Ricoh Aficio SP C830DN, Aficio SP C831DN Field Service Manual. Security Guide. User Guide

Model AP-P3

Machine Code: M124/M125

Field Service Manual

14 September, 2012

Subject to change

Important Safety Notices

Prevention of Physical Injury

1. Before disassembling or assembling parts of the machine and peripherals, make sure that the
machine power cord is unplugged.

2. The wall outlet should be near the machine and easily accessible.

3. 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.

4. The machine drives some of its components when it completes the warm-up period. Be careful to
keep hands away from the mechanical and electrical components as the machine starts operation.

5. The inside and the metal parts of the fusing unit become extremely hot while the machine is
operating. Be careful to avoid touching those components with your bare hands.

Health Safety Conditions

1. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may
cause temporary eye discomfort. Immediately wash eyes with plenty of water. If unsuccessful, get
medical attention.

2. The machine, which use high voltage power source, can generate ozone gas. High ozone density
is harmful to human health. Therefore, the machine must be installed in a well-ventilated room.

Observance of Electrical Safety Standards

The machine and its peripherals must be serviced by a customer service representative who has
completed the training course on those models.

• Keep the machine away from flammable liquids, gases, and aerosols. A fire or an explosion
might occur.

• The Controller board on this machine contains a lithium battery. The danger of explosion exists if a
battery of this type is incorrectly replaced. Replace only with the same or an equivalent type
recommended by the manufacturer. Discard batteries in accordance with the manufacturer's
instructions and local regulations.

• The optional fax and memory expansion units contain lithium batteries, which can explode if
replaced incorrectly. Replace only with the same or an equivalent type recommended by the

1

manufacturer. Do not recharge or burn the batteries. Used batteries must be handled in
accordance with local regulations.

Safety and Ecological Notes for Disposal

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an
open flame.

2. Dispose of used toner, the maintenance unit which includes developer or the organic
photoconductor in accordance with local regulations. (These are non-toxic 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, or adjustment, or performance of procedures other than those specified in this
manual may result in hazardous radiation exposure.

• WARNING: Turn off the main switch before attempting any of the procedures in the Laser Optics
Housing Unit section. Laser beams can seriously damage your eyes.

• CAUTION MARKING:

2

The Aim of Anti-tip Components and Precautions

The anti-tip components are necessary for meeting the requirements of IEC60950-1, the international
standard for safety.

The aim of these components is to prevent the products, which are heavy in weight, from toppling as a
result of people running into or leaning onto the products, which can lead to serious accidents such as
persons becoming trapped under the product. (U.S.: UL60950-1, Europe: EN60950-1)

Therefore, removal of such components must always be with the consent of the customer. Do not remove
them at your own judgment.

Warnings, Cautions, Notes

In this manual, the following important symbols and notations are used.

• A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in
death or serious injury.

• A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in
minor or moderate injury or damage to the machine or other property.

• Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable
data and to prevent damage to the machine.

• This information provides tips and advice about how to best service the machine.

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Symbols, Abbreviations and Trademarks

This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations
are as follows:

See or Refer to

Clip ring

Screw

Connector

Clamp

E-ring

SEF Short Edge Feed

LEF Long Edge Feed

[A] Short Edge Feed (SEF)

[B] Long Edge Feed (LEF)

Trademarks

Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the
United States and /or other countries.

PostScript® is a registered trademark of Adobe Systems, Incorporated.

PCL® is a registered trademark of Hewlett-Packard Company.

Ethernet® is a registered trademark of Xerox Corporation.

PowerPC® is a registered trademark of International Business Machines Corporation.

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Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.

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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

Safety and Ecological Notes for Disposal...................................................................................................2

Laser Safety.....................................................................................................................................................2

The Aim of Anti-tip Components and Precautions.......................................................................................3

Warnings, Cautions, Notes...........................................................................................................................3

Symbols, Abbreviations and Trademarks.........................................................................................................4

Trademarks.....................................................................................................................................................4

1. Product Information

Specifications....................................................................................................................................................19

Product Overview.............................................................................................................................................20

Component Layout.......................................................................................................................................20

Paper Path....................................................................................................................................................21

Drive Layout..................................................................................................................................................22

Machine Codes and Peripherals Configuration............................................................................................24

Guidance for Those Who are Familiar with Predecessor Products..............................................................27

2. Installation

Installation Requirements.................................................................................................................................29

Environment..................................................................................................................................................29

Machine Level..............................................................................................................................................30

Machine Space Requirements....................................................................................................................30

Power Requirements....................................................................................................................................31

Printer Installation.............................................................................................................................................32

Power Socket for Peripherals......................................................................................................................32

Installation Flow Chart.................................................................................................................................32

Installation Procedure..................................................................................................................................34

Unpacking...........................................................................................................................................34

Installing the Toner..............................................................................................................................38

Loading Paper.....................................................................................................................................39

Turning Power On...............................................................................................................................41

Selecting the Panel Display Language..............................................................................................42

6

Printing the Test Page..........................................................................................................................43

Settings Relevant to the Service Contract..........................................................................................43

Settings for @Remote Service (Embedded RC Gate).......................................................................44

Meter Click Charge.....................................................................................................................................47

External USB Keyboard (External Option)................................................................................................50

Moving the Machine...................................................................................................................................51

Transporting the Machine...........................................................................................................................52

Optional Unit Combinations............................................................................................................................53

Machine Options.........................................................................................................................................53

Controller Options.......................................................................................................................................53

1200 LCT (D631)............................................................................................................................................55

Component Check.......................................................................................................................................55

Installation Procedure..................................................................................................................................56

Side Fence Position Change.......................................................................................................................58

Bridge Unit (D634)..........................................................................................................................................60

Component Check.......................................................................................................................................60

Installation Procedure..................................................................................................................................60

2000-sheet booklet finisher (D637) /3000-sheet finisher (D636)............................................................64

Accessory Check..........................................................................................................................................64

Installation Procedure..................................................................................................................................65

Support Tray Installation.....................................................................................................................70

Punch Unit (D570)...........................................................................................................................................71

Component Check.......................................................................................................................................71

Installation Procedure..................................................................................................................................72

Output Jogger Unit (B703).............................................................................................................................77

Accessories...................................................................................................................................................77

Installation....................................................................................................................................................77

Mail Bin (M413)..............................................................................................................................................80

Component Check.......................................................................................................................................80

Installation Procedure..................................................................................................................................81

Anti-Condensation Heater...............................................................................................................................88

Component Check.......................................................................................................................................88

Installation Procedure..................................................................................................................................89

7

For installing the tray heater in the main machine............................................................................89

For installing the tray heater in D580................................................................................................90

For Installing the tray heater in D581................................................................................................92

Controller Options............................................................................................................................................96

Overview......................................................................................................................................................96

I/F Card Slots......................................................................................................................................96

SD Card Slots......................................................................................................................................96

SD Card Appli Move...................................................................................................................................97

Overview.............................................................................................................................................97

Move Exec...........................................................................................................................................98

Undo Exec...........................................................................................................................................98

