Ricoh D009 User manual

D009/D011/D012/D013
SERVICE MANUAL
003315MIU

D009/D011/D012/D013
SERVICE MANUAL

D009/D011/D012/D013
SERVICE MANUAL
003315MIU

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within this document to maintain a level of confidentiality that is in the best
interest of Ricoh Americas Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
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PERMISSION OF RICOH AMERICAS CORPORATION.
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They are used throughout this book in an informational or editorial fashion
only and for the benefit of such companies. No such use, or the use of
any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
©2008 RICOH Americas Corporation. All rights reserved.

The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Americas Corporation.
Users of this manual should be either service
trained or certified by successfully completing a
Ricoh Technical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Americas Corporation
WARNING

LEGEND
COMPANYPRODUCT
CODE GESTETNER LANIER RICOH SAVIN
D009 MP 4000B LD040B Aficio MP 4000B 9040b
D011 MP 4000 LD040 Aficio MP 4000 9040
D012 MP 5000B LD050B Aficio MP 5000B 9050b
D013 MP5000 LD050 Aficio MP 5000 9050
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 01/2008 Original Printing

SM i D009/D011/D012/D013
D009/D011/D012/D013
TABLE OF CONTENTS
INSTALLATION
1. INSTALLATION............................................................................ 1-1
1.1 INSTALLATION REQUIREMENTS ............................................................1-1
1.1.1 ENVIRONMENT ................................................................................1-2
1.1.2 MACHINE LEVEL..............................................................................1-3
1.1.3 MINIMUM SPACE REQUIREMENTS ...............................................1-3
1.1.4 POWER REQUIREMENTS ...............................................................1-4
1.2 INSTALLATION FLOW CHART .................................................................1-5
1.3 MAIN MACHINE INSTALLATION...............................................................1-6
1.3.1 ACCESSORY CHECK ......................................................................1-6
1.3.2 INSTALLATION PROCEDURE .........................................................1-7
1.3.3 MOVING THE MACHINE ................................................................1-15
1.3.4 TRANSPORTING THE MACHINE ..................................................1-15
1.4 PAPER FEED UNIT INSTALLATION (D351) ...........................................1-16
1.4.1 ACCESSORY CHECK ....................................................................1-16
1.4.2 INSTALLATION PROCEDURE .......................................................1-16
1.5 LCT 2000-SHEET (D352).........................................................................1-19
1.5.1 ACCESSORY CHECK ....................................................................1-19
1.5.2 INSTALLATION PROCEDURE .......................................................1-19
1.6 1200-SHEET LCT (D353).........................................................................1-22
1.6.1 COMPONENT CHECK....................................................................1-22
1.6.2 INSTALLATION PROCEDURE .......................................................1-22
1.7 AUTO REVERSE DOCUMENT FEEDER (B802).....................................1-25
1.7.1 COMPONENT CHECK....................................................................1-25
1.7.2 INSTALLATION PROCEDURE .......................................................1-25
1.8 PLATEN COVER INSTALLATION (G329) ...............................................1-30
1.9 1-BIN TRAY UNIT (D389).........................................................................1-31
1.9.1 COMPONENT CHECK....................................................................1-31
1.9.2 INSTALLATION PROCEDURE .......................................................1-31
1.10 BRIDGE UNIT (D386).........................................................................1-34
1.10.1 COMPONENT CHECK ..............................................................1-34
1.10.2 INSTALLATION PROCEDURE..................................................1-34

