Ricoh D025 User manual

D023/D025
SERVICE MANUAL
(Book 1 of 2) 003987MIU
MAINFRAME

D023/D025
SERVICE MANUAL
B00K 1 of 2 MAINFRAME

D023/D025
SERVICE MANUAL
BOOK 1 of 2
MAINFRAME
003987MIU

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 Americas Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH AMERICAS 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 to convey endorsement or other
affiliation with Ricoh products.
©2008 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
injury, damage to property or loss of warranty
protection.
Ricoh Americas Corporation
WARNING

LEGEND
COMPANYPRODUCT
CODE GESTETNER LANIER RICOH SAVIN
D023 MP C2800 LD528C Aficio MP C2800 C2828
D025 MP C3300 LD533C Aficio MP C3300 C3333
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 10/2008 Original Printing

SM i D023/D025
D023/D025
TABLE OF CONTENTS
PRODUCT INFORMATION
1. PRODUCT INFORMATION......................................................1-1
1.1 SPECIFICATIONS................................................................................1-1
1.2 OVERVIEW...........................................................................................1-2
1.2.1 COMPONENT LAYOUT ..............................................................1-2
1.2.2 PAPER PATH..............................................................................1-4
1.2.3 DRIVE LAYOUT...........................................................................1-5
1.3 MACHINE CONFIGURATION ..............................................................1-7
1.4 GUIDANCE FOR THOSE WHO ARE FAMILIAR
WITH PREDECESSOR PRODUCTS................................................1-11
INSTALLATION
2. INSTALLATION .......................................................................2-1
2.1 INSTALLATION REQUIREMENTS.......................................................2-1
2.1.1 ENVIRONMENT ..........................................................................2-1
2.1.2 MACHINE LEVEL........................................................................2-1
2.1.3 MACHINE SPACE REQUIREMENTS .........................................2-2
2.1.4 POWER REQUIREMENTS..........................................................2-2
2.2 OPTIONAL UNIT COMBINATIONS......................................................2-3
2.2.1 MACHINE OPTIONS...................................................................2-3
2.2.2 CONTROLLER OPTIONS ...........................................................2-4
2.2.3 FAX OPTIONS.............................................................................2-5
2.2.4 OTHER OPTIONS.......................................................................2-5
2.3 COPIER INSTALLATION......................................................................2-6
2.3.1 POWER SOCKETS FOR PERIPHERALS...................................2-6
2.3.2 INSTALLATION FLOW CHART...................................................2-7
2.3.3 INSTALLATION PROCEDURE....................................................2-8
Tapes and Retainers.......................................................................2-8

D023/D025 ii SM
Developer and Toner Bottles...........................................................2-9
Paper Trays...................................................................................2-10
Emblem and Decals......................................................................2-11
Manual Pocket Attachment............................................................2-11
Initialize the Developer..................................................................2-12
Settings Relevant to the Service Contract.....................................2-12
Settings for @Remote Service......................................................2-13
2.3.4 MOVING THE MACHINE...........................................................2-17
2.3.5 TRANSPORTING THE MACHINE.............................................2-17
2.4 ONE-TRAY PAPER FEED UNIT (D387).............................................2-18
2.4.1 ACCESSORY CHECK...............................................................2-18
2.4.2 INSTALLATION PROCEDURE..................................................2-19
2.5 CASTER TABLE (D446).....................................................................2-21
2.5.1 COMPONENT CHECK..............................................................2-21
2.5.2 INSTALLATION PROCEDURE..................................................2-21
2.6 PAPER FEED UNIT INSTALLATION (D351)......................................2-23
2.6.1 ACCESSORY CHECK...............................................................2-23
2.6.2 INSTALLATION PROCEDURE..................................................2-24
2.7 2000-SHEET LCT...............................................................................2-26
2.7.1 ACCESSORY CHECK...............................................................2-26
2.7.2 INSTALLATION PROCEDURE..................................................2-26
2.8 1200-SHEET LCT (D353)...................................................................2-29
2.8.1 COMPONENT CHECK..............................................................2-29
2.8.2 INSTALLATION PROCEDURE..................................................2-30
2.8.3 SIDE FENCE POSITION CHANGE...........................................2-32
2.9 AUTO REVERSE DOCUMENT FEEDER (D366)...............................2-33
2.9.1 COMPONENT CHECK..............................................................2-33
2.9.2 INSTALLATION PROCEDURE..................................................2-34
2.10 DOCUMENT FEEDER HANDLE TYPE 5 .....................................2-37
2.10.1 COMPONENT CHECK.........................................................2-37
2.10.2 INSTALLATION PROCEDURE............................................2-38
Preparing before Installing the DF Handle ....................................2-38
Installing the DF Handle................................................................2-40
2.11 1-BIN TRAY UNIT (D414) .............................................................2-43
2.11.1 COMPONENT CHECK.........................................................2-43
2.11.2 INSTALLATION PROCEDURE............................................2-43

