9 PAPER FEED

6.9.1 OVERVIEW

5
4
3
2
1 6

16
7

15 8
9
10

11
14 13 17 12
20 19 18
G065D701.WMF

1. Upper pick-up roller 11. Lower paper lift sensor

2. Upper paper lift sensor 12. Lower pick-up roller
3. Upper paper feed roller 13. Lower paper size dial
4. Upper relay sensor 14. Lower paper size switch
5. Upper relay roller 15. Upper paper size dial

Descriptions
6. Upper separation roller 16. Upper paper size switch Detailed
7. Lower relay sensor 17. Upper paper height 2 sensor
8. Lower relay roller 18. Upper paper height 1 sensor
9. Lower paper feed roller 19. Lower paper height 2 sensor
10. Lower separation roller 20. Lower paper height 1 sensor

Each paper tray, which employs the FRR system, can hold 500 sheets. Two relay
sensors, positioned above each set of relay rollers, detect paper jams. A selection
dial allows you to select the setting for the size of the paper loaded in the tray.

SM 6-31 G065
 PAPER FEED

6.9.2 PAPER FEED DRIVE

[A]
The feed/development motor [A]
drives the pick-up and feed
mechanism of both the upper and [C]
second paper feed stations through
gears and the paper feed clutches
[B].
When the paper feed clutch turns on,
the pick-up roller, paper feed roller, [B]
and separation roller start rotating to
feed the paper. The paper feed
clutch stays on until shortly after the
registration sensor [C] actuates. G065D703.WMF

6.9.3 PICK-UP/SEPARATION ROLLER RELEASE

When the paper tray [A] is not inside
the machine, the separation roller [B] [C]
[E]
is away from the paper feed roller [C]
and the pick-up roller [D] stays in the
upper position.

[A]

[B]
G065D704.WMF

When the paper tray is set into the

machine, it pushes the release lever
[E]. This causes the pick-up roller [D]
to go down and the separation roller
[B] to move up and contact the paper
feed roller.

[D]

G065D763.WMF

G065 6-32 SM
 PAPER FEED

6.9.4 PAPER LIFT

[H] [E] [D]
The paper size switch [A] detects
when the paper tray [B] is set in the
machine, and the tray lift motor [C]
rotates, and the coupling gear [D] [A]
on the tray lift motor engages the [F]
pin [E] on the lift arm shaft [F]. Then
the tray lift arm [G] lifts the tray
bottom plate [H]. [G]

[B]
[C]

G065D702.WMF

When the paper tray is set in the [K] [J]

machine, the pick-up roller [I]
lowers. When the top sheet of paper
reaches the proper height for paper
feed, the paper pushes up the pick-
up roller, and the actuator [J] on the
pick-up roller supporter activates
the paper lift sensor [K] to stop the
tray lift motor.
After several paper feed cycles, the
[I]
paper level gradually lowers and the
paper lift sensor is de-activated.
G065D526.WMF
The tray lift motor turns on again

Descriptions
until this sensor is activated again. Detailed

When the paper tray is removed

from the machine, the tray lift motor
coupling gear disengages the pin
on the lift arm shaft, and the tray
bottom plate then drops under its
own weight.

SM 6-33 G065
 PAPER FEED

6.9.5 PAPER END DETECTION

If there is paper in the paper tray, the
paper end feeler [A] is raised by the [B]
paper stack, and the paper end
sensor [B] is deactivates.
When the paper tray runs out of
paper, the paper end feeler drops into
the cutout [C] in the tray bottom plate
and the paper end sensor is activated.

[A]

[C] G065D706.WMF

6.9.6 PAPER REGISTRATION

[D]
The registration drive roller [A] and
idle roller [B] correct the skew of [C]
the transferred paper to ensure that [F]
the leading edge of the paper is [E]
positioned correctly on the OPC.
[A]
The paper feed/development motor
[C] drives the registration
mechanism.
The registration sensor [E] is
[B]
positioned just before the
registration rollers. When the
leading edge activates the
G065D703.WMF
registration sensor, the registration
clutch is off and the registration
rollers are not turning.
However, the relay clutch [F] remains on slightly longer. This delay allows time for
the paper to press against the registration rollers and buckle slightly to correct
skew.
Next, the registration clutch [D] actuates and the relay clutch re-actuates at the
proper time to align the paper with the image on the drum. The registration rollers
then feed the paper to the image transfer section.
NOTE: The registration sensor is also used for paper misfeed detection.

G065 6-34 SM
 PAPER FEED

6.9.7 PAPER SIZE DETECTION

The paper size switch includes four microswitches. Actuators behind the paper size
dial actuate the sensors.
Each paper size has its own actuator, with a unique combination of notches. To
determine the paper size, the CPU reads which switches the actuator has turned
off.
The CPU disables paper feed from a tray if the paper size cannot be detected. If
the paper size actuator is broken, or if there is no tray installed, the printer control
board recognizes that the paper tray is not installed.
When the paper size actuator is at the “✻” mark, the paper tray can be set up to
accommodate one of a wider range of paper sizes by using one of the user tools
on the machine’s operation panel.

Models Paper Size Switch

North America Europe/Asia 1 2 3 4
81/2" x 13" Portrait A3 Portrait ON ON OFF ON
A4 Landscape A4 Landscape ON ON ON ON
A4 Portrait A4 Portrait ON OFF ON ON
11" x 17" Portrait A5 Portrait OFF OFF ON ON
81/2" x 14" Portrait 8" x 13" Portrait ON OFF OFF OFF
81/2" x 11" Portrait 81/2" x 11" Portrait ON ON OFF OFF
81/2" x 11" Landscape 81/2" x 11" Landscape ON OFF ON OFF
✻ ✻ ON ON ON OFF
ON: Pushed OFF: Not Pushed

Descriptions
Detailed

SM 6-35 G065
 PAPER FEED

6.1.8 PAPER HEIGHT DETECTION

Two paper height sensors [A] and [B], [B]
[A]
working in combination, detect the
Full
amount of paper in the tray.
When the amount of paper decreases,
the bottom plate pressure lever [C]
moves up and the actuator [D] mounted
on the same drive shaft as the pressure [D]
lever rotates. 31 5431

The following combinations of sensor

signals are sent to the printer controller. [C] Near Full

Amount of Paper Height Paper Height

Paper Sensor [A] Sensor [B]
Full OFF ON
Near Full ON ON 31 5431

Near End 1 ON OFF

Near End 2 OFF OFF
Near End 1

31 5431

Near End 2

31 64315

G065D707.WMF

G065 6-36 SM
 BY-PASS TRAY

6.10 BY-PASS TRAY

6.10.1 OVERVIEW

1 2
3

4
5

G065D510.WMF

1. Paper feed roller

2. Paper end sensor
3. Pick-up roller
4. By-pass tray

Descriptions
5. Separation roller Detailed

SM 6-37 G065
 BY-PASS TRAY

6.10.2 BY-PASS TRAY OPERATION

[A]

[B]
G065D500.WMF

[C]

[D]
[E] G065D501.WMF

The by-pass unit is directly driven by the machine through gear [A].
When the print key is pressed, the pick-up solenoid [B] turns on and the pick-up
roller [C] moves onto the paper. When the by-pass tray runs out of paper, the
paper end feeler [D] drops into the cutout in the by-pass tray and the paper end
sensor [E] is activated.

G065 6-38 SM
 BY-PASS TRAY

6.10.3 BY-PASS PAPER SIZE DETECTION

[A]

G065D522.WMF

11" 8 1/2 " 5 1/2 "

A3 B4 A4L B5L A5L B6L

G065D523.WMF

Descriptions
The paper size sensor board [A] monitors the paper width. Detailed
The rear side fence is connected to the terminal plate. The pattern for each paper
width is unique. Therefore, the machine determines which paper has been placed
in the by-pass tray by the signal output from the board. However, the machine does
not determine the paper length from the by-pass tray hardware.

