Ricoh S-C4.5, D115, D116 Field Service Manual
Model S-C4.5
Machine Code: D115/D116
Field Service Manual
26 November, 2010
Important Safety Notices
Prevention of Physical Injury
1. Be sure that the power cord is unplugged before disassembling or assembling parts of the copier or
peripherals.
2. The wall outlet should be near the copier and easily accessible.
3. Note that electrical voltage is supplied to some components of the copier and the paper tray unit even
while the main power switch is off.
4. 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.
5. If you start a job before the copier completes the warm-up or initializing period, keep hands away
from the mechanical and electrical components until job execution has started. The copier will start
making copies as soon as warm-up or initialization is finished.
6. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating.
Be careful to avoid touching those components with your bare hands.
Health Safety Conditions
Toner and developer are nontoxic, but getting either of these into your eyes may cause temporary eye
discomfort. Try to remove with eye drops or flush with water. If material remains in eye or if discomfort
continues, get medical attention.
Observance of Electrical Safety Standards
The copier and its peripherals must be installed and maintained by a customer service representative who
has completed the training course on those relevant models.
• Keep the machine away from flammable liquids, gases, and aerosols. A fire or an explosion might
occur if this precaution is not observed.
Lithium Batteries
Incorrect replacement of lithium battery(s) on the FCU, controller board and memory board unit may pose
risk of explosion. Replace only with the same type or with an equivalent type recommended by the
manufacturer. Discard used batteries in accordance with the manufacturer's instructions.
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Safe and Ecological Disposal
1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly if exposed to an open
flame.
2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations.
(These are nontoxic 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.
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 not specified in this manual, or performance of adjustments or procedures not specified
in this manual, may result in hazardous radiation exposure.
WARNING FOR LASER UNIT
• Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser
beams can seriously damage your eyes.
CAUTION MARKING:
2
Symbols and Abbreviations
This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations is
as follows:
See or Refer to
Clip ring
E-ring
Screw
Connector
Clamp
SEF Short Edge Feed
LEF Long Edge Feed
- Core Technology manual
Cautions, Notes, etc.
The following headings provide special information:
• Failure to obey warning information could result in serious injury or death.
• Obey these guidelines to ensure safe operation and prevent minor injuries.
• This information provides tips and advice about how to best service the machine.
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TABLE OF CONTENTS
Important Safety Notices...................................................................................................................................1
Prevention of Physical Injury..........................................................................................................................1
Health Safety Conditions...............................................................................................................................1
Observance of Electrical Safety Standards.................................................................................................1
Lithium Batteries..............................................................................................................................................1
Safe and Ecological Disposal.......................................................................................................................2
Laser Safety.....................................................................................................................................................2
Symbols and Abbreviations
...............................................................................................................................3
1. Product Information
Specifications......................................................................................................................................................9
Machine Configuration....................................................................................................................................10
Mainframe
....................................................................................................................................................10
System Components....................................................................................................................................11
Overview..........................................................................................................................................................12
Component Layout.......................................................................................................................................12
Electrical Components.................................................................................................................................14
Paper Path....................................................................................................................................................17
Drive Layout..................................................................................................................................................18
Guidance for Those Who are Familiar with Predecessor Products..............................................................20
2. Installation
Installation Cautions.........................................................................................................................................21
Installation Requirements.................................................................................................................................22
Environment..................................................................................................................................................22
Machine Level..............................................................................................................................................22
Minimum Operational Space Requirements.............................................................................................23
Power Requirements....................................................................................................................................24
Copier...............................................................................................................................................................25
Accessory Check..........................................................................................................................................25
Optional Handset
........................................................................................................................................32
Paper Tray Unit (D567)...................................................................................................................................34
Accessory Check..........................................................................................................................................34
Installation Procedure..................................................................................................................................34
Paper Tray Unit Heater....................................................................................................................................37
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Accessory Check..........................................................................................................................................37
