Ricoh D037 User manual

D037/D038/D040/D041
SERVICE MANUAL
003980MIU

D037/D038/D040/D041
SERVICE MANUAL

D037/D038/D040/D041
SERVICE MANUAL
003980MIU

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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
D037 MP C2030 LD520CL Aficio MP C2030 C9020L
D038 MP C2050 LD520C Aficio MP C2050 C9020
D040 MP C2530 LD525CL Aficio MP C2530 C9025L
D041 MP C2550 LD525C Aficio MP C2550 C9025
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
* 10/2008 Original Printing

SM i D037/D038/D040/D041
D037/D038/D040/D041
TABLE OF CONTENTS
PRODUCT INFORMATION
1. PRODUCT INFORMATION.......................................................... 1-1
1.1 SPECIFICATIONS......................................................................................1-1
1.2 MACHINE CONFIGURATION ....................................................................1-2
1.2.1 H-MODEL..........................................................................................1-2
1.2.2 L-MODEL...........................................................................................1-5
1.3 OVERVIEW ................................................................................................1-7
INSTALLATION
2. INSTALLATION............................................................................ 2-1
2.1 INSTALLATION REQUIREMENTS ............................................................2-1
2.1.1 ENVIRONMENT ................................................................................2-1
2.1.2 MACHINE LEVEL..............................................................................2-1
2.1.3 MACHINE SPACE REQUIREMENTS ...............................................2-2
2.1.4 POWER REQUIREMENTS ...............................................................2-2
2.2 OPTIONAL UNIT COMBINATIONS............................................................2-3
2.2.1 MACHINE OPTIONS.........................................................................2-3
2.2.2 CONTROLLER OPTIONS.................................................................2-3
2.3 COPIER INSTALLATION ...........................................................................2-5
2.3.1 POWER SOCKETS FOR PERIPHERALS ........................................2-5
2.3.2 INSTALLATION FLOW CHART ........................................................2-6
2.3.3 ACCESSORY CHECK ......................................................................2-6
2.3.4 INSTALLATION PROCEDURE .........................................................2-9
Tapes and Retainers.............................................................................2-9
Developer and Toner Bottles ..............................................................2-11
Paper Trays ........................................................................................2-13
Emblem and Decals............................................................................2-14
Fax Settings for D037-17 ....................................................................2-14
Initialize the Developer........................................................................2-14

D037/D038/D040/D041 ii SM
Settings Relevant to the Service Contract ..........................................2-15
Settings for @Remote Service............................................................2-16
2.3.5 MOVING THE MACHINE ................................................................2-19
2.3.6 TRANSPORTING THE MACHINE ..................................................2-20
Main Frame.........................................................................................2-20
2.4 PAPER FEED UNIT (D331)......................................................................2-21
2.4.1 ACCESSORY CHECK ....................................................................2-21
2.4.2 INSTALLATION PROCEDURE .......................................................2-21
2.5 PAPER FEED UNIT (D425)......................................................................2-24
2.5.1 COMPONENT CHECK....................................................................2-24
2.5.2 INSTALLATION PROCEDURE .......................................................2-24
2.6 CASTER TABLE (D488)...........................................................................2-27
2.6.1 COMPONENT CHECK....................................................................2-27
2.6.2 INSTALLATION PROCEDURE .......................................................2-27
2.7 ARDF (D366)............................................................................................2-29
2.7.1 COMPONENT CHECK....................................................................2-29
2.7.2 INSTALLATION PROCEDURE .......................................................2-29
2.8 PLATEN COVER INSTALLATION (G329) ...............................................2-33
2.9 SIDE TRAY (D427)...................................................................................2-34
2.9.1 COMPONENT CHECK....................................................................2-34
2.9.2 INSTALLATION PROCEDURE .......................................................2-34
2.10 1-BIN TRAY UNIT (D426)...................................................................2-37
2.10.1 COMPONENT CHECK ..............................................................2-37
2.10.2 INSTALLATION PROCEDURE..................................................2-37
2.11 SHIFT TRAY UNIT (D428)..................................................................2-40
2.11.1 COMPONENT CHECK ..............................................................2-40
2.11.2 INSTALLATION PROCEDURE..................................................2-40
2.12 INTERNAL FINISHER (D429).............................................................2-42
2.12.1 COMPONENT CHECK ..............................................................2-42
2.12.2 INSTALLATION PROCEDURE..................................................2-43
Preparing before Installing the Internal Finisher..................................2-43
Internal Finisher Installation ................................................................2-45
2.13 PUNCH UNIT (D390)..........................................................................2-48
2.13.1 COMPONENT CHECK ..............................................................2-48
2.13.2 INSTALLATION PROCEDURE..................................................2-48
Removing the Internal Finisher ...........................................................2-49
Preparing the Punch Unit before Installing the Internal Finisher .........2-51

