Ricoh D197 User manual

SERVICE MANUAL
D197/D198/D199/
D200/D201/D202

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2014 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
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Ricoh Americas Corporation
WARNING

LEGEND
PRODUCT
CODE COMPANY
LANIER RICOH SAVIN
D197 MP 2554SP MP 2554SP MP 2554SP
D198 MP 3054SP MP 3054SP MP 3054SP
D199 MP 3554SP MP 3554SP MP 3554SP
D200 MP 4054SP MP 4054SP MP 4054SP
D201 MP 5054SP MP 5054SP MP 5054SP
D202 MP 6054SP MP 6054SP MP 6054SP
DOCUMENTATION HISTORY
REV. NO.
DATE
COMMENTS
*
11/2014
Original Printing

SM i D197/D198/D199/D200/D201/D202
D197/D198/D199/D200/D201/D202
TABLE OF CONTENTS
1. PRODUCT INFORMATION...........................................................1-1
1.1 PRODUCT OVERVIEW............................................................................. 1-1
1.1.1 COMPONENT LAYOUT ................................................................... 1-1
1.1.2 PAPER PATH................................................................................... 1-3
1.1.3 DRIVE LAYOUT ............................................................................... 1-6
1.1.4 PARTS LAYOUT .............................................................................. 1-8
Scanner Unit ........................................................................................ 1-8
Paper Feed Unit................................................................................... 1-9
Laser Unit/ PCDU............................................................................... 1-10
Fusing Unit......................................................................................... 1-11
Waste Toner Bottle............................................................................. 1-12
Duplex/Bypass Unit............................................................................ 1-13
Paper Exit/ Reverse Unit.................................................................... 1-14
Air Flow.............................................................................................. 1-15
Drive Unit ........................................................................................... 1-16
Electrical Component......................................................................... 1-17
1.2 MACHINE CODES AND PERIPHERALS CONFIGURATION................. 1-18
1.2.1 SYSTEM CONFIGURATION AND OPTIONS ................................ 1-18
D197/D198/D199 (NA)....................................................................... 1-18
D200/D201 (NA)................................................................................. 1-20
D202 (NA).......................................................................................... 1-22
D197/D198/D199 (EU)....................................................................... 1-24
D200/D201 (EU)................................................................................. 1-26
D202 (EU).......................................................................................... 1-28
D197/D198/D199 (Asia)..................................................................... 1-30
D200/D201 (Asia)............................................................................... 1-32
D202 (Asia)........................................................................................ 1-33
Guidance for Those Who are Familiar with The Predecessor Product1-35
1.2.2 DIFFERENCES BETWEEN SIMILAR MODELS............................. 1-35
D182/D183 vs. D197/D199 ................................................................ 1-35
D129/D130 vs. D200/D201/D202....................................................... 1-36
Differences between D146 Series...................................................... 1-37
2. INSTALLATION.............................................................................2-1
2.1 INSTALLATION REQUIREMENTS............................................................ 2-1

D197/D198/D199/D200/D201/D202 ii SM
2.1.1 ENVIRONMENT ............................................................................... 2-1
2.1.2 MACHINE LEVEL............................................................................. 2-1
2.1.3 MINIMUM SPACE REQUIREMENTS............................................... 2-1
2.1.4 MACHINE DIMENSIONS.................................................................. 2-2
2.1.5 POWER REQUIREMENTS .............................................................. 2-3
2.2 MAIN MACHINE INSTALLATION.............................................................. 2-4
2.2.1 IMPORTANT NOTICE ON SECURITY ISSUES............................... 2-4
Overview.............................................................................................. 2-4
Password Setting Procedure................................................................ 2-5
2.2.2 INSTALLATION FLOW CHART........................................................ 2-9
D197/D198/D199.................................................................................. 2-9
D200/D201/D202................................................................................ 2-10
2.2.3 ACCESSORY CHECK.................................................................... 2-11
2.2.4 INSTALLATION PROCEDURE ...................................................... 2-12
Unloading........................................................................................... 2-12
Tapes and Retainers.......................................................................... 2-12
Toner Bottle........................................................................................ 2-15
Paper Exit Tray Stopper..................................................................... 2-20
Emblem, Decals................................................................................. 2-21
Completion......................................................................................... 2-22
2.2.5 SECURITY SETTINGS................................................................... 2-22
2.2.6 CHECK IMAGE QUALITY / SETTINGS.......................................... 2-23
Loading Paper.................................................................................... 2-23
Checking the copy image with the test chart...................................... 2-23
SP Settings ........................................................................................ 2-23
Upper Tray (Size Adjust Tray 1)......................................................... 2-23
Lower Tray (Size Adjust Tray 2)......................................................... 2-23
By-Pass Tray (By-Pass Size Detection)............................................. 2-24
2.2.7 MOVING THE MACHINE................................................................ 2-24
2.2.8 TRANSPORTING THE MACHINE.................................................. 2-25
2.3 PAPER FEED UNIT PB3210/ PB3220 .................................................... 2-26
2.3.1 ACCESSORY CHECK.................................................................... 2-26
2.3.2 INSTALLATION PROCEDURE ...................................................... 2-26
2.4 PAPER FEED UNIT PB3150................................................................... 2-32
2.4.1 ACCESSORY CHECK.................................................................... 2-32
2.4.2 INSTALLATION PROCEDURE ...................................................... 2-32
2.5 LCIT PB3170/ PB3230............................................................................. 2-37
2.5.1 ACCESSORY CHECK.................................................................... 2-37
2.5.2 INSTALLATION PROCEDURE ...................................................... 2-37