SM 6-39 G065
 DUPLEX UNIT

6.11 DUPLEX UNIT

6.11.1 OVERVIEW

1 2
3

G065D101.WMF

1. Entrance sensor
2. Inverter gate
3. Inverter roller
4. Upper transport roller
5. Lower transport roller
6. Exit sensor

G065 6-40 SM
 DUPLEX UNIT

6.11.2 DUPLEX DRIVE LAYOUT

2
1

G065D103.WMF

1. Inverter roller
2. Inverter motor
3. Upper transport roller

Descriptions
4. Transport motor Detailed
5. Lower transport roller

SM 6-41 G065
 DUPLEX UNIT

6.11.3 DUPLEX BASIC OPERATION

To increase the productivity of the duplex unit, copies are printed as follows.

Larger than A4 Lengthwise/LT Lengthwise (SEF)

The duplex unit can store only one sheet of paper.
Example: 8 pages. The number [A] in the illustration shows the order of pages. The
number [B] in the illustration shows the order of sheets of paper (if
shaded, this indicates the second side).

[A]

2 ⇒ 1 ⇒ 4 ⇒ 3 ⇒ 6 ⇒ 5 ⇒ 8 ⇒ 7
1 1 2 2 3 3 4 4

[B] G065D530.WMF

Up to A4 Lengthwise/LT Lengthwise (SEF)

The duplex unit can store two sheets of paper
Example: 8 pages. The number [A] in the illustration shows the order of pages. The
number [B] in the illustration shows the order of sheets of paper (if
shaded, this indicates the second side).

[A]

2 ⇒ 4 ⇒ 1 ⇒ 6 ⇒ 3 ⇒ 8 ⇒ 5 ⇒ 7
1 2 1 3 2 4 3 4

[B] G065D531.WMF

G065 6-42 SM
 DUPLEX UNIT

6.11.4 DUPLEX UNIT FEED IN AND EXIT MECHANISM

[A]

[D]

[E]

[F]
[C]

[G]

G065D104.WMF G065D105.WMF

Feed-in
The inverter gate solenoid [A] stays off and the inverter rollers [B] rotate clockwise.
Descriptions
A sheet of paper is sent to the inverter section [C]. Detailed

NOTE: The cover guide has been eliminated in order to accommodate paper sizes
longer than A4/LT in the reverse feed path which has been lengthened in
the design of this machine.

Inversion and Exit

The inverter gate solenoid turns on and the inverter motor turns on in reverse
shortly after the trailing edge of the paper passes through the entrance sensor [D].
As a result, the inverter gate [E] is opened and the inverter roller rotates
counterclockwise. The paper is sent to the machine through the upper and lower
transport rollers [F, G].

SM 6-43 G065
 IMAGE TRANSFER AND PAPER SEPARATION

6.12 IMAGE TRANSFER AND PAPER SEPARATION

6.12.1 OVERVIEW

2 3

10 1

9 4

8 5

G065D561.WMF

1. Transfer belt 6. OPC

2. Drive roller 7. Pick-off pawls
3. Transfer belt cleaning blade 8. ID sensor
4. Transfer roller 9. Contact lever
5. Idle roller 10. Transfer belt contact clutch and
cam

G065 6-44 SM
 IMAGE TRANSFER AND PAPER SEPARATION

6.12.2 BELT DRIVE MECHANISM

After the main motor switches on [B]
during printing, the transfer belt [A]
contact clutch [A] switches on after [C]
[F]
a specified interval and the cam [F]
makes a half-turn to raise the [E]
contact lever [E] and bring the
transfer belt [D] into contact with the
drum.
The actuator [C], on the same axis
as the cam, and the transfer belt
position sensor [B] detect whether
the drum and transfer belt are in
contact. [D]
When the main motor is off, or when
the ID sensor pattern is being G065D563.WMF
measured, the transfer belt unit
separates from the drum.
The ID sensor pattern must not be
transferred to the belt. Also, the transfer belt and drum must not remain in contact
for too long, to prevent contamination of the drum with oil or other foreign material
from the transfer belt.

6.12.3 TRANSFER BELT UNIT CONTACT MECHANISM

The belt contact and release
mechanism consists of the belt [E]
contact clutch [A], cam [B], and [A]
contact lever [C]. The belt contact [B]

Descriptions
clutch turns on and the cam Detailed
attached to the clutch rotates half a [C]
complete rotation. The contact
lever, riding on the cam, is lifted up
and the springs [D] push the belt
into contact with the drum.
The transfer belt position sensor [E]
detects the home position of the
cam (this is when the belt is away
from the drum). The belt must be
released from the drum between
print jobs in order to prevent the ID [D]
sensor pattern from being rubbed
G065D563.WMF
off and to prevent contamination of
the drum from the surface of the
belt.

SM 6-45 G065
 IMAGE TRANSFER AND PAPER SEPARATION

6.12.4 IMAGE TRANSFER AND PAPER SEPARATION

MECHANISM
When the registration clutch switches on to
align the leading edge of the paper [A] with
the image on the drum [B], the transfer belt [C]
is [C] is away from the drum.

[B]

[A] G065D552.WMF

At the designated time after the main

motor switches on, the transfer belt
contact clutch switches on and the transfer
belt touches the drum.

G065D553.WMF

When the paper enters the gap between

the belt and the drum, the high voltage
supply board [D] applies a high positive
current to the belt to transfer the image to [D]
the paper.
After receiving the image from the drum,
the paper is fed by the belt. The paper
moves to the end of the transfer belt unit,
where it separates from the belt as the belt
curves away and the paper moves on to
the fusing unit.
G065D521.WMF

G065 6-46 SM
 IMAGE TRANSFER AND PAPER SEPARATION

6.12.5 TRANSFER BELT CHARGE

Mechanism

[C]
[B] [A]

[D]
[E]

G065D564.WMF

The high voltage supply board [A] applies a positive current to the transfer belt [B]
through the terminal block [C], terminal plate [D], and the bias roller [E].
The high voltage supply board adjusts the current to the roller to keep a small but
constant current flow to ground through the belt, paper, and drum. If this current is
Descriptions
not kept constant, efficiency of toner transfer and paper separation will vary with Detailed
paper thickness, type, environmental condition, or changes in transfer belt surface
resistance.

SM 6-47 G065
 IMAGE TRANSFER AND PAPER SEPARATION

Correction for Paper Width and Thickness

A range of SP modes is available in order to adjust the machine so it can handle
papers of non-standard size and thickness.
For paper width, there are two thresholds. The factory settings are 150 mm (5.9”)
and 216 mm (8.5”). Below 216 mm, the transfer current can be increased. By
default, the current is multiplied by 1.2 for the main machine paper trays. For paper
widths below 150 mm, the transfer current can be set higher, but by default it is
kept the same as the current for paper widths below 216 mm. The higher current
allows for the tendency of the current to flow directly from the transfer belt to the
drum and not through the paper which could cause an insufficient amount of toner
to transfer to narrow width paper.
Thick paper must be fed from the by-pass tray because SP modes are available
only for the by-pass tray in order to accommodate thick paper. By default, the
current for paper narrower than 216 mm is 1.5 times the normal current.
This illustration shows the SP modes, which control these currents. The base
transfer current (‘current’ in the diagram) depends on SP2301. This is different for
various parts of the image, and is different for the by-pass tray; see the next page
for details.

SP2-309-1 SP2-309-2
0 Default: 150 mm Default: 216 mm 297 mm

Paper Tray
SP2-309-3 SP2-309-4
Current x 1.0
Current x 1.2 Current x 1.2

By-pass Tray
SP2-309-5 SP2-309-6
Current x 1.0
Current x 1.5 Current x 1.5

G065D571.WMF

G065 6-48 SM
 IMAGE TRANSFER AND PAPER SEPARATION

Transfer Currents to Leading Edge and Image Areas

Transfer current can also be adjusted for the leading edge and the image area, and
for by-pass feed. The timing for starting to apply leading edge current, for the
switchover from leading edge current to image area current, and for switching off at
the trailing edge can also be changed.
The table below lists the SP modes you can use to adjust these settings.

