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MACHINE OVERVIEW

G144/G145 6-6

SM

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. PC Interface (USB , Parallel, wired and wireless Network)
5. Bus, DMA and I/O handling

The operation panel is also included as part of the electrical components.

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Summary of Contents for Aficio BP20N

Page 1: ...G144 G145 SERVICE MANUAL 002540MIU ...

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Page 3: ...G144 G145 SERVICE MANUAL ...

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Page 5: ...G144 G145 SERVICE MANUAL 002540MIU ...

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Page 7: ...ERMISSION OF RICOH CORPORATION All product names domain names or product illustrations including desktop images used in this document are trademarks registered trademarks or the property of their respective companies They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies No such use or the use of any trade name or web site is intended...

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Page 9: ...ation Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury damage to property or loss of warranty protection Ricoh Corporation WARNING ...

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Page 11: ...LEGEND PRODUCT CODE COMPANY GESTETNER LANIER RICOH SAVIN G144 BP20 G145 BP20N DOCUMENTATION HISTORY REV NO DATE COMMENTS 10 2005 Original Printing ...

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Page 13: ... COVER 3 2 3 2 2 BYPASS COVER 3 3 3 2 3 REAR COVER 3 4 3 2 4 TOP COVER 3 6 3 2 5 RIGHT SIDE COVER 3 7 3 2 6 LEFT SIDE COVER 3 8 3 2 7 MIDDLE COVER 3 9 3 3 EXIT ROLLER 3 10 3 4 ENGINE SHIELD ASSEMBLY AND EXIT BOARD 3 11 3 4 1 ENGINE SHIELD 3 11 3 4 2 EXIT BOARD 3 13 3 5 SMPS 3 14 3 6 FUSING UNIT 3 17 3 6 1 FUSING UNIT ASSEMBLY 3 17 3 6 2 THERMOSTAT 3 18 3 6 3 FUSING LAMP 3 19 3 6 4 STRIPPER PAWLS 3...

Page 14: ...A DEMO PAGE AND CONFIGURATION PAGE 4 9 4 3 2 PRINTING A CLEANING SHEET 4 10 4 4 OPERATION PANEL DISPLAY 4 10 4 5 PERIODIC DEFECTIVE IMAGE 4 10 4 6 PRINTOUT PROBLEMS 4 11 4 6 1 INCORRECT PRINT POSITION 4 11 4 6 2 VERTICAL BLACK LINE AND BAND 4 11 4 6 3 VERTICAL WHITE LINE 4 11 4 6 4 HORIZONTAL BLACK BANDS 4 12 4 6 5 BLACK WHITE SPOTS 4 12 4 6 6 LIGHT IMAGE 4 12 4 6 7 DARK BLACK IMAGE 4 13 4 6 8 UNE...

Page 15: ... 9 3 TONER CARTRIDGE DETAILS 4 25 4 10 SOFTWARE PROBLEMS 4 28 4 10 1 PRINTER DOES NOT OPERATE CORRECTLY 1 4 28 4 10 2 PRINTER DOES OPERATE CORRECTLY 2 4 29 4 10 3 ABNORMAL PRINTING 4 30 4 10 4 SPOOL ERROR 4 30 How to Delete Data in the Spool Manager 4 30 SERVICE PROGRAM MODE 5 SERVICE PROGRAM MODE 5 1 5 1 FIRMWARE DOWNLOAD 5 1 5 1 1 DOWNLOAD PROCEDURE 5 1 DOS Command mode 5 1 EWS Embedded Web Serv...

Page 16: ...es 6 10 Safety Devices 6 10 6 3 5 LASER SCANNNING UNIT LSU 6 10 6 3 6 TONER CARTRIDGE 6 11 6 3 7 NEW AIO DETECTION 6 12 6 3 8 TONER END DETECTION 6 12 6 4 ASIC SPGP 6 13 6 4 1 MEMORY 6 13 6 4 2 FLASH MEMORY 6 13 6 4 3 SDRAM 6 14 6 4 4 SENSOR INPUT CIRCUIT 6 15 Paper Empty Sensor 6 15 By pass Tray Sensor 6 15 Paper Feeding 6 15 Paper Exit Sensor 6 15 Cover Open Sensor 6 15 DC Fan Solenoid Driving C...

Page 17: ... 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 8 1 CONNECTION DIAGRAM 8 2 ...

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Page 19: ...Safety Statement This machine is certified in the U S to conform to the requirements of DHHS 21 CFR chapter 1 Subchapter J for Class 1 1 laser products and elsewhere It is certified as a Class I laser product conforming to the requirements of IEC 825 Class I laser products are not considered to be hazardous The laser system and printer are designed to prevent access to laser radiation during norma...