SM iii D023/D025
2.12 SHIFT TRAY UNIT (D388)............................................................2-46
2.12.1 COMPONENT CHECK.........................................................2-46
2.12.2 INSTALLATION PROCEDURE............................................2-46
2.13 BRIDGE UNIT (D386) ...................................................................2-48
2.13.1 COMPONENT CHECK.........................................................2-48
2.13.2 INSTALLATION PROCEDURE............................................2-49
2.14 500-SHEET FINISHER (D372)......................................................2-52
2.14.1 ACCESSORY CHECK .........................................................2-52
2.14.2 INSTALLATION PROCEDURE............................................2-53
2.15 1000-SHEET FINISHER (B408)....................................................2-55
2.15.1 ACCESSORY CHECK .........................................................2-55
2.15.2 INSTALLATION PROCEDURE............................................2-56
2.16 1000-SHEET BOOKLET FINISHER (B793)..................................2-58
2.16.1 ACCESSORY CHECK .........................................................2-58
2.16.2 INSTALLATION PROCEDURE............................................2-59
2.17 PUNCH UNIT................................................................................2-63
2.17.1 COMPONENT CHECK.........................................................2-63
2.17.2 INSTALLATION....................................................................2-65
2.18 MECHANICAL COUNTER (NA ONLY).........................................2-70
2.18.1 INSTALLATION PROCEDURE............................................2-70
2.19 KEY COUNTER BRACKET...........................................................2-72
2.19.1 INSTALLATION PROCEDURE............................................2-72
2.20 KEY COUNTER INTERFACE UNIT..............................................2-74
2.20.1 INSTALLATION PROCEDURE............................................2-74
2.21 COPY DATA SECURITY UNIT TYPE F (B829)............................2-76
2.21.1 INSTALLATION....................................................................2-76
User Tool Setting...........................................................................2-77
2.22 USB2.0/SD SLOT TYPE A............................................................2-78
2.22.1 ACCESSORY CHECK .........................................................2-78
2.22.2 INSTALLATION PROCEDURE............................................2-79
2.22.3 TESTING THE SD CARD/USB SLOT..................................2-82
2.23 ANTI-CONDENSATION HEATER (SCANNER)............................2-83
2.23.1 INSTALLATION PROCEDURE............................................2-83
2.24 TRAY HEATER.............................................................................2-84
2.24.1 INSTALLATION PROCEDURE............................................2-84
2.25 ANTI-CONDENSATION HEATER TYPE A...................................2-85

D023/D025 iv SM
2.25.1 COMPONENT CHECK.........................................................2-85
2.25.2 INSTALLATION PROCEDURE............................................2-86
For installing the tray heater in D351.............................................2-86
Installing the Tray Heater in D352.................................................2-88
For Installing the Tray Heater in D387...........................................2-91
2.26 CONTROLLER OPTIONS.............................................................2-94
2.26.1 OVERVIEW..........................................................................2-94
I/F Card Slots ................................................................................2-94
SD Card Slots................................................................................2-94
2.26.2 SD CARD APPLI MOVE.......................................................2-95
Overview .......................................................................................2-95
Move Exec.....................................................................................2-96
Undo Exec.....................................................................................2-96
2.26.3 POSTSCRIPT 3 ...................................................................2-98
2.26.4 FILE FORMAT CONVERTER..............................................2-99
2.26.5 IEEE1284...........................................................................2-100
Installation Procedure..................................................................2-100
2.26.6 IEEE 802.11 A/G, G (WIRELESS LAN) .............................2-101
Installation Procedure..................................................................2-101
UP Mode Settings for Wireless LAN............................................2-102
SP Mode and UP Mode Settings for
IEEE 802.11 a/g, g Wireless LAN..............................................2-104
2.26.7 BLUETOOTH .....................................................................2-105
2.26.8 DATA OVERWRITE SECURITY UNIT TYPE H (D377).....2-106
Before You Begin the Procedure.................................................2-106
Seal Check and Removal............................................................2-107
Installation Procedure..................................................................2-107
2.26.9 HDD ENCRYPTION UNIT..................................................2-109
Before You Begin the Procedure.................................................2-109
Seal Check and Removal............................................................2-110
Installation Procedure..................................................................2-111
Recovery from a Device Problem................................................2-112
Restoring the encryption key.......................................................2-112
Clearing the NVRAM...................................................................2-113
2.26.10 PICTBRIDGE..................................................................2-114
2.26.11 VM CARD TYPE I...........................................................2-115

