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Ricoh D115 Service Training

Ricoh D115 Service Training

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D115/D116 / S-C4.5
D115/D116
Service Training
Product Overview
S-C4.5
Slide 1
Draft started: 19 November 2010
First draft completed: 22 November 2010
1

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Summary of Contents for Ricoh D115

  • Page 1 D115/D116 / S-C4.5 D115/D116 Service Training Product Overview S-C4.5 Slide 1 Draft started: 19 November 2010 First draft completed: 22 November 2010...

  • Page 2: Machine Appearance

    D115/D116 / S-C4.5 Machine Appearance Auto-Reverse Document Feeder (ARDF) Exit Tray Standard Tray Slide 2...
  • Page 3 D115/D116 / S-C4.5 Machine Appearance (Rear) USB 2.0 SD Slot (D467) Tel & Line Power Switch Slide 3...

  • Page 4: Operation Panel

    D115/D116 / S-C4.5 Operation Panel FAX functions on left side of panel above are standard on D115 and D116 models. Note that unlabeled section on left is labeled with relevant language for region in which machine is to be used.
  • Page 5 D115/D116 / S-C4.5 New for this Model The major technical enhancement for the D115/D116 is Increased copy speed 17 cpm 20 cpm Slide 5...
  • Page 6 D115/D116 / S-C4.5 Who Will Use This Model Small office users (3-10 people) or individuals (as a personal business machine). Mid to large sized offices (10-50 people) as a work group division printer/scanner. Mid to large sized offices as a business personal machine.

  • Page 7: Machine Configuration

    D115/D116 / S-C4.5 ARDF (B872) Machine Configuration - 1/3 ARDF (B872) Standard on D115/D116 500-Sheet Paper Tray Unit (D567) Main Machine (D115/D116) Two may be used together. Note that - when using two D567 units - a tray heater may only be...
  • Page 8 D115/D116 / S-C4.5 Machine Configuration - 2/3 (F/SPF: D116/D115 - 1/2) ARDF Fax Unit Handset (B872) (B433) GW Controller Board Main Machine (D115/D116) 500-Sheet D567 Paper Tray Unit Slide 8...
  • Page 9 D115/D116 / S-C4.5 Machine Configuration - 3/3 (F/SPF: D116/D115 - 2/2) Line USB-A Slot-1 I/F Slot (covered) Slot-2 USB-B Ethernet Optional HDD Connection MBU - Memory Board Unit / FCU - Fax Control Unit / EGB - Main Engine Board HDD - Hard Disk Drive / RAM - Random Access Memory Be sure to remove all thirteen cover screws to access the EGB, MBU, FCU, &...

  • Page 10: System Components

    D115/D116 / S-C4.5 System Components USB 2.0 SD Slot (D467-03) [A]: One of following: HDD Encryption Unit (D377) [B] VM Card (D467) HDD (D467-04) Firmware updates [C]: One of following: Slot-1 IEEE 1234 (B679) Wireless LAN (M344) Slot-2 Gigabit Ethernet...
  • Page 11 D115/D116 / S-C4.5 Controller Board Access Open right door. Remove: Scanner Upper Left Cover Rear cover Scanner upper left cover See FSM for more details Right Door Rear Cover Slide 11...
  • Page 12 D115/D116 / S-C4.5 Optional HDD - 1/3 GW Controller Box Right Door To install the HDD Unit (Hard Disk Drive), first remove the rear cover of the machine, and then the GW Controller Box cover (thirteen screws). Slide 12...
  • Page 13 D115/D116 / S-C4.5 GW Controller Box (Cover Removed) Optional HDD - 2/3 Note: Before plugging in the optional HDD unit, the screw indicated at left must first be removed. After removing the indicated screw, plug in the HDD unit and then reattach the screw...
  • Page 14 D115/D116 / S-C4.5 Optional HDD - 3/3 When attaching the two HDD Unit screws from the end of the GW controller box, attach the screw into the smaller hole first, and the larger hole secondly. This allows for adjustment Smaller Hole and easier attachment.

  • Page 15: Service Training

    D115/D116 / S-C4.5 D115/D116 Service Training Specifications Slide 15...

