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Ricoh BP20 Service Manual

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G144/G145
SERVICE MANUAL
002540MIU

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  • Page 1 G144/G145 SERVICE MANUAL 002540MIU...
  • Page 5 G144/G145 SERVICE MANUAL 002540MIU...
  • Page 7 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
  • Page 9 Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained uncertified users utilizing...
  • Page 11 LEGEND PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN G144 ----- ----- BP20 ----- G145 ----- ----- BP20N ----- DOCUMENTATION HISTORY REV. NO. DATE COMMENTS 10/2005 Original Printing...

  • Page 13: Table Of Contents

    G144/G145 TABLE OF CONTENTS INSTALLATION 1. INSTALLATION................1-1 1.1 INSTALLATION PROCEDURE ..............1-1 PREVENTIVE MAINTENANCE 2. PREVENTIVE MAINTENANCE............ 2-1 2.1 PM INTERVALS ..................2-1 REPLACEMENT AND ADJUSTMENT 3. REPLACEMENT AND ADJUSTMENT ........3-1 3.1 GENERAL PRECAUTIONS...............3-1 3.1.1 SERVICING THE MACHINE ............3-1 3.1.2 RELEASING PLASTIC LATCHES............3-1 3.2 COVERS ....................3-2 3.2.1 FRONT COVER................3-2 3.2.2 BYPASS COVER................3-3...
  • Page 14 3.11 BYPASS TRAY UNIT AND FEED ROLLER ..........3-30 3.11.1 BYPASS TRAY UNIT ..............3-30 3.12 PICK-UP ASSEMBLY AND SOLENOID..........3-32 Pick-up Roller and By-pass Pick-up Roller .........3-34 Paper Feed Unit Pick-up Roller ............3-34 By-pass pick-up roller .................3-35 TROUBLESHOOTING 4. TROUBLESHOOTING ..............4-1 4.1 PAPER PATH....................4-1 4.1.1 PAPER JAM CONDITIONS..............4-2 Jam0 .....................4-2...
  • Page 15 4.7.5 MULTI-FEEDING................4-18 4.7.6 PAPER ROLLED IN THE FUSING UNIT........4-18 4.7.7 PAPER REMAINS ROLLED ON THE OPC DRUM ......4-19 4.8 SET MALFUNCTIONS ................4-20 4.8.1 ALL LEDS BLINK (FUSING ERROR)..........4-20 4.8.2 ALL LEDS BLINK (SCAN ERROR) ..........4-20 4.8.3 PAPER EMPTY ................4-20 4.8.4 PAPER EMPTY WITHOUT INDICATION........4-20 4.8.5 FUSING GEAR MELTS (OVERHEATS).........4-21 4.8.6 COVER OPEN................4-21 4.8.7 NO ERROR LAMP WHEN COVER IS OPENED ......4-21...
  • Page 16 Paper Feed Mechanism................6-5 Drive Mechanism ..................6-5 Laser Scanning Unit................6-5 Development Unit .................6-5 Transfer Unit ..................6-5 Fusing Unit....................6-5 Electrical Components (PBA) ...............6-6 6.3 SYSTEM LAYOUT ..................6-7 6.3.1 PAPER FEED UNIT................6-8 Paper Separation Method ..............6-8 Paper Tray ....................6-8 Pick-up roller..................6-8 By-pass tray..................6-8 Optional Paper Feed Unit ..............6-8 6.3.2 TRANSFER UNIT ................6-9 6.3.3 DRIVE....................6-9...
  • Page 17 6.5.2 SMPS (SWITCHING MODE POWER SUPPLY) ......6-21 1. AC Input....................6-21 2. Rated Output Power .................6-21 3. Consumption Power .................6-21 6.6 ENGINE....................6-22 6.6.1 PAPER FEED .................6-22 SPECIFICATIONS SPECIFICATIONS................7-1 1.1 GENERAL SPECIFICATIONS..............7-1 1.2 CONTROLLER ..................7-2 1.3 SOFTWARE SPECIFICATIONS ...............7-3 1.4 OPTIONAL UNIT SPECIFICATIONS ............7-4 APPENDIX BLOCK DIAGRAM ................
  • Page 19 PRECAUTIONS In order to prevent accidents and damage to the equipment, please read the following precautions before you service the machine. SAFETY WARNING 1. Only qualified service engineers should service this machine. The high voltages and lasers inside this product should be approached with caution. 2.
  • Page 20 SAFETY PRECAUTIONS TOXIC MATERIALS This product contains toxic materials that could cause illness if ingested. 1. If the LCD control panel is damaged, it is possible for the liquid inside to leak out. This liquid is toxic and contact with skin should be avoided. Wash any splashes from eyes or skin immediately for 15 minutes under running water, and contact a doctor.
  • Page 21 9. Ensure that the power sockets and plugs are not cracked or broken in any way. Repair such defects immediately. Take care not to cut or damage the power cable or plugs when moving the machine. 10. Use caution during thunder or lightening storms. Disconnect the machine from the power source when such weather conditions are expected.
  • Page 22 ASSEMBLY/DISASSEMBLY PRECAUTIONS Replace with approved parts only. Take care to note the exact location of parts and the correct cable routing before you disassemble any part of the machine. Ensure all parts and cables are replaced correctly. Perform the following procedures before you disassemble the machine or replace any parts.
  • Page 23 ADDITIONAL SAFETY PRECAUTIONS 1. Use caution with high-temperature parts. The fusing unit operates at a high temperature. Use caution when working on this area of the machine. Wait for the fusing unit to cool down before disassembling it. 2. Do not place your fingers or hair near or into the rotating parts and components.
  • Page 24 ESD PRECAUTIONS Certain semiconductor devices can be damaged by static electricity. Such components are commonly called “Electrostatically Sensitive (ES) Devices”, or ESDs. Examples of typical ESDs are: integrated circuits, some field effect transistors, and semiconductor “chip” components. The techniques outlined below should be strictly followed to help reduce the incidence of component damage caused by static electricity.
  • Page 25 INSTALLATION PREVENTIVE MAINTENANCE REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING SERVICE PROGRAM MODE DETAILED DESCRIPTIONS SPECIFICATIONS APPENDIX...