SP2301 Transfer Current Adjustment

Image areas SP2301-01 1st Side of Paper
SP2301-02 2nd Side of Paper
SP2301-04 By-pass Feed
Leading edge areas SP2301-03 Leading Edge
SP2301-05 Leading Edge By-pass Feed
SP2911 Transfer Current Timing
Timing SP2911-01 On Timing at Leading Edge
SP2911-02 Switch Timing from Leading Edge
to Image Area
SP2911-03 Off Timing at Trailing Edge

Descriptions
Detailed

SM 6-49 G065
 IMAGE TRANSFER AND PAPER SEPARATION

6.12.6 TRANSFER BELT CLEANING MECHANISM

[A]

[C]

[B]

G065D524.WMF

The cleaning blade [A], always in contact with the transfer belt, scrapes off toner
and paper dust remaining on the transfer belt.
Scraped off toner and paper dust falls into the toner collection tank [B] in the
transfer belt unit. This toner is not recycled. When the toner overflow sensor [C]
detects toner overflow, the toner overflow indicator lights. Up to 999 copies can be
made before the toner overflow condition shuts down the machine.

G065 6-50 SM
 IMAGE FUSING AND PAPER EXIT

6.13 IMAGE FUSING AND PAPER EXIT

6.13.1 OVERVIEW

1 2 3 4

18

5
17
6

16 7

8
15
9
14
10
13
12 11
G065D601.WMF

1. Paper exit sensor 10. Cleaning roller

2. De-curler rollers 11. Entrance guide
3. Junction gate 12. Fusing lamp (center)

Descriptions
4. Idle roller (duplex unit) 13. Fusing lamp (ends) Detailed
5. Fusing unit exit sensor 14. Thermistors (central/end)
6. Spring 15. Thermostat (central/end)
7. Fusing exit guide plate 16. Hot roller
8. Pressure roller 17. Hot roller strippers
9. Pressure arm 18. Exit roller

SM 6-51 G065
 IMAGE FUSING AND PAPER EXIT

6.13.2 FUSING DRIVE [A]

The fusing/paper exit motor [A] [C]
drives the fusing unit through the [E]
clutch [B] and the gears [C], and
also drives the paper exit rollers [D]
through a gear and a timing belt [E]. [D]
[B]

G065D903.WMF

6.13.3 FUSING ENTRANCE GUIDE SHIFT MECHANISM

The entrance guide [A] has two
holes on each side to adjust for
paper thickness to prevent creasing.
Normally, the left screw hole [C] on
each side is used.
For thin paper, use screw holes [B]
to move the entrance guide to the
left. This setting allows more direct
access to the gap between the hot
and pressure rollers, and prevents
thin paper from buckling against the
hot roller which can cause blurring
[C]
at the leading edge of the print.
[B]
[A]
G065D610.WMF

G065 6-52 SM
 IMAGE FUSING AND PAPER EXIT

6.13.4 EXIT GUIDE PLATE AND DE-CURLER ROLLERS

The exit guide plate [A] also functions
[D] [C]
as a pressure roller stripper. The exit
guide plate can be moved in order to
remove jammed paper. [B]
Stacking has been improved by
mounting a face-curl correction
mechanism at the paper exit roller.
Two de-curler rollers [B] and [C] have
[A]
been added under the exit roller [D] to
correct the curl that paper acquires
during transport through the fusing unit.

G065D601.WMF

6.13.5 PRESSURE ROLLER

[D]
The pressure springs [A] apply constant [A]
[E]
pressure between the hot roller [B] and
the pressure roller [C]. The applied
pressure can be changed by adjusting
the position of the pressure springs.
The left position [D] is the normal
setting, and the right position [E]
increases the pressure to prevent [B]
insufficient fusing by the fusing unit.

Descriptions
[C] Detailed
G065D663.WMF

6.13.6 CLEANING MECHANISM

The cleaning roller [A], in constant
contact with the pressure roller [B],
[B]
collects toner and paper dust from the
surface of the pressure roller. Because
the cleaning roller is metal, it can collect
adhering matter better than the
pressure roller, which is coated with [A]
Teflon.

G065D515.WMF

SM 6-53 G065
 IMAGE FUSING AND PAPER EXIT

6.13.7 FUSING TEMPERATURE CONTROL

There are two fusing lamps: the first
fusing lamp (center: 650 W) [A] [D]
heats the center of the hot roller,
and the second fusing lamp (ends:
[C]
550 W) [B] heats both ends of the
hot roller. This arrangement
ensures even heat on all surfaces [B]
of the roller.
In order to control the temperature
of the roller, two high response
thermistors are attached to the unit,
one near the center [C] and one at [A] G065D602.WMF
the end [D] of the hot roller.

Temperature Control

°C
Fusing Temp.
200
185°C
180°C
155
150
Center
End
100
Center

50
End

Main SW ON Re-load
G065D519.WMF

There are two types of temperature control: On/off control (Default), and Phase
control.
Either mode can be selected with SP1104 (Fusing Temperature Control).
After the machine is powered on, the CPU checks the ac frequency for 500 ms, in
case phase control is selected later for the temperature control, and then switches
on the fusing lamp.
As soon as both the center and end thermistors detect the print ready temperature
(also known as the “re-load” temperature) , the machine can operate. The “reload”
temperature is 30°C below the fusing temperature (this depends on SP1105-05,
06). As soon as the thermistors detect the fusing temperature, the CPU switches
the lamps off but frequently switches on/off again in order to maintain the fusing
temperature.

G065 6-54 SM
 IMAGE FUSING AND PAPER EXIT

Fusing Idling Temperature

If copies are not sufficiently fused soon after the main power switch is turned on,
fusing idling should be enabled with SP1103-01.
When fusing idling is enabled, it is done when the temperature reaches the re-load
temperature. The re-load temperature can be adjusted with SP1105-05, 06.
In the opposite case, even if fusing idling is disabled, it is done if the temperature at
power-up ≤ 15°C
The fusing idling time is as follows.

Fusing Idling Mode

Temperature at power-on
0: Disabled 1: Enabled SP1103-01
15°C or less 30 s 30 s
SP1103-02
Higher than 15°C Not done 30 s

6.13.8 OVERHEAT PROTECTION

If the hot roller temperature becomes greater than 250°C, the CPU cuts off the
power to the fusing lamp, and SC543 (Fusing Overheat Error) will be displayed.
Even if the thermistor overheat protection fails, there is a thermostat in series with
the common ground line of the fusing lamp. If the temperature of the thermostat
reaches 210°C, the thermostat opens, removing power from the fusing lamp. At the
same time, the machine stops operating. At this time, SC542 (Fusing Temperature
Warm-up Error) will be displayed.

Descriptions
Detailed

SM 6-55 G065
 ENERGY SAVER MODE

6.14 ENERGY SAVER MODE

If the printer remains idle for the selected time interval, the machine automatically
enters the energy saver mode and switches off the fusing lamps to reduce power
consumption.
The customer can select the idle time interval or switch the energy saver mode off.
The Energy Saver selector setting is in the System menu, which can be accessed
at the printer operation panel.

User Tool Settings

Energy Saver On/Off On (default)
1 minute (default), 5 minutes, 15 minutes, 30 minutes, 45
E.Saver Time
minutes, 60 minutes

• After the machine remains idle for the specified time, the CPU switches off the
fusing lamps.
• The machine leaves the energy saver mode and returns to normal operation
when any key on the operation panel is pressed, when the printer receives a
print job from the computer, or after the printer is switched off and on.
• The time from receiving the print start command to making the first print is longer
than when powering up from normal standby mode.
For details, see the Operating Instructions.