  • Page 16: General Specifications

    D115/D116 / S-C4.5 General Specifications Configuration: Desktop Copy Process: Laser scanning & electrophotographic printing Copy speed: 20 ppm A4 / 8½" x 11"; 100% (printing from memory) Warm up: (basic) 10 seconds / (other) approximately 30 seconds First copy time: 7.5 seconds or less...
  • Page 17 D115/D116 / S-C4.5 More Specifications For a more detailed description of machine’s specifications, refer to specifications section of FSM (Field Service Manual), noting in particular the following: Copy paper size Copy paper weight Power consumption and machine dimensions Copy paper capacity...
  • Page 18 D115/D116 / S-C4.5 Machine Configuration - 1/2 There are two machines in this series – D115 and D116. Machine configuration varies depending on version. Examine machine configurations in specifications section of FSM for more details, briefly: D116 - Fax Model (F)
  • Page 19 D115/D116 / S-C4.5 Machine Configuration - 2/2 B872 - ARDF D567 - Paper Tray Unit D467-03 - USB-2.0/SD Slot - Type B (only for D069) D577 - HDD Option, Type 201 B446-83 - PCU (Photo Conductor Unit), Type 1515 D461 - Accessibility Handle, Type C...
  • Page 20 D115/D116 / S-C4.5 D115/D116 Service Training Installation Slide 20...

  • Page 21: Before You Start

    D115/D116 / S-C4.5 Before You Start Read Installation chapter of FSM before installing machine, noting: Environment (ventilation, temperature range, etc.) Space and power requirements. Accessory check (for model you will install). Before installing optional units, be sure to: Switch machine off and remove power cord and network cable.

  • Page 22: Installation

    D115/D116 / S-C4.5 Installation Install machine. See "Installation" of FSM. Install optional paper tray unit and optional paper tray unit heater. Be sure to keep in mind the following when you install machine and paper tray unit: You do not need to pull toner bottle holder completely out of machine.

  • Page 23: Service Program Mode

    D115/D116 / S-C4.5 Service Program Mode Standard maintenance work requires utilization of SP modes. There are two kinds of SP modes for this machine: SP Mode (Service Program mode) SSP Mode (Special Service Program mode) » SP & SSP modes are for service technician only. Do not let users access SP &...
  • Page 24 D115/D116 / S-C4.5 D115/D116 Service Training Machine Overview and Machine Operation Slide 24...

  • Page 25: Component Layout

    D115/D116 / S-C4.5 Component Layout Exposure Lamp Scanner Motor 1st Scanner CCD (on SBU) Lens Block 2nd Scanner Pressure Roller Toner Supply Bottle OPC Drum Bypass Paper Feed Roller Polygon Mirror Motor Laser Unit For more details on component parts, see the FSM (Field Service Manual).
  • Page 26 D115/D116 / S-C4.5 Paper Path Paper Path Paper path is indicated with heavy black lines and arrows. ARDF is optional on some models For a full listing of all major components used in paper path, see full component list in FSM.
  • Page 27 D115/D116 / S-C4.5 Drive Layout Scanner Motor Duplex Motor Exit Roller Toner Bottle Clutch Main Motor Paper Feed Clutch Slide 27 Drive Layout The slide shows some of the drive components. For more details and information, refer to the FSM.

  • Page 28: Block Diagram

    D115/D116 / S-C4.5 Block Diagram For additional details, refer to the FSM (Field Service Manual) Slide 28...
  • Page 29 D115/D116 / S-C4.5 Block Diagram (for GW Controller) For additional details, refer to the FSM. Slide 29...
  • Page 30 D115/D116 / S-C4.5 NVRAM Upload/Download This section depends on which model you have. There are two different procedures. SP5-824-1 (NVRAM Upload) - From the BICU to a flash memory card SP5-825-1 (NVRAM Download) - From a flash memory card to the BICU...
  • Page 31 D115/D116 / S-C4.5 Adjusting Copy Image Adjust copy image area at these times: After clearing engine data (SP-5801-2). If you replace any of these: First scanner or second scanner, lens block, scanner motor, polygon mirror motor, paper tray. Do adjustments as outlined in "Adjusting Copy Image Area"...
  • Page 32 D115/D116 / S-C4.5 Operating Instructions While these are user operations, service technicians should also be generally familiar with them. Read these if you’re not already familiar with them: User Tools: General settings Placing originals and copying Slide 32...
  • Page 33 D115/D116 / S-C4.5 D115/D116 Service Training Scanning and Image Processing Slide 33...

