Ricoh D010 User manual

D010
SERVICE MANUAL
003241MIU

D010
SERVICE MANUAL

D010
SERVICE MANUAL
003241MIU

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©2007 RICOH Americas Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Americas Corporation.
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
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Ricoh Americas Corporation
WARNING

LEGEND
PRODUCT CODE COMPANY
GESTETNER LANIER RICOH SAVIN
D010 DSm625 LD125 Aficio MP 2500 7025
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 09/2007 Original Printing

SM i D010
D010
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION............................................................................ 1-1
1.1 INSTALLATION REQUIREMENTS ............................................................1-1
1.1.1 ENVIRONMENT ................................................................................1-1
1.1.2 MACHINE LEVEL..............................................................................1-2
1.1.3 MINIMUM SPACE REQUIREMENTS ...............................................1-2
1.1.4 POWER REQUIREMENTS ...............................................................1-3
1.2 COPIER INSTALLATION ...........................................................................1-4
1.2.1 POWER SOCKETS FOR PERIPHERALS ........................................1-4
1.2.2 ACCESSORY CHECK ......................................................................1-4
D010 .....................................................................................................1-4
D043 .....................................................................................................1-5
1.2.3 INSTALLATION PROCEDURE .........................................................1-5
1.3 PLATEN COVER INSTALLATION..............................................................1-9
1.3.1 ACCESSORY CHECK ......................................................................1-9
1.3.2 INSTALLATION PROCEDURE .........................................................1-9
1.4 ARDF INSTALLATION .............................................................................1-10
1.4.1 ACCESSORY CHECK ....................................................................1-10
1.4.2 INSTALLATION PROCEDURE .......................................................1-11
1.5 TWO-TRAY PAPER TRAY UNIT INSTALLATION ...................................1-14
1.5.1 ACCESSORY CHECK ....................................................................1-14
1.5.2 INSTALLATION PROCEDURE .......................................................1-14
1.6 ONE-BIN TRAY INSTALLATION..............................................................1-16
1.6.1 ACCESSORY CHECK ....................................................................1-16
1.6.2 INSTALLATION PROCEDURE .......................................................1-16
1.7 BRIDGE UNIT INSTALLATION ................................................................1-19
1.7.1 COMPONENT CHECK....................................................................1-19
1.7.2 INSTALLATION PROCEDURE .......................................................1-19
Installation for a machine WITHOUT the 1-bin tray unit......................1-20
Installation for a machine WITH the 1-bin tray unit .............................1-22
1.8 500-SHEET FINISHER (B792) .................................................................1-24

D010 ii SM
1.8.1 ACCESSORY CHECK ....................................................................1-24
1.8.2 INSTALLATION PROCEDURE .......................................................1-25
Installation of the 500-Sheet Finisher..................................................1-25
1.9 ANTI-CONDENSATION HEATER INSTALLATION..................................1-27
1.10 TRAY HEATERS ................................................................................1-28
1.10.1 TRAY HEATER..........................................................................1-28
1.10.2 TRAY HEATERS FOR THE OPTIONAL PAPER FEED UNIT...1-29
1.11 KEY COUNTER INTERFACE INSTALLATION ..................................1-33
1.12 DDST EXPANSION ............................................................................1-35
1.12.1 ACCESSORY CHECK...............................................................1-35
1.12.2 INSTALLING EXPANSION COMPONENT ................................1-35
Installing Panels and Keys..................................................................1-36
1.13 PCL OPTION ......................................................................................1-38
1.13.1 ACCESSORY CHECK...............................................................1-38
1.13.2 INSTALLING PCL OPTION .......................................................1-38
1.14 MECHANICAL COUNTER..................................................................1-41
1.14.1 COMPONENT CHECK ..............................................................1-41
1.14.2 INSTALLING MECHANICAL COUNTER...................................1-41
When removing the mechanical counter.............................................1-43
1.15 KEY COUNTER INSTALLATION (4 PINS).........................................1-44
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 PM TABLES ...............................................................................................2-1
2.1.1 OPTICS .............................................................................................2-1
2.1.2 DRUM AREA .....................................................................................2-1
2.1.3 PAPER FEED....................................................................................2-2
2.1.4 FUSING UNIT....................................................................................2-3
2.1.5 ARDF.................................................................................................2-3
2.1.6 PAPER TRAY UNIT ..........................................................................2-4
2.2 HOW TO RESET THE PM COUNTER.......................................................2-5
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 GENERAL CAUTIONS ...............................................................................3-1
Rev. 01/2009

