Ricoh DD 5450 Quick start guide

RICOH DD5450/DD5440
Machine Code: C284/C283
Field Service Manual
June, 2016


1
The cause of most accidents is failure to adhere to basic safety rules and observe
safety instructions. It is important to prevent potential causes of accidents from
occurring. In order to do so, read this manual carefully, and be sure to understand
all the safety instructions and correct inspection and servicing procedures that it
provides before beginning repair or servicing work.
Repairing or servicing the machine with insufcient knowledge about it could lead to
unforeseen accidents.
It is not possible to anticipate and describe in a manual such as this every possible
hazard that could arise in the course of repair and servicing. Therefore, besides
observing the safety instructions marked in this manual and on the machine's labels,
service personnel should be safety-conscious and take other safety precautions as
necessary. When performing repair or service work not covered by this manual, you
should obtain safety guidance from an appropriately knowledgeable person.
Introduction
Safety instructions

2
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury is likely to
result.
If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury, or else material
damage, is likely to result.
A " " symbol tells you that a certain action is forbidden. Precisely what
is forbidden is indicated by a picture inside the symbol (in the example
here, the picture means that disassembly is forbidden), or in writing at
the side of the symbol.
A "●" symbol means that a certain action is forbidden and/or that
a specific instruction must be followed. The specific instruction is
indicated by a picture inside the symbol (in the example here, the
instruction is "Remove the power plug from the socket").
●This manual contains the following information: structure and function of major parts,
disassembly and reassembly procedures, specications, and procedures for adjustment,
maintenance, inspection and corrective action. This information is current as of April
2014, and applies basically to the model DD5450/5440. From time to time, parts are
changed to improve quality, performance or safety.
Note therefore that in some cases, certain parts or machine structure aspects described
in the text or illustrations of this manual may not be precisely the same as the product
being serviced.
●Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important
for safety and must be observed.
■ Using the service manual
● Safety-related instructions
● Service work-related instructions
WARNING:
CAUTION:
Examples of pictorial symbols
Safety instructions
Draws attention to important information. If this information is ignored and
the machine is operated or serviced incorrectly, the machine's
performance could drop, or it could break down.
Draws attention to information that is useful for operation or maintenance
of the machine, and to information about its performance, etc.
IMPORTANT
REFERENCE

3
Safety instructions
1. Cautions regarding the installation location
Safety instructions
CAUTION
Installation environment
► Avoid installing the machine in places exposed to direct sunlight.
● Sunlight will cause the temperature in the machine's interior to rise, possibly leading to
malfunction of the control system.
● Sunlight could cause misoperation of the sensors.
● The heat of direct sunlight could cause deformation of the machine's plastic parts.
*Also avoid installation near to a ground glass window; light and heat penetrate such
windows although they are opaque.
► Avoid installing the machine in places subject to high or low temperature or humidity.
● High or low temperature or humidity could cause the machine to operate abnormally.
Suitable temperature and humidity ranges are:
Ambient temperature: 10oC-35oC
Ambient humidity: 40%-70%
Optimum temperature and humidity: 20oC, 65%
● If the machine is installed near to faucets, water heaters or humidiers, or in cool (sunless)
parts of a building or in the vicinity of water sources, the paper could absorb moisture and
curl, leading to misfeeds or poor image quality.
► Avoid installing the machine in places with open ames, or where reected heat or other
hot air currents (from stoves, etc), or cold air currents from air conditioners, etc will strike it
directly.
► Avoid installing the machine in poorly ventilated places.
► Avoid installing the machine in dusty places.
► The machine should not be tilting when it is used.
● Install the machine so that it is level.
(The machine should be level to within 5mm in the front-rear direction, and 5mm in the
lateral direction.)
► Do not install the machine on shaky, sloping or otherwise unstable surfaces.
● The machine could fall over on such surfaces, or fall off them, causing injury.