SM iii D197/D198/D199/D200/D201/D202
Changing the paper size .................................................................... 2-42
2.6 LCIT RT3030 ........................................................................................... 2-44
2.6.1 ACCESSORY CHECK.................................................................... 2-44
2.6.2 INSTALLATION PROCEDURE ...................................................... 2-44
Changing the Paper Size................................................................... 2-50
2.7 CASTER TABLE TYPE M3...................................................................... 2-52
2.7.1 ACCESSORY CHECK.................................................................... 2-52
2.7.2 INSTALLATION PROCEDURE ...................................................... 2-52
For Installing Directly under the Main Machine .................................. 2-53
For Installing under PB3150............................................................... 2-54
2.8 PLATEN COVER PN2000 (D700) ........................................................... 2-56
2.8.1 ACCESSORY CHECK.................................................................... 2-56
2.8.2 INSTALLATION PROCEDURE ...................................................... 2-56
2.9 ARDF DF3090 ......................................................................................... 2-59
2.9.1 ACCESSORY CHECK.................................................................... 2-59
2.9.2 INSTALLATION PROCEDURE ...................................................... 2-59
When feeding thin paper.................................................................... 2-63
2.10 SPDF DF3080.................................................................................... 2-65
2.10.1 ACCESSORY CHECK.............................................................. 2-65
2.10.2 INSTALLATION PROCEDURE................................................. 2-66
Attaching the SPDF............................................................................ 2-66
Attaching the Sub IPU........................................................................ 2-68
Adjust SP Settings.............................................................................. 2-73
2.11 BRIDGE UNIT BU3070...................................................................... 2-74
2.11.1 ACCESSORY CHECK.............................................................. 2-74
2.11.2 INSTALLATION PROCEDURE................................................. 2-74
2.12 1 BIN TRAY BN3110.......................................................................... 2-78
2.12.1 ACCESSORY CHECK.............................................................. 2-78
2.12.2 INSTALLATION PROCEDURE................................................. 2-78
2.13 INTERNAL SHIFT TRAY SH3070...................................................... 2-85
2.13.1 ACCESSORY CHECK.............................................................. 2-85
2.13.2 INSTALLATION PROCEDURE................................................. 2-85
2.14 SIDE TRAY TYPE M3........................................................................ 2-90
2.14.1 ACCESSORY CHECK.............................................................. 2-90
2.14.2 INSTALLATION PROCEDURE................................................. 2-91
2.15 BOOKLET FINISHER SR3170 / FINISHER SR3160......................... 2-94
2.15.1 ACCESSORY CHECK.............................................................. 2-94
Booklet Finisher SR3170 (D688) / Finisher SR3160 (D689).............. 2-94
2.15.2 INSTALLATION PROCEDURE................................................. 2-95

D197/D198/D199/D200/D201/D202 iv SM
2.15.3 ADJUSTMENT AFTER INSTALLING THE FINISHER............ 2-101
How to Check and Adjust the Side-to-Side Registration .................. 2-101
2.15.4 AUXILIARY TRAY................................................................... 2-102
2.16 PUNCH UNIT PU3060..................................................................... 2-103
2.16.1 ACCESSORY CHECK............................................................ 2-103
2.16.2 INSTALLATION PROCEDURE............................................... 2-104
2.17 BOOKLET FINISHER SR3150 / FINISHER SR3140....................... 2-114
2.17.1 ACCESSORY CHECK............................................................ 2-114
Booklet Finisher SR3150 / Finisher SR3140.................................... 2-114
2.17.2 INSTALLATION PROCEDURE............................................... 2-115
SR3150............................................................................................ 2-118
SR3140............................................................................................ 2-118
2.17.3 ADJUSTMENT AFTER INSTALLING FINISHER.................... 2-120
How to Check and Adjust the Side-to-Side Registration .................. 2-120
2.18 PUNCH UNIT PU3050..................................................................... 2-121
2.18.1 COMPONENT CHECK ........................................................... 2-121
2.18.2 INSTALLATION PROCEDURE............................................... 2-122
2.19 INTERNAL FINISHER SR3180........................................................ 2-134
2.19.1 ACCESSORY CHECK............................................................ 2-134
2.19.2 INSTALLATION PROCEDURE............................................... 2-135
Staple Setting as an Initial Setting.................................................... 2-144
2.20 INTERNAL FINISHER SR3130........................................................ 2-146
2.20.1 ACCESSORY CHECK............................................................ 2-146
2.20.2 INSTALLATION PROCEDURE............................................... 2-146
2.21 PUNCH UNIT PU3040..................................................................... 2-155
2.21.1 ACCESSORY CHECK............................................................ 2-155
2.21.2 INSTALLATION PROCEDURE............................................... 2-156
2.22 SMART OPERATION PANEL TYPE M3.......................................... 2-161
2.22.1 ACCESSORY CHECK............................................................ 2-161
2.22.2 INSTALLATION PROCEDURE............................................... 2-161
2.23 ANTI-CONDENSATION HEATER TYPE M12 ................................. 2-165
2.23.1 ACCESSORY CHECK............................................................ 2-165
2.23.2 INSTALLATION PROCEDURE............................................... 2-166
Anti-Condensation Heater (Scanner)............................................... 2-166
Anti-Condensation Heater (PCU)..................................................... 2-176
2.24 ANTI-CONDENSATION HEATER FOR TRAYS.............................. 2-180
2.24.1 ACCESSORY CHECK............................................................ 2-180
2.24.2 INSTALLATION PROCEDURE............................................... 2-181
Anti-Condensation Heater for Paper Feed Tray (Main Unit)............. 2-181