  • Page 27: Installation

    INSTALLATION...

  • Page 29: Installation Procedure

    INSTALLATION PROCEDURE 1. INSTALLATION 1.1 INSTALLATION PROCEDURE Refer to the Operating Instructions for full installation procedures. G144/G145...

  • Page 31: Preventive Maintenance

    PREVENTIVE MAINTENANCE...

  • Page 33: Pm Intervals

    PM INTERVALS 2. PREVENTIVE MAINTENANCE 2.1 PM INTERVALS The intervals shown below are for maintenance items. Environmental conditions and machine use may affect these intervals. Adjust as necessary. NOTE: The intervals shown below are for reference only. The replacement intervals noted here are expected to exceed machine life. However, if the indicated interval is reached, that component should be replaced.

  • Page 35: Replacement And Adjustment

    REPLACEMENT AND ADJUSTMENT...

  • Page 37: General Precautions

    GENERAL PRECAUTIONS 3. REPLACEMENT AND ADJUSTMENT This manual uses the following symbols. : See or refer to  : Screw : Connector: : C-clamp (snap ring) : E- clamp 3.1 GENERAL PRECAUTIONS • Use caution when you disassemble and reassemble components. •...

  • Page 38: Covers

    COVERS 3.2 COVERS 3.2.1 FRONT COVER G144R003.WMF G144R002.WMF 1. Pull the cassette [A] out of the printer. 2. Open the front cover [B] and push the toner cartridge down. Remove it from the machine. G144R004.WMF G144R005.WMF 3. Pull inward to release the hinges [C]. 4.

  • Page 39: Bypass Cover

    COVERS 3.2.2 BYPASS COVER G144R006.WMF 1. Open the tray assembly [A]. 2. Carefully bend the plastic hinge supports toward the center of the machine [B] to release them from the guide hooks. 3. Pull the by-pass tray [C] outwards from the machine. NOTE: A small amount of force can be used when bending the plastic hinges, but do not use...

  • Page 40: Rear Cover

    COVERS 3.2.3 REAR COVER G144R031.WMF 1. Remove the 2 x  and remove the option cover assembly [A]. 2. Remove the cover face [B] in the direction of the arrow as shown above. G144R032.WMF G144/G145...
  • Page 41 COVERS G144R033.WMF 3. Remove the 2 x  as shown above and snap the rear cover [C] out of the machine. G144/G145...

  • Page 42: Top Cover

    COVERS 3.2.4 TOP COVER Remove the following before removing the top cover: Front Cover 3.2.1 Rear Cover 3.2.3 G144R008.WMF 1. Remove the 4 x  as shown above. Lift the top cover [A] from the machine. NOTE: Ensure that no damage is inflicted upon the exit roller [B] when removing the top cover.

  • Page 43: Right Side Cover

    COVERS 3.2.5 RIGHT SIDE COVER Remove the following before removing the right side cover: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 G144R010.WMF 1. Remove the 2 x  as shown above. 2. Release the top latch [A] and the three bottom latches [B] from the frame assembly, in the direction of the arrow.

  • Page 44: Left Side Cover

    COVERS 3.2.6 LEFT SIDE COVER Remove the following before removing the left side cover: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 G144R011.WMF 4. Remove the 2 x  as shown above. 5. Release the top latch [A] and the three bottom latches [B] from the frame assembly, in the direction of the arrow.

  • Page 45: Middle Cover

    COVERS 3.2.7 MIDDLE COVER Remove the following before removing the middle cover: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 G144R009.WMF 1. Remove the 2 x  from the top of the middle cover [B] (screws are on the inside).

  • Page 46: Exit Roller

    EXIT ROLLER 3.3 EXIT ROLLER Remove the following before removing the exit roller: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R012.WMF 1. Gently pull the gear [A] and remove from the exit roller [B]. 2.