G065 6-56 SM
BRIDGE UNIT
B397
 SPECIFICATIONS

1. OVERALL MACHINE INFORMATION

1.1 SPECIFICATIONS
Paper Size: Standard sizes
A6 lengthwise to A3
HLT to DLT
Non-standard sizes
Width: 100 to 305 mm
Length: 148 to 432 mm
Paper Weight: 52 g/m2 ~ 135 g/m2, 16 lb ~ 42 lb

Bridge Unit
B387

SM 7-1 G065
MECHANICAL COMPONENT LAYOUT

1.2 MECHANICAL COMPONENT LAYOUT

1 2

3
6 5 4
A688V500.WMF

1. Upper Exit Roller 5. Relay Sensor

2. Junction Gate Solenoid 6. 2nd Transport Roller
3. Junction Gate 7. Left Exit Roller
4. 1st Transport Roller

G065 7-2 SM
 ELECTRICAL COMPONENT LAYOUT

1.3 ELECTRICAL COMPONENT LAYOUT

1

3
7
4

6
5 A688V501.WMF

1. Left Guide Switch 5. Tray Exit Unit Switch

2. Right Guide Switch 6. Junction Gate Solenoid
3. Tray Exit Sensor 7. Relay Sensor
4. Cooling Fan Motor

1.4 ELECTRICAL COMPONENT DESCRIPTION

Symbol Name Function Index No.
Motors
M1 Cooling Fan Cools the transport unit. 4

Sensors
S1 Tray Exit Checks for misfeeds. 3
S2 Relay Checks for misfeeds. 7
Bridge Unit

Switches
B387

SW1 Tray Exit Unit Detects when the tray exit unit is opened. 5
SW2 Right Guide Detects when the right guide is opened. 2
SW3 Left Guide Detects when the left guide is opened. 1

Solenoids
Junction Gate Moves the junction gate to direct the paper
SOL1 6
to the upper or left tray.

SM 7-3 G065
DRIVE LAYOUT

1.5 DRIVE LAYOUT

2
1

A688V502.WMF

1. Left Exit Roller 3. Upper Exit Roller

2. 2nd Transport Roller 4. 1st Transport Roller

G065 7-4 SM
 JUNCTION GATE MECHANISM

2. DETAILED DESCRIPTION
2.1 JUNCTION GATE MECHANISM

[C]
[B]

[A]
[D]
A688D500.WMF

Depending on the selected mode, the copies are directed up or down by the
junction gate [A], which is controlled by the junction gate solenoid [B].
When the upper tray is selected, the junction gate solenoid turns on and the paper
is sent to the upper tray through the upper exit roller [C].
When the left tray or the finisher is selected, the junction gate stays off and the
paper is sent to the left tray or the finisher through the transport rollers [D] and the
left exit roller.

Bridge Unit
B387

SM 7-5 G065
EXIT SENSOR REPLACEMENT

3. REPLACEMENT AND ADJUSTMENT

3.1 EXIT SENSOR REPLACEMENT

[B]
[A]

A688R500.WMF

[D]
[C]
A688R501.WMF

1. Remove the whole unit from the copier.

2. Remove the rear upper cover [A] (1 screw).
3. Remove the upper cover unit [B] (2 screws, 2 connectors).
4. Remove the exit guide plate [C] (2 screws).
5. Replace the exit sensor [D] (1 connector).

G065 7-6 SM
SPECIFICATIONS
 SPECIFICATIONS

SPECIFICATIONS
1. GENERAL SPECIFICATIONS
Configuration: Desktop
Print Process: Laser beam scanning and electro-photographic printing
Dual component development
Printing Speed: Max. 45 ppm, A4, 81/2" x 11", LEF, simplex/duplex
Parallel Interface: I/F: 36-pin connector, standard
Mode: IEEE 1284 compatible, ECP, Nibble
Network: Topology: Ethernet 10BASE-T/100BASE-TX
Protocol: IPX/SPX, TCP/IP, AppleTalk, IPP, NetBEUI
Cable: 10BASE-T/100BASE-TX shielded twisted pair
Resolution: 600 dpi: PCL5e, PCL6, PostScript 3
300 dpi: PCL5e
Printer Language: PCL5e, PCL5e emulation, PCL6 (5e+XL) emulation, Adobe
Postscript Level 3, RPCS
Resident Fonts: PCL5e, PCL6: 35 Intellifonts, 10 TrueType, 1 Bitmap
PostScript: 136 Adobe Type 1 Fonts
Printing Paper Size: Paper Cassettes: A3/DLT ~ A5 SEF/ HLT SEF
By-pass Tray: A3/DLT ~ A6 SEF
Power Source: 220 ~ 240 V, 50/60 Hz, 8 A or more
120 V, 60 Hz, 12 A or more

Power Consumption 120 V (North America) 220 ~ 240 V (Europe)

(Printer only): Maximum 1,280 W or less 1,350 W or less
Printing 770 W or less 790 W or less
Energy Saver 8 W or less 9 W or less
Power Consumption 120 V (North America) 220 ~ 240 V (Europe)
(Full system): Maximum 1,400 W or less 1,450 W or less
Printing 850 W or less 870 W or less
Energy Saver 8 W or less 9 W or less
Power Consumption Printer Only Full System
(Full system): Sound Power Level
Printing 70 dB (A) 74 db (A)
Standby 42 dB (A) —
Note: The above measurements were made in accordance with ISO 7779 at the operation
position. “Full System” includes the printer with a finisher and large capacity tray (LCT)
installed.

Dimensions (W x D x H): Printer (By-pass tray closed):

670 x 640 x 560 mm (26.4" x 25.2" x 22.0")
Temperature: Operating:
10°~32°C (50°~89.6°F), 15%~80% rH (no condensation)
Storage:
30°C ~ 40°C (22°~104°F), less than 80% rH (no condensation)
Specifications

Weight: 63 kg (138.9 lb.)

Warm-up Time Less than 20 s at 20°C (68°F)
(Standard):
Paper Output Capacity: 500 sheets (80g/m2, 20 lb.)
Memory: 64 MB (standard), expandable up to 320 MB

SM 8-1 G065
SPECIFICATIONS

2. SUPPORTED PAPER SIZES

Paper Tray Unit By-pass Tray LCT Duplex
Name Feed Size (W x L)
NA EU NA EU NA/EU NA\EU
A3 SEF 297 x 420 mm * D * * N Y
B4 SEF 257 x 364 mm * * * * N Y
A4 SEF 210 x 297 mm D D * * N Y
A4 LEF 297 x 210 mm D D * * D Y
B5 SEF 182 x 257 mm * * * * N Y
B5 LEF 257 x 182 mm * * * * N Y
A5 SEF 148 x 210 mm * D * * N Y
A5 LEF 210 x 148 mm N N * * N N
B6 SEF 128 x 182 mm N N S S N N
B6 LEF 182 x 128 mm N N N N N N
A6 SEF 105 x 148 mm N N * * N N
A6 LEF 148 x 105 mm N N N N N N
DLT SEF 11 x 17 in. D * * * N Y
Legal SEF 81/2 x 14 in. D * * * N Y
Letter SEF 81/2 x 11 in. D D * * N Y
Letter LEF 11 x 81/2 in. D D * * D Y
Half Letter SEF 51/2 x 81/2 in. * * * * N Y
Half Letter LEF 81/2 x 51/2 in. N N N N N N
Executive SEF 71/2 x 101/2 in. * * * * N Y
Executive LEF 101/2 x 71/2 in. N N * * N N
F/GL SEF 8 x 13 in. * * * * N Y
Foolscap SEF 81/2 x 13 in. D * * * N Y
Folio SEF 81/2 x 13 in. * * * * N Y
Com10 SEF 41/2 x 91/2 in. N N Y Y N N
Monarch SEF 3.875 x 7.5 in. N N N N N N
C6 SEF 114 x 162 mm N N Y Y N N
C5 SEF 162 x 229 mm N N Y Y N N
DL Env. SEF 110 x 220 mm N N Y Y N N
Custom SEF 100 ~ 297 mm N N S S N N
Custom LEF 148 ~ 432 mm N N S S N N

Notes: D: Paper size specified with dial.

*: Paper size specified from operation panel after dial is set to >.
S: Paper size entered on operation panel.
Y: Supported.
N: Not supported.

G065 8-2 SM
 SPECIFICATIONS

3. SOFTWARE ACCESSORIES
Printer drivers and utility software are provided on one CD-ROM. An automatic run
installer allows you to select which components to install.

3.1 PRINTER DRIVERS

Printer Language Windows 95/98/Me Windows NT4.0 Windows 2000 Macintosh
PCL6 Yes Yes Yes No
PCL5e Yes Yes Yes No
PostScript 3 Yes Yes Yes Yes
RPCS Yes Yes Yes No

NOTE: 1) Windows NT 4.0 printer drivers are for the Intel x 86 platform. There is
no Windows NT 4.0 printer driver for the PowerPC, Alpha, or MIPS
platforms.
2) PS3 drivers are all genuine Adobe PostScript drivers, excluding
Windows 2000 which uses Microsoft PS. A PPD file for each operating
system is provided with the driver.
3) The PostScript 3 driver for the Macintosh supports Mac OS 7.6 or later.
4) The supported Unix versions change from time to time, so please
consult service support staff for the latest information.

