Model K-P3

China Models
(Machine Code: G091-69, -21, -20)

SERVICE MANUAL

30 April, 2008
Subject to change
Trademarks
Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft
Corporation in the United States and /or other countries.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
PCL® is a registered trademark of Hewlett-Packard Company.
Ethernet® is a registered trademark of Xerox Corporation.
PowerPC® is a registered trademark of International Business Machines
Corporation.
Other product names used herein are for identification purposes only and may be
trademarks of their respective companies. We disclaim any and all rights involved
with those marks.
 TABLE OF CONTENTS

1. INSTALLATION............................................................................ 1-1
1.1 ABOUT THIS MANUAL .............................................................................1-1
1.2 INSTALLATION REQUIREMENTS ...........................................................1-1
1.2.1 ENVIRONMENT ...............................................................................1-1
1.2.2 MACHINE LEVEL .............................................................................1-1
1.2.3 MACHINE SPACE REQUIREMENT.................................................1-2
1.2.4 POWER SUPPLY .............................................................................1-3
1.3 MACHINE INSTALLATION........................................................................1-3
1.3.1 MAIN UNIT .......................................................................................1-3
1.3.2 HARDWARE OPTIONS....................................................................1-3
1.3.3 MEMORY OPTIONS ........................................................................1-3
1.3.4 DRIVERS AND SOFTWARE ............................................................1-3
1.3.5 FIRMWARE UPGRADE ...................................................................1-4
1.4 SUPPLIES ..................................................................................................1-4

2. PREVENTIVE MAINTENANCE SCHEDULE ............................... 2-1

2.1 USER MAINTENANCE .............................................................................2-1
2.2 SERVICE MAINTENANCE.........................................................................2-2

3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1

3.1 GENERAL .................................................................................................3-1
3.1.1 PRECAUTIONS ON DISASSEMBLY ...............................................3-1
3.1.2 RELEASING PLASTIC LATCHES....................................................3-3
3.1.3 AFTER SERVICING THE MACHINE................................................3-3
3.2 SPECIAL TOOLS ................................................................................3-3
3.3 COVERS ...................................................................................................3-4
3.3.1 FRONT COVER................................................................................3-4
3.3.2 UPPER COVER................................................................................3-4
3.3.3 BY-PASS TRAY UNIT ......................................................................3-5
3.3.4 EXTERIOR COVERS .......................................................................3-5
3.4 LASER UNIT .............................................................................................3-6
3.4.1 CAUTION DECAL LOCATIONS .......................................................3-6
3.4.2 POLYGON MIRROR MOTOR ..........................................................3-7
3.4.3 LASER SYNCHRONIZATION DETECTOR......................................3-7
3.4.4 LASER UNIT ....................................................................................3-8
3.4.5 LASER DIODE UNIT ........................................................................3-9
3.4.6 LASER BEAM PITCH ADJUSTMENT ............................................3-10
3.5 TRANSFER ROLLER..............................................................................3-11
3.6 TONER END SENSOR ...........................................................................3-11
3.7 FUSING ...................................................................................................3-12
3.7.1 FUSING UNIT.................................................................................3-12
3.7.2 HOT ROLLER AND FUSING LAMP ...............................................3-13
3.7.3 PRESSURE ROLLER.....................................................................3-15
3.7.4 THERMISTOR AND THERMOSTAT..............................................3-16
3.7.5 HOT ROLLER STRIPPERS ...........................................................3-17

i
 3.8 PAPER FEED..........................................................................................3-18
3.8.1 PAPER FEED ROLLER..................................................................3-18
3.8.2 FRICTION PAD ..............................................................................3-18
3.9 BY-PASS TRAY ......................................................................................3-19
3.9.1 BY-PASS TRAY UNIT AND BY-PASS FEED ROLLER .................3-19
3.10 PRINTER CONTROLLER BOARD........................................................3-20
3.11 ENGINE BOARD ...................................................................................3-21
3.12 MAIN MOTOR .......................................................................................3-22
3.13 SOLENOIDS AND CLUTCHES.............................................................3-22
3.14 POWER SUPPLY BOARD AND HIGH VOLTAGE SUPPLY BOARD ...3-23
3.15 COOLING FAN......................................................................................3-24
3.16 IMAGE ADJUSTMENT ..........................................................................3-25
3.16.1 REGISTRATION ADJUSTMENT..................................................3-25
3.16.2 PARALLELOGRAM IMAGE ADJUSTMENT ................................3-25

4. TROUBLESHOOTING ................................................................. 4-1

4.1 SERVICE CALL CONDITIONS .................................................................4-1
4.1.1 SUMMARY .......................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS .............................................................4-2
4.2 CONTROLLER ERROR ............................................................................4-5
4.3 ELECTRICAL COMPONENT DEFECTS ..................................................4-7
4.3.1 SENSORS ........................................................................................4-7
4.3.2 SWITCHES.......................................................................................4-7
4.4 BLOWN FUSE CONDITIONS ...................................................................4-8
4.5 LEDS ..........................................................................................................4-8

5. SERVICE TABLES....................................................................... 5-1

5.1 SERVICE PROGRAM MODE....................................................................5-1
5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ...........5-1
Entering the Service Mode....................................................................5-1
Inputting a Value or Setting for a Service Program ...............................5-1
Exiting Service Mode ............................................................................5-1
5.2 PRINTER CONTROLLER SERVICE MODE .............................................5-2
5.2.1 SERVICE MODE MENU (“1. SERVICE MENU”)..............................5-2
5.2.2 BIT SWITCH PROGRAMMING ........................................................5-2
5.3 PRINTER ENGINE SERVICE MODE........................................................5-3
5.3.1 SERVICE MODE TABLE..................................................................5-3
SP1-xxx: Feed ......................................................................................5-3
SP2-xxx: Drum......................................................................................5-5
SP3-xxx: Process..................................................................................5-6
SP5-xxx: Mode .....................................................................................5-7
SP7-xxx: Data Log ..............................................................................5-14
SP8-xxx: Counters ..............................................................................5-15
5.4 UPDATING THE FIRMWARE .................................................................5-20
5.4.1 CONTROLLER FIRMWARE...........................................................5-20
5.4.2 ENGINE FIRMWARE .....................................................................5-21
5.4.3 ERROR RECOVERY......................................................................5-22
Controller ............................................................................................5-22
Engine.................................................................................................5-22

ii
 5.5 REMOTE FIRMWARE UPDATE (RFU) ..................................................5-23
5.6 LOOP-BACK TEST .................................................................................5-23
5.7 POWER-ON SELF TESTS ......................................................................5-23
5.8 USER PROGRAM MODES .....................................................................5-24
User Mode Tree ..................................................................................5-24
5.9 DIP SWITCHES.......................................................................................5-25
Controller Board..................................................................................5-25

6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1

6.1 OVERVIEW ...............................................................................................6-1
6.1.1 MECHANICAL COMPONENT LAYOUT...........................................6-1
6.1.2 PAPER PATH ...................................................................................6-2
6.2 BOARD STRUCTURE...............................................................................6-3
6.2.1 BLOCK DIAGRAM............................................................................6-3
6.2.2 DESCRIPTIONS...............................................................................6-4
6.2.3 CONTROLLER BOARD ...................................................................6-5
6.3 PRINTING PROCESS ...............................................................................6-6
6.3.1 OVERVIEW ......................................................................................6-6
6.3.2 LASER EXPOSURE .........................................................................6-7
Overview...............................................................................................6-7
Automatic Power Control (APC) ..........................................................6-8
LD Safety Mechanisms .........................................................................6-9
6.3.3 CARTRIDGE OVERVIEW ..............................................................6-10
6.3.4 DRUM CHARGE.............................................................................6-10
6.3.5 DEVELOPMENT.............................................................................6-11
Toner Supply ......................................................................................6-11
Development Unit ...............................................................................6-11
Toner Density Control .........................................................................6-12
Development Bias...............................................................................6-12
Toner End Detection ...........................................................................6-13
6.3.6 IMAGE TRANSFER AND PAPER SEPARATION ..........................6-14
Overview.............................................................................................6-14
Transfer Roller Cleaning .....................................................................6-15
6.3.7 CLEANING .....................................................................................6-15
6.3.8 QUENCHING..................................................................................6-16
6.3.9 ID CHIP AND INTERNAL THERMISTOR.......................................6-16
6.4 PAPER FEED..........................................................................................6-17
6.4.1 OVERVIEW ....................................................................................6-17
Paper Tray ..........................................................................................6-17
By-pass Tray.......................................................................................6-17
6.4.2 PAPER TRAY .................................................................................6-18
Tray Extension ....................................................................................6-18
Paper Sizes ........................................................................................6-18
Paper Lift ............................................................................................6-18
Paper Feed and Registration ..............................................................6-19
Paper Size Detection ..........................................................................6-20
Paper Size Detection ..........................................................................6-20
Paper End Detection...........................................................................6-21
Remaining Paper Detection ................................................................6-22

iii
 6.4.3 BY-PASS TRAY .............................................................................6-23
6.5 IMAGE FUSING AND PAPER EXIT........................................................6-24
6.5.1 OVERVIEW ....................................................................................6-24
6.5.2 FUSING DRIVE ..............................................................................6-25
6.5.3 FUSING ENTRANCE AND GUIDE SHAFT....................................6-25
6.5.4 PRESSURE ROLLER.....................................................................6-26
6.5.5 NEW FUSING UNIT DETECTION..................................................6-27
6.5.6 FUSING TEMPERATURE CONTROL............................................6-28
Overheat Protection ............................................................................6-29
6.5.7 PAPER EXIT ..................................................................................6-29
6.5.8 ENERGY SAVER MODE................................................................6-30
Entering Energy Saver Mode..............................................................6-30
Leaving Energy Saver Mode...............................................................6-30
6.6 CONTROLLER FUNCTIONS ..................................................................6-31
6.6.1 METER CHARGE MODE ...............................................................6-31
Meter-charge Counter Display ............................................................6-31
PM Warning Display ...........................................................................6-31

SPECIFICATIONS......................................................................SPEC-1
1. GENERAL SPECIFICATIONS............................................................. SPEC-1
2. PHYSICAL SPECIFICATIONS ............................................................ SPEC-3
3. CONTROLLER .................................................................................... SPEC-4
4. SUPPORTED PAPER SIZES.............................................................. SPEC-5
5. OPERATION PANEL LED SPECIFICATIONS .................................... SPEC-6
6. EXTERNAL OPTIONS ........................................................................ SPEC-6
7. SOFTWARE ACCESSORIES ............................................................. SPEC-7
7.1 PRINTER DRIVERS .................................................................... SPEC-7
7.2 CD-ROM CONTENTS ................................................................. SPEC-8
8. MACHINE CONFIGURATION ............................................................. SPEC-9
8.1 SYSTEM COMPONENTS ........................................................... SPEC-9
8.2 INTERNAL OPTIONS................................................................ SPEC-10

iv
PERIPHERALS
DUPLEX UNIT (G552)

1. REPLACEMENT AND ADJUSTMENT ..................................G552-1

1.1 EXTERIOR COVERS ......................................................................... G552-1
1.2 DUPLEX BOARD AND SENSORS .................................................... G552-2

2. DETAILED DESCRIPTION ....................................................G552-3

2.1 OVERALL MACHINE INFORMATION ............................................... G552-3
2.1.1 MECHANICAL COMPONENT LAYOUT.................................... G552-3
2.1.2 DRIVE LAYOUT ........................................................................ G552-4
2.1.3 ELECTRICAL COMPONENT LAYOUT ..................................... G552-4
2.2 DETAILED SECTION DESCRIPTIONS ............................................. G552-5
2.2.1 BASIC OPERATION.................................................................. G552-5
Longer than A4 LEF/LT LEF .......................................................... G552-5
Length up to A4 LEF/LT LEF ......................................................... G552-6
2.2.2 FEED IN AND EXIT MECHANISM ............................................ G552-7
Feeding paper into the duplex unit:................................................ G552-7
Inversion and exit:.......................................................................... G552-7

FOUR-BIN MAILBOX (G553)

1. REPLACEMENT AND ADJUSTMENT ..................................G553-1

1.1 EXTERIOR COVERS ......................................................................... G553-1
1.2 OVERFLOW AND VERTICAL TRANSPORT SENSORS .................. G553-2
1.3 MAIN MOTOR .................................................................................... G553-3

2. DETAILED DESCRIPTIONS ..................................................G553-4

2.1 OVERALL MACHINE INFORMATION ............................................... G553-4
2.1.1 MECHANICAL COMPONENT LAYOUT.................................... G553-4
2.1.2 DRIVE LAYOUT ........................................................................ G553-5
2.1.3 ELECTRICAL COMPONENT LAYOUT ..................................... G553-6
2.2 DETAILED SECTION DESCRIPTIONS ............................................. G553-7
2.2.1 BASIC OPERATION.................................................................. G553-7

ONE-BIN SHIFT TRAY (G554)

1. REPLACEMENT AND ADJUSTMENT ..................................G554-1

1.1 EXTERIOR COVERS ......................................................................... G554-1
1.2 SHIFT TIMING AND TRAY PAPER SENSORS ................................. G554-2
1.3 COVER AND OVERFLOW SENSORS .............................................. G554-2
1.4 MAIN MOTOR .................................................................................... G554-3

v
2. DETAILED DESCRIPTIONS ..................................................G554-4
2.1 OVERALL MACHINE INFORMATION ............................................... G554-4
2.1.1 MECHANICAL COMPONENT LAYOUT.................................... G554-4
2.1.2 DRIVE LAYOUT ........................................................................ G554-4
2.1.3 ELECTRICAL COMPONENT LAYOUT ..................................... G554-5
2.1.4 BASIC OPERATION.................................................................. G554-6
2.1.5 SORT MODE OPERATION....................................................... G554-6

PAPER TRAY UNIT (G555)

1. REPLACEMENT AND ADJUSTMENT ..................................G555-1

1.1 PAPER FEED UNIT ........................................................................... G555-1
1.2 PAPER FEED ROLLER ..................................................................... G555-2
1.3 FRICTION PAD .................................................................................. G555-2

2. DETAILED DESCRIPTIONS ..................................................G555-3

2.1 OVERALL MACHINE INFORMATION ............................................... G555-3
2.1.1 MECHANICAL COMPONENT LAYOUT.................................... G555-3
2.1.2 ELECTRICAL COMPONENT LAYOUT ..................................... G555-3
2.2 DETAILED SECTION DESCRIPTIONS ............................................. G555-4
2.2.1 PAPER FEED AND SEPARATION ........................................... G555-4
2.2.2 PAPER LIFT .............................................................................. G555-5
2.2.3 PAPER END DETECTION ........................................................ G555-5
2.2.4 REMAINING PAPER DETECTION............................................ G555-6
2.2.5 PAPER SIZE DETECTION......................................................... G555-7

vi
April, 2008 ABOUT THIS MANUAL

1. INSTALLATION

Installation
1.1 ABOUT THIS MANUAL
This manual covers three China models (G091-69, -21, -20). The differences
among the three models are shown in the section "Specifications". Refer to
"Sepcifications" to recognize the differences.
NOTE: The peripheral's manuals and point-to-point diagram for three models are
the same. Refer to the peripheral's manuals and point-to-point diagram of
the K-P3 China Model

1.2 INSTALLATION REQUIREMENTS

The installation instructions in this section are for the G091 China model machine.

