Ricoh M0A0 User manual

MP 402SPF
Machine Code: M0A0
Field Service Manual
Ver 1.01
Latest Release: -
Initial Release: August, 2016
Copyright (c) 2016 Ricoh Co.,Ltd.

Important Safety Notices
Warnings, Cautions, Notes
In this manual, the following important symbols and notations are used.
A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in death or
serious injury.
A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor or
moderate injury or damage to the machine or other property.
Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable data and to
prevent damage to the machine.
This information provides tips and advice about how to best service the machine.

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General Safety Instructions
For your safety, please read this manual carefully before you use this product. Keep this manual handy for future
reference.
Safety Information
Always obey the following safety precautions when using this product.
Safety During Operation
In this manual, the following important symbols and notations are used.
[A]: ON
[B]: OFF
[C]: Push ON/Push OFF
[D]: Standby
Switches and Symbols
Where symbols are used on or near switches on machines for Europe and other areas, the meaning of each symbol
conforms with IEC60417.

Safety
Prevention of Physical Injury
1. Before disassembling or assembling parts of the machine and peripherals, make sure that the machine and
peripheral power cords are unplugged.
2. The plug should be near the machine and easily accessible.
3. Note that some components of the machine and the paper tray unit are supplied with electrical voltage even if the
main power switch is turned off.
4. Always unplug the power cord from the power source before you move the product. Before you move the
machine, arrange the power cord so it will not fall under the machine.
5. Disconnect all peripheral units (finisher, LCT, etc.) from the mainframe before you move the machine.
6. If any adjustment or operation check has to be made with exterior covers off or open while the main switch is
turned on, keep hands away from electrified or mechanically driven components.
7. The machine drives some of its components when it completes the warm-up period. Be careful to keep hands away
from the mechanical and electrical components as the machine starts operation.
8. The inside and the metal parts of the fusing unit become extremely hot while the machine is operating. Be careful to
avoid touching those components with your bare hands.
9. To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols.
10. Do not use flammable sprays or solvent in the vicinity of the machine. Also, avoid placing these items in the vicinity
of the machine. Doing so could result in fire or electric shock.
11. To avoid fire or explosion, never use an organic cleaner near any part that generates heat.
12. Clean the floor completely after accidental spillage of silicone oil or other materials to prevent slippery surfaces
that could cause accidents leading to hand or leg injuries.
13. Never remove any safety device unless it requires replacement. Always replace safety devices immediately.
14. Never do any procedure that defeats the function of any safety device.
15. Modification or removal of a safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test
the operation of the machine to ensure that it is operating normally and safely after removal and replacement of
any safety device.
16. For replacements use only the correct fuses or circuit breakers rated for use with the machine. Using replacement
devices not designed for use with the machine could lead to a fire and personal injuries.
17. For machines installed with the ADF/ARDF:
When a thick book or three-dimensional original is placed on the exposure glass and the ARDF cover is lowered,
the back side of the ARDF rises up to accommodate the original. Therefore, when closing the ARDF, please be sure
to keep your hands away from the hinges at the back of the ARDF.
18. When using a vacuum cleaner around the machine, keep others away from the cleaner, especially small children.
19. For machines installed with the anti-tip components:
The anti-tip components are necessary for meeting the requirements of IEC60950-1, the international standard for
safety. The aim of these components is to prevent the products, which are heavy in weight, from toppling as a result
of people running into or leaning onto the products, which can lead to serious accidents such as persons