3.2 UTILITY SOFTWARE

Software Description
Agfa Font Manager Font management utility with screens fonts for printer.
(Windows 95/98/Me/, NT40.0, 2000
Smart NetMonitor for Client Printer management utility for client users. Also
(Windows 95/98/Me, NT4.0, 2000) includes peer-to-peer printing utility and
parallel/recovery printing.
Desktop Binder V2 Lite Utility for document management.
(Windows 95/98/Me, NT4.0, 2000)
Printer Utility for Macintosh Provides several convenient functions for printing
from Macintosh clients.
Specifications

SM 8-3 G065
SPECIFICATIONS

4. MACHINE CONFIGURATION
4.1 SYSTEM COMPONENTS

10
9
8
11

6
12
7

13
1

2
4 3
G065V502.WMF

No. Item Machine Code

1 Printer G065
2 LCT (option) A683
3 Paper Tray Unit (option) G520
4 Nine-bin Mailbox (option) G909
5 3000-sheet Finisher (option) A697
6 1000-sheet Finisher (option) A681
7 Mailbox Bridge Unit (option) G912
Punch Unit (option for 3000-sheet Finisher) A812-17 (3-hole)
8
A812-27 (2-hole)
9 Bridge Unit (option) B397
10 HDD (option) G334
11 DIMM 64/128/256 MB (option) G330/G331/G332
12 Barcode Font DIMM (option) G627
13 IEEE 1394 Interface (option) G336

NOTE: The Bridge Unit is required for the finisher (1000 or 3000-sheet), and for
the mailbox.

G065 8-4 SM
 SPECIFICATIONS

4.2 INSTALLABLE OPTION TABLE

Option Note
Paper Tray Unit O
Large Capacity Tray (LCT) V Requires Paper Tray Unit.
By-pass Feed Unit P
Duplex Unit P
Bridge Unit O
1000-Sheet Finisher Requires Paper Tray Unit, Bridge Unit
V
(also Mailbox Bridge Unit if Mailbox is present)
3000-Sheet Finisher Requires Paper Tray Unit, Bridge Unit
V
(also Mailbox Bridge Unit if Mailbox is present)
Punch Unit V Requires 3000-sheet Finisher
Mailbox Requires Bridge Unit, Paper Tray Unit
V
(also Mailbox Bridge Unit if a Finisher is present)
Mailbox Bridge Unit V Requires Mailbox.

P: Standard
O: Available
V: Requires another option

Specifications

SM 8-5 G065
SPECIFICATIONS

5. OPTIONS
5.1 BRIDGE UNIT
Paper Size: Standard:
A6 Lengthwise (SEF) to A3, HLT to DLT
Non-Standard:
Width: 100 to 305 mm
Length: 148 to 432 mm
Paper Weight: 52 g/m2 ~ 135 g/m2, 16 lb. ~ 42 lb.

5.2 1000-SHEET FINISHER

Paper Size: Staple Mode Off: A3 to A6 (L)
DLT to HLT (L)
Staple Mode On: A3, B4, A4, B5
DLT to LT
Paper Weight: Staple Mode Off: 52 ~ 157 g/m2 (14 ~ 42 lb.)
Staple Mode On: 64 ~ 80 g/m2 (17 ~ 20 lb.)
Stapler Capacity: 20 sheets (A3, B4, DLT, LG)
30 sheets (A4, B5, LT)
Paper Capacity: Staple Mode Off:
1,000 sheets (A4/LT or smaller: 80 g/m2, 20 lb.)
500 sheets (A3, B4, DLT, LG: 80 g/m2, 20 lb.)
Staple Mode On:
(80 g/m2, 20 lb., number of sets)
Set Size 2 to 10
11 to 20 21 to 30
Size 2 to 5 6 to 10
A4/LT (S)
100 85 40 25
B5 (S)
A4/LT (L) 50 25 15
A3, B4, DLT, LG 50 25 —
Staple Positions 1
Staple Replenishment: Cartridge (3,000 staples/cartridge)
Power Source: 24 Vdc, 5 Vdc (from the copier/printer)
Power Consumption: 48 W
Weight: 21 kg (46.3 lbs)
Dimensions(W x D x H): 568 mm x 520 mm x 625 mm (22.4" x 20.5" x 24.6")

G065 8-6 SM
 SPECIFICATIONS

5.3 3000-SHEET FINISHER

Paper Size:
Punch Mode Off: Shift Tray: A3 to B5/DLT to LT (B6 lengthwise (SEF), shift
mode off, staple mode off)
Upper Tray: A3 to A6 lengthwise (SEF)/DLT to HLT
Punch Mode On: 2 holes: A3 to A5/DLT to LT
3 holes: A3, B4, A4, B5, DLT, LT all sideways (LEF)
Paper Weight:
Punch Mode Off: Staple mode Off: 52 g/m2 ~ 157 g/m2, 14 ~ 42 lb.
Staple mode On: 64 g/m2 ~ 80 g/m2, 17 ~ 21 lb.
Punch Mode On: 2 holes: 52 g/m2 ~ 128 g/m2, 14 ~ 34 lb.
3 holes: 52 g/m2 ~ 105 g/m2, 14 ~ 28 lb
Tray Paper Capacity: Shift tray/no staple mode (80 g/m2, 20 lb):
Punch mode No punch mode
A4 sideways (LEF)
2,500 sheets 3,000 sheets
LT sideways (LEF)
Other sizes 1,500 sheets 1,500 sheets
2
Shift/staple mode/punch mode (80 g/m , 20 lb.)
Pages/set Sets
B5, A4 lengthwise (SEF) 2 to 9 150
LT lengthwise (SEF) 10 to 40 150 to 37
A4 sideways (LEF) 2 to 9 150
LT sideways (LEF) 10 to 40 250 to 63
Other sizes 2 to 9 100
10 to 25 150 to 60
Shift/staple mode/no punch mode (80 g/m2, 20 lb.)
Pages/set Sets
B5, A4 lengthwise (SEF) 2 to 9 150
LT lengthwise (SEF) 10 to 50 150 to 30
A4 sideways (LEF) 2 to 9 150
LT sideways (LEF) 10 to 50 300 to 60
Other sizes 2 to 9 100
10 to 30 150 to 50
Shift/staple mode/no punch mode (80 g/m2, 20 lb.)
Punch mode No punch mode
A4/LT or smaller 200 sheets 250 sheets
Larger than A4/LT 50 sheets 50 sheets

Stapler Tray Capacity: Pages/set, 80 g/m2, 20 lb.

Punch mode No punch mode
A4/LT or smaller 40 sheets 50 sheets
Larger than A4/LT 25 sheets 30 sheets

Staple Position: 1 staple: 3 positions (Front, Rear, Rear-Oblique)

2 staples: 1 position
Staple Replenishment: Cartridge (5,000 staples)
Specifications

Power Source: 24 Vdc (from printer)

Power Consumption: 48 W
Weight: 45 kg (99 lb.)
Size (W x D x H): 625 x 545 x 960 mm (24.6" x 21.5" x 37.8")

SM 8-7 G065
SPECIFICATIONS

5.4 LARGE CAPACITY TRAY (LCT)

Paper Size: A4 sideways (LEF)/LT sideways (LEF)
Paper Weight: 60 g/m2 ~ 105 g/m2, 16 lb. ~ 28 lb.
Tray Capacity: 1,500 sheets (80 g/m2, 20 lb.)
Remaining Paper Detection: 5 steps (100%, 75%, 50%, 25%, Near end)
Power Source: 24 Vdc, 5 Vdc (from copier)
Power Consumption: 40 W
Weight: 17 kg (37.4)
Size (W x D x H): 390 mm x 500 mm x 390 mm (15.5" x 19.7" x 15.4")