Page 20: ...all and could lead to a fire 4 Do not allow water or other liquids to spill into the printer This can cause electric shock Do not let paper clips pins or other foreign objects fall into the printer These could cause a short circuit leading to an electric shock or fire hazard If foreign objects fall into the machine power off the machine immediately and disconnect the power cord from the wall outle...

Page 21: ...conditions could lead to a fire 13 Do not insert metal objects into the machine through the ventilator fan or other part of the casing This could create contact with a high voltage conductor inside the machine and cause an electric shock HANDLING PRECAUTIONS The following instructions are for your own personal safety to avoid injury and to prevent damage to the machine 1 Ensure that machine is ins...

Page 22: ...ture rating are correct 5 When removing or re fitting any parts do not use excessive force especially when fitting screws into plastic 6 Take care not to drop any small parts into the machine 7 Handling of the OPC Drum The OPC Drum can be damaged if it is exposed to light Take care not to expose the OPC Drum either to direct sunlight or fluorescent light or incandescent lighting Exposure for as li...

Page 23: ...kg including toner cartridge and cassette Use safe lifting and handling techniques Use the lifting handles located on each side of the machine Back injury could result if you do not lift the unit carefully 4 Ensure the machine is installed safely on a level surface capable of supporting its weight Failure to do so could cause the machine to tip or fall possibly causing personal injury or damaging ...

Page 24: ...dup in the vicinity of the assembly 3 Use only a grounded tip soldering iron to solder or desolder ESDs 4 Use only an anti static solder removal device Some solder removal devices not classified as anti static can generate electrical charges sufficient to damage ESDs 5 Do not use Freon propelled chemicals When sprayed these can generate electrical charges sufficient to damage ESDs 6 Do not remove ...

Page 25: ...NCE REPLACEMENT AND ADJUSTMENT TROUBLESHOOTING SERVICE PROGRAM MODE DETAILED DESCRIPTIONS SPECIFICATIONS APPENDIX TAB POSITION 2 TAB POSITION 1 TAB POSITION 3 TAB POSITION 4 TAB POSITION 6 TAB POSITION 5 TAB POSITION 8 TAB POSITION 7 ...

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Page 27: ...INSTALLATION ...

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Page 29: ...INSTALLATION PROCEDURE SM 1 1 G144 G145 Installation 1 INSTALLATION 1 1 INSTALLATION PROCEDURE Refer to the Operating Instructions for full installation procedures ...

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Page 31: ...PREVENTIVE MAINTENANCE ...

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Page 33: ...fect 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 Component Replacement Cycle Done by Pick up Ass y 150 000 pages Service Transfer Roller 60 000 Pages Service Printer Fuser Unit 80 000 Pages Service ...

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Page 35: ...REPLACEMENT AND ADJUSTMENT ...

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Page 37: ...ts stored in memory before you service the machine 2 Remove the toner cartridge before you disassemble parts 3 Unplug the power cord before you service the machine 4 Use a flat clean surface to service the machine 5 Use only approved replacement parts Machine function cannot be guaranteed if unauthorized replacement parts are used 6 Do not force plastic components Refer to 3 1 2 7 Ensure that all ...

Page 38: ...r B and push the toner cartridge down Remove it from the machine 3 Pull inward to release the hinges C 4 Pull the front cover D away from the machine NOTE To prevent damage to the toner cartridge do not expose it to direct light for more than a few seconds G144R003 WMF G144R002 WMF G144R004 WMF G144R005 WMF A B C D ...

Page 39: ...e 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 excessive force or the hinges could be broken G144R006 WMF G144R007 WMF A B C ...

Page 40: ...COVERS G144 G145 3 4 SM 3 2 3 REAR COVER 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 G144R031 WMF G144R032 WMF A B ...

Page 41: ...COVERS SM 3 5 G144 G145 Replacement Adjustment 3 Remove the 2 x as shown above and snap the rear cover C out of the machine G144R033 WMF C ...

Page 42: ...following before removing the top cover Front Cover 3 2 1 Rear Cover 3 2 3 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 G144R008 WMF A B ...

Page 43: ...owing before removing the right side cover Front Cover 3 2 1 Rear Cover 3 2 3 Top Cover 3 2 4 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 3 Remove the right side cover C G144R010 WMF A B C ...

Page 44: ...re removing the left side cover Front Cover 3 2 1 Rear Cover 3 2 3 Top Cover 3 2 4 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 Remove the left side cover C G144R011 WMF A B C ...