  • Page 47: Engine Shield Assembly And Exit Board

    ENGINE SHIELD ASSEMBLY AND EXIT BOARD 3.4 ENGINE SHIELD ASSEMBLY AND EXIT BOARD Remove the following before removing the engine shield and exit board: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 3.4.1 ENGINE SHIELD G144R013.JPG Perform the following before removing the engine shield assembly.
  • Page 48 ENGINE SHIELD ASSEMBLY AND EXIT BOARD 2. Turn the machine on its side and remove the 12 x  from the engine shield assembly [B]. NOTE: All screws must be removed before the safety shield can be removed. 3. Unplug 5x  from the operation panel, fan, and fusing unit.

  • Page 49: Exit Board

    ENGINE SHIELD ASSEMBLY AND EXIT BOARD 3.4.2 EXIT BOARD G144R014.WMF 1. Remove the 2 x  as shown above. 2. Remove the exit board [A]. 3-13 G144/G145...

  • Page 50: Smps

    SMPS 3.5 SMPS Remove the following before removing the SMPS: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R015.WMF G144R016.WMF 1. Unplug one wire [A]. 2. Remove the 3 x  and remove the inlet bracket [B]. 3.
  • Page 51 SMPS G144R017.WMF 4. Unplug the engine harness [D]. G144R018.WMF 5. Remove 2 x  from the IEEE1284 port and the main PBA [E]. 3-15 G144/G145...
  • Page 52 SMPS G144R019.WMF 6. Remove 6 x  and remove the SMPS [F]. NOTE: If you need only to remove the optional memory units or the network card, remove the optional cover only. 3.2.3 G144/G145 3-16...

  • Page 53: Fusing Unit

    FUSING UNIT 3.6 FUSING UNIT Remove the following before removing the fusing unit: Rear Cover 3.2.3 3.6.1 FUSING UNIT ASSEMBLY NOTE: Perform the following procedure only if it is necessary to remove the entire fusing unit assembly. Otherwise, use the individual component procedures. G144R020.WMF 1.

  • Page 54: Thermostat

    FUSING UNIT 3.6.2 THERMOSTAT G144R021.WMF 3. Remove the 2 x . Remove the thermostat [B]. NOTE: Both screws have a nut and a bolt. G144/G145 3-18...

  • Page 55: Fusing Lamp

    FUSING UNIT 3.6.3 FUSING LAMP G144R022.WMF 4. Remove the 2 x  securing the fusing lamp [C]. NOTE: Both screws have a nut and a bolt. 5. Slide the fusing lamp [C] out from the hot roller [D] in the direction of the arrow as shown above.

  • Page 56: Stripper Pawls

    FUSING UNIT 3.6.4 STRIPPER PAWLS G144R049.WMF [A]: Remove the 4 x  securing the fusing unit cover [A]. [B]: Remove the 2 x  securing the guide input [B]. [C]: Disassemble the fusing unit. G144/G145 3-20...

  • Page 57: Reassembling The Fusing Unit

    FUSING UNIT Reassembling the Fusing Unit The 4 x stripper pawls must be put in the correct position before you can reassemble the fusing unit. Perform the following procedure before you put the fusing unit back to the fusing unit assembly. 1.

  • Page 58: Note

    FUSING UNIT Note: The illustration below shows the stripper pawls in the incorrect position. Note that the stripper pawls are not correctly set into the stripper pawl holder slots. Do not place the fusing unit back into the machine with the stripper pawls in the wrong position.

  • Page 59: Thermistor

    FUSING UNIT 3.6.5 THERMISTOR G144R050.WMF Unwrap the thermistor harness [A] as shown above. Remove 1 x  securing the thermistor [B] and remove it 3-23 G144/G145...

  • Page 60: Unplug Fan

    UNPLUG FAN 3.7 UNPLUG FAN Remove the following before removing the fan: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R026.WMF 1. 1 x  from the SMPS. 2. Remove 1 x . Remove the Fan [A]. G144/G145 3-24...

  • Page 61: Laser Scanning Unit

    LASER SCANNING UNIT 3.8 LASER SCANNING UNIT Remove the following before removing the laser scanning unit: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R027.WMF 1. Remove one ground wire [A]. 2. Remove the 4 x  securing the laser scanning unit [B]. 3-25 G144/G145...
  • Page 62 LASER SCANNING UNIT G144R028.WMF 3. Unplug 2 x  [C] as shown above. Remove the laser scanning unit [B]. NOTE: Do not touch the plastic shield of the laser scanning unit. NOTE: The screw slots on the laser scanning unit are numbered. Use the following order when you disassemble/reassemble it: 1) Disassemble: 4-3-2-1 2) Reassemble: 1-2-3-4...

  • Page 63: Drive Unit

    DRIVE UNIT 3.9 DRIVE UNIT Remove the following before removing the drive assembly: Front Cover 3.2.1 Rear Cover 3.2.3 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R029.WMF 1. Unplug 1 x  from the drive assembly board [A]. 2.