Installation Procedure..................................................................................................................................38
USB 2.0/SD Slot Type B.................................................................................................................................45
Accessory Check..........................................................................................................................................45
Installation Procedure..................................................................................................................................45
Testing the SD Card/USB Slot....................................................................................................................51
Optional Paper Tray Grip Handle..................................................................................................................53
Accessories...................................................................................................................................................53
Controller Options............................................................................................................................................55
Overview......................................................................................................................................................55
Wireless LAN (IEEE 802.11a/g) Installation...........................................................................................55
IEEE 1284 Installation.................................................................................................................................57
VM Card Type L (D467).............................................................................................................................58
Gigabit Ethernet...........................................................................................................................................59
HDD Option (D577)...................................................................................................................................61
3. Preventive Maintenance
Maintenance Tables........................................................................................................................................67
How to Clear the PM Counter.........................................................................................................................68
4. Replacement and Adjustment
Precautions........................................................................................................................................................69
General.........................................................................................................................................................69
Lithium Batteries............................................................................................................................................69
Halogen-free Cable....................................................................................................................................69
Static Electricity............................................................................................................................................69
Special Tools and Lubricants...........................................................................................................................70
Exterior Covers and Operation Panel............................................................................................................71
Rear Cover...................................................................................................................................................71
Copy Tray.....................................................................................................................................................71
Operation Panel and Upper Covers..........................................................................................................72
Right Door.....................................................................................................................................................73
Bypass Tray..................................................................................................................................................74
Platen Cover Sensor....................................................................................................................................74
Scanner Unit.....................................................................................................................................................75
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Exposure Glass............................................................................................................................................75
Lens Block.....................................................................................................................................................75
Exposure Lamp, Lamp Stabilizer Board.....................................................................................................76
Scanner Motor.............................................................................................................................................77
Scanner HP Sensor......................................................................................................................................79
Scanner Alignment Adjustment...................................................................................................................79
Fusing................................................................................................................................................................81
Fusing Unit....................................................................................................................................................81
Exit Sensor....................................................................................................................................................82
Hot Roller Stripper Pawls.............................................................................................................................82
Hot Roller and Fusing Lamp........................................................................................................................83
Thermoswitches and Thermistor..................................................................................................................85
Pressure Roller..............................................................................................................................................86
Checking the NIP band...............................................................................................................................87
PCU and Quenching Lamp.............................................................................................................................88
PCU...............................................................................................................................................................88
Quenching Lamp..........................................................................................................................................89
Exhaust Fan and Main Motor.........................................................................................................................90
Exhaust Fan..................................................................................................................................................90
Main Motor..................................................................................................................................................91
Paper Feed........................................................................................................................................................92
Paper Feed Roller and Friction Pad............................................................................................................92