4
WARNING
● The machine's power supply voltage and power consumption depend on the model.
Details of this are given in the tables below. The power supply voltage and power
consumption for the machine are given in the table below. The machine's power supply
voltage is indicated on the rating label located on the machine's left side; the machine
must be connected to a power supply of the voltage indicated.
→ Otherwise, re or electric shock could result.
If the power supply voltage is unstable or if the power supply has insufcient capacity, the
machine may not operate normally.
Make sure that the power supply has sufcient capacity for the system as a whole, including
optional equipment.
*1“With no load” - when the machine is on standby.
“At full load” - when the machine is running at maximum power consumption.
*2Basic type with a computer unconnected
● Use only the power cord that is provided among the accessories.
Insert the power cord plug rmly into the socket, so that proper electrical contact is effected.
● Install the machine close to its power supply. The outlet used should be exclusively for the
machine, and have no other equipment connected to it.
If an extension cord is necessary, it should have a ground terminal, and be of the following
ratings:
* For a 120V AC model: 130V, at least 15A, length not exceeding 5m.
* For a 230V AC model: 250V, at least 8A, length not exceeding 5m.
• Never tread on the power cord or pinch it between other objects, or accidents could result.
CAUTION
2. Cautions for installation work
Using the optional printer stand (cabinet)
Safety instructions
• Lock the casters after the machine is installed.
→Otherwise, the machine could move or fall over, causing injury.
• To move the machine, push it by its mounting base.
→Pushing the Duprinter itself could make it fall over.
•
Install the machine in accordance with the Installation Manual appended to this manual.
230V AC model
Power supply
voltage Connect to outlet of 230V AC, 60Hz, at least
15A
With no load *1
At full load
No more than 250V AC Use power supply meeting
At least 210V AC these requirements
Power
consumption
DD5450 DD5440
Master making 85W 77W
Printing
(Speed 6) 220W 220W
Standing by 7.4W 7.4W
Sleeping
4.8W(0W*2) 4.8W(0W*2)
}

5
WARNING
● Precautions for safe servicing
● Always remove the power cord plug from the outlet before starting work.
→ Otherwise, you could get a shock or your hands/ngers could be injured.
● However, the plug must be left connected to the outlet when performing function checks (of
individual motors, a given series of operations, or electrical circuits).
When motors are operated alone in function checks, interlocks are deactivated, so be aware
of the conditions and positions of related equipment, and take great care not to put your
hands or ngers into moving parts.
● The cutter unit contains hazardous sharp blades. Exercise great care when inspecting the
cutter unit or replacing it or its parts.
→ Otherwise, your hands/ngers could be injured.
● Do not touch the rotating parts when operating the drum removal button and the paper
eject switch or while the machine is running.
→ Otherwise, your hands/ngers could get caught and crushed between the drum and
rollers.
● Working clothes
• Wear clothing that enables you to work safely.
Work clothing should be close-tting.
CAUTION
3. Cautions for maintenance, inspection and servicing
Safety instructions
● The tape dispenser have hazardous blades. Exercise care when inspecting or replacing the
blades.
→ Otherwise, your hands/ngers could be injured.
● Tools
• Use tools that are appropriate for the work.
If an optional tape dispenser is used

6
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5
6
7
8
10
9
■Locations of warning labels
Safety instructions
The locations of the machine's warning labels are shown below. To ensure safe work, read the
labels and heed their instructions. Keep the labels clean at all times. If they become damaged
or come off, replace them with new ones.
Do NOT touch the drum or rollers
when you operate the jog switch.
Do NOT put hands inside machine
while if is operating.
Hands could get caught up
or crushed. R8-T3010
12
3
4
5
CAUTION
M7-T3060
No. Part No. Name Q'ty
1 W9-T301* Warning label 1
2 M7-T306* Caution label 1
3 R8-T308* Caution label 1
4 R8-T301* Warning label 2
5 R8-T304* Caution label 1
6
L8-T109* Warning Label
1
View A
WARNING
Use caution when working
near movable parts.
Disconnect power before
servicing.
6

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3
4
5
6
7
8
10
9
Introduction
Installation Procedure
Description of the Operation
Mechanism
Standards/Adjustment
Maintenance/Check
Troubleshooting
HELP Mode
Others