Page 45: ... Top Cover 3 2 4 1 Remove the 2 x from the top of the middle cover B screws are on the inside 2 Remove the 4 x from the base frame screws are outside at the back bottom center left and right 3 Disconnect the operation panel harness C from the operation panel before you remove the middle cover B Ensure that you do not damage the hook A G144R009 WMF A B C ...

Page 46: ... Right Side Cover 3 2 5 3 2 6 1 Gently pull the gear A and remove from the exit roller B 2 Pull on the latch C and slide the exit roller B out 3 Remove 4 bushings D and 4 springs from the machine NOTE The bushings contain grease Be careful when removing them to prevent this grease from reaching your clothing or the customer s furnishings G144R012 WMF A B C D ...

Page 47: ...oard 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 Perform the following before removing the engine shield assembly NOTE The SMPS shield is a safety shield that separates the high voltage area from the rest of the IC chips 1 Release 1 x black arrow from the SMPS shield A Do not remove the shield at this time G144R013 JPG A ...

Page 48: ...he 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 4 Turn the machine back upright and remove the SMPS shield A 5 Remove the engine shield assembly B from the machine G144R013 WMF B ...

Page 49: ...ENGINE SHIELD ASSEMBLY AND EXIT BOARD SM 3 13 G144 G145 Replacement Adjustment 3 4 2 EXIT BOARD 1 Remove the 2 x as shown above 2 Remove the exit board A G144R014 WMF A ...

Page 50: ...ore 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 1 Unplug one wire A 2 Remove the 3 x and remove the inlet bracket B 3 Remove the 2 x and remove the network board C G144R016 WMF G144R015 WMF A B C ...

Page 51: ...SMPS SM 3 15 G144 G145 Replacement Adjustment 4 Unplug the engine harness D 5 Remove 2 x from the IEEE1284 port and the main PBA E G144R017 WMF G144R018 WMF D E ...

Page 52: ...SMPS G144 G145 3 16 SM 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 G144R019 WMF F ...

Page 53: ...ing 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 1 Unplug the 2 x from the main PBA and the SMPS 2 Remove 4 x Remove the fusing unit assembly A G144R020 WMF A ...

Page 54: ...FUSING UNIT G144 G145 3 18 SM 3 6 2 THERMOSTAT 3 Remove the 2 x Remove the thermostat B NOTE Both screws have a nut and a bolt G144R021 WMF B ...

Page 55: ...lacement Adjustment 3 6 3 FUSING LAMP 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 G144R022 WMF C D ...

Page 56: ...FUSING UNIT G144 G145 3 20 SM 3 6 4 STRIPPER PAWLS 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 G144R049 WMF A B C ...

Page 57: ...ripper pawls A out of the left and right side stripper pawl holder slots shown in white circles below 2 Place the top part of the fusing unit onto the bottom part of the fusing unit 3 Place the 4 x stripper pawls A back into the stripper pawl holder slots shown with two white arrows in the illustration below 4 Push the sides of the stripper pawls securely into the stripper pawl holder slots 5 Reas...

Page 58: ...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 G144R903 TIF ...

Page 59: ...FUSING UNIT SM 3 23 G144 G145 Replacement Adjustment 3 6 5 THERMISTOR Unwrap the thermistor harness A as shown above Remove 1 x securing the thermistor B and remove it G144R050 WMF A B ...

Page 60: ... 3 24 SM 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 1 1 x from the SMPS 2 Remove 1 x Remove the Fan A G144R026 WMF A ...

Page 61: ... 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 1 Remove one ground wire A 2 Remove the 4 x securing the laser scanning unit B G144R027 WMF A B ...

Page 62: ...ove 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 G144R028 WMF C B ...

Page 63: ...r 3 2 3 Top Cover 3 2 4 Left and Right Side Cover 3 2 5 3 2 6 1 Unplug 1 x from the drive assembly board A 2 Remove the 6 x white screws and 2 x ground wires Remove the drive assembly board A NOTE The screws and the screw slots on the drive assembly board are numbered Use the order shown on the board when you disassemble reassemble it G144R029 WMF A ...

Page 64: ...ar 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 3 x Remove the transfer ground A NOTE The transfer ground is designed to prevent unwanted particles from adhering to the transfer roller 2 Unplug 1 x B 3 Remove the PLT holder C and the PTL lens D G144R035 WMF G144R034 WMF A B C D ...

Page 65: ...5 Replacement Adjustment 4 Unlatch the transfer roller E as shown above 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 G144R036 WMF G144R037 WMF E F G H ...