Paper End Sensor.........................................................................................................................................92
Registration Sensor......................................................................................................................................93
Bypass Paper End Sensor...........................................................................................................................94
Bypass Feed Roller......................................................................................................................................94
Bypass Feed Clutch and Friction Pad.........................................................................................................95
Paper Feed and Registration Clutches.......................................................................................................96
Image Transfer..................................................................................................................................................98
Transfer Roller..............................................................................................................................................98
ID Sensor and Duplex Roller.......................................................................................................................99
Discharge plate.........................................................................................................................................100
BICU and Controller Board..........................................................................................................................101
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BICU...........................................................................................................................................................101
Controller Board........................................................................................................................................102
Other Replacements......................................................................................................................................108
Duplex Motor............................................................................................................................................108
High-Voltage Power Supply Board ........................................................................................................109
PSU.............................................................................................................................................................110
Contact-Release Solenoid........................................................................................................................111
Toner Supply Clutch..................................................................................................................................111
FCU.............................................................................................................................................................112
Laser Unit........................................................................................................................................................115
Location of the Caution Decal..................................................................................................................115
Laser Unit....................................................................................................................................................115
LD Unit and Polygon Mirror Motor..........................................................................................................116
ARDF...............................................................................................................................................................117
ARDF...........................................................................................................................................................117
DF Rear Cover...........................................................................................................................................118
Original Feed Unit.....................................................................................................................................118
Separation Roller.......................................................................................................................................119
DF Drive Board..........................................................................................................................................119
Original Set and DF Inverter Sensor........................................................................................................120
DF Registration and DF Exit Sensor..........................................................................................................121
DF Feed Motor..........................................................................................................................................122
DF Transport Motor...................................................................................................................................123
DF Feed Clutch..........................................................................................................................................124
Adjusting Copy Image Area.........................................................................................................................125
Printing........................................................................................................................................................125
Scanning....................................................................................................................................................127
DF Image Adjustment................................................................................................................................130
5. System Maintenance Reference
Service Program.............................................................................................................................................133
SP Tables....................................................................................................................................................133
Using SP and SSP Modes.........................................................................................................................133
Using SP Mode..............................................................................................................................................136
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NVRAM Data Upload/Download..........................................................................................................136
Firmware Update Procedure....................................................................................................................137
Test Pattern Print (SP5-902-001).............................................................................................................142
Memory Clear...........................................................................................................................................145
Machine No. Setting (SP5-811-001).....................................................................................................146
SMC Print (SP5-990)................................................................................................................................147
ID Sensor Error Analysis (SP2-221)........................................................................................................147
Fax Service Tables.........................................................................................................................................149
6. Troubleshooting
SC Tables.......................................................................................................................................................151