  • Page 64: Transfer Unit

    TRANSFER UNIT 3.10 TRANSFER UNIT Remove the following before removing the transfer assembly: Front Cover 3.2.1 Rear Cover 3.2.3 Middle Cover 3.2.7 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 G144R034.WMF G144R035.WMF 1. Remove the 3 x . Remove the transfer ground [A]. NOTE: The transfer ground is designed to prevent unwanted particles from adhering to the transfer roller.
  • Page 65 TRANSFER UNIT G144R036.WMF 4. Unlatch the transfer roller [E] as shown above. G144R037.WMF 5. Unlatch two bushes (both sides) [F] and two springs (both sides) [G] and remove them. 6. Remove the transfer roller [H] from the machine. 3-29 G144/G145...

  • Page 66: Bypass Tray Unit And Feed Roller

    BYPASS TRAY UNIT AND FEED ROLLER 3.11 BYPASS TRAY UNIT AND FEED ROLLER Remove the following before removing the bypass tray and feed roller: Front Cover 3.2.1 Rear Cover 3.2.3 Middle Cover 3.2.7 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 3.11.1 BYPASS TRAY UNIT G144R039.WMF G144R038.WMF...
  • Page 67 BYPASS TRAY UNIT AND FEED ROLLER G144R041.WMF G144R040.WMF 4. Remove feed gear 2 [E] from the machine. 5. Remove feed gear 1 [F] from the machine. NOTE: Feed gear 1 has a bigger bushing than feed gear 2. This will let you know which gear is feed gear 1 and which gear is feed gear 2.

  • Page 68: Pick-Up Assembly And Solenoid

    PICK-UP ASSEMBLY AND SOLENOID 3.12 PICK-UP ASSEMBLY AND SOLENOID Remove the following before removing the pick-up assembly and solenoid: Front Cover 3.2.1 Rear Cover 3.2.3 Middle Cover 3.2.7 Top Cover 3.2.4 Left and Right Side Cover 3.2.5, 3.2.6 1. Remove the pick-up gear [A].
  • Page 69 PICK-UP ASSEMBLY AND SOLENOID G144R045.WMF 3. Disconnect 2 x  from the main board. 4. Remove the 2 x . Remove the pick-up solenoid [C] and the manual solenoid [D]. (Ensure that you thread the cables through the frame.) G144R046.WMF 5.

  • Page 70: Pick-Up Roller And By-Pass Pick-Up Roller

    PICK-UP ASSEMBLY AND SOLENOID Pick-up Roller and By-pass Pick-up Roller It is not necessary to disassemble the main cassette if you only want to replace the pick-up roller and/or the by-pass pick-up roller. The following procedures show how to replace these two rollers only. Paper Feed Unit Pick-up Roller G144R047.WMF 1.

  • Page 71: By-Pass Pick-Up Roller

    PICK-UP ASSEMBLY AND SOLENOID By-pass pick-up roller G144R048.WMF 1. Release the white catch and slide the locking piece as far to the side as possible. 2. Slide the white collar as far to the side as possible. 3. Slide the pick-up roller as far as possible to the side until it is free from the white collar.

  • Page 73: Troubleshooting

    TROUBLESHOOTING...

  • Page 75: Paper Path

    PAPER PATH 4. TROUBLESHOOTING 4.1 PAPER PATH G144T001.WMF 1. Paper feed cassette 4. Fusing unit 2. By-pass tray 5. Laser scanning unit 3. Transfer roller 6. Toner cartridge G144/G145...

  • Page 76: Paper Jam Conditions

    PAPER PATH 4.1.1 PAPER JAM CONDITIONS Jam 0 EXIT Sensor G144T002.WMF The printer feeds paper from the main/optional paper feed unit or by-pass tray after it receives the print command. The fed paper passes over the paper feed sensor. Jam 0 occurs if the sensor is not actuated within a specific time interval. Jam1 EXIT Sensor...

  • Page 77: Jam2

    PAPER PATH Jam2 EXIT Sensor G144T004.WMF The paper passes through the paper exit sensor and out of the machine. Jam2 occurs if the trailing edge of the paper does not actuate the exit sensor within a specific time interval of the paper’s leading-edge activating the exit sensor. G144/G145...

  • Page 78: Clearing Paper Jams

    CLEARING PAPER JAMS 4.2 CLEARING PAPER JAMS Paper jams can occur under the following the conditions: • The tray is loaded incorrectly or overfilled. • The tray has been pulled out during a print job. • The front cover has been opened during a print job. •...
  • Page 79 CLEARING PAPER JAMS G144T006.WMF 2. Open the rear output tray. 3. Loosen the paper if it is caught in the feed rollers. Gently pull the paper out. 4. Close the rear output tray. Open and close the front cover. Printing should begin again automatically.

  • Page 80: Jam0 (Paper Feed Area)

    CLEARING PAPER JAMS 4.2.2 JAM0 (PAPER FEED AREA) Perform the following procedure to solve this paper jam type: G144T007.WMF 1. Slide out the paper tray unit. 2. Grab the visible edge of the paper and gently pull it out of the paper tray as shown above.

  • Page 81: Jam1 (Toner Cartridge Area)

    CLEARING PAPER JAMS 4.2.3 JAM1 (TONER CARTRIDGE AREA) Perform the following procedure to solve this paper jam type. G144T008.WMF 1. Open the front cover and remove the toner cartridge. G144T009.WMF 2. Gently pull the paper toward you as shown above. 3.