3. Preventive Maintenance

Maintenance Items........................................................................................................................................101

Touch Screen Calibration.............................................................................................................................102

4. Replacement and Adjustment

Beforehand.....................................................................................................................................................107

Special Tools..................................................................................................................................................108

Image Adjustment..........................................................................................................................................109

Registration................................................................................................................................................109

Image Area.......................................................................................................................................109

Leading Edge....................................................................................................................................109

Side to Side.......................................................................................................................................109

Adjustment Standard........................................................................................................................109

Paper Registration Standard............................................................................................................110

Adjustment Procedure.......................................................................................................................110

Erase Margin Adjustment..........................................................................................................................111

Color Registration......................................................................................................................................112

Line Position Adjustment...................................................................................................................112

Gamma Correction...................................................................................................................................113

Summary............................................................................................................................................113

Adjustment Procedure.......................................................................................................................115

Exterior Covers...............................................................................................................................................117

Front Door..................................................................................................................................................117

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Left Cover...................................................................................................................................................118

Rear Cover.................................................................................................................................................118

Top Right and Rear Cover........................................................................................................................119

Right Rear Cover.......................................................................................................................................119

Operation Panel........................................................................................................................................120

Paper Exit Cover........................................................................................................................................122

Output Tray................................................................................................................................................123

Ozone Filter...............................................................................................................................................124

Ozone filter for the charge unit.......................................................................................................124

Ozone filter for the AC Controller...................................................................................................125

Laser Optics....................................................................................................................................................126

Caution Decal Location............................................................................................................................126

LD Safety Switch........................................................................................................................................127

Error Messages.................................................................................................................................127

Laser Optics Housing Unit........................................................................................................................128

Preparing the new laser optics housing unit...................................................................................128

Before removing the old laser optics housing unit.........................................................................129

Recovery procedure for no replacement preparation of laser optics housing unit.....................129

Removing the old laser optics housing unit.....................................................................................130

Installing a new laser optics housing unit........................................................................................131

After installing the new laser optics housing unit............................................................................132

Polygon Mirror Motor and Drive Board..................................................................................................133

Airflow Fans...............................................................................................................................................135

Laser Optics Rear Right Thermistor...........................................................................................................135

Image Creation..............................................................................................................................................137

PCDU..........................................................................................................................................................137

Drum Unit and Development Unit............................................................................................................138

Developer..........................................................................................................................................141

Toner Collection Bottle..............................................................................................................................143

Second Duct Fans......................................................................................................................................144

When reinstalling the second duct fans..........................................................................................145

Third Duct Fan............................................................................................................................................145

When reinstalling the third duct fan................................................................................................146

9

Toner Pump Unit........................................................................................................................................146

When installing the new toner pump unit.......................................................................................149

Toner End Sensor......................................................................................................................................152

Image Transfer...............................................................................................................................................153

Image Transfer Belt Cleaning Unit...........................................................................................................153

Image Transfer Belt Unit............................................................................................................................153

Image Transfer Belt....................................................................................................................................155

When reinstalling the image transfer belt.......................................................................................159

Paper Transfer................................................................................................................................................162

Paper Transfer Roller Unit.........................................................................................................................162

Paper Transfer Unit....................................................................................................................................162

ID Sensor Board........................................................................................................................................164

Cleaning for ID sensors....................................................................................................................165

After installing a new ID sensor unit/board ..................................................................................166

Temperature and Humidity Sensor..........................................................................................................166

Drive Unit........................................................................................................................................................167

Gear Unit...................................................................................................................................................167

When installing the drive unit...........................................................................................................174

Adjustment after replacing the gear unit.........................................................................................174

Registration Motor.....................................................................................................................................175

Paper Feed Motor.....................................................................................................................................176

Drum/Development Motors for M, C, and Y.........................................................................................177

Drum/Development Motor-K...................................................................................................................178

ITB Drive Motor.........................................................................................................................................179

Fusing/Paper Exit Motor..........................................................................................................................179

Image Transfer Belt Contact Motor..........................................................................................................180

Duplex Inverter Motor...............................................................................................................................180

Pressure Roller Contact Motor..................................................................................................................182

Duplex/By-pass Motor.............................................................................................................................183

Paper Transfer Contact Motor..................................................................................................................185

Toner Transport Motor..............................................................................................................................187

Toner Collection Unit.................................................................................................................................188

Paper Feed Clutches.................................................................................................................................188

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Development Clutch-Y..............................................................................................................................191

Development Clutches for M and C........................................................................................................192

Development Clutch-K..............................................................................................................................193

Fusing..............................................................................................................................................................195

Fusing Unit..................................................................................................................................................195

Fusing Exit Shutter Plate............................................................................................................................197

Fusing Entrance Guide Plate.....................................................................................................................197

Cleaning Requirement......................................................................................................................199

Fusing Exit Guide Plate Cleaning Procedure...........................................................................................199

Fusing Unit Upper Cover..........................................................................................................................200

Fusing Unit Lower Cover...........................................................................................................................201

Fusing Sleeve Belt Unit..............................................................................................................................202

Oil Absorber Felt..............................................................................................................................205

Pressure Roller............................................................................................................................................206

Stripper Plate.............................................................................................................................................208

Cleaning Requirement......................................................................................................................209

Pressure Roller Thermistors........................................................................................................................209

Pressure Roller Thermostats.......................................................................................................................210

NC Sensors................................................................................................................................................210

Fusing Fan..................................................................................................................................................211

When installing the fusing fan..........................................................................................................212

Paper Exit Fan............................................................................................................................................212

When installing the paper exit fan..................................................................................................213

AC Controller Board Fan..........................................................................................................................213

When installing the AC controller fan.............................................................................................214

Fusing Entrance Thermopiles....................................................................................................................214

When cleaning the lens of the thermopile......................................................................................215

Pressure Roller HP Sensor.........................................................................................................................215

QSU fan.....................................................................................................................................................216

Fusing Unit Shutter Plate Drive Motor......................................................................................................218

Fusing Unit Shutter Plate Home Position Sensor......................................................................................218

Fusing Unit Shutter Plate Drive Mechanism.............................................................................................219

Paper Feed.....................................................................................................................................................222

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Paper Feed Unit.........................................................................................................................................222

Pick-Up, Feed and Separation Rollers.....................................................................................................223

Tray 1 and Tray 2.............................................................................................................................223

Tray Lift Motor............................................................................................................................................224

Vertical Transport, Paper Overflow, Paper End and Paper Feed Sensor.............................................224

Registration Sensor....................................................................................................................................225

By-pass Paper Size Sensor and By-pass Paper Length Sensor.............................................................226

When reinstalling the by-pass paper size sensor..........................................................................227

By-pass Bottom Tray..................................................................................................................................228

By-pass Paper End Sensor........................................................................................................................231

By-pass Pick-up, Feed and Separation Roller, Torque Limiter...............................................................232

By-pass Feed Clutch..................................................................................................................................233

Paper Exit Unit...........................................................................................................................................234