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becoming trapped under the product. (U.S.: UL60950-1, Europe: EN60950-1) Therefore, removal of such
components must always be with the consent of the customer. Do not remove them at your own judgment.
Health Safety Conditions
1. For the machines installed with the ozone filters:
Never operate the machine without the ozone filters installed.
Always replace the ozone filters with the specified types at the proper intervals.
2. The machine, which use high voltage power source, can generate ozone gas. High ozone density is harmful to
human health. Therefore, locate the machine in a large well ventilated room that has an air turnover rate of more
than 50m3/hr/person.
3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary
eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention.
Observance of Electrical Safety Standards
1. The machine and its peripherals must be installed and maintained by a customer service representative who has
completed the training course on those models with exceptions on some machines where the installation can be
handled by the user.
Safety and Ecological Notes for Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame.
2. Dispose of used toner, developer, organic photoconductors, and AIO unit in accordance with local regulations.
(These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per
sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up.
5. The danger of explosion exists if a battery of this type is incorrectly replaced. Replace only with the same or an
equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s
instructions.
Handling Toner
Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling toner on
clothing or the hands.
If toner is inhaled, immediately gargle with large amounts of cold water and move to a well-ventilated location. If
there are signs of irritation or other problems, seek medical attention.
If toner gets on the skin, wash immediately with soap and cold running water.
If toner gets into the eyes, flush the eyes with cold running water or eye wash. If there are signs of irritation or other
problems, seek medical attention.
If toner is swallowed, drink a large amount of cold water to dilute the ingested toner. If there are signs of any
problem, seek medical attention.
If toner spills on clothing, wash the affected area immediately with soap and cold water. Never use hot water! Hot
water can cause toner to set and permanently stain fabric.
Always store toner and developer supplies such as toner and developer packages, cartridges, bottles (including

used toner and empty bottles and cartridges), and AIO unit out of the reach of children.
Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not exposed to direct
sunlight.
Do not use a vacuum cleaner to remove spilled toner (including used toner). Vacuumed toner may cause a fire or
explosion due to sparks or electrical contact inside the cleaner. However, it is possible to use a cleaner designed
to be dust explosion-proof. If toner is spilled over the floor, sweep up spilled toner slowly and clean up any
remaining toner with a wet cloth.
Handling the development unit cooling system
For the machines installed the development cooling system:
1. The development unit cooling system circulates propylene glycol from a sealed tank through hoses that pass
behind cooling plates on the sides of each development unit.
2. The coolant tank is located at the bottom of the cooling box on the back of the main machine.
3. Always obey local laws and regulations if you need to dispose of a tank or the propylene glycol coolant.
4. The tank must never be emptied directly into a local drainage system, river, pond, or lake.
5. Contact a professional industrial waste disposal organization and ask them to dispose of the tank.

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Laser Safety
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The
optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem
is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer
engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when
replacement of the optical subsystem is required.
Use of controls, or adjustment, or performance of procedures other than those specified in this manual may
result in hazardous radiation exposure.
WARNING FOR LASER UNIT
WARNING:
Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams can seriously
damage your eyes.

Safety Instructions for the Color Controller
Fuse
The color controller uses a double pole fuse. If this fuse blows, be sure to replace it with an identical fuse.
Batteries
1. Always replace a battery with the same type of battery prescribed for use with the color controller unit. Replacing
a battery with any type other than the one prescribed for use could cause an explosion.
2. Never discard used batteries by mixing them with other batteries or other refuse.
3. Always remove used batteries from the work site and dispose of them in accordance with local laws and
regulations regarding the disposal of such items.

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Symbols and Abbreviations
This manual uses several symbols.
Symbol
What it means
Screw
Connector
Clip ring
Clamp
FFC
E-ring
Spring
SEF
Short Edge Feed
LEF
Long Edge Feed
[A] Short Edge Feed (SEF)
[B] Long Edge Feed (LEF)
Trademarks
NetWare is registered trademark of Novell, Inc. in the USA.
PostScript® is a registered trademark of Adobe Systems, Incorporated.
PCL® is a registered trademark of Hewlett-Packard Company.
Other product names used herein are for identification purposes only and may be trademarks of their respective
companies. We disclaim any and all rights involved with those marks.