SM v D197/D198/D199/D200/D201/D202
Anti-Condensation Heater for Paper Feed Unit PB3210 / PB3220 .. 2-188
Anti-Condensation Heater for Paper Feed Unit PB3150.................. 2-190
Anti-Condensation Heater for LCIT PB3170/ PB3230...................... 2-192
2.25 CARD READER BRACKET TYPE 3352.......................................... 2-195
2.25.1 ACCESSORY CHECK............................................................ 2-195
2.25.2 INSTALLATION PROCEDURE............................................... 2-196
Scanner Right Cover........................................................................ 2-198
Upper Rear Cover............................................................................ 2-198
2.26 KEY COUNTER BRACKET TYPE M3............................................. 2-199
2.26.1 ACCESSORY CHECK............................................................ 2-199
2.26.2 INSTALLATION PROCEDURE............................................... 2-199
2.27 OPTIONAL COUNTER INTERFACE UNIT TYPE M12.................... 2-203
2.27.1ACCESSORY CHECK............................................................ 2-203
2.27.2 INSTALLATION PROCEDURE............................................... 2-203
2.28 SMART CARD READER BUILT-IN UNIT TYPE M12...................... 2-206
2.28.1 ACCESSORY CHECK............................................................ 2-206
2.28.2 INSTALLATION PROCEDURE............................................... 2-207
2.29 INTERNAL OPTIONS ...................................................................... 2-215
2.29.1 LIST OF SLOTS...................................................................... 2-215
2.30 PRINTER/SCANNER UNIT TYPE M12 ........................................... 2-216
2.30.1 COMPONENT CHECK ........................................................... 2-216
2.30.2 INSTALLATION PROCEDURE............................................... 2-217
2.31 IEEE 1284 INTERFACE BOARD TYPE A ....................................... 2-221
2.31.1 COMPONENT CHECK ........................................................... 2-221
2.31.2 INSTALLATION....................................................................... 2-222
2.32 IEEE 802.11A/G/N INTERFACE UNIT TYPE M2............................. 2-223
2.32.1 ACCESSORY CHECK............................................................ 2-223
2.32.2 INSTALLATION....................................................................... 2-224
2.32.3 USER TOOL SETTINGS FOR IEEE 802.11A/G/N ................. 2-226
SP Mode Settings for IEEE 802.11 Wireless LAN............................ 2-228
2.33 BLUETOOTH INTERFACE UNIT TYPE D....................................... 2-229
2.33.1 COMPONENT CHECK ........................................................... 2-229
2.33.2 INSTALLATION PROCEDURE............................................... 2-229
2.34 FILE FORMAT CONVERTER TYPE E ............................................ 2-230
2.34.1 COMPONENT CHECK ........................................................... 2-230
2.34.2 INSTALLATION....................................................................... 2-230
2.35 USB DEVICE SERVER OPTION TYPE M12................................... 2-232
2.35.1 COMPONENT CHECK ........................................................... 2-232
Interface Board Surface ................................................................... 2-232

D197/D198/D199/D200/D201/D202 vi SM
2.35.2 INSTALLATION PROCEDURE............................................... 2-233
What Do the LED Indications Mean?............................................... 2-236
Notes for Energy Save Mode Setting............................................... 2-236
2.35.3 IP ADDRESS SETTING.......................................................... 2-237
2.36 COPY DATA SECURITY UNIT TYPE G.......................................... 2-239
2.36.1 COMPONENT CHECK ........................................................... 2-239
2.36.2 INSTALLATION....................................................................... 2-239
User Tool Setting.............................................................................. 2-241
2.37 HARD DISK DRIVE OPTION TYPE M12......................................... 2-242
2.37.1 ACCESSORY CHECK............................................................ 2-242
2.37.2 INSTALLATION....................................................................... 2-243
2.38 SD CARD OPTION .......................................................................... 2-245
2.38.1 SD CARD SLOTS ................................................................... 2-245
2.38.2 LIST OF SLOTS USED........................................................... 2-246
2.39 SD CARD APPLI MOVE .................................................................. 2-247
2.39.1 OVERVIEW............................................................................. 2-247
2.39.2 MOVE EXEC........................................................................... 2-247
2.39.3 UNDO EXEC........................................................................... 2-248
2.40 OCR UNIT TYPE M2........................................................................ 2-249
2.40.1 ACCESSORY CHECK............................................................ 2-249
2.40.2 INSTALLATION PROCEDURE............................................... 2-249
2.40.3 RECOVERY PROCEDURE .................................................... 2-252
2.41 BROWSER UNIT TYPE M12........................................................... 2-253
2.41.1 COMPONENT CHECK ........................................................... 2-253
2.41.2 INSTALLATION PROCEDURE............................................... 2-253
To update EXJS............................................................................... 2-255
When checking the version of EXJS................................................ 2-256
Browser unit uninstallation procedure.............................................. 2-257
2.41.3 SETTINGS.............................................................................. 2-257
Browser default setting..................................................................... 2-257
2.42 SD CARD FOR NETWARE PRINTING TYPE M12 ......................... 2-258
2.42.1 COMPONENT CHECK ........................................................... 2-258
2.42.2 INSTALLATION PROCEDURE............................................... 2-258
2.43 POSTSCRIPT3 UNIT TYPE M12..................................................... 2-260
2.43.1 COMPONENT CHECK ........................................................... 2-260
2.43.2 INSTALLATION PROCEDURE............................................... 2-260
2.44 XPS DIRECT PRINT OPTION TYPE M12....................................... 2-262
2.44.1 COMPONENT CHECK ........................................................... 2-262
2.44.2 INSTALLATION PROCEDURE............................................... 2-262