Fusing Exit, Paper Overflow, Junction Paper Jam and Paper Exit Sensor............................................235

Duplex Unit.....................................................................................................................................................237

Duplex Unit................................................................................................................................................237

Duplex Door Sensor..................................................................................................................................238

Duplex Entrance Sensor............................................................................................................................239

Duplex Exit Sensor....................................................................................................................................240

Electrical Components...................................................................................................................................241

Boards........................................................................................................................................................241

Controller Box closed.......................................................................................................................241

Behind the IOB..................................................................................................................................242

Controller Box Open........................................................................................................................242

Controller Unit...........................................................................................................................................243

Controller Box Right Cover.......................................................................................................................243

Controller Box............................................................................................................................................243

When opening the controller box...................................................................................................243

When removing the controller box.................................................................................................244

IOB (In/Out Board)..................................................................................................................................247

BB (Bridge Board).....................................................................................................................................248

BCU............................................................................................................................................................248

When installing the new BCU..........................................................................................................249

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PSU.............................................................................................................................................................250

PSU bracket.......................................................................................................................................250

PSU board.........................................................................................................................................250

PSU fans............................................................................................................................................251

Shutdown Switch.......................................................................................................................................252

ITB Power Supply Board...........................................................................................................................253

High Voltage Supply Board.....................................................................................................................254

High Voltage Supply Board Bracket.......................................................................................................254

AC Controller Board.................................................................................................................................255

AC Controller Board Bracket...................................................................................................................255

Controller Board........................................................................................................................................256

When installing the new controller board......................................................................................258

HDD Fan....................................................................................................................................................258

When installing the HDD fan...........................................................................................................259

HDD............................................................................................................................................................259

When installing a new HDD unit.....................................................................................................260

Toner Bottle Detection Board...................................................................................................................260

NVRAM Replacement Procedure............................................................................................................261

NVRAM on the BCU........................................................................................................................261

NVRAM on the controller board.....................................................................................................262

Tube Cooling Fan (1st Duct Fan).............................................................................................................263

Using Dip Switches........................................................................................................................................264

Controller Board........................................................................................................................................264

BCU Board.................................................................................................................................................264

5. System Maintenance

Service Program Mode.................................................................................................................................265

SP Tables....................................................................................................................................................265

Enabling and Disabling Service Program Mode....................................................................................265

Entering SP Mode.............................................................................................................................265

Exiting SP Mode...............................................................................................................................265

Types of SP Modes....................................................................................................................................265

SP Mode Button Summary...............................................................................................................266

Selecting the Program Number.......................................................................................................267

13

Exiting Service Mode.......................................................................................................................268

Service Mode Lock/Unlock............................................................................................................268

Remarks......................................................................................................................................................268

Display on the Control Panel Screen..............................................................................................268

Others................................................................................................................................................268

Service SP Table............................................................................................................................................270

SP1-XXX (Service Mode)..........................................................................................................................270

Engine SP Tables-1........................................................................................................................................285

SP1-XXX (Feed).........................................................................................................................................285

Engine SP Tables-2........................................................................................................................................299

SP2-XXX (Drum).........................................................................................................................................299

Engine SP Tables-3........................................................................................................................................307

SP3-XXX (Process).....................................................................................................................................307

Engine SP Tables-4........................................................................................................................................327

SP5-XXX (Mode).......................................................................................................................................327

Engine SP Tables-5........................................................................................................................................382

SP6-XXX (Peripherals)...............................................................................................................................382

Engine SP Tables-6........................................................................................................................................390

SP7-XXX (Data Log)..................................................................................................................................390

Input and Output Check................................................................................................................................440

Input Check Table.....................................................................................................................................440

Printer.................................................................................................................................................440

Table 1: Paper Height Sensor..........................................................................................................443

Table 2: Paper Size Switch (Tray 2)...............................................................................................443

Table 3: Paper Size (By-pass Table)...............................................................................................444

[FIN (EUP) INPUT Check] Finisher (D636/ D637).......................................................................445

[FIN (JAK) INPUT Check] 4bin Mail Box (M413)........................................................................447

Bridge Unit (D634)...........................................................................................................................448

Two-Tray Paper Feed Unit (D580)/ LCT 2000 (D581)/ LCT 1200 (D631)............................448

Output Check Table..................................................................................................................................449

Printer.................................................................................................................................................449

[FIN (EUP) OUTPUT Check] (Booklet) Finisher (D636/D637)....................................................455

FIN(JAK)OUTPUT Check 4bin Mail Box (M413).........................................................................457

14

Bridge Unit (D634)...........................................................................................................................457

4bin Mail Box (M413)....................................................................................................................457

Two-Tray Paper Feed Unit (D580)/ LCT 2000 (D581)/ LCT 1200 (D631)............................457

Firmware Update...........................................................................................................................................459

Type of Firmware.......................................................................................................................................459

Before You Begin.......................................................................................................................................460

Updating Firmware...................................................................................................................................461

Preparation........................................................................................................................................461

Updating Procedure.........................................................................................................................461

Error Messages.................................................................................................................................462

Firmware Update Error.....................................................................................................................462

Recovery after Power Loss...............................................................................................................463

Updating the LCDC for the Operation Panel..........................................................................................463

Handling Firmware Update Errors...........................................................................................................464

Error Message Table........................................................................................................................464

NVRAM Data Upload/Download..............................................................................................................466

Uploading Content of NVRAM to an SD card.......................................................................................466

Downloading an SD Card to NVRAM....................................................................................................467

Address Book Upload/Download..............................................................................................................469

Information List...........................................................................................................................................469

Download..................................................................................................................................................469

Upload.......................................................................................................................................................470

Using the Debug Log.....................................................................................................................................471

Overview....................................................................................................................................................471

Switching ON and Setting UP Save Debug Log.....................................................................................471

Retrieving the Debug Log from the HDD.................................................................................................475

Debug Log Codes.....................................................................................................................................476

SP5857-015 Copy SD Card-to-SD Card: Any Desired Key.......................................................476

SP5857-016 Create a File on HDD to Store a Log......................................................................476

SP5857-017 Create a File on SD Card to Store a Log................................................................476

Card Save Function.......................................................................................................................................477

Overview....................................................................................................................................................477

Card Save:........................................................................................................................................477

15

Procedure...................................................................................................................................................477

Error Messages..........................................................................................................................................481

SMC List Card Save Function.......................................................................................................................482

Overview....................................................................................................................................................482

SMC List Card Save.........................................................................................................................482

Procedure...................................................................................................................................................482

File Names of the Saved SMC Lists.........................................................................................................484

Error Messages..........................................................................................................................................485

6. Troubleshooting

Service Call....................................................................................................................................................487

Service Call Conditions.............................................................................................................................487

SC Code Classification....................................................................................................................488

SC Table.........................................................................................................................................................491

Service Call Tables - 1..............................................................................................................................491

SC1xx: Scanning..............................................................................................................................491

Service Call Tables - 2..............................................................................................................................491

SC 2xx: Exposure.............................................................................................................................491

Service Call Tables - 3..............................................................................................................................498