1.2.1 ENVIRONMENT

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

2. Humidity Range: 15 % to 89 % RH
3. Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight).
4. Ventilation: 3 times/hr/person
5. Avoid areas that 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 install this machine in an area where it will be exposed to corrosive
gases.
7. Do not install the machine at locations over 2,500 m (8,125 ft.) above sea level.
8. Put the machine on a strong and level base. Inclination on any side should not
exceed 5 mm.
9. Do not put the machine where it may be subjected to strong vibrations.

1.2.2 MACHINE LEVEL

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

1-1
INSTALLATION REQUIREMENTS April, 2008

1.2.3 MACHINE SPACE REQUIREMENT

Place the machine near the power source, providing the clearance as shown
below:
A: Over 10 cm (4 inches) B
B: Over 10 cm (4 inches)
C: Over 100 cm (40 inches) C
A
D: Over 10 cm (4 inches)

D
G094I500.WMF

1-2
April, 2008 MACHINE INSTALLATION

1.2.4 POWER SUPPLY

Installation
CAUTION
1. Make sure the plug is firmly inserted in the outlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.

220-240 volts, 50 Hz/60Hz: More than 6 A

Permissible voltage Fluctuation: ±10 %
Do not set anything on the power cord

1.3 MACHINE INSTALLATION

Refer to the following sections of the Operating Instructions for installation details
for all models.

1.3.1 MAIN UNIT

1. Installing the Printer Unit: Quick Installation Guide.

2. Connecting the machine to a computer: Quick Installation Guide.

1.3.2 HARDWARE OPTIONS

1. Installing the Paper Feed Unit: Section two of the Set-up Guide.
2. Installing the Duplex Unit: Section two of the Set-up Guide.
3. Installing the One-Bin Shift Tray. Section two of the Set-up Guide.
4. Installing the Four-Bin Mailbox. Section two of the Set-up Guide.

1.3.3 MEMORY OPTIONS

1. Installing the Memory Unit: Section two of the Set-up Guide.

2. Installing the Hard Disk: Section two of the Set-up Guide.

1.3.4 DRIVERS AND SOFTWARE

Refer to section 4 of the Set-up Guide for installation procedures.

1-3
SUPPLIES April, 2008

1.3.5 FIRMWARE UPGRADE

Refer to section 5.4 of the Service Manual.

1.4 SUPPLIES
• Maintenance kit
• AIO

1-4
April, 2008 USER MAINTENANCE

2. PREVENTIVE MAINTENANCE SCHEDULE

2.1 USER MAINTENANCE
The customer can do all PM items with the Maintenance Kit (G770).
Meter-charge mode must be set to “disabled” (engine SP mode 5930).

Maintenance
Preventive
Cross-reference: Section 5.3 Engine service mode
The Operation panel shows “Replace Maintenance Kit” when the PM counter gets
to 90K. After the user replaces the fusing unit in the maintenance kit, the machine
automatically resets the PM counter.

Item Quantity Remarks

Fusing unit 1
Transfer roller 1
Paper feed roller 1 For standard tray
Paper feed roller 2 For optional tray(s)
Friction pad 1 For standard tray
Friction pad 2 For optional tray(s)

2-1
SERVICE MAINTENANCE April, 2008

2.2 SERVICE MAINTENANCE

The table shows the PM items done by service.
NOTE: 1) To disable the user's PM warning set meter-charge mode on in printer
engine service mode.
2) Make sure to reset the PM counters with engine SP mode 7-804 after
you complete PM.
• 7-804-1: Transfer roller
• 7-804-2: Paper feed roller
• 7-804-3: Fusing unit.

Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect

Main unit
Item 90K EM Quantity Remarks
Paper Feed
Paper Feed Roller R C 1 Clean with water
Friction Pad R C 1 Clean with water
Registration Roller C C 1 Clean with water
Bottom Plate Pad C C 1 Clean with water
Around the Drum
Transfer Roller R 1
Fusing Unit and Paper Exit
Hot Roller R 1
Pressure Roller R 1
Hot Roller Strippers G091: 5
R
G094/095: 3
Fusing Thermistor 1 Clean with alcohol if
R C
necessary.
Bushings - Hot Roller R 2
Bushings - Pressure Roller R 2
Fusing Entrance and Exit Guide Clean with water or
C 1 each
Plates alcohol

Paper Tray Unit

90K EM Quantity NOTE
Paper Feed Roller R C 1 Clean with water
Friction Pad R C 1 Dry cloth
Bottom Plate Pad C C 1 Clean with water

2-2
April, 2008 SERVICE MAINTENANCE

One-Bin Shift Tray

90K EM Quantity NOTE
Exit Rollers C Clean with water
Driven Rollers C Clean with water
Transport Rollers C Clean with water
Paper Tray C Clean with water
Tray Paper Sensor C Clean with water

Maintenance
Preventive
Four-Bin Mailbox
90K EM Quantity NOTE
Exit Rollers C Clean with water
Driven Rollers C Clean with water
Trays C Clean with water

2-3
April, 2008 GENERAL

3. REPLACEMENT AND ADJUSTMENT

CAUTION
Turn off the main power switch and unplug the machine before attempting
any of the procedures in this section.

The Replacement and Adjustment procedures in this section are for the G091
China model machine.
NOTE: This manual uses these symbols.
! : See or Refer to  : Screws  : Connector

Replacement
Adjustment
3.1 GENERAL
3.1.1 PRECAUTIONS ON DISASSEMBLY
Use extreme caution when removing and replacing components. The cables in the
machine are located very close to moving parts; proper routing is a must.
After components have been removed, any cables that have been displaced during
the procedure must be restored as close as possible to their original positions.
Before removing any component from the machine, note any cable routings that
may be affected.

Before servicing the machine:

1. Verify that documents are not stored in memory.
2. Remove the toner cartridge before you remove parts.
3. Unplug the power cord.
4. Work on a flat and clean surface.
5. Replace with authorized components only.
6. Do not force plastic material components.
Make sure all components are returned to their original positions.

3-1
GENERAL April, 2008

Laser unit
1. Do not loosen or adjust the screws securing the LD drive board on the LD unit.
Doing so will throw the LD unit out of adjustment.
2. Do not adjust the variable resistors on the LD unit, as these are permanently
adjusted at the factory. If replacement of the LD drive board is necessary,
replace the entire LD unit.
3. Keep the polygon mirror and toroidal lens free of dust. Laser performance is
very sensitive to dust on these components.
4. Do not touch the shield glass or the surface of the polygon mirror with bare
hands.
5. Do not adjust the Laser Synchronization detector on the LD unit, as these are
permanently adjusted at the factory. If the position of the Laser Synchronization
detector has changed from the factory set position, SC 322 will be shown.

Transfer Roller
1. Never touch the surface of the transfer roller with bare hands.
2. Be careful not to scratch the transfer roller, as the surface is easily damaged.

Fusing
1. After installing the fusing thermistor, make sure that it is in contact with the hot
roller and that the roller can rotate freely.
2. Be careful to avoid damage to the hot roller stripper pawls and their tension
springs.
3. Do not touch the fusing lamp and rollers with bare hands.
4. Make sure that the fusing lamp is positioned correctly and that it does not touch
the inner surface of the hot roller.

Paper Feed
1. Do not touch the surface of paper feed rollers.
2. To avoid misfeeds, the side and end fences in each paper tray must be
positioned correctly so as to align with loaded paper size.

3-2
April, 2008 SPECIAL TOOLS

3.1.2 RELEASING PLASTIC LATCHES

Many of the parts are held in place with plastic latches. The
latches break easily, so release them carefully.
To remove such parts, press the hook end of the latch away from
the part to which it is latched.

G094R513.WMF

Replacement
Adjustment
3.1.3 AFTER SERVICING THE MACHINE

1. Make sure all parts that require grounding are properly grounded.
2. Make sure the interlock switch is functioning.
3. Do not leave unused solder or parts inside the machine.
4. Do not leave any tools inside the machine.
5. Make sure all wires are properly connected and routed.
6. Make sure wires are not jammed between parts of the machine.

3.2 SPECIAL TOOLS

Part Number Description Q’ty Remarks
Used in common with other
N8036701 Flash Memory Card - 4MB 1
printers.
Used in common with other
N8031000 Card Case 1
printers.
Used for LD Unit positioning.
Scanner Positioning Pin (4 Used in common with the
A0069104 1
pieces/set) model K-P series and other
models.
Ricoh System Information tool
(Support Tool Version 2)
Released March 31, 2003
Basic version 1
Mail version 1

3-3
COVERS April, 2008

3.3 COVERS
3.3.1 FRONT COVER
To open the front cover, gently push the
cover inward (2 hooks).

G094R514.WMF

3.3.2 UPPER COVER

[B]
Open the front cover and rear cover. [D]
Then remove the AIO. [A]

[C]
[A]: Operation panel (2 hooks)
[B]: Upper exit cover
[C]: Open the exit guide plate.
[D]: Upper cover ( x 4)

G091R201.WMF

3-4
April, 2008 COVERS

3.3.3 BY-PASS TRAY UNIT

NOTE: Remove the by-pass tray unit before removing the exterior covers.

[A]: By-pass tray unit (2 hooks)

[A]

Replacement
Adjustment
G094R006.WMF

3.3.4 EXTERIOR COVERS

To remove the left or right cover, separate the machine from the optional paper
tray unit first.

[C]

[A] [B]

G091R702.WMF
G091R703.WMF
Open the front cover.
[A]: Left cover ( x 2)
[B]: Front cover (3 clamps, 2 harnesses)
[C]: Right cover (3 hooks)

NOTE: Pull out the standard paper tray before removing the front cover.

3-5
LASER UNIT April, 2008

3.4 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.

3.4.1 CAUTION DECAL LOCATIONS

G094R516.WMF

G094R517.WMF

3-6
April, 2008 LASER UNIT

3.4.2 POLYGON MIRROR MOTOR

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

[B]
Upper cover (! 3.3.2) [A]

[A]: Polygon mirror cover ( x 2)

[B]: Polygon mirror motor ( x 4,

Replacement
Adjustment
 x 1)

G094R518.WMF

NOTE: Do not touch the surface of the mirror with bare hands.

3.4.3 LASER SYNCHRONIZATION DETECTOR

Upper cover (! 3.3.2)

By-pass tray unit (! 3.3.3)
Exterior covers (3.3.4)

[A]: Laser synchronization detector ( x 1)

G094R519.WMF

[A]

3-7
LASER UNIT April, 2008

3.4.4 LASER UNIT

Upper cover (! 3.3.2) [A]

Exterior cover (! 3.3.4)

[A]: Clip
[B]: Laser unit ( x 4, 1 flat cable, [B]
 x 2)

When reinstalling the laser unit

G091R203.WMF

Use the scanner positioning pin (P/N: A0069104) to reinstall the unit.

[C]

G091R208.WMF

[C]: Set the positioning pins as shown above. Then secure the laser unit.

3-8
April, 2008 LASER UNIT

3.4.5 LASER DIODE UNIT

[C]

[a] [A]

Replacement
Adjustment
[B]

[D]
[E]
G094R522A.WMF

Laser Unit (! 3.4.4)

[A]: Spring
[B]: LD unit holders (x 2)
[C]: Loosen the screw
[D]: Nut
[E]: LD Unit
NOTE: 1) Do not remove the screws that secure the LD board.
2) Do not touch any variable resistors on the LD board.

When installing the LD Unit:

Tighten the screw [C] until the unpainted portion of the screw [a] is not visible.
After installing the LD unit, check the test pattern for the final adjustment (see the
following procedure).

3-9
LASER UNIT April, 2008

3.4.6 LASER BEAM PITCH ADJUSTMENT

1. Print out the following test patterns – cross-stitch pattern and two-dot argyle
pattern.
• Select the test pattern with SP 2902.
• After selecting a pattern, the display automatically goes to SP 5902. Use SP
5902-1 to print one test pattern.
• After completing the adjustment, reset SP 2902 to ‘no specified’.
2. Check these test patterns. If the laser beam pitch is not correct, the images are
as follows.
• Cross-stitch pattern: Vertical black strips seem to appear.
• Argyle pattern: The density of the diagonal lines is light or the lines have
disappeared.
3. Adjust the LD unit holder position: Tighten or loosen the screw [C] (see the
previous page) until the printout appears as follows.
• Cross-stitch pattern: The thin lines are of uniform thickness (no striping effect
should appear on the printout).
• Grid pattern: The diagonal lines appear clearly and are of normal density.

G094R523.WMF

Adjustment not complete Adjustment complete

3-10
April, 2008 TRANSFER ROLLER

3.5 TRANSFER ROLLER

Remove the AIO.

[A]: Transfer roller

NOTE: Do not touch the transfer
roller surface.

Replacement
Adjustment
[A]

G094R524.WMF

3.6 TONER END SENSOR

Remove the AIO.

[A]: Toner end sensor (4 hooks,

 x 1)

[A]

G094R525.WMF

3-11
FUSING April, 2008

3.7 FUSING
CAUTION
Allow time for the unit to cool before doing the following procedure.

3.7.1 FUSING UNIT

[A]: Rear cover
[B]: Fusing unit (2 hooks [C]) [C]

[B]

[A]

G094R007.WMF

NOTE: Lift both hooks before attempting to remove the fusing unit from the
machine.

3-12
April, 2008 FUSING

3.7.2 HOT ROLLER AND FUSING LAMP

[A]

Replacement
Adjustment
[B]

G094R008.WMF
[C]

[D]

G094R009.WMF

[D]

Fusing Unit (! 3.7.1)

[A]: Left cover ( x 1)
[B]: Upper fusing unit assembly ( x 4, 2 springs)
[C]: Right cover ( x 1)
[D]: Lamp holders ( x 1 each)

NOTE: 1) Remove both springs before taking apart the fusing unit assembly. The
reason for this is to relieve pressure on the unit.
2) When reinstalling the fusing unit assembly, install both springs last. The
reason for this is to reset the springs back to their default position.

3-13
FUSING April, 2008

[A]

G094R526.WMF

[D]
[B]

[C]
G094R003_CHN.WMF

[A]: Fusing Lamp ( x 2)

NOTE: The colored cable must be at the hot roller gear side.
[B]: Guide plate (3 hooks)
[C]: Hot roller strippers (1 spring each)
[D]: Hot roller (2 C-rings, 1 gear, 2 bushings)
NOTE: 1) Take the gear and the pin off first, before removing the hot roller
from the unit.
2) Use a small screwdriver to separate the guide plate from the unit.
3) Before installing the new hot roller, peel off 3 cm (1 inch) from both
ends of the protective sheet on the new hot roller. Make sure to
remove the rest of the paper before starting the machine.