SM iii D037/D038/D040/D041
Installing the Punch and Inverter Unit .................................................2-53
Preparing the Internal Finisher............................................................2-55
Installing the Internal Finisher .............................................................2-56
2.14 USB2.0/SD SLOT TYPE A .................................................................2-60
2.14.1 ACCESSORY CHECK...............................................................2-60
2.14.2 INSTALLATION PROCEDURE..................................................2-60
2.14.3 TESTING THE SD CARD/USB SLOT .......................................2-63
2.15 MECHANICAL COUNTER (NA ONLY)...............................................2-65
2.15.1 INSTALLATION PROCEDURE..................................................2-65
2.16 KEY COUNTER BRACKET ................................................................2-67
2.16.1 INSTALLATION PROCEDURE..................................................2-67
2.17 KEY COUNTER INTERFACE UNIT ...................................................2-69
2.17.1 INSTALLATION PROCEDURE..................................................2-69
2.18 COPY DATA SECURITY UNIT TYPE F (B829)..................................2-71
2.18.1 INSTALLATION .........................................................................2-71
User Tool Setting ................................................................................2-72
2.19 ANTI-CONDENSATION HEATER ......................................................2-73
2.19.1 INSTALLATION PROCEDURE..................................................2-73
2.20 TRAY HEATER (MAINFRAME) ..........................................................2-77
2.20.1 INSTALLATION PROCEDURE..................................................2-77
2.21 TRAY HEATERS (OPTIONAL UNIT)..................................................2-79
2.21.1 INSTALLATION PROCEDURE..................................................2-79
Tray Heater for D425 ..........................................................................2-79
Tray Heater for D331 ..........................................................................2-83
2.22 CONTROLLER OPTIONS ..................................................................2-87
2.22.1 OVERVIEW................................................................................2-87
I/F Card Slots......................................................................................2-87
SD Card Slots .....................................................................................2-87
USB Slots ...........................................................................................2-88
2.22.2 SD CARD APPLI MOVE ............................................................2-88
Overview.............................................................................................2-88
Move Exec ..........................................................................................2-89
Undo Exec ..........................................................................................2-90
2.22.3 POSTSCRIPT 3 (D038/D041 ONLY).........................................2-90
2.22.4 FILE FORMAT CONVERTER (D038/D041 ONLY)....................2-91
2.22.5 IEEE1284 (D038/D041 ONLY)...................................................2-92
Installation Procedure .........................................................................2-92

D037/D038/D040/D041 iv SM
2.22.6 IEEE 802.11 A/G, G (WIRELESS LAN: D038/D041 ONLY) ......2-93
Installation Procedure .........................................................................2-93
UP Mode Settings for Wireless LAN ...................................................2-95
SP Mode and UP Mode Settings for IEEE 802.11 a/g, g Wireless LAN2-96
2.22.7 BLUETOOTH (D038/D041 ONLY).............................................2-97
2.22.8 DATAOVERWRITESECURITY UNIT TYPE I (D362: D038/D041
ONLY) 2-98
Before You Begin the Procedure ........................................................2-98
Seal Check and Removal ...................................................................2-99
Installation Procedure .........................................................................2-99
2.22.9 HDD ENCRYPTION UNIT (D038/D041 ONLY) .......................2-101
Before You Begin the Procedure ......................................................2-101
Seal Check and Removal .................................................................2-102
Installation Procedure .......................................................................2-103
Recovery from a Device Problem .....................................................2-104
Restoring the Encryption key ............................................................2-104
Clearing the NVRAM.........................................................................2-105
2.22.10 PICTBRIDGE .......................................................................2-105
2.22.11 VM CARD TYPE I (D038/D041 ONLY) ................................2-106
Installation Procedure .......................................................................2-106
Firmware Update Procedure.............................................................2-107
2.22.12 BROWSER UNIT TYPE E (D038/D041 ONLY)....................2-108
Installation Procedure .......................................................................2-108
Update Procedure.............................................................................2-109
2.22.13 GIGABIT ETHERNET (D038/D041 ONLY) ..........................2-110
2.22.14 MEMORY UNIT TYPE I 512MB (D038/D041 ONLY) ...........2-111
2.22.15 CHECK ALL CONNECTIONS ..............................................2-112
PREVENTIVE MAINTENANCE
3. PREVENTIVE MAINTENANCE.................................................... 3-1
3.1 MAINTENANCE TABLES...........................................................................3-1
3.2 PM PARTS SETTINGS ..............................................................................3-2
3.2.1 BEFORE REMOVING THE OLD PM PARTS....................................3-2
3.2.2 AFTER INSTALLING THE NEW PM PARTS ....................................3-3
3.2.3 PREPARATION BEFORE OPERATION CHECK..............................3-3
3.2.4 OPERATION CHECK........................................................................3-4
Rev. 05/07/2009