SM iii D010
3.1.1 PCU (PHOTOCONDUCTOR UNIT) ..................................................3-1
3.1.2 TRANSFER ROLLER........................................................................3-1
3.1.3 SCANNER UNIT................................................................................3-1
3.1.4 LASER UNIT .....................................................................................3-2
3.1.5 FUSING UNIT....................................................................................3-2
3.1.6 PAPER FEED....................................................................................3-2
3.2 SPECIAL TOOLS AND LUBRICANTS .......................................................3-3
3.3 EXTERIOR COVERS AND OPERATION PANEL......................................3-4
3.3.1 REAR COVER...................................................................................3-4
3.3.2 TRAY HARNESS COVER .................................................................3-4
3.3.3 COPY TRAY......................................................................................3-5
3.3.4 INNER COVER..................................................................................3-5
3.3.5 UPPER COVERS ..............................................................................3-6
3.3.6 LEFT COVER ....................................................................................3-6
3.3.7 FRONT COVER ................................................................................3-7
3.3.8 FRONT RIGHT COVER ....................................................................3-7
3.3.9 RIGHT REAR COVER.......................................................................3-8
3.3.10 RIGHT DOOR (DUPLEX UNIT) ...................................................3-8
3.3.11 BY-PASS TRAY...........................................................................3-9
3.3.12 RIGHT LOWER COVER............................................................3-10
3.3.13 PLATEN COVER SENSOR .......................................................3-10
3.4 SCANNER UNIT.......................................................................................3-11
3.4.1 EXPOSURE GLASS/DF EXPOSURE GLASS ................................3-11
Exposure Glass...................................................................................3-11
DF Exposure Glass.............................................................................3-11
3.4.2 LENS BLOCK ..................................................................................3-11
3.4.3 LAMP STABILIZER BOARD AND EXPOSURE LAMP ...................3-12
3.4.4 ORIGINAL WIDTH/LENGTH SENSOR ...........................................3-13
Sensor Positions .................................................................................3-14
Rearranging Sensor Positions for China Model (8K/16K) ...................3-14
3.4.5 SCANNER MOTOR.........................................................................3-15
3.4.6 SCANNER HOME POSITION SENSOR .........................................3-16
3.4.7 ADJUSTING SCANNER POSITIONS .............................................3-16
Overview.............................................................................................3-17
Adjusting the First Scanner Contact Points.........................................3-18
Adjusting the Second Scanner Contact Points ...................................3-18
3.5 LASER UNIT ............................................................................................3-20

D010 iv SM
3.5.1 LOCATION OF CAUTION DECAL ..................................................3-20
3.5.2 TONER SHIELD GLASS .................................................................3-20
3.5.3 LASER UNIT ...................................................................................3-21
3.5.4 LD UNIT ..........................................................................................3-21
3.5.5 POLYGONAL MIRROR MOTOR.....................................................3-22
3.5.6 LASER UNIT ALIGNMENT ADJUSTMENT.....................................3-23
3.6 PCU SECTION .........................................................................................3-25
3.6.1 PCU.................................................................................................3-25
3.6.2 PICK-OFF PAWLS AND TONER DENSITY SENSOR....................3-25
3.6.3 OPC DRUM .....................................................................................3-27
3.6.4 CHARGE ROLLER AND CLEANING BRUSH.................................3-28
3.6.5 CLEANING BLADE .........................................................................3-28
3.6.6 DEVELOPER...................................................................................3-29
3.6.7 AFTER REPLACEMENT OR ADJUSTMENT..................................3-30
3.7 TONER SUPPLY MOTOR........................................................................3-31
3.8 PAPER FEED SECTION ..........................................................................3-32
3.8.1 PAPER FEED ROLLER: TRAY 1 ....................................................3-32
3.8.2 PAPER FEED ROLLER: TRAY 2 ....................................................3-32
3.8.3 FRICTION PAD ...............................................................................3-33
3.8.4 PAPER END SENSOR....................................................................3-33
3.8.5 UPPER/LOWER PAPER LIFT MOTORS........................................3-34
3.8.6 EXIT SENSOR ................................................................................3-34
3.8.7 BY-PASS FEED ROLLER AND PAPER END SENSOR.................3-35
3.8.8 REGISTRATION ROLLER ..............................................................3-36
3.8.9 BY-PASS PAPER SIZE SWITCH....................................................3-37
3.8.10 REGISTRATION CLUTCH.........................................................3-38
3.8.11 REGISTRATION SENSOR ........................................................3-38
3.8.12 UPPER PAPER FEED CLUTCH AND BY-PASS FEED CLUTCH3-39
3.8.13 RELAY CLUTCHES...................................................................3-39
3.8.14 UPPER RELAY SENSOR..........................................................3-40
3.8.15 LOWER RELAY SENSOR .........................................................3-40
3.8.16 LOWER PAPER FEED CLUTCH...............................................3-41
3.8.17 UPPER/LOWER PAPER SIZE SENSORS ................................3-41
3.8.18 UPPER/LOWER PAPER LIFT SENSOR ...................................3-42
3.8.19 UPPER/LOWER PAPER HEIGHT SENSORS ..........................3-43
When reassembling the sensor bracket..............................................3-44
3.9 IMAGE TRANSFER..................................................................................3-45