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Table of Contents
1. Product Information..................................................................................................................................................10
Product Overview........................................................................................................................................................ 10
Component Layout.................................................................................................................................................. 10
Paper Path............................................................................................................................................................... 11
Drive Layout ............................................................................................................................................................ 11
Machine Codes and Peripheral Configuration ........................................................................................................... 13
Specifications............................................................................................................................................................... 15
2. Installation................................................................................................................................................................16
Installation Requirements............................................................................................................................................. 16
Environment............................................................................................................................................................. 16
Machine Space Requirements ................................................................................................................................ 16
Machine Dimensions............................................................................................................................................... 17
Power Requirements................................................................................................................................................ 17
Main Machine Installation........................................................................................................................................... 19
Important Notice on Security Issues ........................................................................................................................ 19
Accessory Check..................................................................................................................................................... 23
Installation Procedure.............................................................................................................................................. 24
Instructions for the Customers.................................................................................................................................. 26
Moving the Machine............................................................................................................................................... 27
Paper Feed Unit PB1060/ Paper Feed Unit PB1070................................................................................................. 29
Component Check .................................................................................................................................................. 29
Installation Procedure.............................................................................................................................................. 29
Controller Options....................................................................................................................................................... 31
Overview................................................................................................................................................................. 31
File Format Converter Type M19 (D3BR-04) ............................................................................................................. 32
Accessory Check..................................................................................................................................................... 32
Installation procedure ............................................................................................................................................. 32
IEEE 802.11 Interface Unit Type M24 (M500-08) ................................................................................................... 34
Accessory Check..................................................................................................................................................... 34
Installation procedure ............................................................................................................................................. 34
User Tool Settings for IEEE 802.11a/g/n ............................................................................................................. 35
SP Mode Settings for IEEE 802.11 Wireless LAN.................................................................................................. 36
IEEE 1284 Interface Board Type M19 (D3C0-17).................................................................................................... 38
Accessories.............................................................................................................................................................. 38

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Installation procedure ............................................................................................................................................. 38
USB Device Server Option Type M19 (D3BC-28,-29).............................................................................................. 40
Component Check .................................................................................................................................................. 40
Installation Procedure.............................................................................................................................................. 41
IP Address Setting ................................................................................................................................................... 47
Extended USB Board Type M19 (D3BS-01).............................................................................................................. 49
Component Check .................................................................................................................................................. 49
Installation Procedure.............................................................................................................................................. 49
Data Overwrite Security Unit Type M19 (D3BS-03).................................................................................................. 51
Overview................................................................................................................................................................. 51
Component List........................................................................................................................................................ 51
Before You Begin the Procedure ............................................................................................................................. 51
Installation Procedure.............................................................................................................................................. 53
Configuring "Auto Erase Memory" (Performed by the Customer)........................................................................... 54
XPS Direct Print Option Type M27 (M502-02, -05, -06).......................................................................................... 57
Accessories.............................................................................................................................................................. 57
Installation Procedure.............................................................................................................................................. 57
OCR Unit Type M13 (D3AC-23, -24, -25) ............................................................................................................... 59
Accessory Check..................................................................................................................................................... 59
Overview of Searchable PDF Function ................................................................................................................... 59
Installation Procedure.............................................................................................................................................. 59
Recovery Procedure................................................................................................................................................ 61
Optional Counter Interface Unit Type M12 (B870-21) ............................................................................................. 62
Accessory Check..................................................................................................................................................... 62
Installation procedure ............................................................................................................................................. 62
NFC Card Reader Type M27 (M502-10) ................................................................................................................. 65
Accessory Check..................................................................................................................................................... 65
Installation Procedure.............................................................................................................................................. 65
Enhanced Security HDD Option Type M10 (D792-09) ............................................................................................ 74
Accessory Check..................................................................................................................................................... 74
Installation Procedure.............................................................................................................................................. 74
SD Card Appli Move................................................................................................................................................... 78
Overview................................................................................................................................................................. 78
Notes on Using the SD Merge Function.................................................................................................................. 78
SD Card Applications ............................................................................................................................................. 78

