Ricoh BP20 - Aficio B/W Laser Printer User manual

G144/G145
SERVICE MANUAL
002540MIU

G144/G145
SERVICE MANUAL

G144/G145
SERVICE MANUAL
002540MIU

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interest of Ricoh Corporation and its member companies.
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only and for the benefit of such companies. No such use, or the use o
f
any trade name, or web site is intended to convey endorsement or othe
r
affiliation with Ricoh products.
2005 RICOH Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
p
rocesses and spare parts of office equipmen
t
distributed by Ricoh Corporation. Users of this
manual should be either service trained o
r
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizin
g
information contained in this service manual to
repair or modify Ricoh equipment risk persona
l
injury, damage to property or loss of warrant
y
p
rotection.
Ricoh Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
G144 ----- ----- BP20 -----
G145 ----- ----- BP20N -----
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 10/2005 Original Printing

SM i G144/G145
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

G144/G145 ii SM
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

SM iii G144/G145
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

G144/G145 iv SM
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

SM v G144/G145
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

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.