SM v D010
3.9.1 IMAGE TRANSFER ROLLER .........................................................3-45
3.9.2 IMAGE DENSITY SENSOR ............................................................3-46
3.9.3 DISCHARGE PLATE.......................................................................3-46
Reassembling the discharge plate ......................................................3-47
3.10 FUSING ..............................................................................................3-49
3.10.1 FUSING UNIT ............................................................................3-49
3.10.2 THERMISTOR ...........................................................................3-49
3.10.3 FUSING LAMPS ........................................................................3-50
3.10.4 HOT ROLLER STRIPPER PAWLS............................................3-51
3.10.5 HOT ROLLER ............................................................................3-51
3.10.6 THERMOSTAT ..........................................................................3-52
3.10.7 PRESSURE ROLLER AND BUSHINGS....................................3-52
3.10.8 NIP BAND WIDTH ADJUSTMENT ............................................3-53
3.10.9 CLEANING ROLLER .................................................................3-54
3.11 DUPLEX UNIT ....................................................................................3-55
3.11.1 DUPLEX EXIT SENSOR............................................................3-55
3.11.2 DUPLEX ENTRANCE SENSOR................................................3-55
3.11.3 DUPLEX INVERTER SENSOR .................................................3-56
3.11.4 DUPLEX TRANSPORT MOTOR ...............................................3-56
3.11.5 DUPLEX INVERTER MOTOR ...................................................3-57
3.12 OTHER REPLACEMENTS .................................................................3-58
3.12.1 QUENCHING LAMP ..................................................................3-58
3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD.............................3-58
3.12.3 BICU (BASE-ENGINE IMAGE CONTROL UNIT) ......................3-59
3.12.4 MAIN MOTOR............................................................................3-59
3.12.5 DUPLEX FAN ............................................................................3-60
3.12.6 REAR EXHAUST FAN...............................................................3-60
Replacement Procedure .....................................................................3-60
3.12.7 PSU (POWER SUPPLY UNIT) ..................................................3-61
3.12.8 GEARBOX .................................................................................3-62
Gear Arrangement in the Gearbox......................................................3-63
3.13 COPY ADJUSTMENTS PRINTING/SCANNING ................................3-64
3.13.1 PRINTING..................................................................................3-64
Registration - Leading Edge/Side-to-Side...........................................3-64
Blank Margin.......................................................................................3-65
Main Scan Magnification.....................................................................3-66
3.13.2 SCANNING ................................................................................3-66

D010 vi SM
Registration: Platen Mode...................................................................3-66
Magnification.......................................................................................3-67
Main Scan Magnification.....................................................................3-67
Sub-Scan Magnification ......................................................................3-67
Standard White Density Adjustment ...................................................3-68
3.13.3 ARDF IMAGE ADJUSTMENT....................................................3-68
Sub-scan Magnification.......................................................................3-69
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL CONDITIONS ..................................................................4-1
4.1.1 SUMMARY ........................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS ..............................................................4-2
4.2 ELECTRICAL COMPONENT DEFECTS..................................................4-19
4.2.1 SENSORS .......................................................................................4-19
4.2.2 SWITCHES......................................................................................4-22
4.3 BLOWN FUSE CONDITIONS ..................................................................4-24
4.4 LED DISPLAY ..........................................................................................4-25
4.4.1 BICU................................................................................................4-25
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE.....................................................................5-1
5.1.1 HOW TO ENTER THE SP MODE .....................................................5-1
5.2 COPIER SP MODE TABLES......................................................................5-3
5.2.1 SP1-XXX (FEED) ..............................................................................5-3
5.2.2 SP2-XXX (DRUM) .............................................................................5-8
5.2.3 SP3-XXX (PROCESS) ....................................................................5-12
5.2.4 SP4-XXX (SCANNER) ....................................................................5-18
5.2.5 SP5-XXX (MODE) ...........................................................................5-27
5.2.6 SP6-XXX (PERIPHERALS) .............................................................5-32
5.2.7 SP7-XXX (DATA LOG)....................................................................5-34
5.2.8 SP8-XXX (DATA LOG 2).................................................................5-41
5.2.9 SP9-XXX (ETC.)..............................................................................5-46