SM v D037/D038/D040/D041
REPLACEMENT AND ADJUSTMENT
4. REPLACEMENT AND ADJUSTMENT ........................................ 4-1
4.1 BEFOREHAND...........................................................................................4-1
4.2 SPECIAL TOOLS .......................................................................................4-2
4.3 IMAGE ADJUSTMENT...............................................................................4-3
4.3.1 SCANNING........................................................................................4-3
Scanner sub-scan magnification...........................................................4-3
Scanner leading edge and side-to-side registration..............................4-3
4.3.2 ARDF.................................................................................................4-4
ARDF side-to-side, leading edge registration and trailing edge............4-4
ARDF sub-scan magnification...............................................................4-5
4.3.3 REGISTRATION................................................................................4-5
Image Area ...........................................................................................4-5
Leading Edge........................................................................................4-6
Side to Side...........................................................................................4-6
Adjustment Standard ............................................................................4-6
Paper Registration Standard.................................................................4-6
Adjustment Procedure ..........................................................................4-6
4.3.4 ERASE MARGIN ADJUSTMENT......................................................4-6
4.3.5 COLOR REGISTRATION..................................................................4-7
Line Position Adjustment ......................................................................4-7
4.3.6 PRINTER GAMMA CORRECTION...................................................4-8
Copy Mode ...........................................................................................4-8
Printer Mode .......................................................................................4-13
4.4 EXTERIOR COVERS...............................................................................4-15
4.4.1 PCDU TONER COLLECTION BOTTLE..........................................4-15
4.4.2 FRONT DOOR ................................................................................4-15
4.4.3 ITB CLEANING UNIT COVER.........................................................4-16
4.4.4 LEFT COVER..................................................................................4-17
4.4.5 REAR COVER.................................................................................4-17
4.4.6 REAR LOWER COVER...................................................................4-18
4.4.7 DUST FILTER .................................................................................4-18
4.4.8 RIGHT REAR COVER.....................................................................4-18
4.4.9 OPERATION PANEL.......................................................................4-19
For D038/D041 ...................................................................................4-19

D037/D038/D040/D041 vi SM
For D037/D040 ...................................................................................4-20
4.4.10 TOUCH PANEL POSITION ADJUSTMENT (D038/D041).........4-20
4.4.11 INNER RIGHT COVER..............................................................4-21
4.4.12 INNER COVER..........................................................................4-21
4.4.13 FRONT RIGHT COVER.............................................................4-22
4.4.14 RIGHT UPPER COVER.............................................................4-22
4.4.15 LEFT FRAME AND LEFT FRAME REAR COVER....................4-23
4.4.16 PAPER EXIT COVER................................................................4-23
4.4.17 INVERTER TRAY......................................................................4-24
4.4.18 INNER TRAY.............................................................................4-24
4.4.19 INNER REAR COVER...............................................................4-24
4.5 SCANNER UNIT.......................................................................................4-26
4.5.1 EXPOSURE GLASS........................................................................4-26
4.5.2 ORIGINAL LENGTH SENSORS .....................................................4-27
4.5.3 EXPOSURE LAMP..........................................................................4-28
Reassembling.....................................................................................4-30
4.5.4 SCANNER MOTOR.........................................................................4-30
4.5.5 SENSOR BOARD UNIT (SBU)........................................................4-31
When reassembling............................................................................4-32
4.5.6 EXPOSURE LAMP STABILIZER ....................................................4-32
4.5.7 SCANNER HP SENSOR.................................................................4-32
4.5.8 PLATEN COVER SENSOR.............................................................4-33
4.5.9 FRONT SCANNER WIRE ...............................................................4-34
Reinstalling the Front Scanner Wire ...................................................4-36
4.5.10 REAR SCANNER WIRE............................................................4-38
Reinstalling the Rear Scanner Wire....................................................4-38
4.6 LASER OPTICS .......................................................................................4-40
4.6.1 CAUTION DECAL LOCATION........................................................4-40
4.6.2 LASER UNIT ...................................................................................4-40
Preparing a new laser unit ..................................................................4-41
Before removing the old laser unit ......................................................4-41
Recovery procedure for no replacement preparation of laser unit ......4-42
Removing the laser unit......................................................................4-43
After installing a new laser unit ...........................................................4-44
4.6.3 POLYGON MIRROR MOTOR.........................................................4-45
4.7 IMAGE CREATION...................................................................................4-47
4.7.1 PCDU (PHOTO CONDUCTOR AND DEVELOPMENT UNIT)........4-47