SC3xx: Image Processing – 1.........................................................................................................498

SC3xx: Image Processing – 2.........................................................................................................499

Service Call Tables - 4..............................................................................................................................503

SC4xx: Image Processing - 3..........................................................................................................503

Service Call Tables - 5..............................................................................................................................509

SC5xx: Paper Feed and Fusing.......................................................................................................509

Service Call Tables - 6..............................................................................................................................529

SC6xx: Device Communication.......................................................................................................529

Service Call Tables - 7..............................................................................................................................543

SC7xx: Peripherals...........................................................................................................................543

Service Call Tables - 8..............................................................................................................................553

SC8xx: Overall System....................................................................................................................553

Service Call Tables - 9..............................................................................................................................569

SC9xx: Miscellaneous.....................................................................................................................569

Process Control Error Conditions..................................................................................................................577

16

Developer Initialization Result..................................................................................................................577

Process Control Self-Check Result............................................................................................................578

Vsg Adjustment Result.......................................................................................................................580

Line Position Adjustment Result.................................................................................................................580

Troubleshooting Guide..................................................................................................................................582

Image Quality............................................................................................................................................582

Line Position Adjustment............................................................................................................................584

Test.....................................................................................................................................................585

Countermeasure list for color registration errors............................................................................585

Stain on the Outputs..................................................................................................................................591

Problem at Regular Intervals.....................................................................................................................592

Toner End Recovery Error.........................................................................................................................592

Flow Chart for the Toner End Recovery Error.................................................................................593

Toner Bottle Detection Error......................................................................................................................594

Solid Image or Halftone Image Error......................................................................................................595

Recovery Procedure.........................................................................................................................595

Problem Prevention Procedure.........................................................................................................596

Faulty Cleaning..........................................................................................................................................596

Black or color lines (2-3mm)...........................................................................................................596

Band Image Between 20mm and 30mm.......................................................................................597

Encryption Key Restoration for NVRAM..................................................................................................597

How to restore the old encryption key to the machine..................................................................597

How to do a forced start up with no encryption key.....................................................................598

Other Symptoms........................................................................................................................................599

Flowchart for the error......................................................................................................................600

Countermeasure list for the error.....................................................................................................600

Jam Detection.................................................................................................................................................603

Paper Jam Display.....................................................................................................................................603

Jam Codes and Display Codes................................................................................................................603

Paper Size Code...............................................................................................................................608

Sensor Locations...............................................................................................................................610

Electrical Component Defects.......................................................................................................................611

Sensors.......................................................................................................................................................611

17

Blown Fuse Conditions..............................................................................................................................616

Power Supply Unit............................................................................................................................616

AC Drive Board................................................................................................................................616

7. Energy Saving

Energy Save...................................................................................................................................................619

Energy Saver Modes................................................................................................................................619

Timer Settings....................................................................................................................................619

Return to Stand-by Mode.................................................................................................................620

Recommendation..............................................................................................................................620

Energy Save Effectiveness........................................................................................................................620

Paper Save.....................................................................................................................................................622

Effectiveness of Duplex/Combine Function............................................................................................622

1. Duplex:..........................................................................................................................................622

2. Combine mode:............................................................................................................................622

3. Duplex + Combine:......................................................................................................................623

How to calculate the paper reduction ratio ..................................................................................623

18

1. Product Information

Specifications

See "Appendices" for the following information:

• General Specifications

• Supported Paper Sizes

• Software Accessories

• Optional Equipment

19

1. Product Information

Product Overview

Component Layout

20

1. Paper exit rollers

2. Duplex unit

3. Fusing unit

4. Paper transfer roller

5. Registration roller

6. By-pass feed table

7. Tray 2

8. Tray 1

9. Toner collection bottle

10. Laser optics housing unit

11. PCDU (4 colors)

12. Image transfer belt cleaning unit

13. Image transfer belt unit

14. Toner bottle (4 colors)

15. ID sensor

16. Fusing sleeve belt unit

Paper Path

Product Overview

1. Mail bin

2. Duplex inverter

3. Duplex feed

4. By-pass tray feed

5. Tray 1 feed

6. Tray 2 feed

7. Tray 3: Optional paper feed unit/LCT

The 2000/3000-sheet (booklet) finisher requires the bridge unit and one from the two-tray paper feed
unit or the LCT.

8. Tray 5: Optional LCT 1200

9. Tray 4: Optional paper feed unit

10. Finisher booklet stapler (Optional)

11. Finisher stapler (Optional)

12. Finisher upper tray (Optional)

13. Finisher proof tray (Optional)

14. Output tray

21

1. Product Information

Drive Layout

22

1. Toner supply clutch-K and -CMY:

2. ITB (Image Transfer Belt) contact
motor:

3. Toner transport motor:

4. Development clutch (K, Y, M, C):

5. Drum/Development drive motor
(K, Y, M, C):

6. Paper feed clutch: Switches the drive power between tray 1 and tray 2.

7. Paper feed motor: Drives the paper feed mechanisms (tray 1/tray 2).

Turns on/off the drive power to the toner supply unit (K and ­CMY).

Moves the ITB into contact and away from the color PCDUs.

Drives the toner attraction pumps and the toner collection coils
from the PCDUs, from the transfer belt unit, and inside the
toner collection bottle. Also rotates the toner bottles.

Turns on/off the drive power to the development unit (K, Y,
M, C).

Drives the color drum unit and development unit (K, Y, M, C).

Product Overview

8. By-pass feed clutch:

Turns on/off the drive power to the by-pass pick-up, feed and
separation rollers.

9. Registration motor: Drives the registration roller.

10. By-pass/duplex feed motor:

11. Paper transfer contact motor:

Drives the by-pass pick-up, feed and separation roller, and
duplex transport rollers.

Moves the paper transfer roller in contact with the image
transfer belt.

12. ITB drive motor: Drives the image transfer belt unit.

13. Duplex inverter motor: Drives the duplex inverter rollers and duplex transport rollers.

14. Fusing/paper exit motor: Drives the fusing unit and paper exit section.

23

1. Product Information

Machine Codes and Peripherals Configuration

Item Machine Code Call out Remarks

Mainframe M124/M125 [1] -

Mail bin M413 [2] -

1200-sheet LCT D631 [3] Requires [4] or [5]

2000-sheet LCT D581 [4]

One from the two

Two-tray paper feed unit D580 [5]

One-tray paper feed unit D579 [6] -

3000-sheet finisher D636 [7]

2000-sheet booklet finisher D637 [8]

Punch unit 2/3 holes D570-00 (NA) - Requires [7] or [8]

Punch unit 2/4 holes D570-01 (EU) - Requires [7] or [8]

Punch unit 4 holes

Bridge unit D634 [9] -

D570-02

(Scandinavia)

- Requires [7] or [8]

One from [7] and [8];

Requires one from [4] and [5]

24

Machine Codes and Peripherals Configuration

Item Machine Code Call out Remarks

Output jogger unit B703 - Requires [7]

Item Machine code Call out Remark

PictBridge D645-15

IPDS Unit M416-24

SD Card for Netware
Printing

M416-29

[A]

D640-21 (NA)

VM Card

D640-22 (EU)

D640-23 (AA)

IEEE 1284 B679 [B]

M344-01 (NA)

Wireless LAN

[C]M344-02 (EU)

M344-08 (EU/AA)

M416-30

Gigabit Ethernet

[D] -

D377

Those cards should be
installed from SD slot 2
(lower).