  • Page 34: Scanning Overview

    D115/D116 / S-C4.5 Scanning - Overview Second Mirror First Scanner Second Scanner First Mirror Scanner Motor Third Mirror Lens HP sensor makes sure scanner is at home position. To copy, original is illuminated by xenon exposure lamp. Then 1st, 2nd, and 3rd mirrors move reflected light to lens block. After this, lens transmits it to CCD.
  • Page 35 D115/D116 / S-C4.5 Scanner Drive Timing Belt First scanner is attached to timing belts, which drive 2nd scanner with 2nd scanner's pulleys. First Scanner Timing Belt Shaft Second Scanner Scanner Drive Pulley When scanning in book mode, 2nd scanner moves at half speed of 1st scanner. (Scanner speed is faster for reduction printing, and slower for enlargement printing.)
  • Page 36 D115/D116 / S-C4.5 Image Processing - Overview Slide 36...
  • Page 37 D115/D116 / S-C4.5 Image Processing - Overview Changing Modes: You cannot switch modes at these times: » When accessing user tools. » When scanning an original Practice switching modes and getting multi-access. (Refer to Operating Instructions, General Settings Guide) To learn more about image processing, refer to the...
  • Page 38 D115/D116 / S-C4.5 D115/D116 Service Training Laser Exposure and PCU Slide 38...
  • Page 39 D115/D116 / S-C4.5 Laser Unit Overview Synchronization Detector Lens LD Shutter LD Unit LD unit controls laser output and synchronization. The LD shutter blocks laser-beam path if toner bottle holder is unlatched. Slide 39...

  • Page 40: Ld Safety Switches

    D115/D116 / S-C4.5 LD Safety Switches BICU +5VS +5VE +24V M61880FP LD Drive Board +5VS Front/Right Door Switches Safety switches are installed at front and right doors. Machine will cut power to LD drive board if either door is opened. Corresponding switch cuts power supply (+5VS) to laser diode.
  • Page 41 D115/D116 / S-C4.5 Photoconductor Unit (PCU) -Overview Cleaning Roller Toner Collection Coil Charge Roller OPC Drum Doctor Blade Mixing Auger 1 Development Roller Mixing Auger 2 TD Sensor Slide 41...
  • Page 42 D115/D116 / S-C4.5 Main Motor Drum Drive Drum Drive Shaft Main motor drives Drum the drum through a series of gears and the drum drive shaft. Slide 42...

  • Page 43: Drum Charge

    D115/D116 / S-C4.5 Drum Charge Spring High Voltage Supply Board Drum Charge Roller Wire OPC drum is charged via a contact charge roller. Drum charge roller stays in contact with drum, giving a charge of –900 V on drum surface.

  • Page 44: Charge Roller Voltage Correction

    D115/D116 / S-C4.5 Charge Roller Voltage Correction ID Sensor 4.0 cm Pattern 1.5 cm Development Bias Pattern Voltage transfer from 2 cm ID Sensor Pattern charge roller to drum decreases as ambient temperature and humidity Sub-scan Direction increase. Machine checks Charge Voltage –1650 V...
  • Page 45 D115/D116 / S-C4.5 Charge Roller Cleaning Cleaning Roller A cleaning roller cleans charge roller. You do not need to replace or clean this roller. Slide 45...
  • Page 46 D115/D116 / S-C4.5 New PCU Detection Shipped State PCU Gear Machine automatically detects a new PCU at these times: At time of copier installation When a replacement PCU is installed A new PCU must be initialized before it can be used.
  • Page 47 D115/D116 / S-C4.5 D115/D116 Service Training Development Slide 47...
  • Page 48 D115/D116 / S-C4.5 Development Overview Two mixing augers mix the developer (carrier/toner mix). TD (toner density) sensor and the ID (image density) sensor (shown in a red circle) are used to control copy image density. Development Roller Mixing Auger 1...
  • Page 49 D115/D116 / S-C4.5 Development Bias High Voltage Supply Board Development Roller Toner gets to areas with smallest negative charge. Drum has a large negative charge (-900V). Latent image on drum has a small negative charge (-140 ± 50V). High voltage supply board gives a –600 V bias to development roller.

  • Page 50: Toner Supply

    D115/D116 / S-C4.5 Toner Supply Toner path is same for all models. There are two sources of toner: new toner and recycled toner. Toner A shutter is pushed open by PCU body Collection when a toner bottle is Coil Slit set in machine.

  • Page 51: Toner Bottle

    D115/D116 / S-C4.5 Toner Bottle Lever Toner bottle is same for all models. Toner shutter opens when toner bottle is set into machine. Bottle cap opens when lever is Shutter pressed. Spiral grooves move toner out when bottle rotates. Slide 51...