3-14
April, 2008 FUSING

3.7.3 PRESSURE ROLLER

[D]

[C]

[D]
[B]

Replacement
Adjustment
[C]

[A]
G094R012.WMF

[B]

Fusing Unit (! 3.7.1)

Hot roller and fusing lamp (! 3.7.2)
[A]: Pressure roller
[B]: Bushing
[C]: Pressure roller lever
[D]: Spring

3-15
FUSING April, 2008

3.7.4 THERMISTOR AND THERMOSTAT

[C]
[E]
[D]
[B]

[A]

G094R011.WMF

Hot roller and fusing lamp (! 3.7.2)

[A]: Wire cover ( x 1)
[B]: Grounding plate ( x 2, 1 wire)
[C]: Fusing unit connector ( x 6,  x 1, 2 hooks)
[D]: Thermistor ( x 1, 1 harness)
[E]: Thermostat ( x 1)

NOTE: 1) When removing the thermistor, remove the entire unit first and then
separate it into two parts.
2) Do not touch the thermostat with your hands.

3-16
April, 2008 FUSING

3.7.5 HOT ROLLER STRIPPERS

[A]

Replacement
Adjustment
[B]
G091R510.WMF

[C]

G091R505.WMF

[A]: Guide plate (3 hooks)

[B]: Hot roller strippers (1 spring each)
[C]: Hot roller (2 C-rings, 1 gear, 2 bushings).

NOTE: Before installing the new hot roller, peel off 3 cm (1 inch) from both ends of
the protective sheet on the new roller. Also, remove the rest of the paper
before starting the machine.

3-17
PAPER FEED April, 2008

3.8 PAPER FEED

3.8.1 PAPER FEED ROLLER

[A]: Paper feed roller

NOTE: Pull out the paper tray before
removing the paper feed roller.

G094R002.WMF

[A]
3.8.2 FRICTION PAD

[A]: Friction pad (2 hooks, 1 spring) [A]

NOTE: Remove the paper tray
unit from the machine
before removing the
friction pad.

When reinstalling the friction pad

follow this order
1. Replace the spring.
2. Insert the right side of the friction
G094R010.WMF
pad first followed by the left side.
3. Gently push the friction pad down into the slot and then pull forward very
slightly.

3-18
April, 2008 BY-PASS TRAY

3.9 BY-PASS TRAY

3.9.1 BY-PASS TRAY UNIT AND BY-PASS FEED ROLLER

[A]

Replacement
Adjustment
[B]
G094R527.WMF
[C]

Left Cover (! 3.3.4)

Front Cover (! 3.3.4)
Remove the AIO.

[A]: Paper guide ( x 2) [D]

[B]: Actuator
[C]: Solenoid ( x 1) G094R528.WMF

[D]: By-pass feed roller [E]

[E]: Gear (1 hook)

When reinstalling the paper guide.

1. Set the paper guide on the bushing.
2. Install the right part of the actuator on the paper guide.
3. Install the left part of the actuator in the machine.
4. Install the paper guide.
5. Check that the actuator moves smoothly and swings freely.

3-19
PRINTER CONTROLLER BOARD April, 2008

3.10 PRINTER CONTROLLER BOARD

[A]: Printer controller board ( x 2)

[B]: NVRAM
NOTE: Remove the NVRAM from the
[A]
old printer controller board
and insert it on the new board.

NOTE: 1) Remove the Duplex Unit before

you remove the controller
board.
2) The screws on the printer
controller board are hand
screws. Gently turn these
screws when removing the
printer control board.
3) Pull on the handle to remove G094R005.WMF

the printer controller board from [B]

the machine.

3-20
April, 2008 ENGINE BOARD

3.11 ENGINE BOARD

CAUTION
The engine boards for K-P3d and K-P3l are identical. However, the engine
board for K-P3s is unique. Make sure that you have the correct engine
board for the machine that you are working on.

[B]

Replacement
Adjustment
[C]

[A]

G094R529.WMF

[D]

Left cover (! 3.3.4)

Printer controller board (! 3.10)

[A]: Bracket ( x 7, 1 grounding wire)

NOTE: Be careful not to damage the flat cable.
[B]: Clip
[C]: Engine board ( x 4, all connectors)
NOTE: Remove the NVRAM [D] from the old engine board and insert it on the
new board.

3-21
MAIN MOTOR April, 2008

3.12 MAIN MOTOR

Left cover (! 3.3.4)

[A]: Main motor ( x 4,  x 1)

[A]

G094R530.WMF

3.13 SOLENOIDS AND CLUTCHES

Left cover (! 3.3.4)

[A]: By-pass feed solenoid

( x 1,  x 1)
[B]: Gear (1 hook)
[C]: Stopper ( x 1)
[D]: Relay clutch ( x 1 x 1)
[E]: Paper feed clutch ( x 1) [F]

Main motor (! 3.12)

[F]: Registration clutch [C]
( x 1 x 1)

[E]
G094R531.WMF
[D]
[A] [B]

3-22
April, 2008 POWER SUPPLY BOARD AND HIGH VOLTAGE SUPPLY BOARD

3.14 POWER SUPPLY BOARD AND HIGH VOLTAGE

SUPPLY BOARD
[A]

Replacement
Adjustment
[B]
G094R004.WMF

[D]

[C]

[E]

G094R532.WMF

Left cover (! 3.3.4)

Fusing unit (! 3.7.1)

[A]: PSU cover ( x 2)

[B]: PSU assembly ( x 7, all connectors)
[C]: High voltage supply board ( x 4)
[D]: Choke coil ( x 2  x 1)
[E]: PSU ( x 5)

3-23
COOLING FAN April, 2008

3.15 COOLING FAN

Right cover (! 3.3.4)

[A]

G094R501.WMF

[A]: Cooling fan ( x 1,  x 1)

NOTE: The cooling fan must be reinstalled to the original position. Do not reinstall
the cooling fan opposite to the original position.

3-24
April, 2008 IMAGE ADJUSTMENT

3.16 IMAGE ADJUSTMENT

3.16.1 REGISTRATION ADJUSTMENT
The registration is adjusted using the user mode; “Maintenance-Registration”. For
details, see the Printer Reference operation manual.

3.16.2 PARALLELOGRAM IMAGE ADJUSTMENT

NOTE: Use the scanner-positioning pin (P/N: A0069104) for the adjustment.
Do the following procedure if a parallelogram is printed while adjusting the printing
registration using a trimming pattern.

Replacement
Adjustment
(a) (b)
G094R533.WMF
G094R500.WMF

1. Remove the upper cover (! 3.3.2)

2. Put a positioning pin in one of the holes
3. Loosen four screws and move the laser unit.
4. Tighten the laser unit.
5. Print the trimming area pattern to check the image. If it is still the same, repeat
steps 3 to 5.

3-25
April, 2008 SERVICE CALL CONDITIONS

4. TROUBLESHOOTING
4.1 SERVICE CALL CONDITIONS
The SC codes in this section are for the G091 China model machine.

4.1.1 SUMMARY
There are 2 levels of service call conditions.
Level Definition Reset Procedure
Only a service representative can reset Enter engine SP mode 5810
this SC. This will prevent damage to the and press “#”. When ‘execute’
A machine. is displayed, press “#” again.
You cannot use the machine. Then press ‘Escape’. Then
turn the main power off/on.
The SC can be reset by turning the Set the main power off and on.
B operation switch off and on, if the SC was
caused by a sensor error.

shooting
Trouble-
NOTE: 1) If the problem is with electrical circuit boards, disconnect the connectors
first. Then reconnect the connectors before you replace the PCBs.
2) If the problem is with a motor lock, first examine the mechanical load.
Then replace motors or sensors.

4-1
SERVICE CALL CONDITIONS April, 2008

4.1.2 SC CODE DESCRIPTIONS

Code No. Symptom Possible Cause
302 B Charge roller current leak • Cartridge (charge roller) defective
A charge roller current leak signal is • High voltage supply board
detected. defective
• Defective cartridge connection
320 B Polygon motor error • Polygon motor
The polygon motor does not reach its • Polygon motor cable
operating speed within 10 seconds
after the polygon motor on signal, or
the lock signal is not detected for
more than a certain time during
operation.

322 B 1st laser synchronization error • Laser synchronization detector

The laser synchronization detector board out of position
cannot detect the laser • Laser synchronization detector
synchronization signal for more than board or cable defective
5 consecutive 100 ms intervals. • Laser synchronization mirror out of
position
• LD unit defective
• Engine board defective
323 B LD drive current exceeded • LD unit defective
The LD driver detects this error for
more than 500 ms.
326 B 2nd laser synchronization error • Laser synchronization detector
The 1st LD1 is already on, but the board out of position
laser synchronization detector cannot • LD unit defective
detect the laser synchronization • Engine board defective
signal from the 2nd LD for more than
5 consecutive 100 ms intervals.
391 B Development bias leak • High voltage supply board
A development bias leak signal is defective
detected. • Defective cartridge connection

500 B Main motor lock • Main motor defective

A main motor lock signal is not • Too much load on the drive
detected for more than 700 ms after mechanism
the main motor starts to rotate, or the
lock signal is not detected for more
than a certain time during rotation
after the last signal.

541 A Unstable fusing temperature • Thermistor defective

During warm-up, the fusing • Fusing lamp open
temperature rises by less than 20 °C • Fusing thermostat open
during 11 seconds. • Power supply board defective
The fusing temperature detected by • Defective connection of the fusing
the thermistor was 0 °C 5 seconds unit
after the fusing relay was turned on.

4-2
April, 2008 SERVICE CALL CONDITIONS

Code No. Symptom Possible Cause

542 A Fusing temperature warm-up error • Thermistor defective
The fusing temperature does not • Fusing lamp open
reach more than 80 °C 17.5 seconds • Fusing thermostat open
after the main switch is turned on. • Power supply board Defective
• Defective connection of the fusing
unit
543 A Fusing overheat error • Fusing thermistor defective
A fusing temperature of over 245 °C • Power supply board defective
is detected for 1 second by the fusing
thermistor.
A fusing temperature of over 235 °C
is detected for 1 second after the
fusing lamp has been turned off.
544 A Fusing overheat error (hardware • Power supply unit defective
circuit detection) • I/O board (IOB) defective
The dual monitoring circuitry of the • BICU defective
BICU detects extremely high • Fusing thermistor defective
temperature and tripped the relay
circuit off.

shooting
Trouble-
545 A Fusing lamp stays on • Fusing thermistor defective
The fusing lamp stays on more than • Power supply board defective
12 seconds after the main motor has • Defective connection of the fusing
been turned off. unit
546 A Unstable fusing temperature • Fusing thermistor defective
During standby, within 500 ms, the • Power supply board defective
fusing temperature goes below 60 °C • Defective connection of the fusing
twice or over 60 °C three times. unit
Within 1 minute, a 60 °C increase or
decrease in fusing temperature is
detected during five different one-
second intervals.
547 B Zero cross signal malfunction • Power supply board defective
Zero cross signals are not detected • Defective mains power supply
within 5 seconds. condition
The CPU detects an exhaust fan lock
signal for more than 3.5 seconds.
610 B Communication error - duplex unit • Defective connection between
The engine board cannot engine board and duplex unit
communicate with the duplex unit. • Engine board defective
• Duplex control board defective

4-3
SERVICE CALL CONDITIONS April, 2008

Code No. Symptom Possible Cause

650 B Communication error - GAVD • Engine board defective
• The engine board detects an
unknown device on the I2C I/F
bus (internal bus on the engine
control board).
• The engine board detects an I2C
I/F bus error.
651 B Communication error - FCI • Engine board defective
• The engine board detects an
unknown device on the I2C I/F
bus (internal bus on the engine
control board).
• The engine board detects an I2C
I/F bus error.
726 B Shift tray motor error • Shift motor defective
Tray shift did not finish within a • Shift tray: Left shift sensor or right
certain time after the shift motor shift sensor defective
turned on.

4-4
April, 2008 CONTROLLER ERROR

4.2 CONTROLLER ERROR

The following table describes the controller error codes. These codes are displayed
at power-on, or after the power-on self test, if an error occurs.
Code Description Required Action
640 Engine to controller • Examine the connection between the
communication error. controller and the engine board.
• Replace the engine board if the error is
frequent.
• Replace the controller if the error is frequent.
641 Engine to controller • Examine the connection between the
communication error (no controller and the engine board.
answer). • Replace the engine board if the error is
frequent.
670 Engine response error • Engine board installed incorrectly
• Engine board defective
• Controller board defective
671 Controller-to-operation panel • Controller stalled
communication error at startup • Controller board installed incorrectly

shooting
•

Trouble-
Controller board defective
• Operation panel connector loose or defective
800 Video data error • Examine the connection between the
controller and the engine board.
• Replace the engine board if the error is
frequent.
818 System timeout error • Defective controller
• Replace the controller if it occurs frequently.
819 Kernal end error • HDD error
• Software application error
• RAM shortage
820 Controller CPU error • Replace the controller if the error is frequent.
821 CPU and ASIC timer error • Turn off the machine and turn it back on.
• Replace the controller if the error is frequent.
822 HDD timeout error • Examine the connection between the HDD
and the controller
• Replace the HDD if the error is frequent.
823 NIB self test error • Turn off the machine and turn it back on.
• Examine the connection between the NIB
and the controller.
• Replace the NIB if the error is frequent.
824 NVRAM error • Replace the NVRAM if the error is frequent.
827 SDRAM error • Replace the controller if the error is frequent.
828 Flash ROM error • Replace the controller if the error is frequent.
829 Optional RAM error • Examine the connection of the optional
memory.
• Replace the optional memory if the error is
frequent.
835 Parallel interface error • Replace the controller if the error is frequent.
836 Font ROM error • Not used for this model.
837 Optional font ROM error • Not used for this model.
838 Clock generator error • Replace the controller if the error is frequent.

4-5
CONTROLLER ERROR April, 2008

Code Description Required Action

850 NIB interface error • Replace the controller if the error is frequent.
857 USB I/F Error • The USB driver can generate three types of
errors: RX, CRC, and STALL errors. Only the
STALL error can generate this SC code.
• Defective controller board
860 HDD start-up error • Turn off the machine and turn it back on.
• Examine the connection between the HDD
and the controller.
• Replace the HDD if the error is frequent.
862 HDD damaged cluster error • Replace the HDD if the error is frequent.
863 HDD data unable to read
864 HDD data access error
865 HDD access error
900 Controller counter error • Replace the NVRAM if the error is frequent.
990 Software performance error • Software defective; reboot the machine
• Internal parameter incorrect
• 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. Then report the data and
conditions to your technical control center.
991 Software continuity error • Software bug; reboot the machine
• Internal parameter incorrect
• Insufficient working memory
998 Application start error • Software defective; change the firmware for
the application that failed
• An option required by the application (RAM,
DIMM, board) is not installed
999 Software update error • Try downloading the controller software
again.