Page 66: ...ar 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 1 Disconnect 1 x for the MP solenoid A and 1 x for the MP sensor B 2 Remove the 4 x Remove the by pass assembly Ensure that the cables are threaded through the frame 3 Remove the 2 x from the feed bracket D Remove it from the machine G144R038 WMF G144R039 WMF A B C D ...

Page 67: ...hine 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 6 Remove the feed roller G from the machine 7 Remove feed roller 1 H from the machine G144R040 WMF G144R041 WMF G144R042 WMF E F G H ...

Page 68: ...D 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 2 Remove the pick up assembly B as shown G144R043 WMF 1 2 G144R044 WMF A B ...

Page 69: ...ment 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 5 Remove the rubber pick up E from the pick up roller as shown above G144R045 WMF G144R046 WMF C D E ...

Page 70: ...he following procedures show how to replace these two rollers only Paper Feed Unit Pick up Roller 1 Turn the machine upside down 2 Release the white catch Slide the locking piece as far to the side as possible 3 Slide the white collar as far to the side as possible 4 Slide the pick up roller to the side until it gets free from the white collar 5 Rotate the pick up roller around the drive until it ...

Page 71: ...hite 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 4 Rotate the pick up roller around the drive shaft until it can be removed G144R048 WMF ...

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Page 73: ...TROUBLESHOOTING ...

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Page 75: ... PATH SM 4 1 G144 G145 Trouble shooting 4 TROUBLESHOOTING 4 1 PAPER PATH 1 Paper feed cassette 4 Fusing unit 2 By pass tray 5 Laser scanning unit 3 Transfer roller 6 Toner cartridge 1 2 6 3 5 4 G144T001 WMF ...

Page 76: ...eives 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 The paper moves to the paper exit sensor after it passes the paper feed sensor Jam1 occurs if the sensor is not actuated within a specific time interval EXIT Sensor G144T002 WMF EXIT Sensor G144T003 WMF ...

Page 77: ...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 EXIT Sensor G144T004 WMF ...

Page 78: ... paper Look inside the printer if no paper jam is visible Do not use tweezers or other sharp metal tools to remove jammed paper NOTE Ensure that you remove all paper fragments from the machine if the paper tears as you remove the jam from the machine Otherwise a jam will occur again 4 2 1 JAM2 PAPER EXIT AREA Perform the following procedure to solve this paper jam type 1 Pull the paper straight ou...

Page 79: ...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 NOTE Paper jammed in this area is very close to the fusing unit The fusing unit can become very hot Use caution when removing paper in this area G144T006 WMF ...

Page 80: ... 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 Ensure that the remaining paper in the paper tray unit is correctly aligned 3 Slide the tray back into the machine Open and close the front cover Printing should begin again automatically G144T007 WMF ...

Page 81: ...ure to solve this paper jam type 1 Open the front cover and remove the toner cartridge 2 Gently pull the paper toward you as shown above 3 Ensure that there is no more paper in the machine path s 4 Re install the toner cartridge and close the cover Printing should begin again automatically G144T008 WMF G144T009 WMF ...

Page 82: ...at the paper is below the paper capacity mark on the right inside of the tray Do not remove the paper from the tray if the machine is printing Flex fan and straighten the paper before you load it into the paper feed unit Do not use creased damp or highly curled paper Do not mix paper types Use only recommended print media Ensure that the recommended print side is facing down when you load paper in...

Page 83: ...onditions 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 1 Press and hold the cancel button for approximately 2 seconds to print the Demo page 2 Press and hold the cancel button for approximately 6 seconds to print the Configuration page G144T010 WMF ...

Page 84: ...n panel Error LED Status Open fusing unit error The Error LED red and the Toner Save LED flash simultaneously at 1 second intervals Overheat error The Error LED orange and the Toner Save LED flash simultaneously at 1 second intervals Low heat error The Error LED red and the Toner Save LED flash simultaneously at 4 second intervals LSU not ready error polygon motor error The Error LED green and the...

Page 85: ...e toner cartridge and test again 3 Replace the transfer roller and test again 4 6 3 VERTICAL WHITE LINE Description White vertical lines are visible on the output print Cause Solution 1 Window or internal lenses of LSU mirror are contaminated 2 Particles inside the toner cartridge or low toner 3 Particles contamination or burr on the edge of the toner cartridge window 4 Fusing unit is defective if...

Page 86: ...he OPC drum surface is damaged 3 Transfer roller has reached end of life 1 Print several OPC cleaning mode prints Then run the self test 2 3 times 2 Examine the OPC drum surface and remove any particles with a soft lint free cloth Replace the toner cartridge if the problem persists 3 Replace the toner cartridge if print count has exceeded the 60 K PM interval 4 6 6 LIGHT IMAGE Description Printed ...