  • Page 52: Toner Density Control

    D115/D116 / S-C4.5 Toner Density Control Toner concentration in developer is controlled with these values: Vts: TD sensor initial set of 1.25V. (Used as reference voltage when Vref is not available). Vref: Toner supply reference voltage (calculated value; periodically updated).
  • Page 53 D115/D116 / S-C4.5 Toner Errors Sensor errors occur at these times: ID Sensor: Vsg ≤ 2.5 (when Vsg is read) Vsg < 3.5 (at maximum power) Vsp ≥ 2.5 Vt ≥ 2.64 or Vt < 0.20 You can see current readings with SP 2221 TD Sensor TD <...

  • Page 54: Toner Near End/End Detection

    D115/D116 / S-C4.5 Toner Near End/End Detection Machine will show toner near end at these times: Vt is at Level-6 five times in succession. Vt > 1.85 five times in succession. Machine will show toner end at these times: VT is >= Level-6 or VT> 1.85 n times in a row.
  • Page 55 D115/D116 / S-C4.5 Toner Drum Cleaning & Collection Coil Toner Recycling Cleaning Blade Cleaning blade gets leftover toner from drum after an image transfer. Then toner piles on blade. Toner collect coil moves toner Slit from pile and puts it onto chute.
  • Page 56 D115/D116 / S-C4.5 SP Modes SP 2214: Developer initialization. SP 2802: Forced developer churning. SP 2908: Forced toner supply. SP 2921: Toner supply mode. SP 2926: Standard Vt. SP 2928: Toner end clear Slide 56...

  • Page 57: Replacement And Adjustment

    D115/D116 / S-C4.5 Replacement and Adjustment Do this removal procedure: See “Toner Supply Clutch” in the FSM Preventive Maintenance. You must clean toner bottle holder after you replace the PCU. Learn more: Core Technology Manual Development process Development bias Toner supply...
  • Page 58 D115/D116 / S-C4.5 D115/D116 Service Training Paper Feed Slide 58...
  • Page 59 D115/D116 / S-C4.5 Paper Feed - Overview Exit Roller Paper Feed Roller See the FSM for a more complete list of components. Slide 59...
  • Page 60 D115/D116 / S-C4.5 Drive Mechanism - From Paper Tray Main motor drives gears on Main Motor registration clutch and paper feed clutch. These clutches transmit motion to registration roller and paper feed roller. Registration Roller Registration Clutch Paper Feed Clutch...
  • Page 61 D115/D116 / S-C4.5 Drive Mechanism - Bypass Tray Main Motor Registration Clutch Bypass Feed Clutch Main motor drives gears of registration clutch and bypass feed clutch. Bypass feed clutch moves bypass feed roller. Bypass Feed Roller Slide 61...

  • Page 62: Paper Feed And Separation

    D115/D116 / S-C4.5 Paper Feed And Separation Machine uses a friction-pad feed system, with friction pad located inside paper tray. Slide 62...

  • Page 63: Paper Lift Mechanism

    D115/D116 / S-C4.5 Paper Lift Mechanism Protrusion on frame pushes rounded slider in Latch against spring when tray is closed (by sliding it into machine). This retracts latch, allowing spring to push plate up. Rounded Slider Spring Projection B Latch Spring...
  • Page 64 D115/D116 / S-C4.5 Paper End Detection-Main Tray Paper End Sensor Feeler goes into cutout when paper runs out, activating paper end sensor. Slide 64...
  • Page 65 D115/D116 / S-C4.5 Paper End Detection - Bypass Tray Paper End Sensor Feeler Feeler goes into cutout when paper runs out, activating paper end sensor. Slide 65...
  • Page 66 D115/D116 / S-C4.5 Paper Registration Registration Sensor Slide 66...
  • Page 67 D115/D116 / S-C4.5 D115/D116 Service Training Image Transfer And Paper Separation Slide 67 Image Transfer and Paper Separation Image transfer and paper separation will be covered. In this section you will do these things: Examine how paper is fed through the machine.
  • Page 68 D115/D116 / S-C4.5 Overview Overview Transfer roller is pressed against OPC drum. High- power supply board gives OPC Drum a positive charge to Discharge transfer roller, which Plate causes toner to be transferred from drum to paper. Transfer Roller Machine uses...
  • Page 69 D115/D116 / S-C4.5 Transfer Current Timing Machine has two transfer current levels: Low and High. Low level: High voltage supply board supplies 10µA to transfer roller before image transfer starts. This prevents transfer roller from getting positively charged toner on drum surface.