D009/D011/D012/D013 ii SM
1.11 2000/3000-SHEET FINISHERS (B804/B805).....................................1-38
1.11.1 ACCESSORY CHECK...............................................................1-38
1.11.2 INSTALLATION PROCEDURE..................................................1-39
1.12 PUNCH UNIT (B702) ..........................................................................1-44
1.12.1 COMPONENT CHECK ..............................................................1-44
1.12.2 INSTALLATION PROCEDURE..................................................1-45
1.13 1000-SHEET FINISHER (B408) .........................................................1-49
1.13.1 ACCESSORY CHECK...............................................................1-49
1.13.2 INSTALLATION PROCEDURE..................................................1-50
1.14 KEY COUNTER BRACKET ................................................................1-53
1.14.1 INSTALLATION PROCEDURE..................................................1-53
1.15 KEY COUNTER INTERFACE UNIT ...................................................1-55
1.15.1 INSTALLATION PROCEDURE..................................................1-55
1.16 ANTI-CONDENSATION HEATER (SCANNER) .................................1-57
1.16.1 INSTALLATION PROCEDURE..................................................1-57
1.17 TRAY HEATER...................................................................................1-59
1.17.1 INSTALLATION PROCEDURE..................................................1-59
1.18 TRAY HEATER (OPTIONAL PAPER FEED UNIT) ............................1-61
1.18.1 COMPONENT CHECK ..............................................................1-61
1.18.2 INSTALLATION PROCEDURE..................................................1-61
1.19 HDD OPTION (D362, ONLY FOR D009/D012) ..................................1-69
1.19.1 COMPONENT CHECK ..............................................................1-69
1.19.2 INSTALLATION PROCEDURE..................................................1-70
1.20 DATAOVERWRITESECURITY UNIT TYPE I (D362) .........................1-71
1.20.1 BEFORE YOU BEGIN THE PROCEDURE ...............................1-71
1.20.2 SEAL CHECK AND REMOVAL .................................................1-71
1.20.3 INSTALLATION PROCEDURE..................................................1-72
1.21 COPY DATA SECURITY UNIT...........................................................1-75
1.21.1 INSTALLATION PROCEDURE..................................................1-75
1.22 HDD ENCRYPTION UNIT ..................................................................1-78
1.22.1 BEFORE YOU BEGIN THE PROCEDURE ...............................1-78
1.22.2 SEAL CHECK AND REMOVAL .................................................1-78
1.22.3 INSTALLATION PROCEDURE..................................................1-79
1.22.4 RECOVERY FROM A DEVICE PROBLEM ...............................1-80
1.23 BROWSER UNIT TYPE D ..................................................................1-82
1.23.1 INSTALLATION PROCEDURE..................................................1-82

SM iii D009/D011/D012/D013
PREVENTIVE MAINTENANCE
2. PREVENTIVE MAINTENANCE.................................................... 2-1
2.1 PM TABLE - MAINFRAME .........................................................................2-1
2.2 PM TABLE - OPTIONS...............................................................................2-6
REPLACEMENT AND ADJUSTMENT
3. REPLACEMENT AND ADJUSTMENT ........................................ 3-1
3.1 GENERAL CAUTIONS ...............................................................................3-1
3.1.1 LASER UNIT .....................................................................................3-1
3.1.2 USED TONER ...................................................................................3-1
3.2 SPECIAL TOOLS AND LUBRICANTS .......................................................3-2
3.2.1 SPECIAL TOOLS ..............................................................................3-2
3.2.2 LUBRICANTS....................................................................................3-2
3.3 EXTERIOR COVERS .................................................................................3-3
3.3.1 FRONT DOOR, UPPER AND LOWER INNER COVER....................3-3
3.3.2 LEFT COVER ....................................................................................3-4
3.3.3 REAR COVER...................................................................................3-4
3.3.4 RIGHT REAR COVER.......................................................................3-4
3.3.5 OPERATION PANEL.........................................................................3-5
3.3.6 PAPER EXIT COVER........................................................................3-6
3.3.7 INNER TRAY.....................................................................................3-7
3.4 SCANNER -1..............................................................................................3-8
3.4.1 EXPOSURE GLASS..........................................................................3-8
3.4.2 ORIGINAL LENGTH/WIDTH SENSORS...........................................3-8
3.4.3 EXPOSURE LAMP..........................................................................3-10
3.4.4 SCANNER MOTOR.........................................................................3-12
3.4.5 SENSOR BOARD UNIT (SBU)........................................................3-13
3.4.6 LAMP STABILIZER .........................................................................3-14
3.4.7 SIO (SCANNER IN/OUT) BOARD...................................................3-15
3.4.8 SCANNER HP SENSOR.................................................................3-15
3.4.9 PLATEN COVER SENSOR.............................................................3-16
3.5 SCANNER -2............................................................................................3-17
3.5.1 FRONT SCANNER WIRE ...............................................................3-17
3.5.2 REAR SCANNER WIRE..................................................................3-19