SM vii D197/D198/D199/D200/D201/D202
2.45 IPDS UNIT TYPE M12 ..................................................................... 2-264
2.45.1 ACCESSORIES ...................................................................... 2-264
2.45.2 INSTALLATION....................................................................... 2-264
2.46 EXTERNAL KEYBOARD BRACKET TYPE M3 (D739-10).............. 2-267
2.46.1 COMPONENT CHECK ........................................................... 2-267
2.46.2 INSTALLATION PROCEDURE............................................... 2-267
2.47 DATA OVERWRITE SECURITY UNIT TYPE I (D362) .................... 2-272
2.47.1 OVERVIEW............................................................................. 2-272
2.47.2 COMPONENT LIST ................................................................ 2-272
2.47.3 BEFORE YOU BEGIN THE PROCEDURE............................. 2-272
Seal Check and Removal................................................................. 2-273
2.47.4 INSTALLATION PROCEDURE............................................... 2-274
2.48 SECURITY SETTING....................................................................... 2-275
2.48.1 SECURITY FUNCTION INSTALLATION................................ 2-275
2.48.2 DATA OVERWRITE SECURITY............................................. 2-276
Before You Begin the Procedure...................................................... 2-276
Using Auto Erase Memory ............................................................... 2-276
2.48.3 HDD ENCRYPTION................................................................ 2-278
Before You Begin the Procedure:..................................................... 2-278
Enable Encryption Setting................................................................ 2-278
Backing Up the Encryption Key........................................................ 2-280
Encryption Key Restoration.............................................................. 2-281
2.49 @REMOTE SETTINGS ................................................................... 2-283
2.50 OPERATION GUIDANCE FOR USERS .......................................... 2-288
3. PREVENTIVE MAINTENANCE.....................................................3-1
3.1 PREVENTIVE MAINTENANCE TABLES................................................... 3-1
3.2 IMAGE QUALITY STANDARDS................................................................ 3-2
3.2.1 RESOLUTION .................................................................................. 3-2
3.2.2 MAGNIFICATION RATIO ERROR MARGIN .................................... 3-3
3.2.3 MAGNIFICATION RATIO ERROR MARGIN DEVIATION................ 3-4
3.2.4 PITCH ERROR MARGIN.................................................................. 3-4
3.2.5 PERPENDICULARITY...................................................................... 3-4
3.2.6 LINEARITY ....................................................................................... 3-5
3.2.7 PARALLELISM ................................................................................. 3-5
3.2.8 MISSING IMAGE AREA ................................................................... 3-6
3.2.9 MARGIN POSITION ......................................................................... 3-6
3.3 PAPER TRANSFER QUALITY STANDARDS........................................... 3-7
3.3.1 REGISTRATION............................................................................... 3-7
3.3.2 SKEW ............................................................................................... 3-7

D197/D198/D199/D200/D201/D202 viii SM
Exposure glass..................................................................................... 3-7
ADF...................................................................................................... 3-8
3.4 PM PARTS SETTINGS.............................................................................. 3-9
3.4.1 PM PARTS REPLACEMENT PROCEDURE.................................... 3-9
3.4.2 AFTER INSTALLING THE NEW PM PARTS ................................. 3-10
3.4.3 OPERATION CHECK..................................................................... 3-10
4. REPLACEMENT AND ADJUSTMENT.........................................4-1
4.1 NOTES ON THE MAIN POWER SWITCH................................................. 4-1
4.1.1 PUSH SWITCH................................................................................. 4-1
Characteristics of the Push Switch (DC Switch)................................... 4-1
Shutdown Method ................................................................................ 4-3
Forced Shutdown................................................................................. 4-3
4.2 BEFOREHAND.......................................................................................... 4-4
4.3 SPECIAL TOOLS AND LUBRICANTS ...................................................... 4-5
4.3.1 SPECIAL TOOLS ............................................................................. 4-5
4.3.2 LUBRICANTS................................................................................... 4-5
4.4 COVER REMOVAL ORDER...................................................................... 4-6
4.4.1 COVER LAYOUTS ........................................................................... 4-6
4.4.2 COVER REMOVAL ORDER............................................................. 4-8
4.5 EXTERIOR COVERS ................................................................................ 4-9
4.5.1 FRONT COVER.............................................................................. 4-10
4.5.2 CONTROLLER COVER.................................................................. 4-11
4.5.3 LEFT UPPER COVER.................................................................... 4-12
4.5.4 LEFT REAR COVER ...................................................................... 4-13
4.5.5 LEFT COVER................................................................................. 4-14
4.5.6 CONTROLLER REAR COVER....................................................... 4-15
4.5.7 REAR LEFT COVER ...................................................................... 4-16
4.5.8 REAR RIGHT COVER.................................................................... 4-16
4.5.9 REAR LOWER GAP COVER ......................................................... 4-17
4.5.10 REAR LOWER COVER ............................................................ 4-17
4.5.11 SCANNER REAR COVER........................................................ 4-18
4.5.12 RIGHT REAR COVER .............................................................. 4-18
4.5.13 RIGHT UPPER COVER............................................................ 4-19
4.5.14 RIGHT COVER ......................................................................... 4-20
4.5.15 MAIN POWER SWITCH COVER.............................................. 4-22
4.5.16 INVERTER TRAY...................................................................... 4-22
4.5.17 PAPER EXIT TRAY................................................................... 4-23
4.5.18 PAPER EXIT COVER ............................................................... 4-23
4.5.19 PAPER EXIT LOWER COVER................................................. 4-24