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Move Exec .............................................................................................................................................................. 79
Undo Exec............................................................................................................................................................... 80
Security Settings........................................................................................................................................................... 82
Security Function Installation................................................................................................................................... 82
Data Overwrite Security.......................................................................................................................................... 82
HDD Encryption ...................................................................................................................................................... 84
Settings for @Remote Service ...................................................................................................................................... 89
Points to Check Before Making @Remote Settings.................................................................................................. 89
Execute the @Remote Settings................................................................................................................................. 89
3. Preventive Maintenance...........................................................................................................................................92
Preventive Maintenance Tables................................................................................................................................... 92
Image Quality Standards ............................................................................................................................................ 93
Paper Transfer Quality Standards ............................................................................................................................... 95
4. Replacement and Adjustment...................................................................................................................................96
General Cautions ........................................................................................................................................................ 96
Notes on the Main Power Switch............................................................................................................................ 96
Special Tools ............................................................................................................................................................... 98
Exterior Covers ............................................................................................................................................................ 99
Front Cover Unit ...................................................................................................................................................... 99
Left Cover ..............................................................................................................................................................101
Right Cover............................................................................................................................................................101
Rear Cover, Rear Lower Cover .............................................................................................................................102
Upper Cover ......................................................................................................................................................... 103
Operation Panel.................................................................................................................................................... 105
LED Optics ................................................................................................................................................................. 108
LED Unit................................................................................................................................................................. 108
PCDU.........................................................................................................................................................................115
PCDU ....................................................................................................................................................................115
Toner Cartridge ......................................................................................................................................................... 116
Toner Cartridge..................................................................................................................................................... 116
Image Transfer........................................................................................................................................................... 117
Image Transfer Roller ............................................................................................................................................117
Drive Units .................................................................................................................................................................118
Main Motor...........................................................................................................................................................118
Duplex Exit Motor .................................................................................................................................................118
Toner Supply Clutch..............................................................................................................................................118

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Registration Clutch ................................................................................................................................................119
Paper Feed Clutch................................................................................................................................................. 120
Drive Unit ..............................................................................................................................................................121
Gear Unit ..............................................................................................................................................................122
Bypass Feed Clutch...............................................................................................................................................122
Relay Clutch ..........................................................................................................................................................123
Bypass Bottom Plate Clutch...................................................................................................................................123
Duplex Clutch........................................................................................................................................................124
Junction Gate Solenoid.........................................................................................................................................124
Fusing ........................................................................................................................................................................ 126
Fusing Unit............................................................................................................................................................. 126
Upper Fusing Unit, Lower Fusing Unit ...................................................................................................................126
Fusing Pressure Roller............................................................................................................................................128
Fusing Lamp, Hot Roller ........................................................................................................................................128
Thermostat.............................................................................................................................................................130
Thermistor.............................................................................................................................................................. 130
Hot Roller Stripper................................................................................................................................................. 132
Paper Feed ................................................................................................................................................................ 133
Paper Feed Tray.................................................................................................................................................... 133
Paper Feed Roller.................................................................................................................................................. 133
Friction Pad ........................................................................................................................................................... 133
Paper End Sensor.................................................................................................................................................. 134
Bypass Feed Unit...................................................................................................................................................134
Bypass Feed Roller................................................................................................................................................ 135
Bypass Friction Pad ...............................................................................................................................................137
Bypass Paper End Sensor .....................................................................................................................................138
Bypass Bottom Plate HP Sensor ............................................................................................................................ 138
Paper Size Switch ................................................................................................................................................. 139
Paper Transport ......................................................................................................................................................... 140
Paper Exit Sensor .................................................................................................................................................. 140
Paper Overflow Sensor......................................................................................................................................... 140
Duplex Exit Sensor ................................................................................................................................................ 140
Duplex Entrance Sensor........................................................................................................................................ 141
Registration Roller (Driven)....................................................................................................................................142
Registration Roller (Drive) .....................................................................................................................................143