8
Table of Contents
Introduction
Chapter 1
Description of the Operation
Chapter 3
Standards/Adjustment
Chapter 5
Maintenance/Check
Chapter 6
Troubleshooting
Chapter 7
HELP Mode List
…………………………
290
Overview
…………………………………
294
HELP Mode Functions and Operation Procedures
……
295
Others
Chapter 9
HELP Mode
Chapter 8
Introduction ………………………………………1
Using the service manual ………………………2
Safety instructions
…………………………3
1.
Cautions regarding the installation location
…
……3
2.
Cautions for installation work
……………………
4
3.
Cautions for maintenance, inspection and servicing
…5
■ Locations of warning labels……………6
Electrical Parts Layout and Their Functions
……
392
Scanner Section ……………………………99
Master making/Master Feed/Ejection Section
…107
Paper Feed Section ……………………126
Drum Driving Section ……………………139
Press Section ……………………………145
Paper Ejection Section …………………150
Drum Section ……………………………158
Guaranteed Periodical Maintenance …258
Cleaning and Oiling………………………258
Periodical Maintenance …………………259
Troubleshooting Guide ………………… 262
Error Display …………………………… 286
Scanner Section …………………………226
Master making/Master Feed/Ejection Section
……228
Paper Feed Section………………………235
Drum Driving Section ……………………239
Press Section ……………………………241
Paper Ejection Section …………………243
Drum Section ……………………………244
Electrical System…………………………247
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3
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6
7
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2
3
4
5
6
7
8
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2
3
1
2
1
2
3
1
Installation Procedure
Chapter 2
Machine Installation ………………………22
Platen Cover PN7000………………………36
ADF DF7010 ………………………………38
A3 Color Drum Type D1……………………46
A4 Drum Type D1 …………………………53
Tape Dispenser Type D1 …………………61
Printer Unit (USB) Type D1 ………………72
Printer Unit (NIC) Type D1…………………80
USB slot Type D1 …………………………93
Mechanism
Chapter 4
Exterior
……………………………………
170
Scanner Section
……………………………
185
Master making/Master Feed and Ejection Section
…
192
Paper Feed Section
…………………………
200
Drum Driving Section…………………… 206
Paper Ejection Section
…………………
210
Drum Section
………………………………
218
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2
3
4
5
6
7
1
2
3
4
5
6
7
8
Specifications ……………………………10
Dimensions ………………………………13
System Setup ………………………………14
Part Names and Their Functions …………15
9

1
IntroductionChapter 1
1 Specications ................................... 10
2 Dimensions ...................................... 13
3 System Setup.................................... 14
4 Part Names and Their Functions ........... 15
1. Machine Exteriors............................. 15
2. Inside of Machine ............................. 16
3. Outside/Inside of Print Output Side........ 17
4. Display Screen ................................ 20
5. Setting Screen................................. 20

1
Chapter 1 Specications
10
1 Specifications
1
Model name DD5450 DD5440
Product category Digital Duplicator, oor stand model
Master making
interval 18 sec
(A4, 100%)
20 sec (A4R, 100%)
Resolution (Pel path dir.)
× (line progression dir.)
Scan (input) resolution: 300 dpi × 600 dpi
Print (output) resolution: 300 dpi ×600 dpi
Scanning method Flat bed scanner
Optional ADF
Document weight
64–128 gsm
Optional ADF Capacity
100 sheets (64 gsm), 85 sheets (80 gsm/20 lb Bond)
Document type Sheets, book (max. weight: 10 kg)
Document size MAX. 297×432 mm
(With optional ADF: MIN.100×148 mm)
Scanning area 293×428 mm (297×432 mm when selecting Use setting)
Max. image area 290×423 mm (11.4″ ×16.6″)* 210×355 mm (8.2″×13. 9″)
*With A4/Letter drum 290×207 mm (11.4
″×
8.1
″
)
Feeder capacity 1,500 sheets (64 gsm), 1,280 sheets (20lb Bond), 1,200 sheets (80 gsm)
Stacker capacity
(print tray capacity)
1,500 sheets (64 gsm), 1,280 sheets (20 lb Bond), 1,200 sheets (80 gsm)
Stacker stack height: 150 mm
Paper size MAX: 320×450 mm (12.6"×18")
With optional A4/Letter drum: 320×216 mm (12.6
″
x 8.5
″
)
MIN: 100×150 mm (3.95"×5.5")
50×150 mm is possible with following conditions
● No vertical registration adjustment available
● Paper lead sensor must be turned off
● A plastic guide required on the separator.
Paper weight
45–210 gsm / 12 lb Bond – 110 lb Index
Print speed 45–130 ppm 5 steps & Top Speed 150 ppm
Top Speed: 150 ppm for B4 / A4 / letter / Legal size (B4 or smaller)
With optional long paper unit: 22–65 ppm 5 steps & Top Speed 75 ppm
Zoom <A/B size spec>
100%
Preset reduction/enlargement:
A3: 61%, 70%, 81%, 86%, 115%, 122%, 141%, 163%
B4: 57%, 70%, 81%, 86%, 115%, 122%, 141%, 173%
Adjust X:Y Proportions 50%–500%
Margin adjust 90%–99%
Zoom: 50%–500%