D009/D011/D012/D013 iv SM
3.5.3 TOUCH PANEL POSITION ADJUSTMENT....................................3-22
3.6 LASER UNIT ............................................................................................3-23
3.6.1 CAUTION DECAL LOCATIONS......................................................3-23
3.6.2 LASER UNIT ...................................................................................3-23
3.6.3 POLYGON MIRROR MOTOR .........................................................3-24
3.6.4 LASER SYNCHRONIZATION DETECTOR.....................................3-25
3.6.5 LD UNIT ..........................................................................................3-25
3.7 PCDU .......................................................................................................3-28
3.7.1 PCDU (PHOTOCONDUCTOR AND DEVELOPMENT UNIT) .........3-28
3.7.2 DRUM..............................................................................................3-28
3.7.3 PICK-OFF PAWLS ..........................................................................3-32
3.7.4 CHARGE ROLLER AND CLEANING ROLLER...............................3-33
3.7.5 DRUM CLEANING BLADE 2...........................................................3-34
3.7.6 DRUM CLEANING BLADE 1...........................................................3-34
3.7.7 ID SENSOR.....................................................................................3-35
3.8 DEVELOPMENT ......................................................................................3-36
3.8.1 DEVELOPMENT FILTER ................................................................3-36
3.8.2 DEVELOPMENT ROLLER ..............................................................3-36
3.8.3 DEVELOPER...................................................................................3-37
3.8.4 TD SENSOR....................................................................................3-39
3.9 TRANSFER ..............................................................................................3-40
3.9.1 TRANSFER BELT UNIT..................................................................3-40
3.9.2 TRANSFER BELT ...........................................................................3-40
3.9.3 TONER OVERFLOW SENSOR ......................................................3-43
3.9.4 TRANSFER BELT CLEANING BLADE ...........................................3-43
3.10 PAPER FEED .....................................................................................3-44
3.10.1 PAPER FEED UNIT...................................................................3-44
3.10.2 PICK-UP, FEED AND SEPARATION ROLLERS.......................3-44
3.10.3 TRAY LIFT MOTOR...................................................................3-45
3.10.4 RELAY, TRAY LIFT, PAPER END AND PAPER FEED SENSORS .
...................................................................................................3-45
3.10.5 REGISTRATION SENSOR ........................................................3-46
3.11 FUSING ..............................................................................................3-48
3.11.1 FUSING UNIT ............................................................................3-48
3.11.2 WEB ROLLER UNIT ..................................................................3-48
3.11.3 BRAKE PAD ..............................................................................3-49
3.11.4 WEB HOLDER ROLLER AND WEB ROLLERS ........................3-50

SM v D009/D011/D012/D013
3.11.5 PRESSURE ROLLER CLEANING ROLLER .............................3-53
3.11.6 THERMOSTAT ..........................................................................3-54
3.11.7 THERMISTOR ...........................................................................3-55
3.11.8 HOT ROLLER STRIPPERS.......................................................3-55
3.11.9 FUSING LAMPS ........................................................................3-56
3.11.10 HOT ROLLER AND PRESSURE ROLLER ............................3-57
3.12 PAPER EXIT.......................................................................................3-59
3.12.1 PAPER EXIT UNIT ....................................................................3-59
3.12.2 FUSING EXIT, PAPER OVERFLOW, AND PAPER EXIT
SENSORS ................................................................................................3-59
3.12.3 JUNCTION JAM SENSOR.........................................................3-60
3.12.4 PAPER EXIT MOTOR ...............................................................3-60
3.13 DUPLEX .............................................................................................3-62
3.13.1 DUPLEX UNIT ...........................................................................3-62
3.13.2 RIGHT DOOR COVER ..............................................................3-64
3.13.3 DUPLEX DOOR SENSOR.........................................................3-64
3.13.4 DUPLEX ENTRANCE SENSOR................................................3-64
3.13.5 DUPLEX EXIT SENSOR............................................................3-65
3.13.6 DUPLEX/BY-PASS MOTOR......................................................3-67
3.13.7 DUPLEX INVERTER MOTOR ...................................................3-67
3.14 BY-PASS ............................................................................................3-70
3.14.1 BY-PASS PAPER SIZE SENSOR .............................................3-70
3.14.2 BY-PASS PAPER END SENSOR..............................................3-71
3.14.3 BY-PASS PICK-UP, FEED AND SEPARATION ROLLER,
TORQUE LIMITER ...................................................................................3-71
3.14.4 BY-PASS FEED CLUTCH .........................................................3-72
3.15 DRIVE AREA ......................................................................................3-73
3.15.1 PAPER FEED CLUTCH.............................................................3-73
3.15.2 DEVELOPMENT PADDLE MOTOR ..........................................3-73
3.15.3 TRANSFER/DEVELOPMENT MOTOR .....................................3-74
3.15.4 DRUM MOTOR..........................................................................3-74
3.15.5 FUSING MOTOR .......................................................................3-75
3.15.6 WEB MOTOR ............................................................................3-75
3.15.7 PAPER FEED MOTOR..............................................................3-76
3.15.8 TRANSFER BELT CONTACT MOTOR .....................................3-76
3.15.9 REGISTRATION MOTOR..........................................................3-76
3.15.10 TONER SUPPLY MOTOR .....................................................3-77