5.5 MAILBOX
Number of Trays: 9 trays + proof tray
Tray Capacity: Trays and proof tray: 100 sheets (80 g/m2, 20 lb.)
Paper Size for Trays: Trays:
Max.: A3 or 11" x 17"
Min.: A5 (S) or 11" x 81/2"
Proof tray:
Max.: A3 or 11" x 17"
Min.: A6 (SEF) or 11" x 81/2"
Paper Weight: Trays: 60 ~ 90 g/m2 (16 ~ 24 lb.)
Proof tray: 52 ~ 157 g/m2 (14 ~ 42 lb.)
Power Consumption: 48 W or less (average)
Power Source: DC24 V, 5 V (from the main unit)
Dimensions (W x D x H): 600 mm x 550 mm x 960 mm (23.6" x 21.7" x 37.8")
Weight: 40 kg (88.2 lb)

5.6 PAPER TRAY UNIT

Paper Size: A5 lengthwise (SEF) to A3
HLT lengthwise (SEF) to DLT
Paper Weight: 64 g/m2 ~ 105 g/m2 (20 lb. ~ 28 lb.)
Tray Capacity: 500 sheets (80 g/m2, 20 lb. )
Paper Feed System: FRR
Paper Height Detection: 4 steps (100%, 70%, 30%, Near end)
Power Source: 24 Vdc, 5 Vdc (from the copier)
120 Vac: 115 V version (from the copier)
220 ~ 240 Vac: 224/240 V version (from the copier)
Power Consumption: 50 W
Weight: Less than 25 kg (55.1 lb.)
Size (W x D x H): 540 mm x 600 mm x 270 mm (21.3" x 23.6" x 10.6")

G065 8-8 SM
TECHNICAL SERVICE BULLETINS
 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 001 04/30/2002
APPLICABLE MODEL:
MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45
Note: This copy is intended as a master original

SUBJECT: G065 LOCKUPS WHILE USING THE NETWORK

for reproduction of additional bulletins.

„
FIRMWARE
SYMPTOM:
The printer may hang up while using a local area network under the follow conditions:

• The G065 is connected to a repeater HUB (non-switching HUB).

• The network is very busy.

CAUSE:
When the Rx FIFO of the controller board overflows, the controller board sets the overflow flag and stops
receiving.

SOLUTION:
To prevent the machine from hanging up, the controller firmware has been modified from version 1.02 to
version 1.04.

The controller firmware version 1.04 or higher (G065_Controller_VERD.EXE) can be downloaded through
the Technology Solution Center FTP Site http://tsc.ricohcorp.com.

NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the
FTP Internet Web Site and EPROM / Flash Card Exchange program.

UNITS AFFECTED:
G065 serial numbers cut-in are not available at time of publication.

Copyright  2002 RICOH Corporation. All rights reserved. CONTROL NO 129ABW

 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 002 02/03/2003
APPLICABLE MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45

„
Note: This copy is intended as a master original

SUBJECT: NOTICE FOR TONER BOTTLE INSTALLATION

INFORMATION
GENERAL
for reproduction of additional bulletins.

GENERAL:
We would like to inform you of this symptom as a potential concern related to the toner bottle installation.

SYMPTOM:
When a new toner bottle is shaken with the cap in the unscrewed position, the inner cap pops off.
This may occur under the following conditions:
1. The toner bottle has been stored for a long period of time in a low temperature environment (such as in
an unheated warehouse during the winter).
2. The temperature around the toner bottle suddenly increases by more than 25 degrees Celsius.
3. The toner bottle has been installed between 1 to 9 hours after one or both of the above conditions have
occurred.

CAUSE:
The source of the symptom is as follows:
1. The toner bottle has been stored at a very low temperature. Therefore, the air in the bottle cools and the
bottle's internal air pressure decreases.
2. Outside air slowly leaks into the bottle until the bottle’s internal pressure is equal to the atmospheric
pressure.
3. The bottle has been moved to a warmer environment (with a temperature variation of over 25ºC.).
Therefore, the air in the bottle warms and the internal pressure increases.
4. When the bottle cap has been removed, internal air pressure pops off the inner cap.

NOTE: This problem does not occur for toner bottles that have been stored at normal room temperatures.

Continued...

Copyright  2003 RICOH Corporation. All rights reserved.

Tech Service Bulletin No. G065 – 002
Page 2 of 2

SOLUTION:
The toner bottle has been modified to change the opening process.

ACTION:
1. When moving toner bottles from a very low temperature environment to a much higher temperature
environment, store the bottles for more than 1 day before usage. This will allow the bottle's internal
pressure to equalize with the atmospheric pressure.
2. If it is not possible to take the above action, please perform the following steps before installing the toner
bottle.
3. Hold the toner bottle upright. (Do not shake it.)
4. Loosen the bottle cap (do not remove the cap completely at this time) and hold down the cap for more
than 20 seconds (to prevent the cap from coming off).
5. Remove the cap and the inner cap slowly. (To reduce the air pressure in the toner bottle)
6. Reinsert the inner cap into the bottle and then install the bottle in the machine.
 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 003 02/03/2003
APPLICABLE MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45
Note: This copy is intended as a master original

SUBJECT: NOISE GENERATED FROM BY-PASS FEED SECTION

for reproduction of additional bulletins.

„
MECHANICAL
SYMPTOM:
Noise from by-pass Feed Section

CAUSES:
• Noise generated by vibration of the Electrical Clutch Feed Shaft and Drive Gear:
• Noise from the Bushing of the Driven Roller Shaft:

„
PARTS
SOLUTION:
The following changes have been made to reduce noise.

1. To support the free end of the shaft a bushing has been added:
• The Length of the Feed Shaft has been changed from 229mm to 249mm.
• A Bushing and e-ring has been added.
• The shape of the Tightening Bracket has been modified to accommodate the
new bushing (hole added).

2. To hold the clutch firmly in place:

• A roller has been added to apply pressure against the clutch.
• A Pressure Plate was also added.

3. The material of the bushing has been changed.

Continued…

Copyright  2003 RICOH Corporation. All rights reserved.

Technical Service Bulletin No. G065 - 003
Page 2 of 4

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA140660 AA140753 Feed Shaft 1-1 3/S 11 21
A2326061 G0656801 Tightener Bracket 1-1 3/S 11 38
A2326057 G0656800 Bracket-by-pass Feed Drive 1-1 1 11 41
A2326065 G0656802 Rail By-pass Feed 1-1 3/S 11 39
- GA080002 Bushing – 6mm 0-1 3/S 11 35
- 07200040E Retaining Ring – M4 0-1 - 11 104
- B0046062 Pressure Plate 0-1 - 11 42
AF040575 Driven Roller 0-1 - 11 43
08053480 GA080002 Bushing – 6mm 1-1 3/S 11 102

NOTE: Whenever replacing the old Feed Shaft with the new one, the following parts from the above list
must all be replaced together as a set:
AA140753 – Feed Shaft
G0656801 – Tightener
G0656802 – Rail By-Pass Feed
GA080002 – Bushing 6MM
07200040E – Retaining Ring M4

Continued...
Technical Service Bulletin No. G065 - 003
Page 3 of 4

PREPARATION:

Remove the Tightened Bracket, Retaining Ring, Bushing and

Electrical Clutch as shown below.

REPLACEMENT PROCEDURE
[H]

1. Replace the Feed Shaft with AA140753. [B]

[A]
[F]
[D] [G]
[E]
[C]
2. Attach the Driven Roller [A] to the Pressure Plate [B], and then peel off the outer layers of the double-
sided tape (2 places) on the Pressure Plate.

3. Set the Bushing [C] in the hole in the Pressure Plate, and then mount the two together onto the Feed
Shaft.

NOTE: Be careful not to let the exposed double-sided tape contact the Side Plate.

4. Set Bushing [D] in the cutout on the side

of the Pressure Plate, then push in the
Pressure Plate along with the two
bushings. After it is set in position, attach [J]
e-rings [E] and [F].

5. Press the Pressure Plate firmly against [L]

the Side Plate so that the double-sided
tape catches and secures the two
[N]
together.
[K]
6. Attach the Gear [G].
[M]
7. Attach the Electrical Clutch [H]. [I]

Continued…
Technical Service Bulletin No. G065 - 003
Page 4 of 4

8. Remove the Arm Tightener [N], Gear and Spring (not shown) attached to the original Tightener Bracket
removed in the Prep stage, and attach them to the new Tightener Bracket [I].