4-6
April, 2008 ELECTRICAL COMPONENT DEFECTS

4.3 ELECTRICAL COMPONENT DEFECTS

4.3.1 SENSORS
Component CN Condition Symptom
The Paper Jam indicator will light whenever
Open
a print is made.
Paper Exit 6-B2
The Paper Jam indicator lights even if there
Shorted
is no paper.
The paper overflow message is not
Open displayed even when a paper overflow
Paper Overflow 6-B5
condition exists.
Shorted The paper overflow message is displayed.
The Paper Jam indicator will light whenever
Open
a print is made.
Registration 16-A2
The Paper Jam indicator lights even if there
Shorted
is no paper.
The Paper End indicator lights even if paper
Open
Remaining paper is placed in the 1st paper tray.
16-A5
sensor 1 The Paper End indicator does not light even
Shorted

shooting
Trouble-
if there is no paper in the 1st paper tray.
Remaining paper Open The machine cannot determine the paper
16-A8
sensor 2 Shorted near-end condition properly.
High Toner near-end (toner end) is not detected.
Toner End 16-A12
Low The add toner message is displayed.

NOTE: The CN numbers describe the connector number on the engine board.

4.3.2 SWITCHES
Component CN Condition Symptom
Open The machine does not turn on.
Main
270-1,2 Shorted The machine does not turn off.
The Front Cover Open message is not
Open
Front Cover displayed even if the front cover is opened.
9-1
Safety The Front Cover Open message is
Shorted
displayed even if the front cover is closed.
The Rear Cover Open message is not
Open displayed even if the rear cover or paper
Rear Cover 9-3 exit cover is opened.
Safety 5-3 The Rear Cover Open message is
Shorted displayed even if the rear cover or paper
exit cover is closed.

NOTE: The CN numbers describe the connector number on the engine board
(except for the main switch).

4-7
BLOWN FUSE CONDITIONS April, 2008

4.4 BLOWN FUSE CONDITIONS

Rating Symptom when turning on the main
Fuse
220 - 240 V switch
Power Supply Board
FU1 ---- Machine does not start
FU2 3.15 A/250 V Machine does not start
FU3 5 A/250 V Machine does not start
Machine does not start
FU4 5 A/250 V
(The LEDs turn on for a moment.)

4.5 LEDS
No LEDs are used for this model (except for the NIB - refer to section 6.7).

4-8
April, 2008 SERVICE PROGRAM MODE

5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE
The Service Program Modes in this section are for the G091 China model machine.
CAUTION
Before accessing the service menu, do the following:
Confirm that there is no print data in the printer buffer (the Data In LED
must not be lit or blinking).
If there is some data in the buffer, wait until all data has been printed.

5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE

Entering the Service Mode
There are two ways to enter the service
mode.
Method 1: Turn the machine on while pressing
the “On Line” key and “Escape” key together
until “1. Service Menu1” appears on the
display.
Menu
On Line
NOTE: If you switch the machine off, any jobs

Service
Tables
stored on the hard disk using the
sample print and protected print Job Reset Escape
features will be deleted.
Check first with the user tools to see if
there are any jobs stored with these Form Feed # Enter
features
(Menu key - Sample Print, or
Power Error Data In
Protected Print).
Method 2: Press the “Up/Down arrow” keys
together for about 5 seconds, then press the
“Enter” key. G094S509.WMF

“1. Service Menu1” appears on the display.

NOTE: The machine automatically goes off line when you enter the service mode

Inputting a Value or Setting for a Service Program

Enter the required program mode as explained above. The setting appearing on
the display is the current setting.
Select the required setting using the “Up/Down arrow” keys, then press the “Enter”
key. The previous value remains if the “Enter” key is not pressed.
Exiting Service Mode
Select “3. End” from the service mode main menu, then press the “Enter” key.

5-1
PRINTER CONTROLLER SERVICE MODE April, 2008

5.2 PRINTER CONTROLLER SERVICE MODE

5.2.1 SERVICE MODE MENU (“1. SERVICE MENU”)
Service
Description Function
Mode
Adjusts bit switch settings.
1001 Bit switch
Note: Currently the bit switches are not being used.
1003 Clear Setting Initializes settings in the “System” menu of the user mode.
Prints the service summary sheet (a summary of all the
1004 Print summary
controller settings).
1005 Disp Version Displays the version of the controller firmware.

5.2.2 BIT SWITCH PROGRAMMING

NOTE: Currently, the bit switches are not being used.

Service Menu
1. Enter the SP mode, select “Service Menu”, then press
[Enter] twice. BitSW

2. Select #1, #2, #3, or #4 for the desired bit switch, then
press [Enter]. BitSW
<BitSW#1>
• [] []: Move to the next switch.

Sw#1 00000000
3. Adjust the bit switch using the following keys.
Bit0 _
• [] []: Move to the next bit.
• [Escape]: Exit without saving changes.
• [Enter]: Exit and save changes.
NOTE: The left digit on the display is bit 7 and the right digit is bit 0.

4. Press [Enter] to save changes and exit.

5-2
April, 2008 PRINTER ENGINE SERVICE MODE

5.3 PRINTER ENGINE SERVICE MODE

5.3.1 SERVICE MODE TABLE
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.
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.

SP1-xxx: Feed
1003 Regist sag
Adjusts the relay clutch timing at registration. Relay clutch timing determines
the amount of paper buckle at registration. (A “+” setting causes more
buckling.)
1003 1 Cassette [–8 mm ~+8 mm/0/2 mm step]
1003 2 Multi tray [By-pass] [–8 mm ~+8 mm/0/2 mm step]
1003 3 Duplex Tray [–8 mm ~+8 mm/0/2 mm step]

1104 Fusing control Normal, Phase control

Service
Tables
Use phase control if the room lights flicker when the fusing lamp starts.
Defaults: North America – Normal (On/off control), Europe – Phase

1105 Fusing Temp.

Adjusts the fusing temperatures for printing and standby mode.
1105 1 Fusing temp [150 ~ 200/ 170 / 5 deg.] DFU
Adjusts the fusing temperature for printing on normal paper.
1105 2 Fusing T Stand [140 ~ 175 / 168 / 1 deg.] DFU
Adjusts the fusing temperature for standby mode.

1106 Fusing T Display

1106 1 Displays the current fusing temperature.

1902 OHP clutch rt 1 = 1 rotation, 2 = 2 rotations

Selects the number of rotations for the bypass feed roller when the paper type
is set to “Transparencies”.
If jams occur when transparencies are being used, change the setting to 2.

5-3
PRINTER ENGINE SERVICE MODE April, 2008

1910 Fusing start Normal, Roller turn DFU

Roller turn: Warms up the fusing unit for 20 s just after the power switch has
been turned on or when the machine warms up from energy saver mode.
Normal: There is no 20 s warm-up period. However, just after the main power
switch is turned on, the motor turns to clean the drum.

1912 Warm up control Normal, Curl control

Lowers the fusing temperature (to 150°C) to prevent thin paper from curling.
Use this mode only when a paper jam occurs during duplex rear side printing.

5-4
April, 2008 PRINTER ENGINE SERVICE MODE

SP2-xxx: Drum

2001 Charge rol bias [1000 ~ 2000 / –1675V / 10V step] DFU
Adjusts the voltage applied to the charge roller for printing.

2112 Mainscan mag [-0.5% ~ 0.5% / 0 / 0.1% step]

Adjusts the main scan magnification.

2113 Subscan mag [-0.5% ~ 0.5% / 0 / 0.1% step]

Adjusts the sub scan magnification.

2201 Developer bias [200 ~ 800 / 750V / 10V step] DFU

Adjusts the development bias for printing.

2213 Toner end count [50 ~ 200 / 200 / 50 sheets/step]

Adjusts the number of prints the machine can make after it detects toner near-
end.

2301 Transfer curr [-2 ~ 4 / 0 / 2 µA/step]

Adjusts the correction current applied to the transfer roller.

Service
Tables
2902 Test Pattern
Printing Test Pattern No specified
Various test patterns
Selects a printer test pattern. After selecting a pattern, the display
automatically goes to SP 5902. Use SP 5902 to print either one test pattern
(5902-1) or a few of them (5902-2). Reset SP 2902 to “no specified” after
printing the test pattern, or the selected pattern will appear on every page
printed by the user.
2910 Thermistor adj Yes, No DFU
If this is “Yes”, the machine automatically adjusts the charge roller voltage and
transfer current in response to the temperature within the machine.

2928 Toner end clear Execute DFU

Clears the toner end counter in the engine board. Not used in this machine.

2980 Waste toner cnt

Displays the waste toner counter in the engine board.

5-5
PRINTER ENGINE SERVICE MODE April, 2008

SP3-xxx: Process
3921 Effective info Not used: All items ignored
Cartridge dtct: Cartridge detection only
Normal mode (Cartridge detection and Type ID)
All used: All items used
Selects which of the cartridge ID chip functions are enabled.

3922 Cartridge lmt [15k ~ 40k / 30k / 5k step]

Adjusts the number of prints the machine can make after a new cartridge is
detected.
Do not use a higher value than 30 k, or waste toner could leak from the
waste toner tank.

3923 Cartridge stop No, Yes

Determines whether the machine stops printing after the cartridge counter
reaches the limit set with SP 3922.

3924 Toner end sensor

3924 1 Toner near-end [100 ~ 1000 / 200 / 100 ms step] DFU
Threshold adjustment for toner near-end detection.
3924 2 Toner end [250 ~ 1050 / 550 / 100 ms step] DFU
Threshold adjustment for toner end detection

3925 Cartridge info

3925 1 Machine ID
Displays the model name stored in the toner cartridge IC chip.
3925 2 Version
Displays the cartridge version number stored in the toner cartridge IC chip.
3925 3 Brand ID
Displays the OEM brand name stored in the toner cartridge IC chip.
3925 4 Color ID
Displays the cartridge color name stored in the toner cartridge IC chip.
3925 5 Area ID
Displays the region stored in the toner cartridge IC chip.
3925 6 Kind ID
Displays the part code number stored in the toner cartridge IC chip.
3925 7 Secu ID
Displays the cartridge type ID stored in the toner cartridge IC chip.
3925 8 Maker ID
Displays the maker ID number stored in the toner cartridge IC chip.

5-6
April, 2008 PRINTER ENGINE SERVICE MODE

SP5-xxx: Mode
5024 mm/inch Display Selection 0: Europe/Asia (mm), 1: North America (inch)
Selects the unit of measurement.
After selection, turn the main power switch off and on.

5046 ROM Update Disp Enables or disables the ROM Update utility.
When enabled, this utility will be displayed in the
user program mode. DFU
[0 or 1 / 1 / –]
• 0: Enabled
1: Disabled

5104 A3/11x17 Count Specifies whether the counter is doubled for

A3/11" x 17" paper. If “Yes” is selected, the total
counter counts up twice when A3/11" x 17" paper
is used.
Yes
(double count)
No
(single count)

5305 Auto Off Set

Switches energy saver mode on/off

Service
Tables
Enable, Disable
Enable: Energy saver mode will be used
Disable: Energy saver mode will be ignored

5401 U limit auto select Yes, No

Determines whether the machine adds new user codes in the User
Management Tool in Smart Net Monitor.

5801 Memory Clear

Resets software counters and returns modes and settings to their defaults.
All clear: Clears all data
Engine clear: Clears the printer engine settings
SCS: Clears the systems settings
PRT: Clears user mode system settings
NCS: Network control systems - Clears the items listed in the “Host Interface”
section of the Configuration page.
DCS: Delivery control system (e-mail settings)
MIRS: E-mail addresses
5801 1 Memory all clear
5801 2 Engine memory clear
Resets the following user tool settings:
Maintenance menu: Main scan registration, sub scan registration, image
density, curl control
Resets the settings of the following SPs: 1003, 1104, 1105, 1902, 1910, 2001,
2112, 2113, 2201, 2213, 2301, 2910, 3921, 3922, 3923, 3924, 5930

5-7
PRINTER ENGINE SERVICE MODE April, 2008

5801 3 SCS memory clear

Resets the following user tool settings:
Paper Input menu: Paper type, paper size, tray lock,
System menu: Energy saver timer
Resets the settings of the following SPs: 5009, 5812
Also resets the user code counters.
5801 8 PRT memory clear
Resets the following user tool settings:
Paper Input menu: Tray priority
System menu: Misfeed recovery, print error report, auto continue, memory
overflow, output tray, job separation, memory usage
5801 11 NCS memory clear
Resets the network settings, such as IP address and subnet mask
5801 14 DCS setting
Resets the e-mail settings, such as those stored in SP 5860
5801 16 MIRS setting
Resets the settings used for the e-mail alert feature (such as the
enable/disable setting and the address used for the e-mail alert)

5802 Free run

The machine performs a free run.
Press [Enter] to start.
Press [Enter] to stop.
Please note that the machine will not stop immediately after the [Enter] key is
pressed.

5803 Input check

Displays signals received from sensors and switches.
NOTE: SP Modes other than those listed in this table, are not used in the
machine.
Operation Panel Component Name
5803 1 Front Door Front cover safety switch
5803 2 MainMotLock Main Motor Lock
5803 3 PolygonLock Polygon Motor Lock
5803 5 Duplex door Duplex Unit cover switch
5803 6 Duplex set Duplex Unit
5803 7 Fusing set Fusing Unit
5803 11 StdTrayFul Paper Overflow Sensor
5803 16 Regist Registration Sensor
5803 17 Pap Output Paper Exit Sensor
5803 18 Dup in/out Duplex Inverter Sensor
5803 19 Dup In Duplex Entrance Sensor
5803 20 Duplex Out Duplex Exit Sensor
5803 21 PinBypass Bypass paper sensor
5803 22 NoT1paper Paper end sensor-Standard Paper Tray Unit
5803 23 Tray1 Size Paper size switch-Standard tray
5803 24 T1 Remains Remaining paper sensor-Standard tray
5803 26 No T2 paper Paper end sensor-1st Optional Paper Tray Unit
5803 29 No T3 paper Paper end sensor-2nd Optional Paper Tray Unit
5803 30 Tray 3 Size Paper size switch-2nd Optional Paper Tray Unit

5-8
April, 2008 PRINTER ENGINE SERVICE MODE

5803 Input check

Displays signals received from sensors and switches.
NOTE: SP Modes other than those listed in this table, are not used in the
machine.
Operation Panel Component Name
5803 31 T3 remains Remaining paper sensor-2nd Optional Paper
Tray Unit
5803 32 Carrier 2 Paper feed sensor-1st Optional Paper Tray Unit
5803 33 Carrier 3 Paper feed sensor-2nd Optional Paper Tray Unit
5803 34 Tray 2 size Paper size switch-1st Optional Paper Tray Unit
5803 36 Tray2 Remains Remaining paper sensor-1st Optional Paper Tray
Unit
5803 41 Exit Door Paper output tray cover sensor
5803 42 Sft Carrier Shift tray paper transport sensor
5803 43 Sft to R Shift tray at right
5803 44 Sft to L Shift tray at left
5803 45 PaperinB1 Paper sensor - 1st bin
5803 46 Bin1 Full Paper overflow sensor- 1st bin
5803 47 PaperinB2 Paper sensor - 2nd bin
5803 48 Bin2 Full Paper overflow sensor- 2nd bin
5803 49 PaperinB3 Paper sensor - 3rd bin
5803 50 Bin3 Full Paper overflow sensor – 3 rd bin
5803 51 PaperinB4 Paper sensor - 4th bin
5803 52 Bin4 Full Paper overflow sensor – 4th bin
5803 53 4bin Upr Tr Upper paper transport sensor - Mailbox

