Ricoh BP20N, BP20 Service Manual
G144/G145
SERVICE MANUAL
002540MIU
SERVICE MANUAL
G144/G145
G144/G145
SERVICE MANUAL
002540MIU
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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.
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desktop images, used in this document are trademarks, registered
trademarks or the property of their respective companies.
They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use o
any trade name, or web site is intended to convey endorsement or othe
affiliation with Ricoh products.
2005 RICOH Corporation. All rights reserved.
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WARNING
The Service Manual contains information
regarding service techniques, procedures,
rocesses and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
information contained in this service manual to
repair or modify Ricoh equipment risk persona
injury, damage to property or loss of warrant
rotection.
Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
G144 ----- ----- BP20 ----G145 ----- ----- BP20N -----
GESTETNER LANIER RICOH SAVIN
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
*
10/2005 Original Printing
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
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 ........................................................................3-20
Reassembling the Fusing Unit ............................................................3-21
Note. ...................................................................................................3-22
3.6.5 THERMISTOR................................................................................ 3-23
3.7 UNPLUG FAN .........................................................................................3-24
3.8 LASER SCANNING UNIT .......................................................................3-25
3.9 DRIVE UNIT ............................................................................................3-27
3.10 TRANSFER UNIT..................................................................................3-28
SM i G144/G145
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
Jam1 .....................................................................................................4-2
Jam2 .....................................................................................................4-3
4.2 CLEARING PAPER JAMS ........................................................................4-4
4.2.1 JAM2 (PAPER EXIT AREA) .............................................................4-4
4.2.2 JAM0 (PAPER FEED AREA)............................................................4-6
4.2.3 JAM1 (TONER CARTRIDGE AREA)................................................4-7
4.2.4 TIPS TO AVOID PAPER JAMS........................................................4-8
4.3 SAMPLE PATTERN .................................................................................. 4-9
4.3.1 PRINTING 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 UNEVEN DENSITY ........................................................................4-13
4.6.9 BACKGROUND..............................................................................4-13
4.6.10 GHOST 1......................................................................................4-14
4.6.11 GHOST 2......................................................................................4-14
4.6.12 GHOST 3......................................................................................4-14
4.6.13 GHOST 4......................................................................................4-15
4.6.14 STAINS ON FRONT OF PAGE ....................................................4-15
4.6.15 STAINS ON BACK OF PAGE.......................................................4-15
4.6.16 BLANK PAGE 1............................................................................4-15
4.6.17 BLANK PAGE 2............................................................................4-16
4.7 PAPER FEED PROBLEMS..................................................................... 4-17
4.7.1 INCORRECT PRINT POSITION ....................................................4-17
4.7.2 JAM 0 .............................................................................................4-17
4.7.3 JAM 1 .............................................................................................4-17
4.7.4 JAM 2 .............................................................................................4-18
G144/G145 ii SM
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
4.8.8 NO POWER....................................................................................4-22
4.8.9 PRINTED VERTICAL LINES ARE CURVED..................................4-22
4.9 TONER CARTRIDGE.............................................................................. 4-23
4.9.1 TONER CARTRIDGE PRECAUTIONS ..........................................4-23
4.9.2 REDISTRIBUTING TONER............................................................4-23
4.9.3 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 Server) mode ...................................................5-2
5.1.2 FIRMWARE RECOVERY PROCEDURE .........................................5-4
DETAILED DESCRIPTIONS
6. DETAILED DESCRIPTIONS ........................................................ 6-1
6.1 MACHINE OVERVIEW..............................................................................6-1
6.1.1 FRONT VIEW ...................................................................................6-1
6.1.2 REAR VIEW .....................................................................................6-2
6.1.3 OPERATION PANEL........................................................................6-3
On Line/Error Button............................................................................. 6-3
Toner Save Button................................................................................6-4
On Line/Error Button and Toner Save Button .......................................6-4
Cancel Button .......................................................................................6-4
6.2 MACHINE OVERVIEW..............................................................................6-5
6.2.1 FIRMWARE ......................................................................................6-5
6.2.2 PRINT ENGINE ................................................................................6-5
SM iii G144/G145
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
6.3.4 FUSING UNIT...................................................................................6-9
Thermostat............................................................................................6-9
Thermistor.............................................................................................6-9
Hot Roller..............................................................................................6-9
Pressure Roller .....................................................................................6-9
Safety Features ..................................................................................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 Circuit .........................................................6-15
Motor Drive Circuit ..............................................................................6-16
Transfer ..............................................................................................6-16
Fusing .................................................................................................6-16
LSU.....................................................................................................6-17
6.5 SMPS AND HVPS ...................................................................................6-18
6.5.1 HVPS (HIGH VOLTAGE POWER SUPPLY) ..................................6-19
1. Transfer High Voltage (THV+) ..........................................................6-19
2. Charge Voltage (MHV) .....................................................................6-19
3. Cleaning Voltage (THV-)...................................................................6-19
4. Developing Voltage (DEV)................................................................6-20
5. Supply...............................................................................................6-20
G144/G145 iv SM
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 ............................................................................ 8-1
CONNECTION DIAGRAM................................................................. 8-2
SM v G144/G145
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. Use only approved replacement parts. There are no user serviceable parts
inside the printer. Do not make any unauthorized changes or additions to the
printer. This could cause the printer to malfunction and create electric shock or
fire hazards.
3. Laser 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 normal operation, user maintenance, or prescribed
service activities.
NOTE: Never operate or service the printer with the protective cover removed from
Laser/Scanner assembly. The reflected beam can damage your eyes.