9. Attach the new Tightener Bracket [I] and Bushing [J] and new bushing [K]. Then, the tighten screws in
the order shown. (1,2 then 3)

10. Attach e-rings [L] and [M].

UNITS AFFECTED:
All G065 printers manufactured after the Serial Numbers listed below will have the new style Feed Shaft and
Tightener Bracket installed during production.

MODEL NAME SERIAL NUMBER

Savin MLP45 P7226300158
Gestetner P7145
Ricoh Aficio AP4510 P7226300169

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.
 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 004 02/14/2003
APPLICABLE MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45

SUBJECT: FIRMWARE MODIFICATION

Note: This copy is intended as a master original

GENERAL:

„
for reproduction of additional bulletins.

FIRMWARE
The latest firmware version can be downloaded at the Technology Solution Center FTP Site
http://tsc.ricohcorp.com. Be sure to check the README file for important notes and explanations.

NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the
FTP Internet Web Site and EPROM/Flash Card Exchange program.

G065 FIRMWARE MODIFICATION (CONTROLLER)

FIRMWARE SERIAL FIRMWARE
DESCRIPTION OF MODIFICATION
LEVEL NUMBER VERSION
G0656041 G August 1.07
• SP7-807 SC/Jam Counter Reset does not reset the 2002
counters. Production
• PS:

• The controller freezes when an Acrobat document is

printed out from UNIX.

• The printing speed of a PS job slows down after a

PS3 job is reset.

• When 3-hole punching is selected in the driver but

the actual unit installed is a 2&4 punch unit, the
Punch function is not disabled.

• Punching is canceled once during a job, but multiple

entries for "Punch Cancelled" appear on the Error
Log sheet for that one job.

• PCL:

• CAD data is not printed out correctly.

Continued…

Copyright  2003 RICOH Corporation. All rights reserved.

Tech Service Bulletin No. G065 – 004
Page 2 of 2

FIRMWARE SERIAL FIRMWARE

DESCRIPTION OF MODIFICATION
LEVEL NUMBER VERSION
G0656041 F April 1.06
1. SNMP security vulnerabilities reported by CERT on
2002
Feb.12, 2002 have been confirmed and fixed through
Production
the PROTOS c06-snmpv1 test suite.

• CERT: http://www.cert.org/advisories/CA-2002-03.html

• PROTOS c06-snmpv1 test Suite:

http://www.ee.oulu.fi/research/ouspg/protos/testing/c06
/snmpv1/

2. When making duplex copies onto letterhead paper with

an odd number of originals, the last original is copied
onto the rear side of the last sheet.

Functions added:
Added symbol sets PC-858, Latin 9 and Roman 9 for
display of the EURO currency symbol.

G065 FIRMWARE MODIFICATION (BICU)

FIRMWARE SERIAL FIRMWARE
DESCRIPTION OF MODIFICATION
LEVEL NUMBER VERSION
G0655112 E June 1.33
• Fusing-related SC codes (541, 542) and/or incomplete 2002
fusing occur when making copies first thing in the Production
morning (esp. in cold environments).
 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 005 03/07/2003
APPLICABLE MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45
SUBJECT: HOT ROLLER & C RING

„
Note: This copy is intended as a master original

PARTS
GENERAL:
for reproduction of additional bulletins.

A pressure-release device was added to the fusing unit maintenance kit to prevent deformation of the
Pressure Roller during long periods of storage. However, there have been cases in the field where this
device was not properly removed, and the Hot Roller C-ring detaches when the fusing knob is turned.

To prevent this from occurring, the shape of the C-ring located on gear side has been changed so that it will
stay in place even in such cases. Although this only occurs with the maintenance kit, this modification was
made because the C-ring is common to both the maintenance kit and mainframe. The outer diameter of the
Hot Roller has also been increased by 0.2 mm to allow the new C-ring to fit properly.

The following parts updates are being issued for all G065 Parts Catalogs. Please update your parts catalog
with the following information.

Page 30

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A2324064 - C Ring - Hot Roller 2→1 0 31 16
- G0654140 C Ring - Hot Roller 1 1 31 45 *
AE011064 AE011071 Hot Roller 39.8mm – T0.4 1 0 31 18
* DENOTES NEW ITEM NUMBER

UNITS AFFECTED:
All G065printers manufactured after the serial numbers listed below will have the new style Hot Roller and C
Ring installed during production.

MODEL NAME SERIAL NUMBER

GestetnerP7145 P7226500064
Ricoh Aficio AP4510 P72267xxxxx
Savin MLP45 P7226500064

Copyright  2003 RICOH Corporation. All rights reserved.

 TECHNICAL SERVICE BULLETIN
BULLETIN NUMBER: G065 – 006 03/13/2003
APPLICABLE MODEL:
GESTETNER – P7145
RICOH – AFICIO AP4510
SAVIN – MLP45

SUBJECT: FIRMWARE MODIFICATION – CONTROLLER

Note: This copy is intended as a master original

GENERAL:

„
for reproduction of additional bulletins.

FIRMWARE
The latest firmware version can be downloaded at the Technology Solution Center FTP Site
http://tsc.ricohcorp.com. Be sure to check the README file for important notes and explanations.

NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about the
FTP Internet Web Site and EPROM/Flash Card Exchange program.

G065 CONTROLLER FIRMWARE MODIFICATION

FIRMWARE SERIAL FIRMWARE
DESCRIPTION OF MODIFICATION
LEVEL NUMBER VERSION
Corrects the following: G0656041 D Not 1.04
The machine hangs up when a G065 is connected to a Available
LAN under the following conditions.
1. The G065 is connected to the repeater HUB (Not
switching HUB).
2. The traffic of network is busy.
Corrects the following: G0656041 E Not 1.05
1. An EX error occurs when using a PCL XL mini driver. Available
2. When PLL Auto Continue is ON, the image printed out is
rotated 90 degrees.
3. When using the PCL5e driver with Windows 98, certain
Chinese fonts are not printed out.
4. When the Hungarian display language is selected, the
actual display is in Czech.
5. While downloading PS fonts to a machine with the HDD
option installed, the correct PS serial number cannot be
output.
6. When an undefined command "<ESC>&k#w" is
received, the machine prints it on the output as a
character string – e.g. “<ESC>&k6w”.

Functions added:
1. PC858 has been added to the symbol set supported by
PCL5e.
2. The total printing area of the PCL5e Edge-to-Edge
function is now the same as the HP9000.
3. Font DIMM selection added.

Copyright  2003 RICOH Corporation. All rights reserved.

 TECHNICAL SERVICE BULLETIN

BULLETIN NUMBER: G065 – 007 06/27/2003

APPLICABLE MODEL:
GESTETNER – P7145
LANIER – 2145
RICOH – AFICIO AP4510
SAVIN – MLP45

SUBJECT: DEVELOPMENT ROLLER ASSEMBLY

„PARTS
GENERAL:
The DG has been narrowed form 0.4± 0.5mm to 0.38± 0.03mm to prevent toner from sticking to the operator
side of the development roller. The following part update is being issued for all G065 Parts Catalogs.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
B0043100 B0043101 Development Roller Assy 1 0 29 4

Copyright  2003 RICOH Corporation. All rights reserved. Page 1 of 2

Tech Service Bulletin No. XXXX – 007

UNITS AFFECTED:
All G065 printers manufactured after the serial numbers listed below will have the new part installed during
production.

MODEL NAME SERIAL NUMBER

Lanier 2145 AG P72361xxxxx
Savin MLP45 P7227200094
Gestetner P7145
Ricoh Aficio AP4510 P7227200094

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Page 2 of 2
 TECHNICAL SERVICE BULLETIN

BULLETIN NUMBER: G065 – 008 10/09/2003

APPLICABLE MODEL:
GESTETNER – P7145
LANIER – 2145
RICOH – AFICIO AP4510
SAVIN – MLP45

SUBJECT: SERVICE MANUAL - INSERT

The Service Manual pages listed below must be replaced with the pages supplied.

!
The revised areas have been highlighted by an arrow ⇒.

MANUAL
SERVICE
PAGES:

• 5-3 Updated Information (Printer Controller Bit Switch Settings)

Copyright  2003 RICOH Corporation. All rights reserved.