  • Page 82: Tips To Avoid Paper Jams

    CLEARING PAPER JAMS 4.2.4 TIPS TO AVOID PAPER JAMS Perform the following to reduce paper jam occurrences: • Ensure that the adjustable guides are positioned correctly. • Do not overload the tray. Ensure that the paper is below the paper capacity mark on the right-inside of the tray.

  • Page 83: Sample Pattern

    SAMPLE PATTERN 4.3 SAMPLE PATTERN The sample pattern assists in maintaining the machine and checking for abnormal conditions. 4.3.1 PRINTING A DEMO PAGE AND CONFIGURATION PAGE The demo page and configuration sheet can test whether or not the machine is operating correctly.

  • Page 84: Printing A Cleaning Sheet

    OPERATION PANEL DISPLAY 4.3.2 PRINTING A CLEANING SHEET You should print a cleaning sheet if printed images are blurred, faded, or smeared. The machine cleans the drum inside the toner cartridge when you print a cleaning sheet. A page with toner debris is output when you print the cleaning sheet. Ensure that you discard this sheet.

  • Page 85: Printout Problems

    PRINTOUT PROBLEMS 4.6 PRINTOUT PROBLEMS 4.6.1 INCORRECT PRINT POSITION Description: The print job starts even though the paper is not in the correct feed position. Cause Solution Defective feed sensor actuator Replace the defective actuator 4.6.2 VERTICAL BLACK LINE AND BAND Description: Straight, thin, or dark-black vertical lines are visible on the output print.

  • Page 86: Horizontal Black Bands

    PRINTOUT PROBLEMS 4.6.4 HORIZONTAL BLACK BANDS Description: Dark or blurry horizontal stripes are periodically visible on the output print. Cause Solution Bad contacts on the toner cartridge high Clean all high voltage terminals on the voltage terminals. toner cartridge and set frame. Remove toner and dust particles.

  • Page 87: Dark/Black Image

    PRINTOUT PROBLEMS 4.6.7 DARK/BLACK IMAGE Description: Printed image is dark. Cause Solution No charge voltage from the engine board. Check the connector that connects the HVPS and the engine board. Charge voltage fault due to bad contact between toner cartridge and cartridge set. Clean the high voltage charge terminals.

  • Page 88: Ghost 1

    PRINTOUT PROBLEMS 4.6.10 GHOST 1 Description: “Ghosting” image defect is visible on the output print at 75.5 mm intervals. Cause Solution Bad contacts caused by toner particles Clean all HV contacts. Replace the HVPS between the high voltage terminal in the if the problem persists.

  • Page 89: Ghost 4

    PRINTOUT PROBLEMS 4.6.13 GHOST 4 Description: White “ghosting” defect is visible on output prints at 32 mm intervals. Cause Solution Developer has reached end of life. Replace the toner cartridge. Abnormal output from the HVPS. Check the HVPS supply voltage. Clean the HV terminals on the cartridge and cartridge set.
  • Page 90 PRINTOUT PROBLEMS 4.6.17 BLANK PAGE 2 Description: A blank page, or several blank page (s) are printed [OR] several blank pages are printed when the machine is turned on. Cause Solution Bad ground contacts in the OPC and/or Check if the ground OPC or the OPC toner cartridge.

  • Page 91: Paper Feed Problems

    PAPER FEED PROBLEMS 4.7 PAPER FEED PROBLEMS 4.7.1 INCORRECT PRINT POSITION Description: The print job starts even though the paper is not in the correct feed position. Cause Solution Defective feed sensor actuator Replace the defective actuator 4.7.2 JAM 0 Description: 1) Paper does not exit from the feed cassette.

  • Page 92: Jam 2

    PAPER FEED PROBLEMS 4.7.4 JAM 2 Description: 1) Paper becomes jammed in front of, or inside, the fusing unit. 2) Paper becomes jammed in the discharge roller and in the fusing unit, after it passes through the actuator feed. Cause Solution Jam 2 can appear even if the paper is Check if the exit sensor or actuator exit is...

  • Page 93: Paper Remains Rolled On The Opc Drum

    PAPER FEED PROBLEMS 4.7.7 PAPER REMAINS ROLLED ON THE OPC DRUM Description: Paper remains rolled on the OPC drum. Cause Solution Paper is too thin. Use paper supported by the machine specifications. The face of the paper is curled. Ensure paper is stored correctly. To remove paper in the OPC: 1) Remove the toner cartridge from the machine (do not touch the green OPC...

  • Page 94: Set Malfunctions

    SET MALFUNCTIONS 4.8 SET MALFUNCTIONS 4.8.1 ALL LEDS BLINK (FUSING ERROR) Description: All LEDs on the operation panel blink. Cause Solution Thermostat, fusing power cable or heat Replace the heat lamp or cable harness, lamp circuit is open. or replace the entire fusing unit if necessary.