Summary....................................................................................................................................................151
Engine SC Code Descriptions..................................................................................................................152
GW SC Code Descriptions......................................................................................................................160
Electrical Component Defects.......................................................................................................................177
Sensor/Switch...........................................................................................................................................177
Blown Fuse Conditions..............................................................................................................................178
BICU LED Display......................................................................................................................................179
Card Save Function.......................................................................................................................................180
Overview....................................................................................................................................................180
Procedure...................................................................................................................................................180
Fax Troubleshooting Guide..........................................................................................................................183
7. Energy Saving
Energy Save...................................................................................................................................................185
Energy Saver Modes................................................................................................................................185
Energy Save Effectiveness........................................................................................................................186
Paper Save.....................................................................................................................................................188
Effectiveness of Duplex/Combine Function............................................................................................188
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1. Product Information
Specifications
See "Appendices" for the following information:
• General Specifications
•
Supported Paper Sizes
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1
Machine Configuration
Mainframe
Standard Component Machine Code Remarks
1 Copier [A] D115/D116 -
2 GW Controller Board [C] - Standard
3 ARDF [D] - Standard
4 Fax Unit [E] - Standard
Optional Components Machine Code Remarks
5 500-sheet Paper Feed Unit [B] D567 Two can be used.
6 Handset [F] B433 NA only
1. Product Information
10
1
System Components
Item Machine Code Remarks
Controller Box - [A] Standard
USB2.0/SD Slot D467 [B] Option only for D115
Printer/Scanner unit D468 [C]
SD card for the Printer/Scanner Unit
Standard only for D115
VM Card D467 [D] In SD slot 2 (lower)
IEEE 1284 B679 [E]
One from the fourWireless LAN M344 [E]
Gigabit Ethernet Board G874 [E]
HDD with Security Card D577 [F]
Merge the Security Card into the Printer/
Scanner SD card.
Machine Configuration
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1
Overview
Component Layout
Mainframe
1. Exposure Lamp 20. ID (Image Density) Sensor
2. 1st Scanner 21. Registration Roller
3. CCD (on SBU) 22. Registration Sensor
4. Lens Block 23. Bypass Tray
5. 2nd Scanner 24. Bypass Paper Feed Roller
6. 2nd Mirror 25. Bypass Paper End Sensor
7. 3rd Mirror 26. Bypass Friction Pad
1. Product Information
12
1
8. Platen Cover Sensor 27. Mixing Augers
9. Exposure Glass 28. (Main) Friction Pad
10. Exit Roller 29. Paper Feed Roller
11. Exit Sensor 30. Paper End Sensor
12. Scanner Motor 31. TD (Toner Density) Sensor
13. Hot Roller 32. Bottom Plate
14. Pressure Roller 33. Polygon Mirror Motor
15. Cleaning Blade 34. Laser Unit
16. OPC Drum 35. Toner Supply Bottle (or THM)
17. Discharge Plate 36. Toner Collection Coil
18. Transfer Roller 37. Scanner HP Sensor
19. Development Roller
ARDF
1. Separation Roller 7. Exit Roller
2. Paper Feed Roller 8. Exit Sensor
3. Pick-up Roller 9. Registration Sensor
4. Original Set Sensor 10. Registration Roller
5. Inverter Roller 11. Inverter Sensor
Overview
13
1
6. Junction Gate 12. Transport Roller
Electrical Components
Electrical Components 1
1. Lens Block 11. ID (Image Density) Sensor
2. Exposure Lamp 12. Registration Sensor
3. Lamp Stabilizer Board 13. Paper End Sensor
4. Scanner HP Sensor 14. Toner Density Sensor
5. Platen Cover Sensor 15. Bypass Paper End Sensor
1. Product Information
14
1
6. Scanner Motor 16. Right Door Safety Switch
7. Mechanical Counter 17. Front Door Safety Switch
8. Polygon Mirror Motor 18. Quenching Lamp
9. LD Unit 19. High-Voltage Power Supply Board
10. Exit Sensor 20. Operation Panel Board
Electrical Components 2
1. Duplex Motor 7. Paper Feed Clutch
2. Exhaust Fan 8. Toner Supply Clutch
3. PSU 9. Bypass Feed Clutch
4. Controller Board (GW) 10. Registration Clutch
5. BICU 11. Fusing Solenoid
6. Main Motor
Overview
15
1
ARDF
1. DF Feed Clutch 6. DF Feed Motor
2. Registration Sensor 7. Inverter Sensor
3. Exit Sensor 8. DF Drive Board
4. Left Cover Sensor 9. Junction Gate Solenoid
5. DF Transport Motor 10. Original Set Sensor
1. Product Information
16
1
Paper Path
1. Original Registration Sensor (Document Feeder)
2. Exit Senor (Document Feeder)
3. Inverter Sensor (Document Feeder)
4. Original Set Sensor (Document Feeder)
5. Exit Sensor
6. Paper Path Sensor
7. Registration Sensor
8. By-pass Paper End Sensor
9. Paper Feed Sensor (Optional Tray)
Overview
17
1
10. Paper End Sensor (Optional Tray)
11. Paper End Sensor
Drive Layout
Mainframe
1. Scanner Motor 7. Bypass Feed Clutch (By-pass Tray)
2. Duplex motor 8. Registration Clutch
3. Exit Roller 9. Developer Driver Gear
4. Toner Bottle Clutch 10. Drum Drive Gear
5. Main Motor 11. One-way Gear (Duplex Unit)
6. Paper Feed Clutch 12. Fusing Drive Gear
1. Product Information
18
1
ARDF
1. DF Feed Motor
2. Feed Roller
3. Pick-up Roller
4. Inverter Roller
5. DF Feed Clutch
6. Separation Roller
7. Transport Roller
8. DF Transport Motor
9. Exit Roller
10. Registration Roller
• DF Feed Motor: Drives the feed, separation, pick-up, and transport and inverter rollers.
• DF Transport Motor: Drives the registration and exit rollers.
Overview
19
1
Guidance for Those Who are Familiar with
Predecessor Products
The D115/D116
range of machines is the successor model to the D068/D069 range of machines. If you
have experience with the predecessor line, the following information may be of help when you read this
manual.
Differences from Predecessor Products
D115/D116 D068/D069
Security Card (HDD
Encryption and Data
Overwrite Security Unit)
Standard only for D115 Option only for D069
Copying Speed
20 cpm: Memory copy
16 cpm: ADF 1 to 1
17cpm: Memory copy
16cpm: ADF 1 to 1
• The following parts are unique for D115/D116. When replacing the following parts, use the parts
specified for each model. DO NOT mix up the following parts for D067/D068/D069/D072 and
D115/D116. Otherwise, both of the machine operation and output quality are not guaranteed.
1.
BICU with Controller Unit
•
If wrong part is installed, an image is not correctly copied on outputs with the DF one to one
copy.
2. Laser Unit (Writing Unit)
• If wrong part is installed, a copied image might be too dark or light on outputs.
3. Polygon Scanner Motor (A part of Laser Unit)
• If wrong part is installed, a copied image might be too dark or light on outputs or an SC might
be issued.
4. Model Name Plate
5. Mechanical Counter (S-C4: Assembled, S-C4.5: Service optional part)
1. Product Information
20
1
2. Installation
Installation Cautions
• Before installing an optional unit, do the following:
• Print out all messages stored in the memory, all user-programmed items, and a system parameter list.