SM ix D197/D198/D199/D200/D201/D202
4.5.20 UPPER INNER COVER............................................................ 4-25
4.5.21 PAPER EXIT FRONT COVER.................................................. 4-26
4.5.22 INNER COVER ......................................................................... 4-26
4.5.23 TONER SUPPLY HOUSING..................................................... 4-27
4.6 OPERATION PANEL............................................................................... 4-29
4.6.1 OPERATION PANEL...................................................................... 4-29
4.6.2 KEY CONTROL BOARD ................................................................ 4-30
4.6.3 INTERFACE BOARD...................................................................... 4-32
4.6.4 LCD PANEL.................................................................................... 4-32
4.6.5 LCD................................................................................................. 4-33
Notes when replacing the LCD........................................................... 4-33
Replacement procedure..................................................................... 4-35
4.7 SCANNER UNIT...................................................................................... 4-36
4.7.1 SCANNER EXTERIOR................................................................... 4-36
Scanner Upper Cover......................................................................... 4-36
Scanner Right Cover.......................................................................... 4-36
Scanner Front Cover.......................................................................... 4-37
Scanner Left Cover............................................................................ 4-38
4.7.2 EXPOSURE GLASS....................................................................... 4-38
4.7.3 SCANNER LAMP............................................................................ 4-40
4.7.4 SCANNER MOTOR........................................................................ 4-41
4.7.5 LENS BLOCK ................................................................................. 4-43
4.7.6 ORIGINAL SIZE SENSORS (APS)................................................. 4-44
4.7.7 SIO.................................................................................................. 4-44
4.7.8 SCANNER HP SENSOR................................................................ 4-45
4.7.9 DF POSITION SENSOR................................................................. 4-46
4.7.10 ADJUSTING THE SCANNER WIRE......................................... 4-46
Scanner Wire (Front).......................................................................... 4-46
Scanner Wire Assembly (Front)......................................................... 4-49
Scanner Position Adjustment ............................................................. 4-53
Scanner Wire (Rear) .......................................................................... 4-54
Scanner Wire Assembly (Rear).......................................................... 4-57
4.7.11 MODIFYING THE SCANNER (CONTACT/CONTACTLESS) WHEN
USING ARDF........................................................................................... 4-60
Procedure for the ADF ....................................................................... 4-60
Procedure for the Scanner................................................................. 4-62
4.7.12 MODIFYING THE SCANNER (CONTACT/CONTACTLESS) WHEN
USING SPDF........................................................................................... 4-63
Procedure for the SPDF..................................................................... 4-63

D197/D198/D199/D200/D201/D202 x SM
Procedure for the Scanner................................................................. 4-65
4.8 LASER UNIT............................................................................................ 4-66
4.8.1 CAUTION DECAL LOCATION ....................................................... 4-66
4.8.2 LASER UNIT................................................................................... 4-67
Removing the Laser Unit.................................................................... 4-67
Installing a New Laser Unit................................................................. 4-68
Mainframe Claws................................................................................ 4-68
Laser Unit Claws................................................................................ 4-69
After Installing the New Laser Unit..................................................... 4-70
4.8.3 QUENCHING LAMP....................................................................... 4-70
4.8.4 PCL (PRE CLEANING LIGHT)....................................................... 4-71
4.9 PCDU....................................................................................................... 4-72
4.9.1 BEFORE REPLACING A PCU OR DEVELOPMENT UNIT............ 4-72
4.9.2 PCDU.............................................................................................. 4-72
4.9.3 PCU/DEVELOPMENT UNIT........................................................... 4-74
Notes When Installing the Face Plates............................................... 4-74
Face plate for front side...................................................................... 4-75
Face plate for rear side ...................................................................... 4-75
Installing a PCU.................................................................................. 4-75
Installing a Development Unit............................................................. 4-75
4.9.4 OPC DRUM .................................................................................... 4-77
4.9.5 CHARGE ROLLER, CLEANING ROLLER...................................... 4-78
4.9.6 PICK-OFF PAWLS.......................................................................... 4-79
4.9.7 CLEANING BLADE......................................................................... 4-80
4.9.8 DEVELOPER.................................................................................. 4-81
4.9.9 DEVELOPMENT FILTER ............................................................... 4-87
4.9.10 TD SENSOR ............................................................................. 4-88
4.9.11 DEVELOPMENT MIXING AUGER BEARINGS ........................ 4-89
4.9.12 DEVELOPMENT MIXING AUGER (L / R)................................. 4-91
4.10 WASTE TONER................................................................................. 4-93
4.10.1 WASTE TONER BOTTLE......................................................... 4-93
4.10.2 TONER COLLECTION FULL SENSOR.................................... 4-93
4.10.3 RECYCLING SHUTTER SOLENOID........................................ 4-94
4.10.4 RECYCLING SHUTTER ........................................................... 4-97
4.11 TRANSFER UNIT............................................................................... 4-99
4.11.1 TRANSFER UNIT...................................................................... 4-99
4.11.2 TRANSFER ROLLER UNIT .................................................... 4-101
4.11.3 ID SENSOR ............................................................................ 4-102
Before Replacing the ID Sensor....................................................... 4-102