  • Page 70: Transfer Roller Cleaning

    D115/D116 / S-C4.5 Transfer Roller Cleaning Toner can get onto transfer roller at these times: If you print on paper that is smaller than image size During paper jams. You must clean roller so toner will not get onto back of other prints.
  • Page 71 D115/D116 / S-C4.5 D115/D116 Service Training Fusing and Paper Exit Slide 71...
  • Page 72 D115/D116 / S-C4.5 Overview Paper Path Sensor Exit Roller Pressure Spring Fusing Lamp Pressure Roller Hot Roller This slide shows some of components for fusing unit. For more details, see FSM. Slide 72...
  • Page 73 D115/D116 / S-C4.5 Hot Roller Drive Contact Release Solenoid Hot Roller Paper Exit Roller Contact Release Gear Main Motor See Notes below for details. Slide 73 Hot Roller Drive Mechanism The main motor drives the hot roller through a gear train. One of the gears in the gear train is the contact-release gear.

  • Page 74: Pressure Roller

    D115/D116 / S-C4.5 Pressure Roller Pressure Spring Hot Roller Pressure Roller Pressure Roller Pressure springs constantly press pressure roller against hot roller. Springs can be set in two different positions. Default is set in high-pressure (lower position) position. You can move springs to low-pressure (upper position) position if you want to lower the pressure.

  • Page 75: Pressure Release

    D115/D116 / S-C4.5 Pressure Release Right Door Door Catch Pressure Release Lever Pressure Release When right door opens,(on each side) it pulls open door catch (on each side). This releases pressure on pressure roller, allowing pressure roller to turn freely, assisting in removal of jams.
  • Page 76 D115/D116 / S-C4.5 Separation Separation Hot roller stripper pawls (three) prevent paper from staying on hot roller. Slide 76...

  • Page 77: Fusing Temperature Control

    D115/D116 / S-C4.5 Fusing Temperature Control Temperature Control BICU checks signal from thermistor every 1.5 seconds. Thermistor Center Thermostat End Thermostat BICU controls fusing lamp depending on following conditions: » Current temperature » Previous temperature (1.5 seconds before) » Target fusing temperature Target fusing temperature starts at 180ºC...

  • Page 78: Overheat Protection

    D115/D116 / S-C4.5 Overheat Protection BICU checks fusing temperature through thermistor. Copier has five features to safeguard machine from overheating. Feature 1 BICU switches fusing lamp off when fusing temperature gets too high. Feature 2 BICU (Base engine & Image Control Unit) stops machine when thermistor detects an abnormal condition.

  • Page 79: Energy Saver Modes

    D115/D116 / S-C4.5 Energy Saver Modes All models have these energy saver modes: Low power mode Night/off mode All models exit energy saver mode at these times: When power switch is switched on. When originals are set on document feeder.

  • Page 80: Replacement And Adjustments

    D115/D116 / S-C4.5 Replacement and Adjustments Do these removal procedures: (Reference fusing unit in FSM) Fusing unit. Exit sensor. Hot roller stripper pawls. Hot roller and fusing lamp. Thermoswitch and thermistor. Pressure roller. Nip band adjustment. Contact release solenoid. All parts for fusing unit have same PM intervals. You must replace or clean these components at PM 90 K.
  • Page 81 D115/D116 / S-C4.5 D115/D116 Service Training Duplex Unit Slide 81 Duplex Unit The duplex unit will be covered. In this section you will do these things: Examine the duplex print procedure. Examine the adjustments for the duplex unit. Learn the SP modes used in the duplex unit.

  • Page 82: Mechanical Layout

    D115/D116 / S-C4.5 Mechanical Layout Paper Path Sensor Exit Roller Mechanical Layout Fusing Unit Exit motor drives exit roller and duplex roller. Duplex Roller One of the paper guides on fusing unit is linked to duplex timing sensor. Bypass tray cannot be used for duplex printing.

  • Page 83: Duplex Printing Process

    D115/D116 / S-C4.5 Duplex Printing Process Read about duplex printing process in Duplex Unit of FSM. Examine function of following in duplex print process: Main motor and exit motor Hot roller and pressure roller Duplex timing sensor Exit roller Duplex roller...
  • Page 84 D115/D116 / S-C4.5 Adjustment/SP Modes SP Modes: Examine these SP modes in the FSM: SP 1001: Leading edge registration SP 1002: Side to side registration SP 1003: Paper feed timing SP 2301: Transfer current timing SP 7504 60: Registration duplex: Off...
  • Page 85 D115/D116 / S-C4.5 D115/D116 Service Training ARDF (B872) Slide 85 In this section you will do these things: Examine the mechanical layout for the ARDF. Examine the feed process. Review the replacement and adjustment procedures. When you finish this section, you should know the answers to these questions:...