SM v D023/D025
Installation Procedure..................................................................2-115
2.26.12 BROWSER UNIT TYPE B..............................................2-116
Installation Procedure..................................................................2-116
Update Procedure.......................................................................2-117
2.26.13 GIGABIT ETHERNET.....................................................2-118
2.26.14 CHECK ALL CONNECTIONS ........................................2-119
PREVENTIVE MAINTENANCE
3. PREVENTIVE MAINTENANCE ...............................................3-1
3.1 MAINTENANCE TABLES.....................................................................3-1
3.2 PM PARTS SETTINGS.........................................................................3-2
3.2.1 BEFORE REMOVING THE OLD PM PARTS..............................3-2
3.2.2 AFTER INSTALLING THE NEW PM PARTS...............................3-3
3.2.3 PREPARATION BEFORE OPERATION CHECK........................3-4
3.2.4 OPERATION CHECK ..................................................................3-4
REPLACEMENT AND ADJUSTMENT
4. REPLACEMENT AND ADJUSTMENT....................................4-1
4.1 BEFOREHAND.....................................................................................4-1
4.2 SPECIAL TOOLS..................................................................................4-2
4.3 IMAGE ADJUSTMENT .........................................................................4-3
4.3.1 SCANNING..................................................................................4-3
Scanner sub-scan magnification .....................................................4-3
Scanner leading edge and side-to-side registration ........................4-3
4.3.2 ARDF...........................................................................................4-4
ARDF side-to-side, leading edge registration and trailing edge ......4-4
ARDF sub-scan magnification.........................................................4-5
4.3.3 REGISTRATION..........................................................................4-6
Image Area......................................................................................4-6
Leading Edge..................................................................................4-6
Side to Side.....................................................................................4-6
Adjustment Standard.......................................................................4-6
Paper Registration Standard...........................................................4-6

D023/D025 vi SM
Adjustment Procedure.....................................................................4-6
4.3.4 ERASE MARGIN ADJUSTMENT ................................................4-8
4.3.5 COLOR REGISTRATION ............................................................4-9
Line Position Adjustment.................................................................4-9
4.3.6 PRINTER GAMMA CORRECTION............................................4-10
Copy Mode....................................................................................4-10
Printer Mode..................................................................................4-14
4.4 EXTERIOR COVERS..........................................................................4-16
4.4.1 FRONT DOOR...........................................................................4-16
4.4.2 LEFT COVER ............................................................................4-17
4.4.3 REAR COVER...........................................................................4-17
4.4.4 RIGHT REAR COVER...............................................................4-18
4.4.5 OPERATION PANEL.................................................................4-19
4.4.6 PAPER EXIT COVER................................................................4-20
4.4.7 INNER TRAY.............................................................................4-20
4.4.8 DUST FILTER............................................................................4-21
4.4.9 OZONE FILTER.........................................................................4-22
Ozone filters for the scanner unit...................................................4-22
4.5 SCANNER UNIT.................................................................................4-23
4.5.1 EXPOSURE GLASS..................................................................4-23
4.5.2 ORIGINAL LENGTH/WIDTH SENSORS...................................4-24
4.5.3 EXPOSURE LAMP....................................................................4-25
Reassembling................................................................................4-26
4.5.4 SCANNER MOTOR...................................................................4-27
4.5.5 SENSOR BOARD UNIT (SBU)..................................................4-28
When reassembling.......................................................................4-28
4.5.6 EXPOSURE LAMP STABILIZER...............................................4-29
4.5.7 SIO (SCANNER IN/OUT) BOARD.............................................4-29
4.5.8 SCANNER HP SENSOR ...........................................................4-30
4.5.9 PLATEN COVER SENSOR.......................................................4-31
4.5.10 FRONT SCANNER WIRE....................................................4-32
Reinstalling the Front Scanner Wire..............................................4-33
4.5.11 REAR SCANNER WIRE.......................................................4-36
Reinstalling the Rear Scanner Wire ..............................................4-36
4.5.12 TOUCH PANEL POSITION ADJUSTMENT.........................4-38
4.6 LASER OPTICS..................................................................................4-39