Service
Tables
5803 54 4bin Lwr Tr Lower paper transport sensor - Mailbox

5804 Output check

Turns on electrical components individually for test purposes.
NOTE: SP Modes other than those listed in this table, are not used in the
machine.
Operation Panel Component Name
5804 0 Impossible Not used in this machine
5804 1 Main Motor Main Motor
5804 2 Carr Clutch Relay Clutch
5804 3 Reg Clutch Registration Clutch
5804 5 Tray1 Clutch Paper Feed Clutch
5804 6 Byp Clutch Bypass Feed Solenoid
5804 11 Fan/speedy Exhaust fan
5804 12 Fan/slowly Exhaust fan
5804 13 Fus Relay Fusing Lamp Relay
5804 22 Pol Motor Polygon Motor
5804 23 Pol + LD Polygon Motor and Laser Diode
5804 26 T2 Clutch Paper Feed Clutch-1st Optional Paper Tray
Unit
5804 27 T2 Motor Paper Tray Motor-1st Optional Paper Tray
Unit
5804 28 T3 Clutch Paper Feed Clutch-2nd Optional Paper Tray
Unit

5-9
PRINTER ENGINE SERVICE MODE April, 2008

5804 29 T3 Motor Paper Tray Motor-2nd Optional Paper Tray

Unit
5804 31 Exit motor. Paper exit motor (1-bin shift tray, 4-bin
mailbox)
5804 32 Exit solenoid. Paper exit junction gate solenoid
5804 33 Motor to R. 1-bin shift tray - right
5804 34 Motor to L. 1-bin shift tray - left
5804 35 SP1 solenoid. Mailbox turn gate solenoid 2
5804 36 SP2 solenoid. Mailbox turn gate solenoid 3
5804 37 SP3 solenoid. Mailbox turn gate solenoid 4
5804 41 Dup Side Rt. Duplex Inverter Motor-forward
5804 42 Dup Side Rv Duplex Inverter Motor-reverse
5804 43 Dup Long Duplex Transport Motor
5804 44 Dup Split Inverter Gate Solenoid

5810 Fusing err clear

Resets a service call condition (for fusing unit errors).
After using this SP mode, turn the main switch off and on.

5811 Serial Number DFU

Used to input the machine serial number. This is normally done at the factory.
If you want to know the serial number, print the system parameter list. Press
 and then input “A”.

5812 Service Tel. No. Setting

Use these SP modes to input service and support telephone numbers. Enter
the number and press
Press the  key to input a pause. Press the “Clear modes” key to delete the
telephone number.
5812 1 Tel No. Use this to input the telephone number of the
CE printed on the SP print mode printout.
5812 2 Fax Use this to input the fax number of the CE
printed on the SP print mode printout.

5828 Network
5828 71 Primacy I/F DFU
5828 72 Current I/F Displays what type of network is being used.
5828 111 Login mode (NW) Determines which method the printer is
installed in a Netware environment.
0: File server
1: NDS tree
5828 112 NDS Tree Name (NW) Displays the tree name

5-10
April, 2008 PRINTER ENGINE SERVICE MODE

5832 HDD Init

Initializes the hard disk.
Use this only if there is a hard disk error.

5837 Prog checksum

Displays the checksum for the engine firmware.

5839 IEEE1394: Not used

Do not change the setting.

5840 IEEE802.11b: Not used

Do not change the setting.

5844 USB
5844 1 Transfer rate FS Fixation: Full Speed (Fixed)
HS/FS Auto: High Speed/Full Speed
(Automatic change)
Sets the speed for USB data transmission.
5844 2 Vendor ID DFU
5844 3 Product ID DFU
5844 4 Dev release number DFU

Service
Tables
5845 Delivery Server Setting
Provides items for delivery server settings.
5845 3 Retry Interval [60~900 / 300 / 1]
Determines the time interval between retries before the machine returns to
standby after an error occurs during an image transfer with the delivery
scanner or SMTP server.
5845 4 Number of Retries [0~99 / 3 / 1]
Determines the number of retries before the machine returns to standby after
an error occurs during an image transfer with the delivery or SMTP server.

5851 Bluetooth: Not used

Do not change the setting.

5856 Remote Program Update: Local port. (! 5.5)

When set to “enable” allows reception of firmware data via the local port (IEEE
1284) during a remote ROM update.
Disable, Enable
This setting is reset to “disable” after the machine is cycled off and on

5-11
PRINTER ENGINE SERVICE MODE April, 2008

5857 Save Debug Log: Not used

Do not change the setting.

5858 Debug Log Save Function: Not used

Do not change the setting.

5859 Debug Log Save Key No.: Not used

Do not change the setting.

5860 SMTP/POP3/IMAP
5860 2 SMTP ser port no. Input the SMTP server port number
5860 3 SMTP auth SMTP authentication enable/disable
5860 6 SMTP auth encryp Encryption mode for SMTP authentication
enable/disable (Only valid if 5860 3 is set to
“enable”)
5860 7 POP before SMTP Enable/disable POP before SMTP. If the SMTP
server does not have authentication, you can
enable POP before SMTP, them POP
authentication is available (SP 5860 13)
5860 8 POP to SMTP wait When using POP before SMTP, this SP mode
determines the maximum wait time between POP
authentication and connection with SMTP.
Communication stops if this time is exceeded.
5860 13 POP auth encryp If POP before SMTP is enabled, then you can
use this SP to enable or disable encryption mode
for POP authentication
5860 14 POP serv port no. Input the POP server port number
5860 22 SMTP from replace If SMTP authentication is enabled, this SP mode
determines which name is included in the e-mail
header
0: Normal sender name
1: User name used by the authentication feature

5866 E-mail alert 0: Date not added to mail header

1: Date added to mail header

5869 RAM disk setting DFU

5902 Test print

Prints the test pattern that you selected with SP 2902.
5902 1 1 sheet test
Prints one copy of the test pattern
5902 2 Cont test
Prints consecutive copies of the test pattern

5-12
April, 2008 PRINTER ENGINE SERVICE MODE

5907 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 .

5930 Meter charge mode No, Yes

Enables or disables meter-charge mode.
Important: Turn the main switch off/on after changing this setting.
Meter charge mode enabled:
• “Replace Maintenance Kit” is not displayed on the operation panel when the PM
counter runs out (the technician replaces the maintenance kit items)
• The meter charge counter is shown immediately after the Menu key is pressed.
• The technician must reset the PM counter after finishing PM.
Meter charge mode disabled:
• “Replace Maintenance Kit” is displayed on the operation panel when the PM
counter runs out (the user replaces the maintenance kit items)
• The meter charge counter is not shown when the Menu key is pressed.
• The PM counter resets automatically after the user replaces the fusing unit.

5970 Debug Serial Output DFU

SP print mode

Service
5990

Tables
5990 2 SP (Mode Data List) Prints summary sheet for the item selected.
5990 7 NIB Summary

5-13
PRINTER ENGINE SERVICE MODE April, 2008

SP7-xxx: Data Log

7001 Operation time
Displays the total number of engine rotation cycles made so far.
Note: One cycle is calculated as 3.9 s of drum rotation.
However, this counter also includes idle rotations.
This counter is not reset at PM.

7003 Total counter

Displays the controller total counter. This counter is used for meter charge,
and it appears when the user presses the Menu key (if meter charge mode is
enabled).
It does not count up when certain items, such as service reports, are printed
(see section 6.6.1. for a complete list of conditions).

7801 ROM version display

Displays the firmware version (system, engine, and duplex).
7803 1 System Version
7803 2 Engine Version
7803 3 Duplex Version

7803 PM Counter
Displays the PM counter. This is not a page counter. It estimates the page
count using the engine rotation cycle count. It counts up one page when the
engine has made the average number of rotations that is required for one
page of a three-page job.
7803 1 Transfer roller
7803 2 Paper feed roller
7803 3 Fusing unit

7804 PM counter reset

Resets the PM counter.
Important: If a technician replaces the PM items, reset this counter after
replacing these items.
7804 1 Transfer roller
7804 2 Paper feed roller
7804 3 Fusing unit

7832 Diag Result

Press # to display a list of error codes. Nothing is displayed if no errors have
occurred.

7901 Assert Info DFU (Used for debugging.)

7901 1 Assert Info DFU
7901 2 # of Lines DFU
7901 3 Location DFU

5-14
April, 2008 PRINTER ENGINE SERVICE MODE

7993 Total counter

Displays the engine total counter. It counts up for all prints, including service
reports.

SP8-xxx: Counters
8064 P: 1-0-07 P: FIN Jobs
8064 7 Others

8067 O: 1-0-07 O: FIN Jobs

8067 7 Others

8381 T: 2-2-01 T:AplOut/PGS

8381 1

8384 P: 2-2-01 P:AplOut/PGS

8284 1

8387 O: 2-2-01 O:AplOut/PGS

8387 1

Service
Tables
8391 T: 2-2-01 LrgSize Out/PGS
8391 1 A2

8411 T: 2-2-04 DupOut/Sheets

8411 1

8421 T: 2-2-05 T:Dup nUp OutPGS

Mechanical Counter by
Print Mode
8421 1 Simplex> Duplex Counts pages
8421 4 Simplex Combine Combine pages
8421 5 Duplex Combine Combine pages
8421 6 2> Combines 2 in 1
8421 7 4> Combines 4 in 1
8421 8 6> Combines 6 in 1
8421 9 8> Combines 8 in 1
8421 10 9> Combines 9 in 1
8421 11 16> Combines 16 in 1
8421 12 Booklet Prints books
8421 13 Magazine Prints magazines

5-15
PRINTER ENGINE SERVICE MODE April, 2008

8424 P: 2-2-05 P: Dup nUP OutPGS

Controller Counter by
Print Mode
8424 1 Simplex>Duplex Counts pages
8424 4 Simplex Combine Counts pages
8424 5 Duplex Combine Counts pages
8424 6 2> Combine pages
8424 7 4> Combine pages
8424 8 6> Combines 2 in 1
8424 9 8> Combines 4 in 1
8424 10 9> Combines 6 in 1
8424 11 16> Combines 16 in 1
8424 12 Booklet Prints books
8424 13 Magazine Prints magazines

8427 O: 2-2-05 O: Dup nUP OutPGS

Others by Print Mode
8427 1 Simplex> Duplex Counts pages
8427 4 Simplex Combine Combine pages
8427 5 Duplex Combine Combine pages
8427 6 2> Combines 2 in 1
8427 7 4> Combines 4 in 1
8427 8 6> Combines 6 in 1
8427 9 8> Combines 8 in 1
8427 10 9> Combines 9 in 1
8427 11 16> Combines 16 in 1
8427 12 Booklet Prints books
8427 13 Magazine Prints magazines

8441 T: 2-2-07 T: Copy Size/PGS

Mechanical Total Counter
by Page Size
8441 1 A3
8441 2 A4
8441 3 A5
844 1 4 B4
8441 5 B5
8441 6 DLT
8441 7 LG
8441 8 LT
8441 9 HLT
8441 10 12 x 18/ 13 x 19
8441 254 Others: Fixed
8441 255 Others: Custom

5-16
April, 2008 PRINTER ENGINE SERVICE MODE

8444 P: 2-2-07 P: Copy Size/PGS

Controller Count by Page
Size
8444 1 A3
8444 2 A4
8444 3 A5
8444 4 B4
8444 5 B5
8444 6 DLT
8444 7 LG
8444 8 LT
8444 9 HLT
8444 10 12 x 18/ 13 x 19
8444 254 Others: Fixed
8444 255 Others: Custom

8447 O: 2-2-07 O: Copy Size/PGS

Others Count by Page
Size
8447 1 A3
8447 2 A4
8447 3 A5
8447 4 B4

Service
Tables
8447 5 B5
8447 6 DLT
8447 7 LG
8447 8 LT
8447 9 HLT
8447 10 12 x 18/ 13 x 19
8447 254 Others: Fixed
8447 255 Others: Custom

8451 2-2-08 Feed Tray Sheets

Counter by Tray
8451 1 Bypass Tray
8451 2 Standard Tray
8451 3 1st optional tray
8451 4 2nd optional tray
8451 5 Not used in this machine
8451 6 Not used in this machine
8451 7 Not used in this machine
8451 8 Not used in this machine
8451 0 Not used in this machine

5-17
PRINTER ENGINE SERVICE MODE April, 2008

8461 T: 2-2-09 T:Paper Type

Counter by Paper Type
8461 1 Normal
8461 2 Recycled
8461 3 Special
8461 4 Thick
8461 5 Normal (Front)
8461 6 Thick (Back)
8461 7 OHP
8461 8 Other

8464 P: 2-2-09 T: Paper Type

Controller Counter by
Paper Type
8464 1 Normal
8464 2 Recycled
8464 3 Special
8464 4 Thick
8464 5 Normal (Front)
8464 6 Thick (Back)
8464 7 OHP
8464 8 Other

8521 T: 2-2-15 T:FIN Proc/PGS

Total Edit by Print Mode
8521 7 Others

8524 P: 2-2-15 P: FIN Proc/PGS

Total Controller Edit by
Print Mode
8524 1-6 Not used in this machine
8524 7 Others

8581 T: Admin Counter

Total Counter
8581 1 Total

8591 O: 2-2-23 O: Admin Counter

Total Counter
8591 1 A3/DLT
8591 2 Duplex Counter
8591 3 Not used in this machine

5-18
April, 2008 PRINTER ENGINE SERVICE MODE

8771 3-0-01 DevelCnt/PGS

Total Development
Counter
8771 1 Total

8801 3-0-05 Toner Remain

Toner Counter
8801 1 Bk

8941 3-6-01 MachStatus Time

Checks the Machine
Status
8941 1 Operation time
8941 2 Stand-by time
8941 3 Energy Saver time
8941 4 Sleep mode
8941 5 Off mode time
8941 6 Downtime/SC
8941 7 Downtime/Printer Jam
8941 8 Downtime/Scn Jam
8941 9 Downtime/Toner End

Service
Tables

5-19
UPDATING THE FIRMWARE April, 2008

5.4 UPDATING THE FIRMWARE

CAUTION
Do not turn off the machine while downloading the firmware.