If multiple applications are
required, merge all
applications in one SD card
with SP mode. ( p.97 "SD
Card Appli Move")

You can only install one of
these at a time.

25

1. Product Information

512MB Memory Option M354-03

[E] -

1GB Memory Option M416-27

HDD*1 (250GB) M416-28 [F] -

Data Overwrite Security,
HDD Encryption

The hard disk (M416-28) is supplied with the M125 model as standard equipment.

*1

- - Included in the controller ROM

26

Guidance for Those Who are Familiar with Predecessor Products

Guidance for Those Who are Familiar with
Predecessor Products

Machines M124/M125 are successor models to Machines G188/G189. If you have experience with
the predecessor products, the following information will be of help when you read this manual.

Different Points from Predecessor Products

Item M124/M125 G188/G189

Controller Type GW+ Controller GW Controller

New Fusing Unit without the
Decurler

Fusing Unit NEW QSU-DH fusing system IH roller fusing system

SMC data SD card download or printing Printing only

Operation Panel Tiltable Operation Panel

Includes USB/SD slot

USB2.0/SD Slot Standard Optional

Data Overwrite Security,
HDD Encryption

Included in the controller ROM SD card

Yes No

Stationary Operation Panel

27

1. Product Information

28

2. Installation

Installation Requirements

Environment

1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)

2. Humidity Range: 15% to 80% RH

3. Ambient Illumination: Less than 1500 lux (do not expose to direct sunlight)

4. Ventilation: 3 times/hr/person or more

5. Do not let the machine get exposed to the following:

1) Cool air from an air conditioner

2) Heat from a heater

6. Do not install the machine in areas that are exposed to corrosive gas.

7. Install the machine at locations lower than 2,000 m (6,560 ft.) above sea level.

8. Install the machine on a strong, level base. (Inclination on any side must be no more than 5 mm.)

9. Do not install the machine in areas that get strong vibrations.

• Do not leave the toner bottle in a place directly exposed to sunlight.

29

2. Installation

• The toner bottle must be kept at a temperature of 35°C (95°F) or less. Be careful not to leave the
toner bottle in a hot place when transporting or storing it.

Machine Level

Front to back: Within 5 mm (0.2")

Right to left: Within 5 mm (0.2")

Machine Space Requirements

• This machine, which uses high voltage power sources, can generate ozone gas. High ozone
density is harmful to human health. Therefore, the machine must be installed in a well-ventilated
room.

A: Over 100 mm (3.9")

B: Over 100 mm (3.9")

C: Over 100 mm (3.9")

D: Over 750 mm (29.5")

Put the machine near the power source with the clearance shown above.

30

Power Requirements

• Insert the plug firmly in the outlet.

• Do not use an outlet extension plug or cord.

• Ground the machine.

1. Input voltage level:

120 to 127 V, 60 Hz: More than 12 A (NA)

220 V to 240 V, 50 Hz/60 Hz: 10 A (EU/AA/China)

2. Permissible voltage fluctuation: +8.66 %/ -10 % (NA)

Permissible voltage fluctuation: ± 10 % (Others)

3. Do not put things on the power cord.

Installation Requirements

31

2. Installation

Printer Installation

• Make sure that the image transfer belt is in its correct position (away from the PCDUs) before you
move the machine. Otherwise, the image transfer belt and the black PCDU can be damaged.

Power Socket for Peripherals

• Rating voltage for peripherals.

• Make sure to plug the cables into the correct sockets.

Installation Flow Chart

This flow chart shows the best procedure for installation.

32

Printer Installation

You need the optional paper tray unit or the LCT if you want to install the finisher (D636 or D637) or
1200-sheet LCT (D631).

The punch unit is for 2000-sheet booklet finisher (D637) and 3000-sheet finisher (D636).

33

2. Installation

Installation Procedure

• Remove the tape from the development units before you turn the main switch on. The development
units can be severely damaged if you do not remove the tape.

Put the machine on the paper tray unit or the LCT first if you install an optional paper tray unit or the
optional LCT at the same time. Then install the machine and other options.

• Keep the shipping retainers after you install the machine. You may need them in the future if you
transport the machine to another location.

Unpacking

• When lifting the machine, use the handle and grips on both sides of the machine.

• If not, the machine could be dropped. This may cause an injury and may damage the machine.

1. Pull out the handle [A].

34

Printer Installation

2. Lift the machine with four people by using the handle and grips on both sides of the machine.

• Do not remove the tapes before placing the machine.

• Lower the machine slowly and carefully, so as not to pinch your hands.

3. Push back the handle [A] into the machine.

35

2. Installation

4. Push up the lever [C] on the right door, and then open the right door.

36

5. Remove the tape [A].

6. Close the right door.

7. Open the front door [F].

8. Turn the two green levers [G] counterclockwise.

9. Open the drum positioning plate [H].

Printer Installation

10. Remove and pull out the four tapes horizontally from all PCUs.

• Make sure that all tapes are removed.

11. Close the drum positioning plate.

12. Turn the green levers clockwise to lock the levers.

37

2. Installation

Installing the Toner

1. Shake the toner bottle up and down five or six times before installing.

38

2. Insert the each toner bottle into the machine with the label facing up.

3. Close the front door.

Loading Paper

1. Pull out the tray 1 [A] of the machine.

Printer Installation

2. Remove the tape [A].

3. Take out the contents from tray 1.

39

2. Installation

4. Adjust the end plate [A] to A4 LEF/Letter LEF size.

5. Load paper in tray 1, and then close tray 1.

40

6. Attach the tray number decals to the trays.

7. Pull out the feeler [D] for the output-tray-full detection mechanism.

Turning Power On

Printer Installation

• Turn off the power switch whenever you plug in and unplug the power cord.

1. Make sure that the power switch is set to " " (Standby).

2. Plug in the machine.

41

2. Installation

3. Turn on the power switch.

• Do not turn off the power switch until initialization is completed (‘Ready’ appears on the display
when initialization is completed). Otherwise, the machine may malfunction.

Selecting the Panel Display Language

To change the panel display language, it is necessary to register available languages in the User Tools.
Specify the settings according to the following procedure.

• You can select one of these languages (the default is English): Japanese, English, German, French,
Italian, Dutch, Swedish, Norwegian, Danish, Spanish, Finnish, Portuguese, Czech, Polish,
Hungarian, Simplified Chinese, Russian, Greek, Catalan, Turkish, or Brazilian Portuguese.

• You do not have to do this procedure if you use English. Do this procedure if you want to use a
different language.

1. Turn on the power switch of the machine.

42

Printer Installation

• “Ready” shows on the panel display after the machine warms up.