• If there is a printer option on the machine, print out all data in the printer buffer.
• Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.
21
2
Installation Requirements
Environment
–Temperature and Humidity Chart–
• Temperature Range: 10°C to 32°C (50°F to 89.6°F)
• Humidity Range: 15% to 80% RH
•
Ambient Illumination: Less than 1,500 lux (Do not expose to direct sunlight.)
• Ventilation: Room air should turn over at least 3 times/hr/person
• Ambient Dust: Less than 0.1 mg/m
3
• Do not install the machine where it will be exposed to direct sunlight or to direct airflow (from a fan,
air conditioner, air cleaner, etc.).
• Do not install the machine where it will be exposed to corrosive gas.
• Place the machine on a firm and level base.
• Do not install the machine where it may be subjected to strong vibration.
Machine Level
Front to back: Within 5 mm (0.2") of level
2. Installation
22
2
Right to left: Within 5 mm (0.2") of level
Minimum Operational Space Requirements
Place the machine near the power source, providing clearance as shown.
A: Front – 750 mm (29.6")
B: Left – 100 mm (3.9")
C: Rear – 100 mm (3.9")
D: Right – 100 mm (3.9")
E: Depth – 450 mm (17.7")
F: Width – 485 mm (19.1")
• The 750-mm front space indicated above is sufficient to allow the paper tray to be pulled out.
Additional space is required to allow an operator to stand at the front of the machine.
Installation Requirements
23
2
• Actual minimum space requirement for left, rear, and right sides is 10mm (0.4") each, but note that
this will not allow room for opening of the bypass tray, right door or ARDF unit.
Power Requirements
• Make sure that the wall outlet is near the machine and easily accessible. After completing installation,
make sure the plug fits firmly into the outlet.
•
Avoid multiple connections to the same power outlet.
• Be sure to ground the machine.
Input voltage:
North America:
110 – 120 V, 60 Hz, 8 A
Europe: 220 – 240 V, 50/60 Hz, 4 A
Image quality guaranteed at rated voltage ± 10%.
Operation guaranteed at rated voltage ± 15%.
2. Installation
24
2
Copier
Accessory Check
Printer/Scanner and Fax Model (D115)/ Fax Model (D116)
Description Q’ty
NECR (-17) 1
EU Safety Sheet (-27) 1
Paper Size Decal (-17, -27, -29) 1
Operating Instructions – Book (-17, -29) 1 set
Operating Instructions – CD ROM (-17, -29) 1 set
Handset Bracket (-17) 1
Screw for Handset Bracket (-17) 2
Modular Cable (-17) 1
Connecter Cover for TEL (-17) 1
Ferrite Core for TEL Line 1
Ferrite Core (-17, -27, -29) 1
EMC Caution Sheet (-27) 1
EULA Sheet (-17, -27, -29) 1
Caution Decal (-17, -27, -29) 1
Installation Procedure
• Make sure that the copier remains unplugged during installation.
Copier
25
2
1. Remove the all strips of tape.
2. Remove the bag [A], SMC and A3 sheet of paper on the exposure glass.
3. Remove the spacing wedge [B].
2. Installation
26
2
4. Remove the three scanner lock pins. (A tag is hanging from each pin.) To remove: Grasp the base of
the pin [C], turn the pin 90 degrees, and pull it down and out.
5.
Remove the tags from the pins.
6. Break each pin off the base [C].
7. Discard the pin part [D].
8. Set each base [C] back into its original hole, turning it 90° to lock it into place. (Be sure to do this for
all three pins.)
9. Open the front door [E].
10. Lift lever
[F], press in on latch [G] and pull the bottle holder [H] out. (You do not need to pull it completely
out of the machine.)
11. Take a new bottle of toner, and shake it several times.
Copier
27
2
12. Remove the outer cap [I].
• Do not remove the inner cap [J].
13. Load the bottle on the holder.
• Do not forcefully turn the toner bottle on the holder. After you turn on the main power switch, the
copier sets the bottle in place.
14.
Push the bottle holder back into the machine.
15. Press the latch [K] down to lock the holder.
16. Remove the padding [L].
2. Installation
28
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