Troubleshooting Melco G3 Error Codes and Printing Problems

Troubleshooting Melco G3 Error Codes and Printing Problems

Dean Armando

Error Codes

REPLACE INK CARTRIDGE SOON

Possible Causes

  • The maintenance tank needs to be reset

Possible Solutions

Possible Prevention

  • Do not let the maintenance tank fall below 50%.

Lights are flashing on the control panel

Possible Causes

  • Green lights flashing mean that the printer is receiving data, charging ink, or cleaning the print head. This is a normal function.
  • Red lights flashing mean that the printer has encountered a fatal operation.

Possible Solutions

  • Power down the printer. Count to ten. Power the printer up again. If the problem persists, see the section on startup issues.

NO MAINTENANCE CART (but the maintenance tank is installed)

no_main_tank_message.png

Possible Causes

  • The table is in the loading position. This is a normal function.

Possible Solutions

  • The message will clear with the table is moved to the print position.

Startup Problems

Platen moves and stops. The red limit light is on.

Possible Causes

  • The table height has exceeded maximum

Possible Solutions

  • Press the down button on the table control panel until the limit light switches off.

During printer startup, the error message service call (1601) appears. On the printer control panel, the two orange lights are flashing and the green light is on. The table control panel display reads error 0002.

Possible Causes

  • Cartridge or tank problem detected.

Possible Solutions

  • The message is informing the user that something is wrong with the chips and/or cartridges.
    1. Power down the printer.
    2. Start the printer in diagnostic mode (F1 + Power on)
    3. The following messages will be displayed
    4. The most common solution is to reinsert the cartridge and or the ARChip. The ARChips may also need to be cleaned from any dust or dirt. 
    5. This error indicates that there is a cartridge issue (cartridge not inserted properly, missing or damaged chip, or maintenance tank not reset).

Paper Error (press the down button. load paper correctly)

Possible Causes

  • There is a wrong setting in the printer setup properties.

Possible Solutions

  • This error appears when a setting inside the printer menu has been changed. This setting is the "Printer Setup>PPR SIZE CHECK" which always needs to be "OFF".
    1. Power down the printer.
    2. Start the printer in diagnostic mode (F1 + Power on)
    3. Locate the setting in the printer control panel menu.
    4. Enter the printer setup properties and check for the setting "PPR SIZE CHECK"
    5. Set it to "OFF"
    6. Restart the printer in normal mode.

Service call 150C

Possible Causes

  • There is a wrong operation in the printer startup.

Possible Solutions

  • This error message indicates that the gear system which moves the print head during the initialization cannot function properly. If after a simple restart the problem persists, contact Melco Tech for information on removing the gear system and resizing the spring inside.

Service call 1226 

Possible Causes

  • Wrong table movement has been detected during startup.

Possible Solutions

  • This error appears when the user doesn't press SHIFT+F1 when the "load paper" message appears and instead presses the HOME button. It can also appear after the "Load Paper Correctly" message. in this case, the table will move suddenly to the back of the printer where it will reach the terminal switch.
  • If the 1226 error appears during the startup, it could be caused from a pending print job.
    1. Remove the USB cable from the printer.
    2. Restart the printer.
    3. Clear all pending print jobs from the computer.
  • If the error still persists, it could be cause by an over-tight movement belt of the table or table movement problem.

Printing Problems

When printing, the print head moves, but no ink sprays out

Possible Causes and Solutions

  • The printer needs a head cleaning.
    • Perform a head cleaning and nozzle check.
    • Perform a powerful cleaning cycle and a nozzle check.
  • The dampers are faulty or expired.
    • Order replacement dampers.
  • Capping station is clogged.
    • The capping station may need cleaning.
    • If the print head did not seat properly, all of the nozzles may be clogged.
  • No ink is flowing from the cartridge.
    • A vacuum can be created in the ink cartridge. Replace with a new cartridge.
  • The ribbon cable to the print head is burnt or not connected.
    • This can happen if you replaced a print head and did not ensure that the cable was properly attached.
  • Main board is bad.
    • There is a chance that the main board is bad or has a defect. 


The printer is not responding to a print job.

Possible Causes and Solutions

  • The printer is not ready to print the job.
    • Check for the ready message at the printer display.
  • There is a connection problem.
    • Check the USB connection. Remove the cable and reinsert it.
  • There is a communication error between the printer and computer.
    • Restart the printer and the computer to ensure that all pending jobs have been deleted.

Possible Solutions

  • Use shorter SB cables and avoid switches or hubs with large traffic loads.
  • Properly cancel print jobs without leaving jobs in the spooler.

The print head is leaking ink

Possible Causes and Solutions

  • The print head was damaged by crashing into an obstruction.
    • Order a replacement print head.
  • The capping station is dirty.
    • Thoroughly clean the capping station. This will prevent buildup on the capping station and the print head.
  • Too much is in the cartridges.
    • If the cartridges are overfilled, there could be too much pressure in the ink lines and ink could be forced out of the print head. Cartridges should be filled below the maximum ink line.
  • Altitude is affecting the ink pressure.
    • Higher altitudes can affect the pressure in and around the ink system. If you are experiencing a large amount of issues and are at a higher altitude, fill the ink cartridges with a lesser amount.
  • The printer is not level.
    • If the printer is not level, the ink system will not be level either. This will also have an effect on the pressure in and around the ink system. Make sure the printer is level.
  • Faulty cartridges.
  • The dampers are faulty or expired.

Possible Solutions

  • Always adjust the table height.
  • Clean the capping station on a regular basis.
  • Clean debris from around the print head on a regular basis.
  • Keep the printer level.
  • Don't overfill the ink cartridges.

Print head clogging issues

Possible Causes and Solutions

  • The capping station is dirty and either not cleaning the print head completely or adding more debris to the print head and causing the print head to become clogged.
    • Thoroughly clean the capping station and the wiper blade as described in the daily or weekly maintenance procedures.
  • Ink in the nozzle opening has dried out from exposure to air for an extended period.
    • Perform head cleans until a decent nozzle check is achieved.
    • Perform a powerful cleaning cycle and check for a decent nozzle check.
    • A serious or permanent clog of the print head may require replacing the print head.
  • The print head was damaged by crashing into an obstruction.
    • Order a replacement print head.

Possible Solutions

  • Perform the daily, weekly, and monthly maintenance procedures as described.
  • Perform head cleans and nozzle checks before printing on garments.
  • Pretreated fabric must not contact the print head as the pretreatment will react with the print head surface and potentially block nozzles. Should contact occur, clean the print head immediately with alcohol.

Load Paper. On the table control panel display appears preparation error 0020

Possible Causes and Solutions

  • The preparation to print couldn't start correctly.
    • This message may appear after the printer has printed the white layer and before the CMYK layer. To bypass, press Shift+F1. The print job does not get lost and the garment is not damaged. It has been noted that if the maintenance tank is over 50% full, this may happen more frequently. To prevent, empty and reset the maintenance tank more often.

Cancelling a print job

Possible Causes and Solutions

  1. Immediate stop to the printing - Power OFF the printer.
  2. Cancel the printing - Cancel the job and all other pending jobs from the printer spooler in the windows control panel "Printers and Faxes". Ensure on the computer that all print jobs have been deleted.
  3. Restart printer.

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