  • Page 95: Fusing Gear Melts (Overheats)

    SET MALFUNCTIONS 4.8.5 FUSING GEAR MELTS (OVERHEATS) Description: Constant jams when paper enters the fusing unit, or the fusing unit rollers do not turn. 1. Paper constantly becomes jammed in the fusing unit. 2. Fusing unit rollers do not turn. Cause Solution Fusing lamp, thermostat, or thermistor are...

  • Page 96: Power

    SET MALFUNCTIONS 4.8.8 NO POWER Description: LEDS on the operation panel do not light when the power is turned Cause Solution Check if the power input and SMPS Replace the power supply cord or SMPS. operate correctly. Replace the power or SMPS fuses if necessary.

  • Page 97: Toner Cartridge

    TONER CARTRIDGE 4.9 TONER CARTRIDGE Ensure that toner cartridges approved for use by the manufacturer are used in this machine. Machine operation is not guaranteed if toner cartridges not approved by the manufacturer are used in this machine. 4.9.1 TONER CARTRIDGE PRECAUTIONS Do not expose the toner cartridge to direct light for more than a few minutes.
  • Page 98 TONER CARTRIDGE G144T011.WMF G144T012.WMF 2. Gently shake the toner cartridge [D] in the direction of the arrow as shown above. Put the toner cartridge [D] back into the machine and close the front cover [C]. G144/G145 4-24...

  • Page 99: Toner Cartridge Details

    TONER CARTRIDGE 4.9.3 TONER CARTRIDGE DETAILS Description Signs Cause and Check and Solution Light image/partially • Printed image is If the image is light, shake the toner blank image light, dirty, or not cartridge and try to print again. If the (cartridge has clear.
  • Page 100 TONER CARTRIDGE White/Black Spot • Light black or dark Toner cartridge rollers are contaminated black dots are with unwanted particles if light black or visible periodically dark black dots show periodically on the on the image. image. In this condition perform the OPC •...
  • Page 101 TONER CARTRIDGE “Ghost” image and • Print out is too light Check the following if the printout is too other contamination or dark, or, partially light, too dark, or partially contaminated: contaminated. 1) Check if unwanted matter remains on • A completely black terminal contact points of the cartridge page is printed out.

  • Page 102: Software Problems

    SOFTWARE PROBLEMS 4.10 SOFTWARE PROBLEMS 4.10.1 PRINTER DOES NOT OPERATE CORRECTLY 1 Description: The printer does not operate in printing mode when the power is turned on. Description Solution Perform the self-test mode. Use the menu There are no problems with the machine if the buttons (menu, enter, enter) and print the test test print works correctly.

  • Page 103: Printer Does Operate Correctly 2

    SOFTWARE PROBLEMS 4.10.2 PRINTER DOES OPERATE CORRECTLY 2 Description: After receiving the print command there is either no response from the printer, or the print speed is slow. Incorrect machine set-up and/or printer malfunction are the cause of this condition. Description Solution Not enough free hard disk space to...

  • Page 104: Abnormal Printing

    Printer driver error Ensure that the correct driver is loaded. Use the driver supplied on the CD, or download the correct driver from the Ricoh web site. DO NOT use the Microsoft driver supplied with the Windows operating system. If the...

  • Page 105: Service Program Mode

    SERVICE PROGRAM MODE...

  • Page 107: Firmware Download

    FIRMWARE DOWNLOAD 5. SERVICE PROGRAM MODE 5.1 FIRMWARE DOWNLOAD 5.1.1 DOWNLOAD PROCEDURE There are two ways to upgrade the machine firmware: 1. Command Prompt 2. EWS (Embedded Web Server) Connect the machine to a PC via a parallel cable for the “Command Prompt” firmware download procedure, or through the network for the “EWS”...

  • Page 108: Ews (Embedded Web Server) Mode

    FIRMWARE DOWNLOAD EWS (Embedded Web Server) Mode Firmware for this machine can be upgraded by connecting to a PC through a network. A command to upgrade the program must be entered. You must save the correct firmware file to the PC. 1.
  • Page 109 FIRMWARE DOWNLOAD 5. Ensure that ‘Upgrade Firmware’ is selected, as shown below. G144S902.TIF 6. Select “Upgrade Printer Firmware” [A], as shown below. Click the browse button and select the Printer Firmware file you saved in the PC. NOTE: Proceed to step 9 only if you want to upgrade the “Network Firmware” also. 7.

  • Page 110: Firmware Recovery Procedure

    FIRMWARE DOWNLOAD 9. Ensure that “Upgrade Firmware” is selected, as shown below. 10. Select “Upgrade Network Firmware”, [B] as shown below. Click the browse button and select the network firmware file you saved in the PC. 11. Click the “Update Network Firmware” button. 12.

  • Page 111: Detailed Descriptions

    DETAILED DESCRIPTIONS...

  • Page 113: Machine Overview

    MACHINE OVERVIEW 6. DETAILED DESCRIPTIONS 6.1 MACHINE OVERVIEW 6.1.1 FRONT VIEW G144D001.WMF [A] Paper output tray [E] Standard paper feed unit [B] Operation panel [F] Optional paper feed unit [C] Power switch [G] Bypass tray [D] Paper level indicator [H] Front cover G144/G145...