D009/D011/D012/D013 vi SM
3.16 ELECTRICAL COMPONENTS ...........................................................3-78
3.16.1 CONTROLLER UNIT .................................................................3-78
3.16.2 HDD UNIT (STANDARD FOR D011/D013) ...............................3-78
3.16.3 CONTROLLER BOARD.............................................................3-79
3.16.4 MOTHER BOARD......................................................................3-81
3.16.5 BICU ..........................................................................................3-82
3.16.6 IOB.............................................................................................3-82
3.16.7 PSU ...........................................................................................3-83
3.16.8 HIGH VOLTAGE POWER SUPPLY BOARD.............................3-84
3.16.9 FUSING EXHAUST FAN ...........................................................3-84
3.16.10 CONTROLLER FAN...............................................................3-85
3.17 COPY ADJUSTMENTS ......................................................................3-86
3.17.1 OVERVIEW................................................................................3-86
3.17.2 PRINTING..................................................................................3-86
3.17.3 SCANNING ................................................................................3-90
3.17.4 ADF IMAGE ADJUSTMENT ......................................................3-92
3.17.5 TOUCH SCREEN CALIBRATION .............................................3-92
TROUBLESHOOTING
4. TROUBLESHOOTING ................................................................. 4-1
4.1 SERVICE CALL CONDITIONS ..................................................................4-1
4.1.1 SUMMARY ........................................................................................4-1
4.1.2 SC CODE DESCRIPTIONS ..............................................................4-2
4.2 SC TABLES: SC1XX ..................................................................................4-3
4.3 SC TABLES: SC2XX ..................................................................................4-7
4.4 SC TABLES: SC3XX ..................................................................................4-9
4.5 SC TABLES: SC4XX ................................................................................4-12
4.6 SC TABLES: SC5XX -1 ............................................................................4-14
4.7 SC TABLES: SC5XX -2 ............................................................................4-19
4.8 SC TABLES: SC6XX ................................................................................4-22
4.9 SC TABLES: SC7XX -1 ............................................................................4-28
4.10 SC TABLES: SC7XX -2 ......................................................................4-33
4.11 SC TABLES: SC8XX -1 ......................................................................4-36
4.12 SC TABLES: SC8XX -2 ......................................................................4-42
4.13 SC TABLES: SC9XX ..........................................................................4-48
4.14 ELECTRICAL COMPONENT DEFECTS............................................4-52