 Rev. 10/2003 PRINTER CONTROLLER SERVICE MODE

5.2.3 PRINTER CONTROLLER BIT SWITCH SETTINGS

Position: 7 6 5 4 3 2 1 0
Display: 0 0 0 0 0 0 0 0

Bit Switch 1 Default

0 0
1 0
2 1
3 0
Do not change.
4 0
5 0
6 0
7 0
Bit Switch 2
0 0
1 0 Do not change.
2 0
⇒ 3
4
0
0
PDL Sniffing. See PUB(C)-051 for details.

5 0
Do not change.
6 0
7 0
Bit Switch 3
⇒ 0 0 PS Fonts Download. See PUB(C)-045 for details.
1 0

Service
Tables
2 0
3 0
4 0 Do not change.
5 0
6 0
7 0
Bit Switch 4
0 0
1 0
2 0
3 0
Do not change.
4 0
5 0
6 0
7 0

SM 5-3 G065
 TECHNICAL SERVICE BULLETIN

BULLETIN NUMBER: G065 – 009 10/17/2003

APPLICABLE MODEL:
GESTETNER – P7145
LANIER – 2145
RICOH – AFICIO AP4510
SAVIN – MLP45

SUBJECT: FUSING EXIT SENSOR

GENERAL:

„
The Fusing Exit Sensor has been changed to Chromium-free components to further minimize potential
impact on the environment. Also, the specification of the sensor has been changed to eliminate false Jam

PARTS
Code 14 – Fusing Exit Sensor jams. The following part update is being issued for all G065 Parts Catalogs.
Please update your parts catalog with the following information.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AW010090 AW010061 Exit Sensor - Fusing 1-1 0 27 18

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Copyright  2003 RICOH Corporation. All rights reserved. Page 1 of 1

FIRMWARE HISTORY
 FIRMWARE HISTORY
PUBLISHED DATE: 06/10/2003

PRODUCT CODE: G065

APPLICABLE MODEL:
GESTETNER – P7145
LANIER – 2145
RICOH – AFICIO AP4510
SAVIN – MLP45
Flash
Memory

GENERAL: Card

The latest firmware version can be downloaded at the Technology Solutions Center FTP Site at
http://tsc.ricohcorp.com. Be sure to check the README file for important notes and explanations.

„
FIRMWARE
NOTE: Refer to Facts Line Bulletin # FL002 and Publication Bulletin #023 for more information about
the FTP Internet Web Site and EPROM/Flash Card Exchange program.

The revised areas have been highlighted by an arrow ⇒.

TABLE OF CONTENTS:
CONTROLLER FIRMWARE HISTORY: ......................................2
BICU FIRMWARE HISTORY: ......................................................5

Copyright  2003 RICOH Corporation. All rights reserved. Page 1 of 5

Firmware History for G065

CONTROLLER FIRMWARE HISTORY:

Version Program No. C. SUM Effective Date

On board 1 : 9342
1.02 G0656041C 1st Mass Production
On board 2 : 0485
On board 1 : DDAA
1.04 G0656041D December 2001 production.
On board 2 : 980E
On board 1: FC4E
1.05 G0656041E February 2002 production.
On board 2: 3311
On board 1: 8C55
1.06 G0656041F April 2002 production.
On board 2: CE77
On board 1: 2A9A
1.07 G0656041G August 2002 production.
On board 2: C022
On board 1: 50EC
1.08 G0656041H October 2002 production.
On board 2: 21E3
On board 1: CCFC
1.09 G0656041J November 2002 production.
On board 2: F42A
1.10 On board 1: 1704
G0656041K December 2002 production.
On board 2: 4047

⇒ 1.11 G0656041L
On board 1: 480D
On board 2: ACB0
March 2003 production.

Page 2 of 5
 Firmware History for G065

FIRMWARE
LEVEL DESCRIPTION OF MODIFICATION

⇒ 1.11 1. PCL
- Barcodes are separated (shifted) when printed out.
- The downloaded PCL Barcode fonts are not printed correctly on the PCL font list.
- Duplex face settings (front/rear) are not applied correctly when specified with PCL
commands).
- Selecting HDD fonts or DIMM fonts may reduce the amount of available memory.
- CAD print files:
• Increased the number of available pen selections from 8 to 256. Note: BitSW
#3, -3 must be turned ON.
• The "null" character is ignored when contained in the HP/GL2 data
• The status flag for the bold selection command is refreshed when contained
in the HP/GL2 data.

Functions added:
- Supports mixed binding orientations with duplex jobs using cover sheets -
Supports SAP Barcode & OCR printing.

2. PS
-PS error occurs when unknown media type is specified
-Slow Printing from AutoCAD
-PS print file is printed out as a text file, i.e. not recognized as a PS file
Functions added:
- PJL commands added for Edge to Edge printing:
• ON = "PJL SET EDGETOEDGE=YES"
• OFF = "PJL SET EDGETOEDGE=NO"
3. System
- Slow printing when feeding from Tray 3 or 4.

1.10 1. PCL
- Some downloaded fonts are not printed out.
- The dither pattern for PCL XL is sometimes rotated with respect to the image.
- Some characters overlap when using scalable fonts.
1.09 1. PCL
- “θ” cannot be printed when selecting a Bitmap font.
- When a font in the DIMM is specified using the LB command of GL/2, it cannot be
printed correctly.
2. GPS
- Form line setting cannot be held on the PCL menu.
3. System
- A failure occurs with the cluster recovery processing for a certain system area after
an SC863 (HDD error), and the SC cannot be cleared with power off/on.
- Wording correction: "Replace tonerwaste-toner” to "Replace Toner Bottle”.
1.08 Euro symbol is not printed when using the PS driver.
For the workaround procedure.Æ See Pub(c)-045 Euro symbol is not printed with the PS
driver.

Page 3 of 5
Firmware History for G065

FIRMWARE
LEVEL DESCRIPTION OF MODIFICATION

1.07 1. SP7-807 SC/Jam Counter Reset does not reset the counters.

2. PS:
- The controller freezes when an Acrobat document is printed out from UNIX.
- The printing speed of a PS job slows down after a PS3 job is reset.
- When 3-hole punching is selected in the driver but the actual unit installed is a 2&4 punch
unit, the Punch function is not disabled.
- Punching is canceled once during a job, but multiple entries for "Punch Cancelled" appear
on the Error Log sheet for that one job.

3. PCL:
- CAD data is not printed out correctly.
1.06 1. SNMP security vulnerabilities reported by CERT on Feb.12, 2002 have been confirmed
and fixed through the PROTOS c06-snmpv1 test suite.
-CERT: http://www.cert.org/advisories/CA-2002-03.html
-PROTOS c06-snmpv1 test Suite:
http://www.ee.oulu.fi/research/ouspg/protos/testing/c06/snmpv1/
2. When making duplex copies onto letterhead paper with an odd number of originals, the
last original is copied onto the rear side of the last sheet.

Functions added:
1. Added symbol sets PC-858, Latin 9 and Roman 9 for display of the EURO currency
symbol.

Page 4 of 5
Firmware History for G065

BICU FIRMWARE HISTORY:

Version Program No. Effective Date

1.34 G0655112F December 2002 prod.
1.33 G0655112E June 2002 prod.
1.32 G0655112D April 2002 prod.
1.31 G0655112C December 2001 prod.
1.30 G0655112B 1st mass production

FIRMWARE
LEVEL DESCRIPTION OF MODIFICATION

1.34 Thermostat is activated after small paper sizes (B5 or smaller) are fed continuously from
the bypass tray as undefined sizes.
1.33 Fusing-related SC codes (541, 542) and/or incomplete fusing occur when making copies
first thing in the morning (esp. in cold environments).
1.32 SC545 (Fusing Lump Remains On) sometimes occurs when printing out onto a large
number of small sheets (e.g. 200 or more, A5 SEF).
The print speed with A5/HLT at SEF is slow compared to that of A4/LT at LEF.
1.31 “Close Lower Right Cover” is displayed when an error occurs with Trays 1 or 2, and “Tray
Error” is then displayed when the lower right cover is closed.
1.30 1st Mass Production.

Page 5 of 5