  • Page 114: Rear View

    MACHINE OVERVIEW 6.1.2 REAR VIEW G144D002.WMF [A] Face up door [C] USB port [B] Parallel port [D] Power receptacle G144/G145...

  • Page 115: Operation Panel

    MACHINE OVERVIEW 6.1.3 OPERATION PANEL G144D001.WMF The machine has the following buttons on the operation panel. [A]: On line/error [B]: Toner save [C]: Cancel On Line/Error Button: The machine is ready to print when this button is green. The machine is experiencing an error such as jammed paper, cover open or empty toner cartridge when this button is red.

  • Page 116: Toner Save Button

    MACHINE OVERVIEW Toner Save Button This LED goes on and the toner save mode is enabled when you press the cancel button for 0.5 sec. The LED goes off and toner save mode is disabled when you press the cancel button again. On Line/Error Button and Toner Save Button The machine experiences internal problems if On Line/Error and Toner Save button LEDs blink at the same time.

  • Page 117: Machine Overview

    MACHINE OVERVIEW 6.2 MACHINE OVERVIEW 6.2.1 FIRMWARE The machine firmware controls the printing process. 6.2.2 PRINT ENGINE Paper Feed Mechanism The paper feed mechanism consists of the following: 1) 250 sheet paper feed unit 2) By-pass tray 3) Pick-up rollers, friction pads and feed rollers. Together with sensors in the feed path, these mechanisms serve to control paper registration and guide the paper through the image transfer, image development, image fusing and exit assemblies.

  • Page 118: Electrical Components (Pba)

    MACHINE OVERVIEW Electrical Components (PBA) The main control board consists of the following: 1. Main Processor ASIC (166MHz SPGPm) 2. Memory Components (Flash Rom, Control Program, and DRAM) 3. Engine interface components (motor control, fusing unit control, HVPS control, sensors etc) 4.

  • Page 119: System Layout

    SYSTEM LAYOUT 6.3 SYSTEM LAYOUT EXIT Sensor G144D003.WMF [A] Fusing unit [E] Paper feed sensor [B] Laser scanning unit [F] Paper empty sensor [C] Toner cartridge [G] OPC [D] By-pass tray [H] Paper feed unit G144/G145...

  • Page 120: Paper Feed Unit

    SYSTEM LAYOUT 6.3.1 PAPER FEED UNIT The paper feed unit consists of the following. • Standard paper tray unit • Optional paper feed unit • By-pass tray Paper Separation Method Individual sheets are separated in the paper feed unit via the feed/friction pad method.

  • Page 121: Transfer Unit

    SYSTEM LAYOUT 6.3.2 TRANSFER UNIT A PTL (Pre-transfer Lamp) and a transfer roller migrate toner from the OPC drum onto the paper. The PTL shines additional light onto the OPC, which reduces the electrical charge on the surface of the OPC drum and improves the transfer efficiency.

  • Page 122: Safety Features

    SYSTEM LAYOUT Safety Features The machine has the following countermeasures to prevent overheating: 1. 1st protection device: Hardware shuts down when the machine temperature reaches 207 C. 2. 2nd protection device: Software shuts down when the machine temperature reaches 220 C for 3 seconds 3.

  • Page 123: Toner Cartridge

    SYSTEM LAYOUT 6.3.6 TONER CARTRIDGE -430V -950V -580V G144D901.WMF [A]: Charging roller [D]: Doctor blade [B]: OPC drum [E]: Supply roller [C]: Developing roller [F]: Transfer roller The toner cartridge contains the OPC unit and toner unit. The OPC unit consists of the OPC drum and charging roller.

  • Page 124: New Aio Detection

    SYSTEM LAYOUT 6.3.7 NEW AIO DETECTION A new supply AIO cartridge has a ID chip. The machine detects that a new cartridge has been installed when the chip is detected. The machine then resets the total dot counter (TOTAL TONER COUNT) and CRU print counter (Cru Prints).

  • Page 125: Asic(Spgp)

    ASIC(SPGP) 6.4 ASIC(SPGP) • ARM946ES • 32-bit RISC embedded processor core • 6KB instruction cache and 16KB data cache • No tightly coupled memory • Memory protection unit & CP15 control program • Dual bus architecture for bus traffic distribution •...

  • Page 126: Sdram

    ASIC(SPGP) 6.4.3 SDRAM SDRAM is used for the following: • Swath buffer in printing • Scan buffer in scanning • ECM buffer in fax receiving • System working memory area: • Size: 16MB • Max Frequency: 100MHz G144/G145 6-14...

  • Page 127: Sensor Input Circuit

    ASIC(SPGP) 6.4.4 SENSOR INPUT CIRCUIT Paper Empty Sensor The CPU monitors the paper empty sensor (photointerrupter). The printer flashes the red ERROR LED when the paper feed unit is empty. By-pass Tray Sensor Paper in the by-pass tray is detected by the by-pass sensor (photointerrupter) on the frame.