SM vii D010
5.3 PRINTER/SCANNER SP MODE TABLES (DDST CONTROLLER ONLY)5-47
5.3.1 PRINTER SERVICE MODE ............................................................5-47
5.3.2 SCANNER SYSTEM AND OTHERS...............................................5-47
5.4 USING SP MODES ..................................................................................5-48
5.4.1 ADJUSTING REGISTRATION AND MAGNIFICATION ..................5-48
5.4.2 ID SENSOR ERROR ANALYSIS (SP 3310) ...................................5-48
5.4.3 DISPLAY APS DATA (SP 4301-1) ..................................................5-49
5.4.4 MEMORY CLEAR ...........................................................................5-50
With Flash Memory Card ....................................................................5-51
Without Flash Memory Card ...............................................................5-52
5.4.5 INPUT CHECK ................................................................................5-52
Conducting an Input Check.................................................................5-52
Input Check Table for Mainframe (SP 5803).......................................5-52
Input Check Table for Finisher (SP 6124)...........................................5-56
5.4.6 OUTPUT CHECK ............................................................................5-58
Conducting an Output Check for Mainframe.......................................5-58
Output Check Table for Mainframe (SP 5804)....................................5-58
Output Check Table for Finisher (SP 6128) ........................................5-60
5.4.7 SERIAL NUMBER INPUT (SP 5811) ..............................................5-61
Specifying Characters.........................................................................5-61
5.4.8 NVRAM DATA UPLOAD/DOWNLOAD (SP 5824/5825) .................5-61
Overview.............................................................................................5-62
NVRAM Upload (SP 5824-1) ..............................................................5-62
NVRAM Download (SP 5825-1)..........................................................5-63
5.4.9 FIRMWARE UPDATE PROCEDURE..............................................5-63
Engine (BICU) Firmware Update Procedure.......................................5-64
DDST (Printer Scanner) Update Procedure........................................5-65
5.4.10 TEST PATTERN PRINT (SP 5902-1) ........................................5-67
Executing Test Pattern Printing...........................................................5-67
Test Patterns.......................................................................................5-67
5.4.11 PAPER JAM COUNTERS (SP 7504) ........................................5-69
5.4.12 SMC PRINT (SP 5990) ..............................................................5-71
5.4.13 ORIGINAL JAM HISTORY DISPLAY (SP 7508)........................5-71
Viewing the Copy Jam History ............................................................5-71
Jam History Codes..............................................................................5-72
5.4.14 ADF APS SENSOR OUTPUT DISPLAY (SP 6901)...................5-72
Sensor Positions .................................................................................5-72

D010 viii SM
Reading Data......................................................................................5-73
DETAILED SECTION DESCRIPTIONS
6. DETAILED SECTION DESCRIPTIONS ....................................... 6-1
6.1 OVERVIEW ................................................................................................6-1
6.1.1 COMPONENT LAYOUT....................................................................6-1
6.1.2 PAPER PATH....................................................................................6-2
6.1.3 DRIVE LAYOUT ................................................................................6-3
6.2 BOARD STRUCTURE................................................................................6-4
6.2.1 BLOCK DIAGRAM.............................................................................6-4
6.2.2 BICU (BASE ENGINE AND IMAGE CONTROL UNIT) .....................6-4
6.2.3 SBU (SENSOR BOARD UNIT)..........................................................6-5
6.3 COPY PROCESS OVERVIEW...................................................................6-6
6.4 SCANNING.................................................................................................6-8
6.4.1 OVERVIEW .......................................................................................6-8
6.4.2 SCANNER DRIVE .............................................................................6-9
6.4.3 ORIGINAL SIZE DETECTION IN PLATEN MODE..........................6-10
6.5 IMAGE PROCESSING .............................................................................6-13
6.5.1 OVERVIEW .....................................................................................6-13
6.5.2 SBU (SENSOR BOARD UNIT)........................................................6-14
6.5.3 IPU (IMAGE PROCESSING UNIT) .................................................6-15
Overview.............................................................................................6-15
Image Processing Modes ...................................................................6-15
Image Processing Path.......................................................................6-17
Original Modes....................................................................................6-18
SP Modes for Each Image Processing Step .......................................6-18
Auto Shading ......................................................................................6-19
White Line Erase.................................................................................6-20
Black Line Erase .................................................................................6-21
Auto Image Density (ADS)..................................................................6-21
Scanner Gamma Correction ...............................................................6-21
Main Scan Magnification.....................................................................6-22
Mirroring for ADF Mode ......................................................................6-22
Filtering ...............................................................................................6-23
ID Gamma Correction .........................................................................6-24
Gradation Processing .........................................................................6-24