1
Chapter 1 Specications
11
1
Model name DD5450 DD5440
<Inch size spec>
100%
Preset reduction/enlargement: 50%, 64%, 77%, 121%, 129%, 154%
Adjust X:Y Proportions 50%–500%
Margin adjust 90%–99%
Zoom: 50%–500%
Auto zoom: 50%, 60%, 64, 70%, 77%, 78%, 91%, 100%, (121%),
129%, 137%, 141%, 154%, (200%), 212%, 275%
Registration adjustment (Can be adjusted during a printing operation)
Vertical Registration
adjustable
15 mm Electrical, by 0.5 mm increment
Side Registration
adjustable 10 mm
Manual
Image modes Text (default), Photo, Text/Photo (2 types), Pencil, Screen (2 types)
Contrast control Scan density: 5 steps
Master density: 5 steps
Print density: 5 steps
Ink supply method Automatic control
Color print By replacing a drum unit
Master feeding Automatic
Master ejection Automatic
Used master capacity 55
Control panel 5.7 inch QVGA color TFT panel, Touch panel
LCD language English, French, German, Spanish, Italian, Russian, Japanese, Chinese
(simplied), Chinese (traditional), Korean Thai, Polish
Other function
Multiple exposure (2, 4, 8 & 16-up, custom: max 5×5=25-up)
Book shadow erasure (adjustable)
Condential safeguard
Panel setting memory (9 patterns of control panel settings can be stored.)
Status LED
90-degree rotation, 180-degree rotation
Optimize print (according to print speed)
Automatic pressure control (according to print speed)
Initial setting (paper size / print speed / document mode / scan density /
print density on booting / ink save mode
Master re-make (save the data from last master making)
Document density detection
Feed heavy weight paper mode
Repeat counter (default print number)
Fine start
Pre-print
Entry of sets & prints
Energy save mode (LCD turned off)
Automatic power off (power turned off by time specied)
Ink replenishing mode
Auto-reset
Online print (USB2.0 High-Speed) (For compatibility, please refer to
model/specications.)
Minimum print restriction (0–9999 sheets)
Edit function (trim & make-up)
Short-cut setting
Prints per set/ prints per document program
LCD brightness control
Clock setting
Buzzer setting

1
Chapter 1 Specications
12
1
- - Online print (Printer Driver) - -
Color separation (equipped in online printer driver) (via online only)
Multiple exposure (Printer Driver) (via online only, no compatibility with
Mac OS X)
(Multiple: 2, 4, 6, 8, 9, 16, 25-up/page,
Combine: 2, 4, 6, 8, 9, 16, 25-images/page)
Online
USB interface (standard USB2.0 High-Speed) (USB cable must be 3 m
or shorter)
• Windows XP, • Windows Vista, • Windows 7, • Windows 8 (Desktop apps only)
• Mac OS X Leopard 10.5 (Intel), • Mac OS X Snow Leopard 10.6,
• Mac OS X Lion 10.7
LAN interface (FS-100U2) (Optional)
• Windows XP, • Windows Vista, • Windows 7, • Windows 8 (Desktop apps only)
• Mac OS X Leopard 10.5 (Intel), • Mac OS X Snow Leopard 10.6,
• Mac OS X Lion 10.7
Option
ADF DF7010
Platen Cover PN7000
Spare drum A4 / Letter drum (for DD5450 only)
Tape dispenser (Type D1)
USB Slot, Printer Unit (USB), Printer Unit (NIC)
Power supply 100–240 V, 50/60 Hz, 200 W 2.4–1.0 A
Power consumption Master making: 78 W, Printing (Speed6): 220 W, Standing by: 8.0 W,
Energy saving: 0 W (When not connected online. When online: 4.8 W)
Energy consumption rate
When printing: 17.1 Wh/h, When not printing: 16.8 Wh/h
Noise level Sound pressure level
When standing by: 0 dB, When printing: 66.0 dB
Safety demands
Electrical Appliance and Material Safety Law, CE, CCC, EAC, FCC,
RoHS, Chinese RoHS, China environmental labeling, VCCI, UL, WEEE,
BSMI, Green Purchasing Law (Japan), Eco mark (Japan) Energy Start,
Color Universal Design, Green Mark (Taiwan)
Dimension
In use: 1401 (W) × 688 (D) × 1080 (H) mm
Folded: 770 (W) × 688 (D) × 1080 (H) mm
With optional ADF attached:
In use: 1401 (W) × 688 (D) × 1222 (H) mm
Folded: 770 (W) × 688 (D) × 1222 (H) mm
Weight 102 kg (when packed: 118 kg)
Operating
temperature 10–35 degrees (C) (50–95 degrees (F))
Model name DD5450 DD5440
Specications are subject to change without prior notice due to continual improvements.