Page 87: ...emblies 2 Replace the toner cartridge 3 Gently shake the toner cartridge side to side 5 6 times and try to print again Replace the toner cartridge if the problem persists 4 6 9 BACKGROUND Description A faint background type of imaging defect is visible throughout the output print Cause Solution 1 The machine has not printed large quantities of low coverage pages or the machine has not been used fo...

Page 88: ...all HV contacts Replace the HVPS if the problem persists 3 Replace the toner cartridge 4 Replace the transfer roller 5 Turn the machine off Wait 30 minutes and turn the machine on again Attempt to print 6 Replace the toner cartridge 4 6 11 GHOST 2 Description Ghosting image defect is visible on the output print at 75 mm intervals Cause Solution Higher voltage required when printing on card stock t...

Page 89: ...aning mode 2 3 times Then perform the self test 2 3 times 4 6 15 STAINS ON BACK OF PAGE Description Uneven background defects are visible on backside of the output print at 47 1 or 75 4 mm intervals Cause Solution 1 Transfer roller is contaminated 2 Pressure roller is contaminated 1 Perform the PC cleaning mode 2 3 times Then perform the self test 2 3 times Replace the transfer roller if the probl...

Page 90: ...Cause Solution 1 Bad ground contacts in the OPC and or toner cartridge 2 Solenoid is not functioning correctly 1 Check if the ground OPC or the OPC ground Zener diode is defective Clean the terminals on the toner cartridge and cartridge set 2 Perform the engine self test mode in Tech Mode to check if the solenoid is functioning normally Replace the main PBA if the problem persists ...

Page 91: ...the pick up roller and registration sensor may be contaminated 6 Feed sensor may be defective Verify in Tech Mode 1 Replace the solenoid 2 Repair replace as required 3 Clean with a soft cloth dampened with isopropyl alcohol or water Replace if necessary 4 Clean with a soft cloth dampened with isopropyl alcohol or water Replace if necessary 5 Ensure all rollers are clean 6 Check the SMPS PBA Main P...

Page 92: ...it and remove the jammed paper Then clean the surface of the pressure roller with dry gauze Check all ribs claws and springs 4 7 5 MULTI FEEDING Description Multiple sheets of paper are fed at the same time Cause Solution 1 Paper size guides may not be set correctly main paper tray unit and by pass tray 2 Solenoid does not operate correctly 3 Friction pad is contaminated 4 Paper has a rough surfac...

Page 93: ... paper is curled 1 Use paper supported by the machine specifications 2 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 drumnsurface with bare hands 2 Rotate the gear wheel and remove the paper from the cassette 3 Clean all fingerprints from the OPC with a soft tissue Ensure no scratching occurs to the drum surface...

Page 94: ...ve LSU cable or faulty connector 2 LSU motor is defective 3 Check the HSYNC signal 1 Replace the LSU 2 Replace the main board If the problem persists replace the LSU 4 8 3 PAPER EMPTY Description The paper empty lamp remains on with paper still remaining in the paper feed cassette Cause Solution 1 Defective paper sensor actuator or faulty sensor 2 Defective PBA 3 Defective cables or connectors 1 R...

Page 95: ...or actuator may be stuck 2 Hook lever on the front cover may be damaged or broken 3 Sensor switch on the main PBA may be defective 1 Check and replace the actuator if necessary 2 Replace the front cover 3 Replace the main PBA if necessary 4 8 7 NO ERROR LAMP WHEN COVER IS OPENED Description The error LED does not light when the print cover is opened Cause Solution 1 Hook lever or actuator may be s...

Page 96: ...s do not come on after you replace the SMPS 1 Replace the power supply cord or SMPS Replace the power or SMPS fuses if necessary 2 Check the operation panel connector Replace if necessary 3 Replace the main PBA 4 8 9 PRINTED VERTICAL LINES ARE CURVED Description Vertical lines on the output print are not straight Cause Solution Check the 24V power supply to the LSU Replace the LSU if 24 is stable ...

Page 97: ...proved by redistributing the toner if the printed image is light due to low toner supply In this situation shake the toner cartridge side to side 5 to 6 times However to ensure high quality printouts the toner cartridge should be replaced 4 9 2 REDISTRIBUTING TONER White streaks or light output prints are visible when the toner cartridge is near end of life At this time the LCD display shows the T...

Page 98: ...IDGE G144 G145 4 24 SM 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 G144T011 WMF G144T012 WMF B C D ...