2. Press the "User Tools" key.

3. Press "Administrator Tools" in "System Settings".

4. Press "Select Switchable Languages".

5. Using the language button displayed on the User Tools screen, select the required language (this
will then be selectable at any time with a toggle setting), and then press "OK".

• Only languages available for the machine are displayed.

• At least one language must be selected.

6. Return to the User Tools menu, and then keep pressing the language button until the language you
want to select appears.

• The language selected in "Select Switchable Languages" becomes available for selection by
a toggle setting.

Printing the Test Page

1. You can check if the machine works correctly by printing a test page such as the configuration
page. However, you cannot check the connection between the machine and the computer by
printing the test page.

2. Turn on the power switch.

3. Press the "User Tools" key.

4. Press "Printer Features".

5. Press "List/Test Print".

6. Press "Configuration Page".

7. The test printing starts shortly after.

8. Turn off the power switch.

Settings Relevant to the Service Contract

Change the necessary settings depending on the each customer's service contract. For details, refer to
"Meter Click Charge" following this section.

43

2. Installation

Settings for @Remote Service (Embedded RC Gate)

• Prepare and check the following check points before you visit the customer site. For details, ask the
@Remote key person.

Check points before making @Remote settings

1. The setting of SP5816-201 in the mainframe must be "0".

2. Print the SMC with SP5990-002 and then check if a device ID2 (SP5811-003) must be correctly
programmed.

• 6 spaces must be put between the 3-digit prefix and the following 8-digit number (e.g.
xxx______xxxxxxxx).

• ID2 (SP5811-003) and the serial number (SP5811-001) must be the same (e.g. ID2:
A01______23456789 = serial No. A0123456789)

3. The following settings must be correctly programmed.

• Proxy server IP address (SP5816-063)

• Proxy server Port number (SP5816-064)

• Proxy User ID (SP5816-065)

• Proxy Password (SP5816-066)

4. Get a Request Number.

5. Execute the @Remote Settings.

6. Enter the SP mode.

7. Input the Request number which you have obtained from @Remote Center GUI, and then press the
"OK" key with SP5816-202.

8. Confirm the Request number, and then press the "EXECUTE" key with SP5816-203.

9. Check the confirmation result with SP5816-204.

Value

Meaning Solution/ Workaround

0 Succeeded -

1 Request number error Check the request number again.

Communication error (proxy

3

enabled)

Communication error (proxy

4

disabled)

Check the network condition.

Check the network condition.

44

Proxy error (Illegal user name or

5

password)

Check Proxy user name and password.

Printer Installation

Value Meaning Solution/ Workaround

6 Communication error Check the network condition.

8 Other error See "SP5816-208 Error Codes" below this.

Request number confirmation

9

executing

Processing… Please wait.

10. Make sure that the screen displays the Location Information with SP5816-205 only when it has
been input at the Center GUI.

11. Press the "EXECUTE" key to execute the registration with SP5816-206.

12. Check the registration result with SP5816-207.

Value Meaning Solution/ Workaround

0 Succeeded -

1 Request number error Check the request number again.

2 Already registered Check the registration status.

Communication error (proxy

3

enabled)

Communication error (proxy

4

disabled)

Proxy error (Illegal user name or

5

password)

8 Other error See "SP5816-208 Error Codes" below this.

Request number confirmation

9

executing

13. Exit the SP mode.

Check the network condition.

Check the network condition.

Check Proxy user name and password.

Processing… Please wait.

45

2. Installation

SP5816-208 Error Codes

Cause Code Meaning Solution/ Workaround

Operation Error,
Incorrect Setting

-12002

Inquiry, registration attempted
without acquiring Request No.

-12003 Attempted registration without
execution of a confirmation and no
previous registration.

-12004 Attempted setting with illegal entries
for certification and ID2.

-12005 @Remote communication is
prohibited. The device has an
Embedded RC gate-related
problem.

-12006 A confirmation request was made
after the confirmation had been
already completed.

-12007 The request number used at
registration was different from the
one used at confirmation.

Obtain a Request Number
before attempting the Inquiry or
Registration.

Perform Confirmation before
attempting the Registration.

Check ID2 of the mainframe.

Make sure that "Remote
Service" in User Tools is set to
"Do not prohibit".

Execute registration.

Check Request No.

46

-12008
Update certification failed because

mainframe was in use.

-12009 The ID2 in the NVRAM and that of
the certificate does not match.

-12010 The certificate domain has not been
initialized.

Check the mainframe
condition. If the mainframe is in
use, try again later.

-

-

Printer Installation

Cause Code Meaning Solution/ Workaround

-2385 Other error -

Error Caused by
Response from
GW URL

-2387 Not supported at the Service
Center

-2389 Database out of service -

-2390 Program out of service -

-2391

-2392 Parameter error -

-2393 External RCG not managed -

-2394 Mainframe not managed -

-2395 Box ID for external RCG is illegal. -

-2396

-2397 Incorrect ID2 format

-2398 Incorrect request number format Check the Request No.

Two registrations for the same
mainframe

Mainframe ID for external RCG is
illegal.

-

Check the registration
condition of the mainframe

-

Check the ID2 of the
mainframe.

Meter Click Charge

Basically, there are two ways to set up this function.

Meter click change enabled (SP 5-930-001 set to ‘enabled’): The counter can be displayed and
printed by the customer. The technician can then call the customer and ask them to read the counter.

Meter click charge disabled (SP 5-930-001 set to ‘disabled’; this is the default setting): The counter
cannot be displayed or printed by the customer. To check the counter, the technician must print the SMC
report (SP 5-990).

• You must select one of the counter methods (developments/prints) in accordance with the contract
(* SP5-045-001).

47

2. Installation

48

Item SP No. Function Default

Meter Click
Charge

Meter Click
Charge: PCU

SP5-930-001

SP5-930-010

Enables or disables Meter Click Charge.

When enabled:

• The counter menu shows
immediately after you push the
"Menu" key. The "Counter Method"
(SP5-045) sets the type of the
counter.

• You can print the counter from the
counter menu.

When disabled:

• The counter menu does not show.

Enables or disables the PM alert for the
PCUs.

If this SP is enabled, an alert message is
displayed when the PCUs need to be
replaced.

Printer Installation

"0": OFF

"1": No alert

Meter Click
Charge:
Image
Transfer Belt
Unit

Meter Click
Charge:
Fusing Unit

Counter
method

A3/DLT
double count

SP5-930-014

SP5-930-016

SP5-045-001

SP5-104-001

Enables or disables the PM alert for the
image transfer belt unit.

If this SP is enabled, an alert message is
displayed when the image transfer belt
unit needs to be replaced.

Enables or disables the PM alert for the
fusing unit.

If this SP is enabled, an alert message is
displayed when the fusing unit needs to
be replaced.

Specifies if the counting method used in
meter charge mode is based on
developments or prints.

Specifies whether the counter is doubled
for A3/DLT paper.

"1": No alert

"1": No alert

“1”: Prints

“0”: Single
counting

49

2. Installation

-001: shows or sets the telephone
number of the service representative.