SM xi D197/D198/D199/D200/D201/D202
Replacement Procedure................................................................... 4-102
4.11.4 TRANSFER UNIT OPEN/CLOSE LED ................................... 4-103
4.11.5 TEMPERATURE/HUMIDITY SENSOR................................... 4-104
4.11.6 FUSING ENTRANCE SENSOR.............................................. 4-105
4.11.7 TRANSFER UNIT OPEN/CLOSE SENSOR ........................... 4-106
4.12 DRIVE UNIT..................................................................................... 4-107
4.12.1 DRUM/WASTE TONER MOTOR............................................ 4-107
4.12.2 DEVELOPMENT MOTOR....................................................... 4-107
4.12.3 FUSING/PAPER EXIT MOTOR (D197/D199 ONLY).............. 4-107
4.12.4 FUSING MOTOR (D200/D201/D202 ONLY)........................... 4-108
4.12.5 PAPER EXIT MOTOR (D200/D201/D202 ONLY)................... 4-108
4.12.6 REGISTRATION MOTOR....................................................... 4-108
4.12.7 PAPER FEED MOTOR ........................................................... 4-109
4.12.8 VERTICAL TRANSPORT MOTOR ......................................... 4-109
4.12.9 TRANSFER ROLLER CONTACT MOTOR............................. 4-109
4.12.10 TONER HOPPER................................................................ 4-110
4.12.11 TONER SUPPLY MOTOR................................................... 4-112
4.13 FUSING UNIT .................................................................................. 4-114
4.13.1 FUSING UNIT ......................................................................... 4-114
Replacement.................................................................................... 4-114
4.13.2 FUSING ENTRANCE GUIDE PLATE ..................................... 4-117
Cleaning the Fusing Entrance Guide Plate ...................................... 4-117
4.13.3 FUSING EXIT GUIDE PLATE................................................. 4-118
4.13.4 FUSING UPPER COVER........................................................ 4-119
4.13.5 FUSING LOWER COVER....................................................... 4-120
4.13.6 HEATING SLEEVE BELT UNIT.............................................. 4-121
Replacement.................................................................................... 4-122
To Clear SC544-02 or SC554-02..................................................... 4-123
4.13.7 PRESSURE ROLLER AND PRESSURE ROLLER BEARINGS4-124
Adjustment before Replacing the Pressure Roller and Pressure Roller
Bearings........................................................................................... 4-124
Replacement.................................................................................... 4-124
4.13.8 THERMOSTAT UNIT.............................................................. 4-126
4.13.9 FUSING ROLLER TEMPERATURE SENSOR ....................... 4-126
4.13.10 PRESSURE ROLLER TEMPERATURE SENSOR.............. 4-126
4.13.11 FUSING THERMOPILE....................................................... 4-127
4.13.12 NOTES WHEN REASSEMBLING THE FUSING UNIT....... 4-128
Harness route: when looking at the bottom of the fusing unit........... 4-128
Harness route: when looking at the side of the fusing unit............... 4-128

D197/D198/D199/D200/D201/D202 xii SM
4.14 PAPER EXIT.................................................................................... 4-129
4.14.1 PAPER EXIT UNIT.................................................................. 4-129
4.14.2 PAPER EXIT SWITCHING SOLENOID.................................. 4-130
4.14.3 PAPER EXIT SENSOR........................................................... 4-131
4.14.4 REVERSE SENSOR............................................................... 4-132
4.14.5 PAPER EXIT FULL SENSOR ................................................. 4-133
4.14.6 REVERSE MOTOR................................................................. 4-134
4.14.7 FUSING EXIT SENSOR.......................................................... 4-135
4.15 PAPER FEED .................................................................................. 4-136
4.15.1 PAPER FEED UNIT................................................................ 4-136
1st Paper Feed Unit......................................................................... 4-136
2nd Paper Feed Unit........................................................................ 4-137
4.15.2 PAPER DUST COLLECTION UNIT........................................ 4-139
4.15.3 PICK-UP ROLLER, PAPER FEED ROLLER, SEPARATION
ROLLER, TORQUE LIMITER................................................................ 4-141
4.15.4 1ST / 2ND PAPER FEED TRAY LIFT MOTOR....................... 4-143
4.15.5 1ST / 2ND PAPER FEED SENSOR........................................ 4-144
4.15.6 VERTICAL TRANSPORT SENSOR........................................ 4-145
4.15.7 LIMIT SENSOR....................................................................... 4-146
4.15.8 1ST PAPER END SENSOR / 2ND PAPER END SENSOR.... 4-146
4.15.9 REGISTRATION SENSOR ..................................................... 4-148
4.16 DUPLEX UNIT ................................................................................. 4-149
4.16.1 DUPLEX/BY-PASS MOTOR................................................... 4-149
4.16.2 DUPLEX ENTRANCE MOTOR............................................... 4-150
4.16.3 DUPLEX ENTRANCE SENSOR............................................. 4-151
4.16.4 DUPLEX EXIT SENSOR......................................................... 4-153
4.17 BYPASS TRAY UNIT....................................................................... 4-154
4.17.1 BYPASS TRAY ....................................................................... 4-154
4.17.2 BYPASS PAPER END SENSOR............................................ 4-156
4.17.3 BYPASS PICK-UP ROLLER................................................... 4-157
4.17.4 BYPASS PAPER FEED ROLLER........................................... 4-158
4.17.5 BYPASS SEPARATION ROLLER........................................... 4-158
4.17.6 TORQUE LIMITER.................................................................. 4-158
4.17.7 BYPASS WIDTH SENSOR..................................................... 4-159
4.17.8 BYPASS LENGTH SENSOR .................................................. 4-161
4.18 PCBS AND OTHER ITEMS ............................................................. 4-162
4.18.1 OVERVIEW............................................................................. 4-162
Around the Controller Box................................................................ 4-162
Around the Power Supply Box ......................................................... 4-163