Page 99: ... seconds the toner has almost reached end of life Replace the toner cartridge 4 Shake the toner cartridge if white vertical bands show and try to print again If the problem persists the cartridge has reached end of life Replace the toner cartridge Toner contamination Toner contamination is visible at regular intervals on the output print Toner contamination is visible at random intervals over the ...

Page 100: ... drum 3 The transfer roller s life has expired if a black or white image is broken at irregular intervals In this condition replace the transfer roller Also check the transfer voltage and readjust it if necessary Recycled Product Toner cartridge appears to be in poor condition Dirty or rough texture on output prints Poor background in the image 1 The toner cartridge is recycled if the following ar...

Page 101: ... the problem persists 2 Check the following if a black image is printed out 1 Check if unwanted matter remains on terminal contact points of the cartridge set 2 Check if the terminal and charge roller contacts are correctly assembled Perform the following if the above are true Examine the charge roller contacts Clean them if they appear dirty or contaminated Replace the toner cartridge if the prob...

Page 102: ... Check the following if you use Windows 1 Check that the printer driver in the controller is correctly set up 2 Ensure that the correct port is selected and Use On line is selected in the driver Print a test page from the driver properties if the printer driver is correctly set up Check with which application that printing does not work Open Memo Pad and try to print Adjust the setup within that p...

Page 103: ...provide more space on the hard disk with the disk utilities program Printer error occurs even if there is enough space in the hard disk Ensure the connection between the cable and printer port is correct Ensure the port settings in CMOS are correct if you use the parallel port Parallel port related problems in the CMOS set up Select ECP for the printer port SPP and normal modes support 8 bit data ...

Page 104: ...Description Solution Insufficient space on the hard disk in the directory assigned for the basic spool Delete unnecessary files to free up space for spool storage Previous printing errors were not resolved Delete jnl files Reboot Windows and attempt to print again There may be a conflict with other drivers or programs Close all programs except the one you need to use An application program or prin...

Page 105: ...SERVICE PROGRAM MODE ...

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Page 107: ...page before beginning the download procedure In the case of catastrophic data loss this page will serve as a record of the printer settings NOTE Do not turn off the machine power while updating the firmware DOS Command Mode Firmware for this machine can be upgraded by connecting to a PC via a parallel cable A command to upgrade the program must be entered You must save the correct firmware file to...

Page 108: ... be entered You must save the correct firmware file to the PC 1 Print out the configuration page as a backup reference for the data and settings 2 Download the firmware to the PC NOTE Download both the Printer Firmware and Network Firmware if you want to upgrade both 3 Access the EWS with the correct IP address 4 Select Maintenance as shown below continued on next page G144S901 TIF ...

Page 109: ...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 Click the Update Printer Firmware button 8 Ensure that the firmware has been completely updated G144S902 TIF G144S904 TIF A ...

Page 110: ...in the PC 11 Click the Update Network Firmware button 12 Ensure that the firmware has been completely updated 5 1 2 FIRMWARE RECOVERY PROCEDURE The machine will not operate if the update procedure did not successfully complete In this case perform the following steps 1 Turn the machine power off and then on 2 Perform the steps in download procedure 5 1 1 The machine will restart the upgrade activi...

Page 111: ...DETAILED DESCRIPTIONS ...

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Page 113: ...ons 6 DETAILED DESCRIPTIONS 6 1 MACHINE OVERVIEW 6 1 1 FRONT VIEW 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 G144D001 WMF A B C D E F G H ...

Page 114: ...MACHINE OVERVIEW G144 G145 6 2 SM 6 1 2 REAR VIEW A Face up door C USB port B Parallel port D Power receptacle G144D002 WMF A B C D ...

Page 115: ...error such as jammed paper cover open or empty toner cartridge when this button is red If you press the cancel button when the printer is receiving data the button blinks red and cancels the print job The button blinks red if there is no paper in the paper feed unit Load paper to the paper feed to resolve the error condition The button blinks green slowly when the printer receives print data The b...

Page 116: ...e button 2 Print configuration page In Ready mode press and hold this button for about 6 seconds until all LEDs blink quickly Then release the button 3 Clean inside of the printer In Ready mode press and hold this button for about 10 seconds until all LEDs turn on Release the button The machine prints one cleaning sheet after this procedure 4 Cancel a print job Press this button during printing Th...

Page 117: ...es The paper path has an anti static connection to ground which eliminates paper feed problems due to static charge on the paper Drive Mechanism The main drive mechanism uses a 2 phase motor It drives the OPC paper pick up and paper feed rollers using a gear train mechanism Laser Scanning Unit The machine uses the laser scanning unit LSU of the mechanism to create images on the OPC drum Laser Scan...