When using this product, these basic safety precautions should always be
followed to reduce risk of fire, electric shock, and injury to persons.
WARNING
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. See a doctor immediately if the liquid gets into the mouth
or is swallowed.
2. Please keep toner cartridges away from children. The toner powder contained
with the toner cartridge may be harmful if swallowed. Contact a doctor
immediately if toner powder is swallowed.
ELECTRIC SHOCK AND FIRE SAFETY PRECAUTIONS
Failure to follow the following instructions could cause electric shock or fire.
1. Use only the correct voltage. Failure to do so could damage the printer and
potentially cause a fire or electric shock.
2. Use only the power cable supplied with this machine. Use of an incorrectly
specified cable could cause the cable to overheat and potentially cause a fire.
3. Do not overload the power socket. This could lead to overheating of the cables
inside the wall 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 outlet.
5. Never touch the plugs on either end of the power cable with wet hands. This
can cause electric shock.
6. Remove the power plug from the wall socket when servicing the printer.
7. Use caution when you insert or remove the power plug. The power plug must
be inserted completely. Otherwise, a poor contact could cause overheating and
lead to a fire. (When removing the power plug, grip the plug firmly and pull. Do
not pull the power cable out by pulling on the cord itself.)
8. Do not allow the power cable to become twisted or bent sharply around
corners. Do not place objects on top of the power cable. If the power cable is
damaged, it could overheat and cause a fire. Exposed cables could cause an
electric shock. Replace a damaged power cable immediately. Do not reuse or
repair a damaged cable. Some chemicals can also attack the coating on the
power cable, weakening the cover or exposing cables. This can cause fire and
shock risks.
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. Do not touch
the machine or the power cord if it is still connected to the wall socket in these
weather conditions.
11. Avoid damp or dusty areas. Install the machine in a clean, well-ventilated
location. Do not position the machine near a humidifier. Dampness and dust
build-up inside the machine can lead to overheating and cause a fire.
12. Do not position the machine in direct sunlight. This will cause the temperature
inside the machine to rise, possibly leading to machine failure and, in extreme
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 installed on a level surface, capable of supporting its
weight. Failure to do so could cause the machine to tip or fall.
2. Avoid placing fingers or hair in close proximity to any rollers, gears, or fans
within this machine while the machine is in operation.
3. Do not place any small metal objects, containers of water, chemicals, or other
liquids close to the machine. This can cause damage, shock, or fire if spilled
into the machine.
4. Do not install the machine in areas with high dust or moisture levels, beside
open windows, or close to a humidifier or heater.
5. Do not place candles, burning cigarettes, etc. on the machine. A fire may occur.
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.
1. Check the contents of the machine
memory and make a note of any
user settings. These will be erased
if the main board or network card
is replaced.
2. Ensure that power is disconnected
before you service or replace any
electrical parts.
3. Disconnect printer interface cables
and power cables.
4. Use only approved spare parts.
Ensure that part number, product name,
voltages, current and/or temperature 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 little as 5 minutes can damage the surface’s
photoconductive properties and will result in print quality degradation.
Remove the OPC Drum and store it in a black bag or other lightproof
container. Take care when working with the covers (especially the top cover),
since light can be admitted to the OPC area and can damage the OPC Drum.
• Take care not to scratch the green surface of OPC Drum Unit. If the green
surface of the Drum Cartridge is scratched or touched, the print quality will be
compromised.
CAUTION1.TIF
Caution2.tif
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.
3. This machine weighs 12.7kg, 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.
CAUTION3.TIF
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 the machine.
5. Do not install the machine on a sloping or unstable surface. After installation,
double-check that the printer is stable.
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.
CAUTION
Ensure that no power is applied to the chassis or circuit, and observe all other
safety precautions.
1. Immediately before handling a semiconductor component or semiconductorequipped assembly, drain any electrostatic charge on your body by touching a
known earth ground. Alternatively, employ a commercially available wrist strap
device, which must be removed for your personal safety reasons prior to
applying power to the unit under test.
2. After removing an electrical assembly equipped with ESDs, place the assembly
on a conductive surface, such as aluminum or copper foil, or conductive foam,
to prevent electrostatic charge buildup 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 a replacement ESD from its protective packaging until
immediately prior to installing it. Most replacement ESDs are packaged with all
leads shorted together by conductive foam, aluminum foil, or a comparable
conductive material.
7. Immediately before removing the protective shorting material from the leads of
a replacement ESD, touch the protective material to the chassis or circuit
assembly into which the device will be installed.
8. Maintain continuous electrical contact between the ESD and the assembly into
which it will be installed, until the ESD or assembly is completely plugged or
soldered into the circuit.
9. Minimize bodily motions when handling unpackaged replacement ESDs.
Normal motions, such as the brushing together of clothing fabric and lifting
one’s foot from a carpeted floor, can generate static electricity sufficient to
damage an ESD.
INSTALLATION
PREVENTIVE MAINTENANCE
REPLACEMENT AND ADJUSTMENT
TROUBLESHOOTING
TAB
POSITION 1
TAB
POSITION 2
TAB
POSITION 3
TAB
POSITION 4
SERVICE PROGRAM MODE
DETAILED DESCRIPTIONS
SPECIFICATIONS
APPENDIX
TAB
POSITION 5
TAB
POSITION 6
TAB
POSITION 7
TAB
POSITION 8
INSTALLATION
INSTALLATION PROCEDURE
1. INSTALLATION
1.1 INSTALLATION PROCEDURE
Refer to the Operating Instructions for full installation procedures.
Installation
SM 1-1 G144/G145
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