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Registration Sensor................................................................................................................................................144
Electrical Components............................................................................................................................................... 145
FCU Board ............................................................................................................................................................145
Speaker.................................................................................................................................................................149
PSU........................................................................................................................................................................ 150
Controller Board ................................................................................................................................................... 153
NVRAM on the Controller Board.......................................................................................................................... 155
BiCU......................................................................................................................................................................155
EEPROM on the BiCU ...........................................................................................................................................156
HDD ...................................................................................................................................................................... 157
Toner End Sensor .................................................................................................................................................. 159
HVPS .....................................................................................................................................................................160
HVPS with Bracket.................................................................................................................................................160
Fusing Fan .............................................................................................................................................................160
PCDU Cooling Fan................................................................................................................................................161
PSU Cooling Fan................................................................................................................................................... 162
DC Switch..............................................................................................................................................................162
Front Door Interlock Switch................................................................................................................................... 162
Rear Door Interlock Switch....................................................................................................................................163
Temperature/Humidity Sensor.............................................................................................................................. 163
SPDF ..........................................................................................................................................................................164
SPDF Unit .............................................................................................................................................................. 164
SPDF Front Cover.................................................................................................................................................. 166
SPDF Rear Cover................................................................................................................................................... 167
SPDF Top Cover.................................................................................................................................................... 167
SPDF Original Tray ...............................................................................................................................................168
Original Feed Unit.................................................................................................................................................168
SPDF Friction Pad..................................................................................................................................................168
SPDF Drive Motor .................................................................................................................................................169
SPDF Top Cover Sensor ........................................................................................................................................ 169
SPDF Original Set Sensor...................................................................................................................................... 169
SPDF Registration Sensor ......................................................................................................................................170
DFRB......................................................................................................................................................................171
SPDF Feed Clutch..................................................................................................................................................171
SPDF Feed Sensor.................................................................................................................................................172
SPDF Feed Sensor Actuator ..................................................................................................................................173

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SPDF CIS...............................................................................................................................................................173
Scanner .....................................................................................................................................................................178
Scanner Unit (with SPDF) ......................................................................................................................................178
Scanner Upper Cover...........................................................................................................................................180
SPDF Open/Closed Sensor.................................................................................................................................. 180
Carriage................................................................................................................................................................ 181
Carriage Unit HP Sensor.......................................................................................................................................182
Scanner Motor...................................................................................................................................................... 183
5. System Maintenance............................................................................................................................................. 184
Service Program Mode .............................................................................................................................................184
Enabling and Disabling Service Program Mode ..................................................................................................184
Types of SP Modes................................................................................................................................................184
Remarks................................................................................................................................................................. 189
SP Mode Tables ........................................................................................................................................................191
Test Pattern Printing....................................................................................................................................................192
Firmware Update.......................................................................................................................................................193
Overview...............................................................................................................................................................193
Firmware Type ......................................................................................................................................................193
Procedure..............................................................................................................................................................194
Error Screens During Updating .............................................................................................................................198
Updating JavaVM ..................................................................................................................................................... 203
Creating an SD Card for Updating....................................................................................................................... 203
NVRAM Data Upload/Download ...........................................................................................................................206
Uploading Content of NVRAM to an SD card .....................................................................................................206
Downloading an SD Card to NVRAM .................................................................................................................207
UP/SP Data Import/Export....................................................................................................................................... 208
Overview...............................................................................................................................................................208
UP Data Import/Export......................................................................................................................................... 208
SP Data Import/Export .........................................................................................................................................211
Possible solutions for import/export problems......................................................................................................212
Address Book Export/Import .................................................................................................................................... 215
Export....................................................................................................................................................................215
Import....................................................................................................................................................................216
Specification..........................................................................................................................................................216
RFU Updating the Firmware ......................................................................................................................................218