SM vii D037/D038/D040/D041
When installing a new PCDU..............................................................4-47
4.7.2 DRUM UNIT AND DEVELOPMENT UNIT.......................................4-48
New unit detection for the development unit.......................................4-50
4.7.3 TONER HOPPER UNIT ..................................................................4-50
Toner hopper unit: K, C, M..................................................................4-50
Toner hopper unit: Y...........................................................................4-51
When installing a new toner hopper unit.............................................4-52
4.7.4 TONER SUPPLY MOTOR...............................................................4-52
4.7.5 TONER COLLECTION MOTOR......................................................4-54
4.7.6 PCDU TONER COLLECTION BOTTLE FULL SENSOR ................4-56
4.7.7 PCDU TONER COLLECTION BOTTLE SET SWITCH...................4-56
4.7.8 RFID BOARD ..................................................................................4-57
4.8 IMAGE TRANSFER..................................................................................4-58
4.8.1 ITB CLEANING UNIT ......................................................................4-58
When installing the ITB cleaning unit..................................................4-58
4.8.2 ITB TONER COLLECTION BOTTLE FULL SENSOR.....................4-58
4.8.3 ITB (IMAGE TRANSFER BELT) UNIT ............................................4-59
4.8.4 ITB UNIT MOTOR...........................................................................4-60
4.8.5 IMAGE TRANSFER BELT...............................................................4-60
When reinstalling a new image transfer belt .......................................4-64
4.8.6 ITB CONTACT MOTOR ..................................................................4-64
4.8.7 ITB CONTACT SENSOR.................................................................4-65
4.9 PAPER TRANSFER.................................................................................4-67
4.9.1 PTR (PAPER TRANSFER ROLLER) UNIT.....................................4-67
4.9.2 OPENING THE PAPER TRANSFER UNIT.....................................4-68
4.9.3 ID SENSOR BOARD.......................................................................4-68
Cleaning for ID sensors ......................................................................4-69
After installing a new ID sensor unit/board..........................................4-70
4.9.4 TEMPERATURE AND HUMIDITY SENSOR...................................4-70
4.10 DRIVE UNIT........................................................................................4-72
4.10.1 GEAR UNIT ...............................................................................4-72
Adjustment after reinstalling the gear unit...........................................4-73
4.10.2 REGISTRATION MOTOR..........................................................4-74
4.10.3 PAPER FEED MOTOR: T1........................................................4-74
4.10.4 PAPER FEED MOTOR: T2........................................................4-75
4.10.5 DRUM MOTOR: CMY................................................................4-75
4.10.6 DEVELOPMENT MOTOR: CMY................................................4-76

D037/D038/D040/D041 viii SM
4.10.7 DRUM/DEVELOPMENT MOTOR: K .........................................4-76
4.10.8 DEVELOPMENT CLUTCH: K....................................................4-77
4.10.9 FUSING/PAPER EXIT MOTOR.................................................4-77
4.11 FUSING ..............................................................................................4-80
4.11.1 PM PARTS.................................................................................4-80
4.11.2 FUSING UNIT............................................................................4-80
When installing the fusing unit ............................................................4-81
4.11.3 ENTRANCE GUIDE PLATE.......................................................4-81
Cleaning Requirement........................................................................4-81
4.11.4 STRIPPER PLATE.....................................................................4-82
Cleaning Requirement........................................................................4-83
4.11.5 EXIT GUIDE PLATE CLEANING PROCEDURE.......................4-84
4.11.6 PRESSURE ROLLER FUSING LAMP.......................................4-84
4.11.7 HEATING ROLLER FUSING LAMP ..........................................4-86
4.11.8 FUSING BELT ...........................................................................4-87
4.11.9 HEATING, FUSING AND TENSION ROLLER...........................4-90
When reinstalling the fusing roller.......................................................4-91
4.11.10 PRESSURE ROLLER ............................................................4-91
Cleaning Requirement........................................................................4-93
4.11.11 HEATING ROLLER THERMOSTATS....................................4-93
4.11.12 HEATING ROLLER THERMISTOR .......................................4-93
Cleaning Requirement........................................................................4-94
4.11.13 PRESSURE ROLLER THERMISTOR....................................4-94
Pressure Roller Thermistor: Center ....................................................4-94
Pressure Roller Thermistor: Center ....................................................4-95
Cleaning Requirement........................................................................4-96
4.11.14 PRESSURE ROLLER THERMOSTAT...................................4-96
4.11.15 THERMOPILE........................................................................4-96
When cleaning the lens of the thermopile...........................................4-97
4.11.16 CLEANING UNIT (OPTION) INSTALLATION PROCEDURE 4-98
4.12 PAPER FEED...................................................................................4-100
4.12.1 PAPER TRAY..........................................................................4-100
4.12.2 FEED ROLLER........................................................................4-100
Tray 1 and Tray 2..............................................................................4-100
When reinstalling the feed roller........................................................4-100
4.12.3 FRICTION PAD........................................................................4-100
When reinstalling the friction pad......................................................4-101