1
Chapter 1 Dimensions
13
2 Dimensions
2
622
1405
555228
1080
710
980
688370
Unit: mm

1
Chapter 1 System Setup
14
3 System Setup
1. Before Installation
The machine and its optional equipment are set up as follows:
Cabinet (N/A)
Tape dispenser
type D1
ADF/Platen Cover
Lan Unit
Personal Computer
Drum Unit
: Documents prepared on a personal computer can be printed on this machine.
The PC interface kit is required to connect this machine to a personal computer.
:Option
REFERENCE
3
USB Slot

1
Chapter 1 Part Names and Their Functions
15
4 Part Names and Their Functions
1. Machine Exteriors
4
No. Name Function
1 Connector (PC) Use to connect a PC. *It varies by conguration.
2 Scanner button Press to open the scanner unit.
3 USB port Use to connect a USB ash drive. * It varies by conguration.
4Feed tray descend
switch Press to lower the feed tray.
5 Feed tray Load papers on this tray.
6 Support tray Use this when you set the large size papers.
7 Caster lock Locks the printer in position on the oor. Always lock the caster locks when
installing the printer.
8 Cabinet (Option) Place the printer on this cabinet. *It varies by conguration.
9 Front cover Open to replace ink pack and drum unit, etc.
10 Control panel Displays operations and status, and sets functions.
11 Scale Put the document along this scale.
12 Glass The document is placed on this glass.
13 Scanner cover Keeps the document in contact with the document glass plate.
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2
3
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6
7

1
Chapter 1 Part Names and Their Functions
16
2. Inside of Machine
4
No. Name Function
14 Drum removal
button Pressing this button rotates the drum and stops it in position to be
removed. And then LED lights up.
15 Master cover
open lever Press to open the master cover. Used when replacing the
master, etc.
16 Feed pressure
adjuster lever Adjusts paper feed pressure according to paper thickness.
17 Separation
pressure adjuster
knob Adjusts separation pressure according to paper thickness.
18 Side separator
height adjuster
knob
Adjusts side separator height according to paper thickness.
19 Side guide Slide to match the width of the paper.
20 Side guide lever Adjusts the side guides to paper size.
21
Feed tray
horizontal
registration
adjuster dial
Use to adjust the print position (horizontal).
22 Scanner unit Open to set the roll master.
Inside of the master cover area.
Master cover
Roll master Cutter
Drum release lever
Ink holder
Ink pack
Paper feed rollers
22
14
16
17
18
19
20
21
15

1
Chapter 1 Part Names and Their Functions
17
3. Outside/Inside of Print Output Side
4
No. Name Function
23 Master ejection
box open button Press to open the master ejection box.
24 Paper eject switch Press and hold to rotate the drum for the set time.
Use to remove paper jams, etc.
25 Jump plate lever Slide to match the size of printed paper.
26 Master ejection
box cover open
lever
Press to open the master ejection box cover.
Use when disposing of used master, etc.
27 Master ejection
core Use when disposing of used master.
28 Master ejection
box cover Open when disposing of used master.
Master ejection section
23
24
25
26
28
27Top fan

1
Chapter 1 Part Names and Their Functions
18
4
No. Name Function
29 Key card slot Slot a key card. *It varies by conguration.
30 Side fence Slide to match the size of printed paper.
31 Paper stopper Slide to match the size of printed paper.
32 Print tray Holds printed papers.
33 Connectors
(Optional) Use to connect options.
29
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31
32
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