Service Tel:
Telephone /
Facsimile

SP5-812-001 and

-002

-002: shows or sets the fax number of
the service station. The number is printed
on the counter list when the "Meter Click
Charge" is enabled. User can send a fax
message with the counter list.

-

External USB Keyboard (External Option)

Customers can use an external USB keyboard when the software keyboard is shown on the operation
panel, if an external USB keyboard is connected to the USB port at the side of the operation panel or
the controller box USB port.

If customers would like to use an external USB keyboard, execute the following steps to enable this
feature.

1. Connect the external keyboard to the USB port at the right side of the operation panel or the
controller box USB port.

• The external keyboard that is available in this machine is principally for the Windows OS.
However, no compatibility check is done, and there is no warranty.

2. Enter the SP mode and set SP5075-001 to ON (1) (USB keyboard).

3. Exit the SP mode and turn the main power off and on.

50

Printer Installation

4. Select a language type for the external USB keyboard with [User Tools] [System Settings]
[General Features] [External Keyboard].

5. Press [OK] to set it.

6. Turn the main power off and on.

Moving the Machine

This section shows you how to manually move the machine from one floor to another floor. See the
section "Transporting the Machine" if you have to pack the machine and move it a longer distance.

• Remove all trays from the optional paper feed unit or LCT.

• Remove peripherals physically attached to the main machine: Paper feed unit, LCT and finisher.

• Attach the caster stands for the paper feed unit or LCT if these have been removed before moving
the machine.

51

2. Installation

Transporting the Machine

1. Remove the toner cartridges. This prevents toner flow into the toner supply tube, which is caused by
vibration during transport. This can also cause the tube to be clogged with toner.

2. Make sure there is no paper left in the paper trays. Then fix down the bottom plates with a sheet of
paper and tape.

3. Empty the toner collection bottle. Then attach securing tape to stop the toner bottle from coming
out.

4. Do one of the following:

• Attach shipping tape to the covers and doors.

• Shrink-wrap the machine tightly.

• After you move the machine, make sure you do the "Auto Color Registration" as follows. This
optimizes color registration.

• 1. Do the "Forced Line Position Adj. Mode c" (SP2-111-3).

• 2. Then do the "Forced Line Position Adj. Mode a" (SP2-111-1).
To check if SP 2-111-1 was successful, watch the screen during the process. A message is
displayed at the end. Also, you can check the result with SP 2-194-10 to -12.

• Make sure that the side fences in the trays are correctly positioned to prevent color registration
errors.

52

Optional Unit Combinations

Machine Options

U: User installation, C: CE installation

No. Options Remarks

1 One-tray paper feed unit U

Optional Unit Combinations

2 Two-tray paper feed unit U

3 2000-sheet LCT U

4 1200-sheet LCT C Requires No.2 or 3

5 Bridge unit C -

6 3000-sheet finisher C One from No.6 and No.7.

7 2000-sheet booklet finisher C

8 *Punch kit (3 types) C

9 Output Jogger Unit C Requires No. 6 or No. 7.

10 Mail bin C

*: Child options (Child options require a parent option.)

• For details about installation procedures for the user installation options, see "Hardware Guide" of
this model.

One from No.1, No.2, No.3

Requires No.5 and one from No.2 and
No.3.

No.6 or No.7 required.

One of the three types

Controller Options

U: User installation, C: CE installation

53

2. Installation

No. Options Remarks

1 IEEE 1284 U

One from No.1 and No.2

2 Wireless LAN U

3 Gigabit Ethernet U Gigabit Ethernet Slot

4 HDD U Option only for M124

5 PictBridge U

6 IPDS Unit U

You can merge all applications in one SD
card with SP mode. (

p.97 "SD Card

Appli Move").

7 SD Card for Netware Printing U

8 VM Card U

If the VM card is installed, merge
applications in VM card.

9 512MB Memory Option U

One from No.10 and No.11

10 1GB Memory Option U

• For details about installation procedures for the user installation options, see "Hardware Guide" of
this model.

54

1200 LCT (D631)

Component Check

Check the quantity and condition of the components against the following list.

No. Description Q'ty

1 Front Bracket 1

2 Rear Bracket 1

3 Stud Screw 4

4 Joint Pin 2

5 LCT 1

1200 LCT (D631)

55

2. Installation

Installation Procedure

• Unplug the main machine power cord before starting the following procedure.

• The Paper Tray Unit (D580) or LCT 2000-sheet (D581) must be installed before installing this
1200-sheet LCT.

56

1. Unpack the LCT and remove the tapes.

2. Remove the stand covers [A].

3. Release the locks [B] of the front and rear caster stands.

4. Remove the caster stands [C].

5. Remove the paper path cover [A], connector cover [B] and six hole covers [C].

1200 LCT (D631)

6. Insert the joint pins [A].

7. Attach the front [B] and rear brackets [C]. ( x 2 each)

57

2. Installation

8. Pull out the front and rear rails [A], and then hang them on each bracket [B].

9. Connect the LCT cable [C] to the main machine.

10. Slide the LCT [D] into the main machine.

11. Make sure that the front and rear sides of the LCT are closely attached to the main machine.

Side Fence Position Change

1. Open the right door of the LCT.

2. Push the down switch to lower the tray bottom plate until it reaches its lowest position.

58

3. Remove the front and rear side fences [A, B] ( x 1 each).

4. Install the side fences in the correct position (A4 LEF/ LT LEF/ B5 LEF).

1200 LCT (D631)

5. Pull the end fence [A] for B5 size paper as shown ( x 1) if the side fences are adjusted for B5 size
paper.

6. Close the right door.

7. Turn on the main power switch, and then go into the SP mode.

8. Input the correct paper size for the1200-sheet LCT with SP5181-018.

59

2. Installation

Bridge Unit (D634)

Component Check

Check the quantity and condition of the components against the following list.

No. Description Q'ty

1 Bridge Unit 1

2 Frame Cover 1

3 Knob screw 1

4 Long Knob Screw 1

5 Holder bracket 1

6 Guide 2

Installation Procedure

• Unplug the machine power cord before starting the following procedure.

60

Bridge Unit (D634)

• If you will install a finisher unit (D636 or D637) on the machine, install it after installing the bridge
unit (D634).

1. Remove all tapes.

2. If the sensor feeler [A] is out, fold it into the machine.

3. Remove the connection cover [A] ( x 1).

61

2. Installation

4. Remove the inner tray [A].

5. Remove the connector cover [B] ( x 1).

6. Install the bridge unit [A].

7. Open the bridge unit cover [B]

8. Secure it with the knob screw [C] and long knob screw [D].

9. Attach the frame cover [E].

10. Close the bridge unit cover [B].

62

11. Reassemble the machine.

12. Install the optional finisher (refer to the finisher installation procedure).

• Holder bracket [A] is used in the installation procedure of the finisher (D636 or D637). Do not
install it yet.

Bridge Unit (D634)

13. Turn on the main power switch of the machine.

Check the bridge unit operation.