5.4.1 CONTROLLER FIRMWARE

NOTE: 1) Turn the machine off before starting the firmware update procedure.
2) Controller/NIB firmware includes the following firmware types:
* Card 0: Platform & Rescue
* Card 1: Printer
* Card 2: Web Support
Use the cards in numerical order starting from card 0, then card 1 and
then card 2

1. Prepare a card that contains the required

firmware.
2. Turn off the power and remove the cover
[A] (1 screw).
3. Insert the card [B] into the card slot [C]
and turn on the power.
4. Push the “Online Key” when “Platform
and Rescue” is displayed (in the case of
card 0).
NOTE: Card 1 will display “Printer” and
card 2 will display “Web Support”.
[C]
5. The firmware download is finished when
“Updated” is displayed. [B] G094S510.WMF

6. After the firmware download has finished, [A]

turn off the power and remove the card.
7. Repeat step 3 to 6 for the remaining firmware cards.
8. After the firmware download has finished, turn off the power and remove the
card. Then replace the cover [A].
9. Turn on the power, and print the service summary report to confirm that the
new firmware version has been installed.

5-20
April, 2008 UPDATING THE FIRMWARE

5.4.2 ENGINE FIRMWARE

CAUTION
The engine firmware for K-P3d and K-P3l is identical. However, the engine
firmware for K-P3s is unique. Before you update the engine firmware, make
sure that you have the correct firmware for the machine that you are
working on.

NOTE: There is only one Engine Firmware card.

1. Prepare a card that contains the required firmware.

2. Turn off the power and remove the cover [A] (1 screw).
3. Insert the card [B] into the card slot [C].
4. Open the front door and then turn on the power.
NOTE: Opening the front door during the engine firmware procedure prevents
overheating in the fusing unit.
5. Push the “Online Key” when “Engine” is displayed.
6. The firmware download is finished when “Updated” is displayed.
7. After the firmware download has finished, turn off the power and remove the
card.

Service
Tables
8. Close the front door and then replace the cover [A].
9. Turn on the power, and print the service summary report to confirm that the
new firmware version has been installed.

5-21
UPDATING THE FIRMWARE April, 2008

5.4.3 ERROR RECOVERY

Controller
If an error occurs during updating the controller firmware, use the following
procedure. This procedure will force the controller to boot from the firmware card.
1. Prepare a card with the required controller firmware version.
2. Turn off the machine and remove the controller.
3. Change the DIP Switch 2 - No. 1 setting to “ON”.
Parallel I/F

CN1
Engine Board

Controller
NIB Board
SW2

Bit 1 2 3 4
ON
OFF

G094S504.WMF

4. Put back the controller

5. Insert the card into the card slot on the controller.
NOTE: When you see the machine from the back, the “A” side of the card must
face the right.
6. Turn on the machine. The machine automatically starts to download the
software.
7. When downloading is finished, “Updated” is displayed.
8. Turn off the machine. Then remove the card.
9. Reset the DIP Switch 2 - No.1 setting to “OFF” and then put back the controller.
NOTE: 1) You must perform steps 5 to 8 for all three firmware cards.
2) The default settings of the DIP Switches are all “OFF”.
10. Turn on the machine, and print the service summary report.

Engine
If a download attempt failed, try downloading the new firmware again using the
normal firmware download procedure described in section 5.4.2.

5-22
April, 2008 REMOTE FIRMWARE UPDATE (RFU)

5.5 REMOTE FIRMWARE UPDATE (RFU)

Refer to the general RTB for the RFU procedure.

NOTE: 1) Before you do the RFU procedure the machine must be in the Frame
Priority setting. This can be set in the memory priority function of the
system menu of the user tools. The reason for this is the Frame Priority
setting uses less of the installed system memory than the Font Priority
setting.
2) You cannot do the RFU if the machine is set to the Font Priority.

5.6 LOOP-BACK TEST

This self-diagnostic test requires a loop-back connector (P/N: G0219350).
1. Turn off the machine and attach the loop-back connector to the parallel
interface.
2. Turn on the machine while pressing the “On Line” key and “# Enter” key
together.
3. The machine prints the diagnostic report automatically.
• To check the error codes, use engine SP mode 7832.
• Refer to section 4.2 for details about the error codes.

Service
Tables
5.7 POWER-ON SELF TESTS
The controller tests the following devices at power-on. If an error is detected, an
error code is stored in the controller board.
• CPU, ASIC and clock
• Flash ROM
• Resident and optional SDRAM
• Parallel interface
• NIB
• NVRAM
• Optional HDD (if installed)

• To check the error codes, use engine SP mode 7832.

• Refer to section 4.2 for details about the error codes.

5-23
USER PROGRAM MODES April, 2008

5.8 USER PROGRAM MODES

Press the “Menu” button and use the “Up/Down arrow” keys to scroll through the
menu listing. To go back to a higher level, press the “Escape” key. After changing
the settings, press the “On Line” key. The user menu list can be printed using
“Menu List” in the “List/Test Print” user mode.
User Mode Tree
User Mode Counter (Meter-charge mode must be switched on by the SP mode)

Sample Print (optional HDD required)

Locked Print (optional HDD required)

Paper Input Bypass Size

Tray Paper Size
Paper Type
Tray Locking
Tray Priority
List/Test Print

Maintenance Image Density

Registration
Curl Prevention
HDD Format (optional HDD required)
WL. LAN Signal (Wireless LAN required)
WL. LAN Defaults (Wireless LAN required)
Key Repeat
Menu Protect
Paper Size Error

System Print Error Report

Auto Continue
Memory Overflow
Copies
Printer Lang.
Sub Paper Size
Page Size
Edge to Edge Print
Def. Print Lang.
Duplex (optional duplex unit required)
Energy Saver
Memory Usage
Unit of Measure
Edge Smoothing
Toner Saving
Spool Printing
Letterhead Mode
RAM Disk
Notify by E-Mail
E-Mail Date

Host Interface I/O Buffer

I/O Timeout
Network Setup (NIB required)
IEEE1394 Setup (IEEE1394 required)
IEEE802.11b Setup (Wireless LAN required)
USB Setting
Bluetooth

PCL Menu Orientation

Form Lines
Font Source
Font Number
Point Size
Font Pitch
Symbol Set
Courier Font
Ext. A4 Width
Append CR to CF
Resolution
PS menu Data Format
Resolution

PDF menu PDF: Change PW

Resolution
Language

G094S511.WMF

5-24
April, 2008 DIP SWITCHES

5.9 DIP SWITCHES

Controller Board
DIP Switch 2 (Bit 1) on the controller is used for error recovery after a firmware
updating procedure failed.

NOTE: The default settings of the DIP Switches are all “OFF”.
Parallel I/F

CN1
Engine Board

Controller
NIB Board
SW2

Bit 1 2 3 4
ON

Service
Tables
OFF

G094S504.WMF

5-25
April, 2008 OVERVIEW

6. DETAILED SECTION DESCRIPTIONS

6.1 OVERVIEW
The descriptions in this section are for the G091 China model machine.

6.1.1 MECHANICAL COMPONENT LAYOUT

15 1
14
2

13 4

12

11
6

G094D522.WMF 7
10
9 8

Descriptions
1. Laser unit 9. Registration roller Detailed

2. Cartridge (AIO-type) 10. Transfer roller

3. Charge roller 11. Drum
4. Development roller 12. Pressure roller
5. By-pass feed tray 13. Hot roller
6. By-pass feed roller 14. Paper exit roller
7. Paper feed roller 15. Quenching lamp
8. Friction pad

6-1
OVERVIEW April, 2008

6.1.2 PAPER PATH

[A]

[C]

[B]

[D]
G091D109.WMF

[A]: Optional four-bin mailbox

[B]: Optional paper tray unit
[C]: Optional duplex unit
[D]: Optional one-bin shift tray unit

G091D110.WMF

6-2
April, 2008 BOARD STRUCTURE

6.2 BOARD STRUCTURE

6.2.1 BLOCK DIAGRAM

IEEE1284 Memory
Interface DIMM
Standard
components
NIB HDD

Standard
PCB USB 2.0 Printer
Controller
Board
Optional
components

Power Polygon Synch.

Motors Motor LDDR
Pack Detector

PCI Bus

Operation
(Laser Control Block) Panel

Engine Board
PSU

Descriptions
Detailed
Fusing Lamp

Paper
ID Chip 4-bin 1-bin Tray Duplex
Unit Clutches Sensors Thermistor
(Cartridge) Mailbox Shift Tray Unit
(Upper)

Paper
Tray
Unit
(Lower)

G091D910_CHN.WMF

The engine board controls all the mechanical components.

The printer controller board connects to the engine board through a PCI bus.

6-3
BOARD STRUCTURE April, 2008

6.2.2 DESCRIPTIONS
1. Engine Board
The engine board controls these functions:
• Engine sequence
• Machine and printer engine operation
• Timing for external options
• High voltage supply, laser, and fusing
• Sensors, motors, and solenoids
2. Printer Controller Board
The printer controller board controls these functions:
• Printer-to-host interface
• Operation panel interface
• Interfacing and control of the NIB, printer interface boards, and other
options (HDD and DRAM DIMM)
3. LDU
This controls the laser diodes.

4. Network Interface Board (NIB)

The network interface board connects the printer to a network.

5. HDD Unit (Option)

The HDD unit holds the data for these functions:
• More soft fonts
• Collation
• Locked print
• Sample print
• Downloading forms for form overlay

6. Memory DIMM (Option: 64MB/128MB/256MB DRAM)

This gives more memory for printer processing, collation, and for soft fonts.

7. Operation Panel Board

Controls the display panel, the LED, and the key pad.

8. Standard interface boards

The machine has these built-in printer interfaces:
• IEEE1284 (also known as Centronics or parallel port), USB, Ethernet

6-4
April, 2008 BOARD STRUCTURE

6.2.3 CONTROLLER BOARD

PCI Option I/F

PCI Option
CPU

USB2.0 I/F
USB2.0
PCI
HDD I/F

Engine I/F
ASIC
PICCOLO PCI

IEEE 1284 I/F

SDRAM-DIMM
SDRAM
(Option)

FLASH
ROM

NIB I/F
Font ROM

Control Signals

Data Bus
ROM-
DIMM

Descriptions
Detailed
NVRAM

IC CARD
I/F

Controller Board

G091D909_CHN.WMF

The PICCOLO ASIC controls all the functions of the printer

PICCOLO
controller board.
CPU TX4955 300 Mhz
Resident: 64 MB SDRAM
RAM
Option: 1 slot SDRAM DIMM (64/128/256 MB)
Flash: 16 MB ROM (Emulation)
ROM
Mask: 4 MB (PCL/PS font)
NVRAM Stores the controller settings
HDD 6 GB

6-5
PRINTING PROCESS April, 2008

6.3 PRINTING PROCESS

6.3.1 OVERVIEW

1
7

2
6

4
G094D525.WMF

1. Drum Charge:
The charge roller gives the drum a negative charge.
2. Laser Exposure:
A laser beam writes the print data on the drum.
3. Development:
The development roller moves toner to the latent image on the drum surface.
4. Image Transfer:
The transfer roller moves the toner from the drum to the paper.
5. Separation:
The separation plate helps to remove the paper from the drum.
6. Cleaning:
The cleaning blade removes remaining toner on the drum surface after the
image moved to the paper.
7. Quenching:
The light from the quenching lamp cancels the charge that stays on the drum.

6-6
April, 2008 PRINTING PROCESS

6.3.2 LASER EXPOSURE

Overview 2
1

3
11

10

9
6

8 7
G094D526.WMF

1. LD unit 7. Synchronization detector

2. Laser shutter 8. Toroidal lens

Descriptions
3. Shield glass 9. 1st mirror

Detailed
4. Polygon mirror 10. 2nd mirror
5. F-Theta lens 11. Detector mirror
6. Drum

• Synchronization detector: The 1st mirror, 2nd mirror, and the detector mirror
reflect the beam from the LD unit to the synchronization detector.
• Two laser beams: The LD unit writes two lines at the same time.
• LD safety shutter: When the user opens the front cover, the shutter closes and
blocks the laser beam path.
• After you replace the LD unit, adjust its position (see Replacement and
Adjustment).
• The thermistor next to the laser unit (not shown) checks the temperature inside
the machine. The machine automatically corrects the charge roller and transfer
voltages for this temperature.

6-7
PRINTING PROCESS April, 2008

Automatic Power Control (APC)

Engine Board LD Drive Board

+5VLD

PD LD

ALOFF APD

ALD

Data
LD
GAVD
Control IC
BLOFF PD LD

BPD
DROPEN
BLD

VREF
Regu-
lator

G094D527.WMF

The LD control IC on the engine board automatically controls power for the laser
diodes. The laser diode power is adjusted in the factory.
NOTE: Do not touch the variable resistors on the LD unit in the field.

6-8
April, 2008 PRINTING PROCESS

LD Safety Mechanisms

PSU Engine Board

+24V

Front Cover SW

Rear Cover SW

LD Drive Board

Regulator
+5VLD

LD
Control IC

G094D528.WMF

Laser Safety Switch

Descriptions
There are safety switches on the front and rear covers. These switches stop the

Detailed
laser while the cover is open.
If the user opens one of these covers, the +5VLD power to the laser diodes is
stopped.

Laser Shutter [A]

The laser shutter [A] is for back-up safety. If
the switches do not work, the +5VLD power
gets to the laser diodes if the cover is open.
The laser shutter cuts the laser beam when
the front cover is open.

G094D529.WMF

6-9
PRINTING PROCESS April, 2008

6.3.3 CARTRIDGE OVERVIEW

[I] [J] [A] [B]

[C]
[H]

[G] G094D530.WMF
[F] [E] [D]

[A]: Charge roller [F]: Drum

[B]: Developer tank [G]: Drum shutter
[C]: Toner tank [H]: Waste toner tank
[D]: Reverse roller [I]: Toner collection roller
[E]: Development roller [J]: Cleaning blade

This type of cartridge is known as an “All-in One” (AIO) cartridge.

6.3.4 DRUM CHARGE [B]

[A]: Charge roller
[B]: Cleaning pad

• The charge roller [A] gives the drum

surface a negative charge of
approximately –900 V.
• The cleaning pad [B] touches the charge
roller to clean the surface. [A]
G094D531.WMF

6-10
April, 2008 PRINTING PROCESS

6.3.5 DEVELOPMENT

[A]
[A]: Toner tank
[B]: Agitator [H]
[C]: Pre-doctor blade
[D]: Development roller [G]
[E]: Drum
[F]: Doctor blade
[G]: Reverse roller [F]
[H]: Developer tank

[E]

G094D532.WMF
[D] [C] [B]

Toner Supply
The agitator [B] mixes toner and sends it to the development roller.

Development Unit

Descriptions
Detailed
This machine uses a one-roller development system. The high voltage supply
applies -700V to the development roller.
When the user removes the developer seal, the developer falls and the magnetic
reverse roller [G] mixes the developer.
This machine does not use a TD sensor or ID sensor to control toner density. The
pre-doctor blade [C] and the doctor blade [F] control the toner density.

6-11
PRINTING PROCESS April, 2008

Toner Density Control

[A] [A]
[B] [B]

[C] [C]

G094D533.WMF G094D534.WMF

More toner is fed when the toner Less toner is fed when the toner
coating on the development roller coating on the development roller

[A]: Pre-doctor blade

[B]: Doctor blade
[C]: Circulation of developer
A mixture of toner and developer circulates at the pre-doctor blade [A].
When the toner on the development roller decreases, the circulating region [C] gets
smaller to let more toner get to the development roller.
When the toner on the development roller increases, the circulating region [C] gets
bigger to let less toner get to the development roller.