  • Page 86: Specifications

    D115/D116 / S-C4.5 Specifications Paper sizes: A4 SEF, A5 SEF 8½" x 5½“ SEF, 8½“ x 14“ SEF Paper weight: 52-105 g/m² (14-28 lb) Tray Capacity: 50 sheets (80 g/m², 21 lb) Transport: Roller transport Feed order: Top first Separation: FRR (Feed and Reverse Roller)
  • Page 87 D115/D116 / S-C4.5 Mechanical Layout Separation Roller Paper Feed Roller Pick-up Roller Inverter Roller Junction Gate Exit Roller Mechanical Layout This slide shows some of components for ARDF. Slide 87...

  • Page 88: Electrical Component Layout

    D115/D116 / S-C4.5 Electrical Component Layout - 1 Left Cover Sensor Registration Sensor Inverter Sensor DF Drive Board Original Set Sensor Junction Gate Solenoid Slide 88...
  • Page 89 D115/D116 / S-C4.5 Electrical Component Layout-2 DF Drive Board Slide 89...
  • Page 90 D115/D116 / S-C4.5 Electrical Component Layout - 3 DF Drive Board Slide 90...
  • Page 91 D115/D116 / S-C4.5 ARDF Drive Layout - 1/2 Feed Roller Pick-up Roller DF Feed Motor Inverter Roller Transport Roller DF Feed Motor drives Separation Roller separation, pick-up, transport, and inverter rollers. See FSM for more details on B872. Slide 91...
  • Page 92 D115/D116 / S-C4.5 ARDF Drive Layout - 2/2 DF Transport Motor Exit Roller DF Transport motor drives registration and exit rollers. Registration Roller See FSM for more details on B872. Slide 92...
  • Page 93 D115/D116 / S-C4.5 Paper Transport - Pick up and Feed Paper Feed Roller Original Set Sensor Original Size Detection Original pushes down feeler of original set sensor when original is placed on feeder table. ARDF does not detect paper sizes.
  • Page 94 D115/D116 / S-C4.5 Paper Transport Pickup and Separation Separation: ARDF uses FRR (feed & reverse roller) system. DF-Feed Motor drives DF pickup roller, DF feed roller, DF separation roller, and transport roller. Pickup roller drives top sheet(s) between feed and separation roller, where top sheet is separated and fed to transport rollers.
  • Page 95 D115/D116 / S-C4.5 Paper Transport - Two-sided Originals Two-sided Transport Details After original has been fed to registration sensor by transport roller, DF feed motor briefly stops. After scanner moves to DF scan position, front side of original is scanned.
  • Page 96 D115/D116 / S-C4.5 Paper Transport - Two-sided Originals - 1/3 Slide 96...
  • Page 97 D115/D116 / S-C4.5 Paper Transport - Two-sided Originals - 2/3 Slide 97...
  • Page 98 D115/D116 / S-C4.5 Paper Transport - Two-sided Originals - 3/3 Slide 98...

  • Page 99: Replacement And Adjustment

    D115/D116 / S-C4.5 Replacement and Adjustment Before you start: Remove exterior cover and original table. (See Replacement and Adjustment section of ARDF (B872) FSM) Practice removal procedures for the following as outlined in FSM Pick-up roller Paper feed roller Separation roller...
  • Page 100 D115/D116 / S-C4.5 Rear Cover - 1/2 Replacement and Adjustment ARDF Open ARDF Release three hooks Slide 100...
  • Page 101 D115/D116 / S-C4.5 Rear Cover - 2/2 Replacement and Adjustment Original Tray Rear Cover Left Cover Open left cover Open original tray Slide 101...
  • Page 102 D115/D116 / S-C4.5 Original Feed Unit Replacement and Adjustment Original Feed Unit Open left cover Slide 102...
  • Page 103 D115/D116 / S-C4.5 Separation Roller Replacement and Adjustment Separation Separation Roller Cover Roller Separation Roller Stopper Open left cover Slide 103...
  • Page 104 D115/D116 / S-C4.5 SP Modes and SC Codes These SP modes are used for the ARDF: SP 6006 1: Side to side/front registration SP 6006 2: Leading registration SP 6006 3: Trailing erase SP 6006 5: Sub-scan magnification SP 6009 1: ARDF free run in duplex mode...