Page 118: ...ssor 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 PC Interface USB Parallel wired and wireless Network 5 Bus DMA and I O handling The operation panel is also included as part of the electrical components ...

Page 119: ...44 G145 Detailed Descriptions 6 3 SYSTEM LAYOUT 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 PR EXIT Sensor G144D003 WMF A B C D E F G H ...

Page 120: ...nd side paper guides can be adjusted to handle the various paper sizes A paper empty sensor detects the presence of paper capacity 250 sheets An indicator flag on the front of the paper tray unit shows the amount of paper remaining in the tray Pick up roller The pick up roller picks up and feeds paper into the printer It also removes static charge on the paper By pass tray The by pass tray holds n...

Page 121: ...nd heat to melt and bond toner into the paper Thermostat The thermostat cuts off the power to the fusing lamp which prevents machine overheating Power to the fusing lamp is cut when the thermostat temperature reaches 160 C Thermistor The thermistor detects the surface temperature of the hot roller This information goes to the main processor which uses this information to regulate the temperature o...

Page 122: ... protects the user A caution label is attached where the customer can see it easily when the rear cover is opened 6 3 5 LASER SCANNNING UNIT LSU The LSU converts video data into an electrostatic latent image on the surface of the OPC drum This is accomplished by controlling the laser beam and exposing the surface of the OPC drum with the laser light A rotating polygon mirror reflects the laser lig...

Page 123: ...r The toner cartridge unit consists of the toner supply roller developing roller and doctor blade There is no toner near end sensor in the machine However the machine has a toner remaining amount sensor A cleaning blade is used to collect the used toner Developing method Non magnetic one element contact method Toner non magnetic one element shatter type toner Toner life span 3 000 sheets IDC Patte...

Page 124: ...er than that for the supply CRU 6 3 8 TONER END DETECTION The machine does not have a toner end sensor The amount of toner is checked via software The machine counts and adds up black dots as toner consumption For example the following occurs when the machine prints 5 of black rate chart Starter cartridge Approx 4 750 000 000 dots will be added Supply cartridge Approx 7 500 000 000 dots will be ad...

Page 125: ... video controller with RET algorithm Line Memory Lookup Table Memory 512 x 8 4096 x 16 Engine controller Motor control unit Motor speed lookup table memory 128 x 16 x 2 Pulse width modulation unit 4 channels are supported ADC Interface unit 3 ADC channels are available ADC core ADC8MUX8 maximum clock frequency 3 MHz USB 2 0 interface Package 272 pins PBGA Power 1 8V Core 3 3V IO power operation Sp...

Page 126: ...IC SPGP G144 G145 6 14 SM 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 ...

Page 127: ... Jam0 shows red ERROR LED if the feed sensor is not detected within 1 second after paper is fed Paper Exit Sensor The exit sensor on the engine board along with the actuator on the frame detect when paper exits from the machine The CPU detects the on off time of the exit sensor and reports normal operation or jam status The red ERROR LED lights if Jam 2 error occurs Cover Open Sensor The cover ope...

Page 128: ... value Fusing The resistance value of the thermistor detects the temperature of the heat roller s surface The A D converter measures the thermistor resistance and lets the CPU determine the temperature of the heat roller The AC power is controlled by comparing the target temperature to the value from the thermistor An error shows if the value from the thermistor is out of the controlling range dur...

Page 129: ...the light sensor detects the beam and LReady occurs when the polygon motor speed reaches normal The LSU is ready when these two conditions are satisfied The errors in the table below show the possible error types when one or both of the two conditions is not satisfied Error Type Description Polygon motor error The polygon motor speed does not become stable Hsync error The polygon motor speed is st...

Page 130: ... 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 The CPU modifies the voltage settings to provide ideal voltages to create images The HVPS uses the 24V to output the high voltage for the THV MHV BIAS circuitry Then the high voltage output is supplied to the toner OPC cartridge and transfer roller ...

Page 131: ...asures the OPC voltage to determine the resistance The resistance is affected by changes in temperature and humidity The control program is then used to enable the THV voltage The voltage is adjusted to compensate for the environmental conditions Output voltage control method Transfer output voltage is sourced and controlled by changing the duty cycle of the THV PWM signal 2 Charge Voltage MHV Inp...

Page 132: ...se time 50 ms max Output voltage fall time 50 ms max Output loading range 10MΩ 1000 MΩ Output control signal BIAS PWM CPU output HV output when PWM is low 5 Supply Output voltage 400 V 800V DC 50 V ZENER with DEV Input contrast of the output stability degree under 5 Loading contrast 5 or less Output voltage rise time 50 ms max Output voltage fall time 50 ms max Output loading range 10 MΩ 1000 MΩ O...