Development Bias
Print Data: White Black Toner

GND
-140V Laser Exposed Area

-700V Developmemt Roller

-900V Drum Surface Voltage

G094D535.WMF

Toner transfers from the development roller to the areas on the drum that were
exposed to the laser.

6-12
April, 2008 PRINTING PROCESS

Toner End Detection

[A]
[A]: Toner tank
[B]: Toner end sensor

The toner end sensor detects toner

near-end by the voltage output.

[B]

G094D536.WMF

Toner near-end
When the output from the toner end sensor is below a given level, the machine
displays “Low on Toner” to tell the user.

Toner end
After toner near-end, the machine can print 200 more pages, and then it prevents
printing. At this time, “Replace Toner Cartridge” is displayed. The 200-page limit
can be changed with engine SP 2213.
The machine also displays “Replace Toner Cartridge” when the output from the

Descriptions
Detailed
toner end sensor is below a given level.
NOTE: To prevent waste toner tank overflow, you can make the machine stop
printing if the total number of prints per cartridge is more than 30k. To
make the machine stop, use engine SP 3923.
To adjust the 30k limit, use engine SP 3922.

6-13
PRINTING PROCESS April, 2008

6.3.6 IMAGE TRANSFER AND PAPER SEPARATION

Overview
[A] [B]

[C] G094D537.WMF

[A]: Drum
[B]: Development roller
[C]: Transfer roller
[D]: Transfer roller
[E]: Separation plate [F]
[F]: High voltage supply [E]

[D]

G094D538.WMF

This machine uses a transfer roller [C] to pull the toner from the drum [A] to the
paper. The high voltage supply [F] applies a positive current (+18µA) to the transfer
roller [C]. To adjust the current applied to the transfer roller [C], use engine SP
2301. The separation plate [E] helps to remove paper from the drum.

6-14
April, 2008 PRINTING PROCESS

Transfer Roller Cleaning

After a paper jam or when the user sets the incorrect paper size, toner can transfer
to the rear side of printouts. To prevent this, the machine automatically cleans the
transfer roller before the next printing cycle.
During transfer roller cleaning, the high voltage supply applies a negative current
(–3µA) to the transfer roller.
The machine cleans the transfer roller in these conditions:
• At power on
• During fusing unit warm-up
• Immediately after a jam is removed
• When the front cover is opened and closed
• After a job which is 10 pages or larger

6.3.7 CLEANING
[A]
[A]: Cleaning blade
[B]: Drum [D]
[C]: Toner collection
roller
[D]: Waste toner
tank

[C]

Descriptions
Detailed
[B] G094D539.WMF

The cleaning blade [A] removes toner that remains on the drum. The toner
collection roller [C] moves the toner to the waste toner tank.
There is no waste toner overflow detection. See “Toner End Detection” for more on
how to prevent waste tank overflow.

6-15
PRINTING PROCESS April, 2008

6.3.8 QUENCHING

[A]: Quenching lamp

[B]: Drum
[A]

[B]

G094D540.WMF

Light from the quenching lamp [A] (LED) gets to the drum [B] through the opening
at the top of the cartridge.

6.3.9 ID CHIP AND INTERNAL THERMISTOR

[C]
[A]: ID chip
[B]: Internal Thermistor
[C]: Cartridge

[A]

[B]
G094D541.WMF

The cartridge contains an ID chip.

6-16
April, 2008 PAPER FEED

6.4 PAPER FEED

6.4.1 OVERVIEW
1 2 3

9
5

G094D002.WMF

7 6
1. Registration Roller 6. Friction pad
2. Paper end sensor 7. Feed roller
3. Relay Roller 8. Paper tray
4. By-pass feed roller 9. Remaining paper sensors (1 and 2)

Descriptions
Detailed
5. By-pass friction pad

Paper Tray
Paper Feed System: Feed roller and friction pad
Paper Lift Mechanism: Tray arm and spring
Paper End Detection: Remaining paper sensors
Paper end sensor
Paper Size Detection: Paper size switch
Tray Capacity: 500 sheets
Tray Extension: Available

By-pass Tray
Paper Feed System: Feed roller and friction pad
Paper Lift Mechanism: Cams and springs
Paper Detection: By-pass tray paper sensor
Paper Size Detection: None
Tray Capacity: 100 sheets

6-17
PAPER FEED April, 2008

6.4.2 PAPER TRAY

Tray Extension [A]

The user can extend the tray

manually to hold paper longer
than A4/Letter size.
To use longer paper:
• Release the two locks [A]
• Then extend the tray and close
the locks.
These paper sizes can be used:

G094D003.WMF

Paper Sizes
Tray Mode Possible Paper Sizes
Short (default) A5 (LEF), B5 (LEF/SEF), A4 (LEF/SEF), 10.5"x7.25" (LEF),
LT (LEF/SEF)
Long B4 (SEF), A3 (SEF), 8.5"x13" (SEF), 8"x13" (SEF), 8.25"x13" (SEF), LG
(SEF), DLT (SEF)

Paper Lift [D]

[C]
When the user puts the tray [A]
in the machine, the bottom plate
[B] lifts as follows.
• The slopes on the guide
blocks [C] on the machine lift [E]
the tray arms [D] up.
• The springs [E] between the
tray arms and bottom plates
lift the plate.
• The springs [E] keep the top
sheet of the paper at the
correct height.

[A] [B]
G094D004.WMF

6-18
April, 2008 PAPER FEED

Paper Feed and Registration

[H]
[B]

[D]

[A]
[F]
[E]
[G]
[C] G094D102.WMF

[A]: Feed roller [E]: Friction pad

[B]: Registration roller [F]: Registration sensor
[C]: Paper feed clutch [G]: Relay clutch

Descriptions
[D]: Registration clutch [H]: Relay roller

Detailed
NOTE: 1) The friction pad cannot be adjusted.
2) The machine makes a paper buckle at the registration roller to correct
paper skew.
3) The paper buckle can be adjusted with engine SP 1003.

6-19
PAPER FEED April, 2008

Paper Size Detection

[A]

[B]

G094D542.WMF

[A]: Paper size switch

[B]: Paper size dial

Paper Size Detection

SW 1 2 3
Size
A3 ! ! !
A4 LEF ! " "
A4 SEF ! ! "
A5 LEF " ! !
LT LEF " ! "
LT SEF ! " !
∗ " " !
!: ON (Not pushed)
": OFF (Pushed)

• The machine disables paper feed from a tray if it cannot detect the paper size.
This occurs when the paper size actuator is broken or no tray is installed.
• When the dial is at the “*” mark, the user can set the paper tray up for a wider
range of paper sizes with a User Tool (Paper Input menu – Tray Paper Size).

6-20
April, 2008 PAPER FEED

Paper End Detection

• When there is no paper in the tray, the feeler [A] falls into the cutout in the
bottom plate, and the paper end sensor comes on.

[A]

G094D543.WMF

Descriptions
Detailed

6-21
PAPER FEED April, 2008

Remaining Paper Detection

• Remaining paper is detected by the combination of the remaining paper sensor
signals. The signals from the sensors indicate whether there are 500, 450, 250,
or 50 sheets remaining.

[B]

[A]

G091D111.WMF

[A]: Remaining paper sensor 1

[B]: Remaining paper sensor 2

Remaining paper Remaining paper

Amount of paper
sensor 1 sensor 2
1-50 sheets (10%) OFF OFF
51-250 sheets (50%) OFF ON
251-450 sheets (90%) ON ON
451-500 sheets (100%) ON OFF
OFF: Unblocked, ON: Blocked

6-22
April, 2008 PAPER FEED

6.4.3 BY-PASS TRAY

[D]
[E]

G094D103.WMF [A]

[B] [C]

Descriptions
Detailed
[F]
G094D101.WMF

• The by-pass paper sensor [A] detects when paper is placed on the tray.
• The CPU energizes the by-pass feed solenoid [B]. Then the by-pass feed roller
[C] starts to feed paper to the registration roller [D] through the relay roller [E].
• The by-pass feed roller shaft has two cams [F]. These cams release the bottom
plate to press the stack of paper against the feed roller.
• There is no width sensor.

NOTE: To prevent bad effects from too much friction between the feed roller and
friction pad, the feed roller contains a metal plate.

6-23
IMAGE FUSING AND PAPER EXIT April, 2008

6.5 IMAGE FUSING AND PAPER EXIT

6.5.1 OVERVIEW
1

10
3

9
4

8
5

7 G094D503.WMF 6

1. Paper exit roller 6. Hot roller

2. Hot roller strippers 7. Fusing pressure roller
3. Thermostat 8. Pressure spring
4. Thermistor 9. Fusing exit roller
5. Fusing lamp 10. Paper exit sensor

6-24
April, 2008 IMAGE FUSING AND PAPER EXIT

6.5.2 FUSING DRIVE

[A]

G094D504.WMF

The main motor [A] drives the fusing unit through a gear train.

6.5.3 FUSING ENTRANCE AND GUIDE SHAFT

Descriptions
Detailed
[B]

[A] [B] [B]

G094D545.WMF

NOTE: 1) The entrance guide [A] is adjustable for paper thickness to prevent
creasing.
2) If creasing occurs frequently in the fusing unit, remove all screws [B]
and slide the entrance guide to the right. Replace the two end screws
only. Do not replace the middle screw.
3) This procedure allows paper to have more direct access to the gap
between the hot roller and the pressure roller.

6-25
IMAGE FUSING AND PAPER EXIT April, 2008

6.5.4 PRESSURE ROLLER

[A]

G094D505.WMF

• To change the applied pressure, adjust the position of the pressure springs [A].
The factory setting for the spring position is at the top (minimum pressure).

6-26
April, 2008 IMAGE FUSING AND PAPER EXIT

6.5.5 NEW FUSING UNIT DETECTION

[A]

G094D546.WMF

There are two types of fusing unit: Service part, and Maintenance Kit part.
NOTE: Only the fusing unit in the maintenance kit has this detection mechanism.
In the maintenance kit fusing unit, the looped wire on the fusing unit connector
contains a fuse [A]. When power is switched on after installing a new fusing unit,
the engine board detects the fusing unit through the looped wire. However, the fuse
opens very shortly afterwards.
What happens next depends on the setting of engine SP mode 5930 (Meter
Charge):

Descriptions
Detailed
If Meter Charge Mode is enabled
• After the technician replaces the fusing unit, the maintenance counter must be
reset with engine SP mode 7-804.
• 7-804-1: Transfer roller
• 7-804-2: Paper feed roller
• 7-804-3: Fusing unit).

If Meter Charge Mode is disabled (default setting)

• After the fusing unit has been replaced, the CPU detects the new unit and
automatically removes the “Replace Maintenance Kit” message. Then, the
maintenance counter resets automatically.

6-27
IMAGE FUSING AND PAPER EXIT April, 2008

6.5.6 FUSING TEMPERATURE CONTROL

(°C)
200
printing

168 standby

138 Ready to print

100

0
t
Main SW on
G094D547_CHN.WMF

When the main switch turns on, the CPU turns on the fusing lamp using the soft
start process. The lamp stays on until the thermistor detects the standby
temperature. Then the CPU maintains this temperature using on-off control. To
start printing, the CPU raises the temperature to the printing temperature.
The fusing temperature for each mode is as follows:

Condition Temperature Note

The machine can
Ready to print 138 °C start to print any
time.
Standby mode 168 °C On-off control
Print start ~ 2 min. ~
Printing 4 min ~
2 minutes 4 min.
Tray 170 °C 165 °C 160 °C
By-pass (Envelopes) 180 °C 180 °C 180 °C
On-off control
By-pass (Post Cards) 185 °C 185 °C 185 °C
By-pass (Others) 170 °C 165 °C 160 °C
Envelope Feeder 180 °C 180 °C 180 °C
Thick Paper 185 °C 185 °C 185 °C

NOTE: The soft start process prevents the room lights from flickering.

6-28
April, 2008 IMAGE FUSING AND PAPER EXIT

Overheat Protection
• If the hot roller temperature becomes greater than 240 °C, the CPU cuts off the
power to the fusing lamp. At this time, SC543 will be generated.
• 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
becomes greater than 210 °C, the thermostat opens, removing power from the
fusing lamp. At this time, the machine stops operation.

6.5.7 PAPER EXIT

[B]

[A]

Descriptions
Detailed
G094D601.WMF

[A]: Paper overflow detection sensor

[B]: Paper exit sensor

• When the paper overflow detection sensor [A] is activated, the machine detects
that the paper stack height has exceeded a certain limit and stops printing.
• The paper exit sensor [B] detects paper misfeeds.

6-29
IMAGE FUSING AND PAPER EXIT April, 2008

6.5.8 ENERGY SAVER MODE

When the machine is not being used, the energy saver feature reduces power
consumption by switching off the fusing lamp.

Entering Energy Saver Mode

Energy saver mode starts after the machine has been idle for a certain time. The
user specifies the time and the following choices are available:

NOTE: Press the Menu key on the operation panel, and access the System
menu).
• Off (energy saver mode never activates)
• 5 minutes
• 15 minutes
• 30 minutes (default)
• 60 minutes
When the machine is in energy saver mode, the CPU turns off the fusing lamp.
However, the +24V, +12V, and +5V lines are still active.

Leaving Energy Saver Mode

The machine leaves energy saver mode when one of the following happens.
• Print command received from the PC
• Any cover opened and closed
• Any operation panel keys pressed

6-30
April, 2008 CONTROLLER FUNCTIONS

6.6 CONTROLLER FUNCTIONS

6.6.1 METER CHARGE MODE

Meter-charge Counter Display

When meter charge mode (engine SP 5930) is Menu:
switched on, the meter-charge counter menu is the first Counter
item shown on the user menu.
(The “Sample Print” menu appears first when the meter-charge mode is switched
off.)

PM Warning Display
When meter charge mode (engine SP 5930) is switched on, “Replace Maintenance
Kit” will not be displayed at 90k prints.
NOTE: The default setting for this machine is meter-charge mode off.
Item Meter-charge On Meter-charge Off Remarks
Meter-charge Shown as the first
Not shown User menu
counter item in the user menu
“Replace Maintenance
PM Warning Not shown Kit” displayed at 90k
prints
PM Service Customer
Automatically reset
Printer engine
when the fusing unit is
PM Counter Reset manually service mode “PM
replaced using the
counter”
maintenance kit

Descriptions
Detailed
The meter-charge counter is not the same as the PM counter. This is because, in
the following cases, the meter-charge counter does not count up.
• Blank rear side during duplex printing
• Blank page when using the “Cover Page” or “Two in One” features
• Service reports
NOTE: The meter-charge counter cannot be reset.