  • Page 105: Preventive Maintenance

    D115/D116 / S-C4.5 Preventive Maintenance These need to be replaced at PM interval 90K: Separation roller Pick-up roller Feed roller Clean remaining parts when necessary. Slide 105...

  • Page 106: Service Training

    D115/D116 / S-C4.5 D115/D116 Service Training Paper Tray Unit (D567) Slide 106 Paper Tray Unit (D567) The optional paper tray unit will be discussed. In this section you will do these things: Examine the mechanical layout for the paper tray unit.
  • Page 107 D115/D116 / S-C4.5 Overview Paper tray unit is an option for this machine. Paper tray unit uses standard mechanisms for these: Paper feed (friction pad method) Paper lift (springs) Paper end detection (feeler method) Paper tray unit does not have any mechanism to detect paper size.
  • Page 108 D115/D116 / S-C4.5 Specifications Paper sizes: A4 SEF 8½" x 11" SEF 8½" x 13" SEF 8½" x 14" SEF Paper weight: 60-90 g/m² ( 16-24 lb) Tray Capacity: 500 sheets Paper feed system: Feed roller and friction pad Slide 108...

  • Page 109: Mechanical Component Layout

    D115/D116 / S-C4.5 Mechanical Component Layout Feed Roller Optional Tray Heater Bottom Plate Friction Pad Slide 109...
  • Page 110 D115/D116 / S-C4.5 Drive Layout Paper Feed Motor Paper Feed Clutch Feed Roller Friction Pad Find these components if you’re not already familiar with them. Slide 110...
  • Page 111 D115/D116 / S-C4.5 Paper Feed and Separation Paper Feed Roller Friction Pad Find these components if you’re not already familiar with them. Slide 111...
  • Page 112 D115/D116 / S-C4.5 Paper Lift Mechanism Latch Springs Bottom Plate When pushing down bottom plate, latch will set, Runner locking plate down, compressing spring below. After loading paper, when pushing paper tray back into Rounded Slider machine, runner pushes rounded slider, releasing latch.

  • Page 113: Paper End Detection

    D115/D116 / S-C4.5 Paper End Detection Paper End Feeler Paper End Sensor Cutout If there is paper in tray, feeler will push up and sense this. If there is no paper in tray, feeler drops in the cutout and activates sensor.

  • Page 114: Side And End Fences

    D115/D116 / S-C4.5 Side and End Fences End Fence Side Fence Side Fence: Set width to A4, 8¼", or 8½". End fence: Set from 11" to 13", with standard settings at 11", A4, and 13". To feed 14" paper, end fence must be removed (and stored in an internal storage compartment).
  • Page 115 D115/D116 / S-C4.5 Replacement and Adjustment Examine how to remove paper tray unit from machine before you do replacement procedures. (Read Paper Tray Unit section of FSM.) You will usually have to replace these (PM interval every 120K) in the field due to normal wear and tear.
  • Page 116 D115/D116 / S-C4.5 Feed Roller & Friction Pad Replacement and Adjustment Feed Roller Remove the paper tray Shaft before replacing any parts Assembly Clip Ring Friction Pad Slide 116...
  • Page 117 D115/D116 / S-C4.5 Sensors Replacement and Adjustment Paper Feeler Feed Sensor Paper Sensor (right) Remove the paper tray before replacing any parts Slide 117 PTU - Paper Tray Unit...
  • Page 118 D115/D116 / S-C4.5 Drive (Drive Block) Replacement and Adjustment Drive Remove PTU Block (Paper Try Unit) from copier. Open right door of PTU (right) Slide 118 PTU - Paper Tray Unit...
  • Page 119 D115/D116 / S-C4.5 Drive (Paper Feed Motor) Replacement and Adjustment Remove Drive Block (see previous slide) Paper Feed Motor Slide 119...
  • Page 120 D115/D116 / S-C4.5 Drive (Paper Feed Clutch) Replacement and Adjustment Paper Feed Clutch Clutch Cover Remove Drive Block Detach Clutch Cover Slide 120...
  • Page 121 D115/D116 / S-C4.5 Drive (Tray Main Board) Replacement and Adjustment Tray Main Board Slide 121...