SM vii D023/D025
4.6.1 CAUTION DECAL LOCATION...................................................4-39
4.6.2 LASER OPTICS HOUSING UNIT..............................................4-40
Preparing the new laser optics housing unit..................................4-40
Before removing the old laser optics housing unit.........................4-40
Recovery procedure for no replacement preparation
of laser optics housing unit............................................................4-41
Removing the old laser optics housing unit...................................4-42
Installing a new Laser Optics Housing Unit...................................4-43
After installing the new laser optics housing unit...........................4-43
4.6.3 POLYGON MIRROR MOTOR AND DRIVE BOARD .................4-45
4.7 IMAGE CREATION.............................................................................4-47
4.7.1 PCU ...........................................................................................4-47
4.7.2 DRUM UNIT AND DEVELOPMENT UNIT.................................4-48
Developer......................................................................................4-50
4.7.3 TONER COLLECTION BOTTLE................................................4-52
4.7.4 SECOND DUCT FAN ................................................................4-53
When reinstalling the second duct fan...........................................4-54
4.7.5 THIRD DUCT FAN.....................................................................4-55
When reinstalling the third duct fan...............................................4-55
4.7.6 TONER PUMP UNIT..................................................................4-56
When you install the new toner pump unit.....................................4-58
4.7.7 TONER END SENSOR..............................................................4-61
4.8 IMAGE TRANSFER............................................................................4-62
4.8.1 IMAGE TRANSFER BELT UNIT................................................4-62
4.8.2 IMAGE TRANSFER BELT CLEANING UNIT.............................4-63
4.8.3 IMAGE TRANSFER BELT.........................................................4-64
When reinstalling the image transfer belt ......................................4-66
4.9 PAPER TRANSFER............................................................................4-68
4.9.1 PAPER TRANSFER ROLLER UNIT..........................................4-68
4.9.2 PAPER TRANSFER UNIT.........................................................4-69
4.9.3 HIGH VOLTAGE SUPPLY BOARD - DISCHARGE PLATE.......4-71
4.9.4 ID SENSOR BOARD .................................................................4-72
Cleaning for ID sensors.................................................................4-72
After installing a new ID sensor unit/board....................................4-73
4.9.5 TEMPERATURE AND HUMIDITY SENSOR.............................4-74
4.10 DRIVE UNIT..................................................................................4-75

D023/D025 viii SM
4.10.1 GEAR UNIT..........................................................................4-76
When installing the drive unit.........................................................4-80
Adjustment after replacing the gear unit........................................4-80
4.10.2 REGISTRATION MOTOR....................................................4-82
4.10.3 PAPER FEED MOTOR ........................................................4-83
4.10.4 DRUM/DEVELOPMENT MOTORS FOR M, C, AND Y........4-84
4.10.5 DRUM/DEVELOPMENT MOTOR-K.....................................4-85
4.10.6 ITB DRIVE MOTOR .............................................................4-85
4.10.7 FUSING/PAPER EXIT MOTOR ...........................................4-86
4.10.8 IMAGE TRANSFER BELT CONTACT MOTOR...................4-86
4.10.9 PAPER TRANSFER CONTACT MOTOR ............................4-87
4.10.10 DUPLEX INVERTER MOTOR..........................................4-88
4.10.11 DUPLEX/BY-PASS MOTOR.............................................4-90
4.10.12 TONER TRANSPORT MOTOR........................................4-91
4.10.13 TONER COLLECTION UNIT............................................4-92
4.10.14 PAPER FEED CLUTCHES...............................................4-93
4.10.15 DEVELOPMENT CLUTCH-Y............................................4-95
4.10.16 DEVELOPMENT CLUTCHES FOR M AND C..................4-97
4.10.17 DEVELOPMENT CLUTCH-K............................................4-98
4.11 FUSING.........................................................................................4-99
4.11.1 PM PARTS...........................................................................4-99
4.11.2 FUSING UNIT ....................................................................4-100
4.11.3 PRESSURE ROLLER LAMP..............................................4-101
4.11.4 FUSING LAMP...................................................................4-103
4.11.5 FUSING BELT AND PRESSURE ROLLER .......................4-104
When reassembling the fusing unit .............................................4-106
4.11.6 HEATING, FUSING AND TENSION ROLLER...................4-108
4.11.7 HEATING ROLLER THERMOSTATS................................4-108
4.11.8 HEATING ROLLER THERMISTOR ...................................4-109
4.11.9 PRESSURE ROLLER THERMISTOR
AND THERMOSTAT...........................................................4-110
4.11.10 FUSING GEAR AND ONE-WAY CLUTCH.....................4-111
4.11.11 HEATING ROLLER BEARING AND
INSULATING BUSHING .................................................4-111
4.11.12 PRESSURE ROLLER BEARING....................................4-112