6-31
April, 2008 SPECIFICATIONS

SPECIFICATIONS
1. GENERAL SPECIFICATIONS
Comparing the models of the G091 series
G091-69 (K-P3D) G091-21 (K-P3L) G091-20 (K-P3S)
Paper Size A3/11”x17” A3/11”x17” A3/11”x17”
PPM: Simplex 32 (A4/LT) 32 (A4/LT) 28 (A4/LT)
PPM: Duplex 31.5 (A4/LT) 31.5 (A4/LT) 28 (A4/LT)
CPU 300Mhz x1 300Mhz x1 300Mhz x1
Max. resolution 1,200 dpi 1,200 dpi 1,200 dpi
First print* 6.5sec. 6.5sec. 6.5sec.
Paper input capacity 600/1,600 600/1,600 600/1,600
(Std/Max)
AIO yield (prints) 20k or 12k 20k or 12k 20k, 12k, or 6k
Starter AIO yield 6k 6k 3k
(prints)
RAM (Std/Max) 64MB/320MB 64MB/320MB 64MB/320MB
HDD option Approx. 6GB Approx. 6GB Approx. 6GB
Ethernet NIC Standard Option Option
USB2.0 Standard Standard Standard
IEEE802.11b Not available Not available Not available
IEEE1394 Option (Complies with Option (Complies with Option (Complies with IP
IP over 1394) IP over 1394) over 1394)
Bluetooth Not available Option Option
Duplex Option Option Option
4-bin Mailbox Option Option Option
1-bin Shift Tray Option Option Option
Drivers RPCS, PCL5e/6, PS3 RPCS, PCL5e/6, PS3 RPCS, PCL5e/6, PS3
Dimensions 478x437x343(mm) 478x437x343(mm) 478x437x343(mm)
WxDxH 18.8x17.2x13.5 (inch) 18.8x17.2x13.5 (inch) 18.8x17.2x13.5 (inch)
Weight 20Kg/44lbs 20Kg/44lbs 20Kg/44lbs
*Gray cells show where specifications are different between the models.
*First print speed: The time after data processing completion to printed paper
output completion.
Spec.

SPEC-1
SPECIFICATIONS April, 2008

The specifications in this section are for the G091 China model machine.
Configuration Desktop
Paper size A3 / 11"x17" SEF – A6 SEF
Technology Laser beam scanning & Electro photographic printing
Dual component toner development AIO is used
Print Resolution 300 dpi, 600 dpi, 1200 dpi
Smoothing Yes (on, off)
Continuous Print Speed See "Comparing the models of the G091 series".
Duplex Print Speed See "Comparing the models of the G091 series".
First Print Speed 6.5 seconds or less (A4/LT, LEF from standard tray)
Copy Paper Weight Paper Tray 60-105 g/m² (16-28 lb.)
By-pass tray 52-162 g/m² (14-43 lb.)
Optional paper tray 60-105 g/m² (16-28 lb.)
Duplex 64-105 g/m² (17-28 lb.)
Warm-up Time 19 seconds or less from power on (23 °C, 73 °F)
12 seconds or less from energy saver mode
Paper Input Size Standard tray A3 / 11" x 17" – A5 LEF
By-pass tray A3 / 11" x 17" – A6 SEF
By-pass tray-Custom size Length: 148 - 432 mm
paper Width: 90 - 305 mm
Com#10, C5, C6, DL. Monarch
Optional Envelope Feeder Com#10, C5, C6, DL. Monarch
Optional paper tray unit A3 / 11" x 17" – B5 LEF
Up to 2 units can be
installed.
Paper Input Capacity Standard tray and 500 sheets (80 g/m², 20 lb.)
Optional paper trays
By-pass tray 100 sheets (80 g/m², 20 lb.)
Optional Envelope feeder 60 envelopes
Output Capacity 250 sheets (Maximum 500 sheets)
Total Counter Electric Counter
Environmental Standard CCC Regulation

SPEC-2
April, 2008 SPECIFICATIONS

2. PHYSICAL SPECIFICATIONS
Power Source 220 V - 240 V, 50/60 Hz: More than 6.0 A
Power Consumption Main Unit Full system
(including NIB)
Maximum 850 W or less 920 W or less
Printing 620 W or less 650 W or less
Energy Saver 6.5 W or less 10.5 W or less
Noise Emission Mainframe Only Full System
Printing 67 dB or less 71 dB or less
Stand-by 40 dB or less 40 dB or less
Energy Saver 40 dB or less 40 dB or less
Sound Pressure Level Printing 55dB or less (Operating position)
Energy Saver 30dB or less (Operating position)
Weight 19.5 Kg. 43 lb. (including Paper Tray and AIO)
Dimensions Excluding standard tray 478 x 410 x 343 mm
(W x D x H) Including standard try 478 x 437/575 x 343 mm

Spec.

SPEC-3
SPECIFICATIONS April, 2008

3. CONTROLLER
CPU TX4955 300Mhz
Printer Languages RPCS, PCL6, PCL5e emulation, Adobe PS3 (genuine), Adobe PDF
Resolution RPCS 600/1200 dpi
PCL6 600/1200 dpi
PCL5e 300/600 dpi
PS3 600/1200 dpi
Resident Fonts PCL 35 Intellifonts, 10 TrueType fonts, 1 bitmap font
PS 136 Type1 fonts
Font Manager and 31 additional fonts for PCL to be loaded to the PC,
Euro currency ok.
Drivers RPCS Win 2000, XP, Server 2003, Vista
PCL6 Win 2000, XP, Server 2003, Vista
PCL5e Win 2000, XP, Server 2003, Vista
PS3 Win 2000, XP, Server 2003, Vista
Mac OS 8.6.0 or later, Mac OSX (10.1 or later)
ROM Flash: 16 MB (Emulation)
Mask: 4MB (PCL/PS font)
RAM Resident 64 MB SDRAM
Option 1 slot SDRAM DIMM (64/128/256 MB)
HDD Option: Approximately 6 GB
Interface USB2.0 (Win98, 2000, ME, XP, Server 2003)
Standard
Bi-directional IEEE1284 10/100 Base-TX
Firmware Update Flash Memory card (3 cards)
RFU (Remote Firmware Update)
Network Protocol TCP/IP (including IPP), IPX/SPX, NetBEUI, Apple Talk
NRS Supported

SPEC-4
April, 2008 SPECIFICATIONS

4. SUPPORTED PAPER SIZES

Paper Trays
By-pass Env.
Paper Size (W x L) Main Unit/Option Duplex
Tray Feeder
US Eur/Asia
A3 297 x 420 mm Y#/Y Y/Y Y# N Y
B4 257 x 364 mm Y#/Y# Y#/Y# Y# N Y
A4 SEF 210 x 297 mm Y#/Y Y/Y Y# N Y
A4 LEF 297 x 210 mm Y/Y Y/Y Y# Y Y
B5 SEF 182 x 257 mm Y#/Y# Y#/Y# Y# N Y
# #
B5 LEF 257 x 182 mm Y /Y Y#/Y# Y# N Y
A5 SEF 148 x 210 mm N N Y# N N
A5 LEF 210 x 148 mm Y#/N Y/N Y# N Y
A6 SEF 105 x 148 mm N N YC N N
Ledger 11" x 17" Y/Y Y#/Y Y# N Y
Legal 8.5" x 14" Y/Y Y#/Y Y# N Y
Letter SEF 8.5" x 11" Y/Y Y/Y Y# N Y
Letter LEF 11" x 8.5" Y/Y Y/Y Y# N Y
Half Letter SEF 5.5" x 8.5" N N Y# N N
Half Letter LEF 8.5" x 5.5" N N N N N
Executive SEF 7.25" x 10.5" N/Y# N/Y# Y# N N
Executive LEF 10.5" x 7.25" Y#/Y# Y#/Y# Y# N Y
# #
F 8" x 13" Y /Y Y#/Y# Y# N Y
#
Foolscap 8.5" x 13" Y/Y Y#/Y# Y# N Y
Folio 8.25" x 13" Y#/Y# Y#/Y# Y# N Y
Com10 Env. 4.125" x 9.5" N N Y# Y# N
Monarch Env. 3.875" x 7.5" N N Y# Y# N
C6 Env. 114 x 162 mm N N Y# Y# N
C5 Env. 162 x 229 mm N N Y# Y# N
DL Env. 110 x 220 mm N N Y# Y# N
8K 267 x 390 mm Y#/Y# Y#/Y# Y# N Y
16K SEF 195 x 267 mm Y#/Y# Y#/Y# Y# N Y
16K LEF 267 x 195 mm Y#/Y# Y#/Y# Y# N Y
Custom Minimum:
90 x 148 mm
N/YC N/YC YC N N
Maximum:
305 x 432 mm

Y: Supported. The paper size sensor detects the paper size.

Y#: Supported. The user has to select the correct paper size for the tray.
YC: Supported. The user has to enter the width and length of the paper.
N: Not supported.
Spec.

SPEC-5
SPECIFICATIONS April, 2008

5. OPERATION PANEL LED SPECIFICATIONS

LED Color Appearance Meaning
Off Power off or in Energy Saver mode
Power Green Flashing Warming up

On Power on and not in Energy Saver mode

Off No data
Data being received or processed or the printer is
Data In Green Flashing
spooling
Data being received or processed; more data
On
coming
Off Printer off-line

Online Green Flashing Going off-line

On Ready to print
No messages or error conditions requiring
Off
Error Red attention
On Printer requires service

6. EXTERNAL OPTIONS
Paper Size A3/ 11" x 17”-B5 LEF
Paper Weight 60 – 105g/m², 16 – 28 lb.
Paper Feed Unit Paper Capacity Maximum 500 sheets
(G555) Dimensions
468 x 410/545 x 130 mm
(W x D x H)
Weight 6 kg
Paper Size A3/ 11" x 17”-A5 LEF
Paper Weight 64 – 105g/m², 18 – 28 lb.
Duplex Unit
Dimensions
(G552) 419 x 378 x 257 mm
(W x D x H)
Weight 6 kg
Paper Size A3/ 11" x 17”-A5 LEF
Paper Stack 50 sheets / bin (80g/m2)
4-Bin Mailbox Paper Weight 60 – 105g/m², 16 – 28 lb.
(G553) Dimensions
465 x 395 x 285 mm
(W x D x H)
Weight 5.5 kg
Paper Size A3/ 11" x 17”-A5 LEF
Paper Stack 250 sheets / bin (80g/m2)
1-Bin Shift Tray Paper Weight 60 – 105g/m², 16 – 28 lb.
(G554) Dimensions
465 x 395 x 160 mm
(W x D x H)
Weight 3.5 kg.

SPEC-6
April, 2008 SPECIFICATIONS

7. SOFTWARE ACCESSORIES
The printer drivers and utility software are provided on one CD-ROM. An auto-run
installer allows you to select which components to install.

7.1 PRINTER DRIVERS

Printer Windows Windows Server Windows
Macintosh
Language 2000 XP 2003 Vista (Note)
PCL 6 Yes Yes Yes Yes No
PCL 5e Yes Yes Yes Yes No
PS3 Yes Yes Yes Yes Yes
RPCS Yes Yes Yes Yes No

NOTE: 1) The CD-ROM provided with the Kir-P3s contains a driver for Windows
Vista, but the CD-ROMs for K-P3D and K-P3L do not contain a driver for
Windows Vista.
2) The PS3 drivers are all genuine AdobePS drivers, except for Windows
2000, which uses Microsoft PS. A PPD file for each operating system is
provided with the driver.
3) The PS3 driver for Macintosh supports Mac OS 7.6 or later versions.

Spec.

SPEC-7
SPECIFICATIONS April, 2008

7.2 CD-ROM CONTENTS

Utilities and Drivers CD-ROM
Environment Contents Language Remarks
English, Win 2000, XP, Server 2003, Vista
RPCS Driver (K-P3s only)
Simplified Chinese
English, Win 2000, XP, Server 2003, Vista
PCL6 Driver Simplified Chinese (K-P3s only)
English, Win 2000, XP, Server 2003, Vista
PCL5e Driver Simplified Chinese (K-P3s only)

Adobe PS3 Printer English only Win 2000, XP, Server 2003, Vista
Driver (K-P3s only)
Windows
Font Manager Win 2000, XP, Server 2003, Vista
English only (K-P3s only)
2000
SmartNetMonitor English, Win 2000, XP, Server 2003, Vista
(Client) Simplified Chinese (K-P3s only)
SmartNetMonitor English, Win 2000, XP, Server 2003, Vista
(Admin) Simplified Chinese (K-P3s only)
Win 2000, XP, Server 2003, Vista
1394 UTILITY English only
(K-P3s only)
README.TXT English only –

Adobe PS3 Printer Mac OS 8 and 9

English only
Driver
Macintosh PS Descriptions English only Mac OS 8 and 9
Printer Utility for Mac OS 8 and 9, Mac OS X
English only
Mac

Operating Instructions CD-ROM

Environment Contents Language Remarks
English,
Setup Guide
Simplified Chinese
English,
Printer Reference
Simplified Chinese
Windows/ NIC Operating English,
Macintosh Instructions Simplified Chinese
English,
PS Supplement
Simplified Chinese
Adobe Acrobat English,
Reader Simplified Chinese

SPEC-8
April, 2008 SPECIFICATIONS

8. MACHINE CONFIGURATION
8.1 SYSTEM COMPONENTS
[D]

[C]

[A] [B]

[E]

[F]

G091V107.WMF

Item Machine Code No. Remarks

Main Unit G091 A The NIB is standard for this K-P3d.
Optional Units
Duplex Unit G552 B
Up to two tray units can be
Paper Tray Unit G555 E, F
installed.
Four-Bin Mailbox G553 C
One-Bin Shift Tray G554 D
Spec.

SPEC-9
SPECIFICATIONS April, 2008

8.2 INTERNAL OPTIONS

K-P3D K-P3L/ K-P3s

[D]
Bluetooth
USB I/F USB I/F
I/F Board
Ethernet I/F Ethernet I/F
Optional NIB

CN2

CN2
(standard for G073 model) (standard for G073 model)
[B]

CN1

CN1
[C]
CN5 (SLOT1) USB I/FCN5 (SLOT1)
Parallel I/F

Parallel I/F
Ethernet I/F

CN2
CPU Memory DIMM CPU (standard for 69 model) Memory DIMM

CN1
ASIC Controller Board ASIC Controller Board [B]
CN5 (SLOT1)

Parallel I/F
CPU Memory DIMM
ASIC Controller Board
IC Card I/F

IC Card I/F
CN4

CN4
NVRAM

NVRAM

IC Card I/F

CN4
NVRAM
[A]
[A]
HDD Unit HDD Unit
HDD Unit

G091V900_CHN.WMF G091V900_KAI.WMF

Internal Options
HDD G575 [A]
G330/G331/ [B]
Memory 64/128/256 MB
G332
Bluetooth G354 [C] Only for the K-P3l and P3s models
Ethernet NIC G646 [D] Only for the K-P3l and P3s models
Barcode Font DIMM G627
Others
AIO Cartridge (20K/12K) G213/G775 For all K-P3 models
AIO Cartridge (6K) G795 Only for the K-P3s model
Maintenance Kit G770

NOTE: The K-P3D model has an on-board Ethernet interface.

SPEC-10