  • Page 122: Service Training

    D115/D116 / S-C4.5 D115/D116 Service Training Fax Unit Slide 122...
  • Page 123 D115/D116 / S-C4.5 Fax Unit - Overview Basic fax unit consists of two PCBs: one FCU and one MBU. FCU controls all fax communications and fax features (together with controller board). MBU contains ROM and SRAM. Also, FCU has an NCU circuit.
  • Page 124 D115/D116 / S-C4.5 FCU Board FCU (Facsimile Control Unit) controls fax communications, video interface to base copier’s engine, and all the fax options. Slide 124...
  • Page 125 D115/D116 / S-C4.5 FCU Details - 1/2 FCU (Facsimile Control Unit) controls fax communications, video interface to base copier's engine, and all fax options. FACE3 (Fax Application Control Engine) (DCR) Data Compression and Reconstruction DMA control Clock generation DRAM backup control Modem (FAME) V.34, V33, V17, V.29, V.27ter, V.21, and V.8...
  • Page 126 D115/D116 / S-C4.5 FCU Details - 2/2 Flash ROM on this board contains FCU firmware, and SRAM contains system data and user parameters. Even if FCU is changed, system data and user parameters are kept on MBU board. 3MB flash ROMs for system software storage...
  • Page 127 D115/D116 / S-C4.5 Specifications - Fax Type: Desktop type transceiver Circuit: PSTN, PBX Original size: Book (face down) Maximum length: 297 mm (11.7 inch) Maximum width: 216 mm ( 8.5 inch) ADF (face up) Length: 128-1200 mm ( 5.0-47.2 inch) Width: 105-297 mm ( 4.1-11.7 inch)
  • Page 128 D115/D116 / S-C4.5 D115/D116 Service Training Preventive Maintenance Slide 128...
  • Page 129 D115/D116 / S-C4.5 Before You Start Make sure you understand all warnings and precautions before you service machine. Most parts have a PM interval of 90 K (PCU has a PM interval of 45 K). Some parts require cleaning only. You do not need to replace these parts.
  • Page 130 D115/D116 / S-C4.5 Copy Image Adjustments - Overview Copy image adjustments need to be done after doing the following: Memory all clear Replacement of first or second scanner Replacement of lens block Replacement of polygon mirror Replacement of paper tray...

  • Page 131: Printing Adjustments

    D115/D116 / S-C4.5 Printing Adjustments Leading edge registration: Check this for each paper tray. Use SP 1001 and make sure registration is set to correct tolerance levels. Side to side registration: Use SP 1002 and make sure registration is set to correct tolerance levels.
  • Page 132 D115/D116 / S-C4.5 Scanning Adjustments Leading edge registration: Use SP 4010 for this adjustment. Sub-scan magnification: Use SP 4008 for this adjustment. Main scan magnification: Use SP 4009 for this adjustment. Scan Auto Adjustment - See Scan Auto Adjustment in the Preventive Maintenance chapter of the FSM.
  • Page 133 D115/D116 / S-C4.5 D115/D116 Service Training Troubleshooting Slide 133...
  • Page 134 D115/D116 / S-C4.5 Overview SC codes refer to hardware or firmware malfunctions of copy/print engine. SC codes are shown on LCD screen of operation panel. This machine has four levels of service call conditions. Make sure you note which codes can be cleared by user and which codes cannot be cleared by user.
  • Page 135 D115/D116 / S-C4.5 Sensor/Switch Open Errors Examine Service Call Conditions in Troubleshooting Unit. This table explains symptoms machine will exhibit when a sensor or switched circuit is in an open condition. Open front or right door. Make sure "Close Front/Right Cover"...

  • Page 136: Blown Fuse Conditions

    D115/D116 / S-C4.5 Blown Fuse Conditions Read Blow Fuse Conditions section of Troubleshooting Unit of FSM. It shows what happens if a power supply board fuse burns out. Pull copy tray out and simulate a blown fuse condition. Slide 136...

  • Page 137: Machine Functions

    D115/D116 / S-C4.5 Machine Functions Do these practical assignments to learn more about how to troubleshoot machine: Test patterns: Print several different test patterns indicated in the "Test Pattern Print (SP 5902-1)" section of Service Tables unit in FSM. Output check: Use output check mode to test operation of polygon motor, main motor, and fan motor.

  • Page 138: Sensors And Switches

    D115/D116 / S-C4.5 Sensors and Switches Practice these to learn how to troubleshoot sensors and switches: Input check: This lets you check condition of most sensors and switches in machine. ID sensor analysis (SP 2221) lets you check these: » Vsg (displayed as Vg) »...
  • Page 139 D115/D116 / S-C4.5 End of Course Slide 139...

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