SM xiii D197/D198/D199/D200/D201/D202
4.18.2 IPU.......................................................................................... 4-164
IPU Sub (If SPDF is installed) .......................................................... 4-164
4.18.3 BCU......................................................................................... 4-165
When installing the new BCU........................................................... 4-165
Replacing the NVRAM (EEPROM) on the BCU............................... 4-166
4.18.4 CONTROLLER BOARD.......................................................... 4-167
NVRAM on the controller board ....................................................... 4-170
4.18.5 HDD ........................................................................................ 4-173
Adjustment after replacement .......................................................... 4-173
4.18.6 HVPS ...................................................................................... 4-174
4.18.7 PSU......................................................................................... 4-175
PSU Fuse Location.......................................................................... 4-176
4.18.8 HEATER BOARD.................................................................... 4-176
4.18.9 CONTROLLER BOX............................................................... 4-177
4.18.10 TEMPERATURE SENSOR ................................................. 4-179
4.19 FANS/FILTERS................................................................................ 4-180
4.19.1 ODOR FILTER........................................................................ 4-180
4.19.2 DUST FILTER......................................................................... 4-181
4.19.3 DEVELOPMENT EXHAUST FAN........................................... 4-182
4.19.4 PAPER EXIT COOLING FAN ................................................. 4-183
4.19.5 FUSING FAN .......................................................................... 4-184
4.19.6 DEVELOPMENT BEARING COOLING FAN (D200/D201/D202
ONLY) 4-185
4.19.7 PSU COOLING FAN (D200/D201/D202 ONLY) ..................... 4-186
4.20 ADJUSTMENT AFTER REPLACEMENT......................................... 4-187
4.20.1 PRINTING............................................................................... 4-187
Registration - Leading Edge/Side-to-Side........................................ 4-187
Blank Margin.................................................................................... 4-191
Main Scan Magnification.................................................................. 4-193
Parallelogram Image Adjustment ..................................................... 4-193
4.20.2 SCANNING ............................................................................. 4-195
Registration: Platen Mode................................................................ 4-195
Magnification.................................................................................... 4-196
4.20.3 SCANNER WIRE .................................................................... 4-197
4.20.4 ADF IMAGE ADJUSTMENT ................................................... 4-197
Registration...................................................................................... 4-197
Sub Scan Magnification.................................................................... 4-198
4.20.5 TOUCH SCREEN CALIBRATION........................................... 4-199
5. SYSTEM MAINTENANCE............................................................. 5-1

D197/D198/D199/D200/D201/D202 xiv SM
5.1 SERVICE PROGRAM MODE.................................................................... 5-1
5.1.1 ENABLING AND DISABLING SERVICE PROGRAM MODE ........... 5-1
Entering SP Mode................................................................................ 5-1
Exiting SP Mode................................................................................... 5-1
5.1.2 TYPES OF SP MODES.................................................................... 5-1
SP Mode Button Summary................................................................... 5-2
Switching Between SP Mode and Copy Mode for Test Printing........... 5-3
Selecting the Program Number............................................................ 5-3
Exiting Service Mode............................................................................ 5-4
Service Mode Lock/Unlock................................................................... 5-4
PM Counter/ Firmware Update............................................................. 5-5
5.1.3 REMARKS........................................................................................ 5-7
Others .................................................................................................. 5-8
The following symbols are used in the SP mode tables....................... 5-8
5.2 SP MODE TABLES - SP1000.................................................................... 5-9
5.2.1 SP1-XXX (FEED).............................................................................. 5-9
5.3 SP MODE TABLES - SP2000.................................................................. 5-33
5.3.1 SP2-XXX (DRUM)........................................................................... 5-33
5.4 SP MODE TABLES - SP3000.................................................................. 5-42
5.4.1 SP3-XXX (PROCESS).................................................................... 5-42
*SP3-012 Display result detail............................................................ 5-43
5.5 SP MODE TABLES - SP4000.................................................................. 5-63
5.5.1 SP4-XXX (SCANNER).................................................................... 5-63
5.6 SP MODE TABLES - SP5000-1............................................................... 5-84
5.6.1 SP5-XXX (MODE)........................................................................... 5-84
5.7 SP MODE TABLES - SP5000-2............................................................. 5-125
5.7.1 SP5-XXX (MODE)......................................................................... 5-125
Bit assignment for SP5-828-087 ...................................................... 5-156
5.8 SP MODE TABLES - SP5000-3............................................................. 5-164
5.8.1 SP5-XXX (MODE)......................................................................... 5-164
5.9 SP MODE TABLES - SP6000-1............................................................. 5-200
5.9.1 SP6-XXX (PERIPHERALS) .......................................................... 5-200
5.10 SP MODE TABLES - SP6000-2....................................................... 5-219
5.10.1 SP6-XXX (PERIPHERALS)..................................................... 5-219
5.11 SP MODE TABLES - SP7000-1....................................................... 5-237
5.11.1 SP7-XXX (DATA LOG)............................................................ 5-237
5.12 SP MODE TABLES - SP7000-2....................................................... 5-257
5.12.1 SP7-XXX (DATA LOG)............................................................ 5-257
5.13 SP MODE TABLES - SP8000-1....................................................... 5-276