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RFU Performable Condition...................................................................................................................................218
Package Firmware Update........................................................................................................................................ 219
Overview...............................................................................................................................................................219
Immediate Update ................................................................................................................................................220
Update at the Next Visit (Reserve) ........................................................................................................................222
Update via SD card ..............................................................................................................................................228
Capturing the Debug Logs.........................................................................................................................................231
Overview...............................................................................................................................................................231
Retrieving the Debug Logs.....................................................................................................................................232
6. Troubleshooting..................................................................................................................................................... 238
Self-Diagnostic Mode................................................................................................................................................238
Self-Diagnostic Mode at Power On...................................................................................................................... 238
Service Call ...............................................................................................................................................................239
Summary ...............................................................................................................................................................239
SC100 (Scanning)................................................................................................................................................ 240
SC200 (LED Optics) .............................................................................................................................................246
SC300 (Image Processing –1) ............................................................................................................................247
SC400 (Image Processing –2) ............................................................................................................................248
SC500 (Paper Feed and Fusing) ..........................................................................................................................248
SC600 (Device Communication)..........................................................................................................................254
SC700 (Peripherals) ............................................................................................................................................. 263
SC800 (Controller)...............................................................................................................................................264
SC900 (Others) .................................................................................................................................................... 295
Jam Detection ............................................................................................................................................................297
Jam Displays .........................................................................................................................................................297
Jam History............................................................................................................................................................297
Sensor Position Layout...........................................................................................................................................298
Sensor Position ......................................................................................................................................................298
Troubleshooting......................................................................................................................................................... 301
Image Position Adjustment ....................................................................................................................................301
Registration Adjustment......................................................................................................................................... 301
Scanner, SPDF Image Adjustment.........................................................................................................................302
Problem at Regular Intervals ................................................................................................................................. 304
Paper Feed (Skew)................................................................................................................................................ 306
Stack Error (Spilling of the Paper Stacked in the Output Tray) .............................................................................307
Recycled or Thin Paper Is Severely Curled after Printing ...................................................................................... 308

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7. Detailed Descriptions ............................................................................................................................................ 309
Overview...................................................................................................................................................................309
Mechanical Component Layout............................................................................................................................309
Drive Layout .......................................................................................................................................................... 310
Tray Layout and Paper Path ..................................................................................................................................311
Guidance for Those Who Are Familiar with Predecessor Products.......................................................................311
LED Unit .....................................................................................................................................................................312
General Descriptions.............................................................................................................................................312
Mechanisms ..........................................................................................................................................................313
Toner Cartridge, PCDU (Photo Conductor Development Unit) .................................................................................316
Mechanism............................................................................................................................................................ 316
Toner Cartridge.....................................................................................................................................................317
PCDU ....................................................................................................................................................................319
Related SPs............................................................................................................................................................ 323
Image Transfer and Paper Separation ......................................................................................................................324
Overview...............................................................................................................................................................324
Details ...................................................................................................................................................................324
Related SPs............................................................................................................................................................ 325
Paper Feed ................................................................................................................................................................ 326
Overview...............................................................................................................................................................326
Mechanism............................................................................................................................................................ 326
Image Fusing ............................................................................................................................................................. 333
Overview...............................................................................................................................................................333
Details ...................................................................................................................................................................333
Related SPs............................................................................................................................................................ 337
Paper Exit/ Duplex Unit ............................................................................................................................................338
Overview...............................................................................................................................................................338
Details ...................................................................................................................................................................338
Electrical Parts............................................................................................................................................................ 340
Block Diagram ...................................................................................................................................................... 340
Board Outline........................................................................................................................................................340
SPDF ..........................................................................................................................................................................342
Overview...............................................................................................................................................................342
Mechanism............................................................................................................................................................ 343
Scanner .....................................................................................................................................................................347