SM vii D009/D011/D012/D013
4.14.1 SENSORS .................................................................................4-52
4.14.2 SWITCHES ................................................................................4-56
4.15 BLOWN FUSE CONDITIONS.............................................................4-58
SERVICE TABLES
5. SERVICE TABLES....................................................................... 5-1
5.1 SERVICE PROGRAM MODE.....................................................................5-1
5.1.1 SERVICE PROGRAM MODE OPERATION......................................5-1
5.1.2 SERVICE PROGRAM MODE TABLES.............................................5-2
5.2 SP1-XXX: FEED-1......................................................................................5-3
5.3 SP1-XXX: FEED-2....................................................................................5-11
5.4 SP1-XXX: FEED-3....................................................................................5-16
5.5 SP2-XXX: DRUM-1...................................................................................5-20
5.6 SP2-XXX: DRUM-2...................................................................................5-28
5.7 SP2-XXX: DRUM-3...................................................................................5-34
5.8 SP3-XXX: PROCESS-1............................................................................5-37
5.9 SP4-XXX: SCANNER-1............................................................................5-40
5.10 SP4-XXX: SCANNER-2 ......................................................................5-54
5.11 SP4-XXX: SCANNER-3 ......................................................................5-60
5.12 SP5-XXX: MODE-1.............................................................................5-75
5.13 SP5-XXX: MODE-2.............................................................................5-91
5.14 SP5-XXX: MODE-3.............................................................................5-95
5.15 SP5-XXX: MODE-4...........................................................................5-118
5.16 SP5-XXX: MODE-5...........................................................................5-134
5.17 SP6-XXX: PERIPHERALS-1.............................................................5-142
5.18 SP7-XXX: DATA LOG-1 ...................................................................5-152
5.19 SP7-XXX: DATA LOG-2 ...................................................................5-160
5.20 SP8-XXX: DATA LOG2-1 .................................................................5-170
5.21 SP8-XXX: DATA LOG2-2 .................................................................5-180
5.22 SP8-XXX: DATA LOG2-3 .................................................................5-189
5.23 SP8-XXX: DATA LOG2-4 .................................................................5-199
5.24 SP8-XXX: DATA LOG2-5 .................................................................5-209
5.25 INPUT CHECK - 1 ............................................................................5-216
5.25.1 COPIER ...................................................................................5-216
5.26 INPUT CHECK -2 .............................................................................5-222
5.26.1 OPTIONS.................................................................................5-222

D009/D011/D012/D013 viii SM
5.27 OUTPUT CHECK -1 .........................................................................5-227
5.27.1 COPIER ...................................................................................5-227
5.28 OUTPUT CHECK -2 .........................................................................5-233
5.28.1 1000-SHEET FINISHER (B408) ..............................................5-233
5.28.2 2000/3000-SHEET (BOOKLET) FINISHER .............................5-234
5.29 USING SP MODES...........................................................................5-236
5.29.1 TEST PATTERN PRINTING ....................................................5-236
5.29.2 SMC PRINT OUT LISTS: SP5-990..........................................5-237
5.29.3 NIP BAND WIDTH ADJUSTMENT: SP1-109 ..........................5-238
5.29.4 MEMORY CLEAR: SP5-801 ....................................................5-239
5.29.5 SOFTWARE RESET................................................................5-241
5.29.6 SYSTEM SETTINGS AND COPY SETTING RESET ..............5-241
5.29.7 COPIER SETTING RESET......................................................5-242
5.30 UPDATING THE FIRMWARE...........................................................5-244
5.30.1 BEFORE YOU BEGIN .............................................................5-244
5.30.2 UPDATING FIRMWARE..........................................................5-244
5.30.3 HANDLING FIRMWARE UPDATE ERRORS ..........................5-246
5.31 NVRAM DATA UPLOAD/DOWNLOAD.............................................5-249
5.31.1 UPLOADING NVRAM DATA (SP5-824) ..................................5-249
5.31.2 DOWNLOADING NVRAM DATA (SP5-825)............................5-249
5.32 SD CARD APPLI MOVE ...................................................................5-250
5.32.1 OVERVIEW..............................................................................5-250
5.32.2 MOVE EXEC............................................................................5-250
5.32.3 UNDO EXEC............................................................................5-251
5.33 SELF-DIAGNOSTIC MODE..............................................................5-252
5.33.1 SELF-DIAGNOSTIC MODE AT POWER ON ..........................5-252
5.33.2 SELF-DIAGNOSTIC TEST FLOW ...........................................5-253
5.33.3 DETAILED SELF-DIAGNOSTIC MODE ..................................5-253
5.33.4 EXECUTING DETAILED SELF-DIAGNOSIS...........................5-254
5.34 USING THE DEBUG LOG ................................................................5-255
5.34.1 OVERVIEW..............................................................................5-255
5.34.2 SWITCHING ON AND SETTING UP SAVE DEBUG LOG ......5-255
5.35 DIP SWITCHES ................................................................................5-261
5.35.1 I/O BOARD: DIP SW101..........................................................5-261