SM xv D197/D198/D199/D200/D201/D202
5.13.1 SP8-XXX (DATA LOG 2)......................................................... 5-276
Keys and abbreviations in Data Log 2.............................................. 5-277
5.14 SP MODE TABLES - SP8000-2....................................................... 5-310
5.14.1 SP8-XXX (DATA LOG 2)......................................................... 5-310
5.15 PRINTER SP MODE........................................................................ 5-335
5.15.1 SP1-XXX (SERVICE MODE) .................................................. 5-335
5.16 SCANNER SP MODE...................................................................... 5-349
5.16.1 SP1-XXX (SYSTEM AND OTHERS)....................................... 5-349
5.16.2 SP2-XXX (SCANNING-IMAGE QUALITY).............................. 5-353
5.17 INPUT CHECK TABLE..................................................................... 5-355
5.17.1 MAIN MACHINE – INPUT CHECK.......................................... 5-355
5.17.2 ADF D779 – INPUT CHECK................................................... 5-368
5.17.3 1-PASS ADF D683 – INPUT CHECK...................................... 5-369
5.17.4 2000/3000 SHEETS FINISHER D688 / D689 – INPUT CHECK5-372
5.17.5 INTERNAL FINISHER D690 – INPUT CHECK....................... 5-379
5.17.6 1000 SHEETS FINISHER D687 – INPUT CHECK.................. 5-380
5.17.7 BRIDGE UNIT D685 – INPUT CHECK ................................... 5-384
5.17.8 INTERNAL FINISHER D766 – INPUT CHECK....................... 5-385
5.17.9 INTERNAL SHIFT TRAY D691 – INPUT CHECK................... 5-386
5.17.10 1 BIN TRAY D692 – INPUT CHECK ................................... 5-386
5.18 OUTPUT CHECK TABLE................................................................. 5-387
5.18.1 MAIN MACHINE – OUTPUT CHECK...................................... 5-387
5.18.2 ADF D779 – OUTPUT CHECK ............................................... 5-397
5.18.3 1-PASS ADF D683 – OUTPUT CHECK.................................. 5-398
5.18.4 2000/3000 SHEETS FINISHER D688 / D689 – OUTPUT CHECK
5-399
5.18.5 INTERNAL FINISHER D690 – OUTPUT CHECK................... 5-403
5.18.6 1000 SHEETS FINISHER D687 – OUTPUT CHECK.............. 5-404
5.18.7 BRIDGE UNIT D685 – OUTPUT CHECK ............................... 5-406
5.18.8 INTERNAL SHIFT TRAY D691 – OUTPUT CHECK............... 5-406
5.18.9 INTERNAL FINISHER D766 – OUTPUT CHECK................... 5-407
5.19 TEST PATTERN PRINTING ............................................................ 5-408
5.20 FIRMWARE UPDATE...................................................................... 5-410
5.20.1 OVERVIEW............................................................................. 5-410
5.20.2 FIRMWARE TYPE .................................................................. 5-410
5.20.3 PROCEDURE ......................................................................... 5-411
Update procedure............................................................................. 5-412
5.20.4 ERROR SCREENS DURING UPDATING .............................. 5-416
5.21 UPDATING JAVAVM ....................................................................... 5-424

D197/D198/D199/D200/D201/D202 xvi SM
5.21.1 CREATING AN SD CARD FOR UPDATING........................... 5-424
Updating Procedure......................................................................... 5-424
List of Error Messages ..................................................................... 5-425
5.22 UPDATING THE EXJS..................................................................... 5-428
5.22.1 TO UPDATE EXJS.................................................................. 5-428
5.22.2 WHEN CHECKING THE VERSION OF EXJS ........................ 5-430
5.23 NVRAM DATA UPLOAD/DOWNLOAD............................................ 5-431
5.23.1 UPLOADING CONTENT OF NVRAM TO AN SD CARD........ 5-431
5.23.2 DOWNLOADING AN SD CARD TO NVRAM.......................... 5-432
5.24 UP/SP DATA IMPORT/EXPORT ..................................................... 5-433
5.24.1 OVERVIEW............................................................................. 5-433
Import/export conditions................................................................... 5-433
5.24.2 UP DATA IMPORT/EXPORT.................................................. 5-433
Data that can be imported and exported.......................................... 5-433
Data that cannot be imported or exported........................................ 5-434
Exporting Device Information........................................................... 5-434
Importing Device Information ........................................................... 5-435
5.24.3 SP DATA IMPORT/EXPORT .................................................. 5-437
Data that can be imported and exported.......................................... 5-437
Exporting Device Information........................................................... 5-437
Importing Device Information ........................................................... 5-439
5.24.4 POSSIBLE SOLUTIONS FOR IMPORT/EXPORT PROBLEMS5-440
5.25 ADDRESS BOOK EXPORT/IMPORT.............................................. 5-443
5.25.1 EXPORT ................................................................................. 5-443
5.25.2 IMPORT.................................................................................. 5-444
5.25.3 SPECIFICATION..................................................................... 5-444
5.26 RFU UPDATING THE FIRMWARE.................................................. 5-445
5.26.1 RFU PERFORMABLE CONDITION........................................ 5-445
5.27 PACKAGE FIRMWARE UPDATE.................................................... 5-446
5.27.1 OVERVIEW............................................................................. 5-446
Types of firmware update files, supported update methods:............ 5-447
5.27.2 IMMEDIATE UPDATE............................................................. 5-447
5.27.3 UPDATE AT THE NEXT VISIT (RESERVE)........................... 5-450
How to Set the Machine to Download Firmware Later (RESERVE). 5-450
How to Check if the Firmware Downloaded with RESERVE............ 5-452
How to Install Firmware Downloaded with RESERVE...................... 5-454
5.27.4 UPDATE VIA SD CARD.......................................................... 5-456
5.28 CAPTURING THE DEBUG LOGS ................................................... 5-459
5.28.1 OVERVIEW............................................................................. 5-459