  • Page 128: Motor Drive Circuit

    ASIC(SPGP) Motor Drive Circuit The main motor drives the following: • Paper feed unit • Developing unit • Fusing unit • Exit assembly Software controls the acceleration, constant speed, and deceleration. An A3977 driver IC drives the motor. Transfer PWM (Pulse Width Modulation) controls the charging voltage, developing voltage, and the transfer voltage.

  • Page 129: Lsu

    ASIC(SPGP) The LSU consists of the laser diode and the polygon motor control. When the printing signal is detected, the laser diode turns on and the polygon motor is enabled. HSync occurs when the light sensor detects the beam, and LReady occurs when the polygon motor speed reaches normal.

  • Page 130: Smps And Hvps

    SMPS AND HVPS 6.5 SMPS AND HVPS The SMPS and HVPS are on the same board. The SMPS supplies DC power to the system. It takes either 110V or 220V and outputs the +5V and +24VS to the main and other circuit boards. The HVPS creates the high voltage for the THV/MHV/Supply/Dev circuits and supplies it to the toner cartridge.

  • Page 131: Hvps (High Voltage Power Supply)

    SMPS AND HVPS 6.5.1 HVPS (HIGH VOLTAGE POWER SUPPLY) 1. Transfer High Voltage (THV+) • Input voltage: 24 V DC ± 15% • Output voltage: Max +5.0KV ± 5 %, (duty variable, no loading ). 1.2KV ±15% • Output voltage trigger: 6.5 uA •...

  • Page 132: Developing Voltage (Dev)

    SMPS AND HVPS 4. Developing Voltage (DEV) • Input voltage: 24 V DC ± 15% • Output voltage: -200V ~ -600V DC ±20V • Output voltage fluctuation range: PWM control • Input contrast of the output stability degre :±5 % or less •...

  • Page 133: Smps (Switching Mode Power Supply)

    SMPS AND HVPS 6.5.2 SMPS (SWITCHING MODE POWER SUPPLY) The SMPS powers the entire system and is assembled by an independent module, so it is possible to employ it for common use. It is mounted at the bottom of the set and consists of the AMPS part, which supplies the DC power for driving the system, and the AC heater control part, which supplies the power to fuser.

  • Page 134: Engine

    ENGINE 6.6 ENGINE 6.6.1 PAPER FEED Pick-up roller drive is controlled by the pick-up solenoid, if paper is fed from the paper tray unit. The on/off of the solenoid is controlled by the general output port or the external output port. The machine feeds the paper based upon the operation of the manual sensor and the main motor.

  • Page 135: Specifications

    SPECIFICATIONS...

  • Page 137: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS 1.1 GENERAL SPECIFICATIONS Configuration Desktop Paper size A4/Lt Print Resolution Maximum 1200 x 1200 dpi Default 600 x 600 dpi RET Chip Supported Gray Scale Level 128 Gray Print Speed A4-20 ppm Letter-22 ppm Duplex Print Speed Not Supported First Print Speed Stand-by: 10 seconds...

  • Page 138: Controller

    CONTROLLER 1.2 CONTROLLER SPGPm 166 MHz Printer Languages Standard PCL6 Auto Emulating Supported Sensing Interfaces Standard IEEE1284, USB 2.0 Memory (1 slot) Standard/Max 16MB/144MB Type SDRAM Font Type-Flash Memory Number- 45 Scalable, 1 Bitmap Network 10/100 Base TX G144/G145...

  • Page 139: Software Specifications

    SOFTWARE SPECIFICATIONS 1.3 SOFTWARE SPECIFICATIONS Windows 95/98/NT4.0/2000/Me/XP Linux OS including Red Hat, Caldera, Debian, Mandrake, Slackware, SuSE, and Turbo Linux Printer driver Compatibility Default Remote Supported control panel USB: Supported Status Network: Supported monitor Parallel: Not supported English, Korean, German, French, Spanish, Italian, Dutch, Languages Portuguese, Russian, Swedish,...

  • Page 140: Optional Unit Specifications

    OPTIONAL UNIT SPECIFICATIONS 1.4 OPTIONAL UNIT SPECIFICATIONS Paper tray unit Capacity 250 sheets (Life: 150 K) A4, A5, Letter, Legal, Executive, Oficio, Folio, ISO, B5, Media JIS B5 Paper weight 16-24 lb (60-90 g/m²) Memory Memory Supported upgrade Memory type SDRAM Memory unit 32 MB, 128 MB...

  • Page 141: Appendix

    APPENDIX...

  • Page 143: Block Diagram

    BLOCK DIAGRAM APPENDIX BLOCK DIAGRAM G144X01.WMF G144/G145...

  • Page 144: Connection Diagram

    CONNECTION DIAGRAM CONNECTION DIAGRAM ROM DIMM CN 14 NETWORK (OPTION) CN 7 ROM DIMM CN 13 LSU CLK nL READY POLYGON nP MOTOR MOTOR 24VS CN 15 nH SYNC 36 PIN CN 5 nLD ON MAIN BOARD 3.3V PTL LED ARRAY CN 11 CN 16 24VS...

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