Page 133: ... Rated Frequency 50 60 Hz Frequency range 47 63 Hz Input Current Under 4 0A 2 0A When the fuser lamp is off and input output voltages are in range 2 Rated Output Power No Item CH1 CH2 CH3 Remark 1 Channel name 3 3V 5V 24V 2 Connector pin CON 3 3 3V Pin 3 4 GND Pin 5 6 CON 3 5V Pin 8 GND Pin 7 CON 3 24V Pin 11 13 GND Pin 9 10 3 Rated output 3 3 V 5 3 2 3 4 V 5 V 5 4 75 5 25 V 24 V 10 21 6 26 4 V 4 ...

Page 134: ... Jam0 shows if the feed sensor remains off after a certain time the feed sensor tries again This means that the leading edge of the paper doesn t pass the feed sensor within a certain time The feed sensor does not actuate even though the paper has reached the feed sensor This means that the sensor is faulty Jam1 The trailing edge of the paper does not pass the feed sensor within a certain time onc...

Page 135: ...SPECIFICATIONS ...

Page 136: ......

Page 137: ... mode Standard tray A3 DLT A5 By pass tray A3 DLT A6 Free size By pass tray Custom size paper Length 160 432 mm 5 8 17 Width 90 305 mm 3 5 12 Com 10 C5 C6 DL Monarch Optional Envelope Feeder Com 10 C5 C6 DL Monarch Paper Input Size Optional paper tray unit Up to 2 units can be installed A3 DLT A5 Standard Optional paper trays 2 x 250 sheets 80 g m 20 lb Normal paper 50 sheets 80 g m 20 lb Paper In...

Page 138: ... CPU SPGPm 166 MHz Standard PCL6 Printer Languages Auto Emulating Sensing Supported Interfaces Standard IEEE1284 USB 2 0 Standard Max 16MB 144MB Memory 1 slot Type SDRAM Font Type Flash Memory Number 45 Scalable 1 Bitmap Network 10 100 Base TX ...

Page 139: ...uese Russian Swedish Norwegian Finish Danish Chinese Taiwanese Printer driver Contents Printer driver Acrobat reader Manual SM Electronic registration Layout 1 Orientation Portrait Landscape Rotate 180 degrees 2 Layout options Type pages per slide page order 3 Favorites Paper 1 Copies 2 Paper options Size source type 3 Favorites Graphics 1 Resolution 1200 dpi 600 dpi 2 Toner save Printer setting o...

Page 140: ...y unit Paper weight 16 24 lb 60 90 g m Memory upgrade Supported Memory type SDRAM Memory Memory unit 32 MB 128 MB Option 10 100 Base Tx Protocol SPX IPX TCP IP Ethertalk SNMP HTTP 1 1 DLC LLC Network Operating system MS Windows 98 NT ME 2000 XP SUN Solaris HP UX SCO Novell Netware Macintosh Hard Disk Not Supported Mailbox Not Supported Serial Not Supported Local talk Not Supported ...

Page 141: ...APPENDIX ...

Page 142: ......

Page 143: ...et Voltage Detector USB 2 0 IEEE1284 SPG Pm SDR AM 16MB FLASH MEMORY 2MB MAIN MOTOR A3977 Motor driver Heater AC Controller Block SMPS Block HVPS Block EXIT SENSOR F G 24V 5V 3 3V GND LSU FAN PANEL 24V Cover Open Switch MHV OPC GND SUPPLY DEV THV BIAS PWM THV PWM MHV PWM MPF SENSOR MP SENSOR P EMPTY SENSOR FEED SENSOR EEPROM Crystal 12 MHZ Freq Spread Main Clock G144X01 WMF ...

Page 144: ...4VS MP EMPTY 24VS LED READY THV READ LED ERROR THV PWM THV EN BIAS PWM MHV PWM LED TONER SAVE KEY DEMO FAN FUSER ON P EXIT SMPS HVPS SENSOR 100 PIN CN 14 CN 13 CN 7 CN 15 CN 5 36 PIN MAIN BOARD CN 16 CN 4 CN 8 CN 10 CN 11 CN 9 8 PIN 4 PIN CN 17 CN 6 CN 1 CN 2 1 2 1 2 1 2 3 4 1 2 3 4 ROM DIMM ROM DIMM SCF OPTION CARTRIDGE INFO THERMISTOR 1 2 3 4 DCU MOTOR 1 2 3 4 THER 1 THER 2 A A B B 3 3V DCU DATA...

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