63

2. Installation

2000-sheet booklet finisher (D637) /3000­sheet finisher (D636)

Accessory Check

Check the quantity and condition of the accessories against the following list.

No. Description Q'ty

1 Rear joint bracket 1

2 Front joint bracket 1

3 Ground (earth) plate 1

4 Tapping screws - M4 x14 4

5 Tapping screws - M3 x 8 1

6 Tapping screws - M3 x 6 2

7 Upper output tray 1

8 Support Tray 1

9 Lower output tray (D637 only) 1

10 Cushion (with double-sided tape) 1

64

2000-sheet booklet finisher (D637) /3000-sheet finisher (D636)

Installation Procedure

• Unplug the main machine power cord before starting the following procedure.

If this finisher is installed on this machine, the following options must be installed before installing this
finisher.

• Bridge Unit (D634)

• Two Tray Paper Feed Unit (D580) or LCT (D581)

65

2. Installation

1. Unpack the finisher and remove all tapes and packing materials from the finisher.

2. Open the front door, and then remove all tapes and packing materials from the inside of the
finisher.

66

2000-sheet booklet finisher (D637) /3000-sheet finisher (D636)

3. Pull out the jogger unit [A], and then remove all tapes and retainers.

4. Attach the cushion [B] to the finisher.

• Make sure that the cushion is placed within 0 to 1 mm from the edge of the cover.

5. Install the ground plate [C] on the finisher ( x 2; M3 x 6).

67

2. Installation

6. Attach the rear joint bracket [D] ( x 2; M4 x 14).

7. Attach the front joint bracket [E] and the holder bracket [F] ( x 2; M4 x 14).

• Holder bracket [F] must be placed outside the front joint bracket [E]. This bracket is provided
with the Bridge Unit (D634).

8. Pull the lock lever [G] ( x 1).

9. Slowly push the finisher to the left side of the machine, keeping its front door open until the brackets
[D] [E] go into their slots.

10. Push the lock lever [G], and then secure it ( x 1).

11. Close the front door of the finisher.

68

2000-sheet booklet finisher (D637) /3000-sheet finisher (D636)

12. Connect the finisher connector [H] to the machine.

13. Install the upper output tray [I] ( x 1; M3 x 8).

14. Only for D637, install the lower output tray [J].

15. Turn on the main power switch of the machine.

16. Check the finisher operation.

69

2. Installation

Support Tray Installation

If a stacking problem occurs several times on the upper output tray [A], put the support tray [B] on the
tray as shown.

• Keep this tray in the manual pocket if this tray does not need to be installed.

70

Punch Unit (D570)

Punch Unit (D570)

The Punch Unit (D570) is installed in the 2000-Sheet Booklet (D637) Finisher/ 3000-Sheet Finisher
(D636).

Component Check

Check the quantity and condition of the components against the following list.

No. Description Q'ty

1 Punch-out Waste Unit 1

2 Slide Drive Unit 1

3 Punch Waste Hopper 1

4 Wire harness: short-circuit 1

5 Screws: M3 x 6 5

6 Side-to-Side Detection Unit 1

7 Punching Unit 1

71

2. Installation

Installation Procedure

• Unplug the main machine power cord before starting the following procedure. If the 2000-sheet
booklet/ 3000-sheet finisher has been installed, disconnect it and pull it away from the machine.

1. Remove all tapes and shipping retainers.

72

2. If the finisher is connected to the machine, disconnect the power connector [A] and separate the
finisher from the machine.

3. Remove the rear cover [B] ( x 2) and open the front door.

• At the bottom of the rear cover, make sure to disconnect the tabs that attach the cover to the
frame.

4. Remove the guide plate [C] ( x 2).

5. Remove the shipping retainer [A] from the punch unit ( x 2).

Punch Unit (D570)

6. Move the punch unit [A] along its rails into the finisher. Make sure that the pin engages correctly at
the front and rear.

7. Connect the cables [B] of the finisher to the connectors (CN601 and CN602) on the punch unit
board ( x 2, x 1).

• The cables [B] are coiled and attached to the PCB.

73

2. Installation

8. Attach the slide drive unit [A] to the finisher and connect it to the punch unit ( x 2, x 1). Push
in the slide drive unit at when you attach the screw .

9. Make sure that the punch unit moves freely and is not blocked by the screws.

10. Put the side-to-side detection unit [A] in the machine. Make sure that the two pins are engaged
correctly at the front.

11. Make sure that the side-to-side detection unit moves smoothly on its rails. If it does not, make sure
that the rails are aligned with their grooves.

12. Attach the side-to-side detection unit and connect it at the rear ( x 2, x 1, x 1).

13. Pull the short connector out of the connector [B] then connect the cable of the finisher ( x 1).

• This is the 3-pin connector.

74

14. Connect "Wire harness: short-circuit" [A] to the CN110 connector.

Punch Unit (D570)

15. At the front, use a pair of wire cutters to remove the part [A] of the cover.

16. Install the punch-waste transport unit [B] in the finisher.

17. Make sure that the punch-waste transport unit moves smoothly on its rails. If it does not, make sure
that the rails are aligned with the grooves.

18. Remove the short connector from the connector [C].

• This is the 4-pin connector.

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2. Installation

19. Connect the cable to connector [C] and attach the punch-waste transport unit ( x 1, x 1,
x 1).

20. Set the hopper [A] in its holder.

21. Reassemble the finisher, and then install it on the main machine.

22. Connect the power cord to the outlet, and then turn the main power switch on.

23. Check the punch unit operation.

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Output Jogger Unit (B703)

Accessories

Check the accessories and their quantities against this list.

No. Description Q'ty

1 Jogger Unit 1

2 Tapping Screws M3x6 2

Output Jogger Unit (B703)

Installation

The Output Jogger Unit B703 is installed only on the 3000-Sheet Finisher (D636) and 2000-sheet
Booklet Finisher (D637).

• Always switch the machine off and unplug the machine before doing any of the following
procedures

1. Turn the main machine switch off.

2. Disconnect the finisher from the main frame.

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2. Installation

3. Use the flat head of a screwdriver to remove the left upper cover [A].

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4. Remove the cover plate [A] ( x 2). Keep the screws.

Output Jogger Unit (B703)

5. While holding the jogger unit with the connector on the left, put the hooks on the frame of the
jogger unit [A] into the holes in the left and right side of the finisher frame.

6. Connect connector [B] to the socket ( x 1).

7. Attach the jogger unit [C] to the finisher ( x 2).

8. Reattach the jogger unit cover [D] to the jogger unit ( x 2).

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2. Installation

Mail Bin (M413)

Component Check

Check the quantity and condition of the components against the following list.

No. Description Q'ty

1 Tray 4

2 Rear Hold Bracket 1

3 Front Hold Bracket 1

4 Mail Bin 1

5 Right Stay 1

6 Guide Plate 1

7 Mail Bin Solenoid 1

8 Harness 1

9 Clamp (Not used) 1

10 Screw: M3x8 2

11 Screw: M4x10 3

12 Screw: M3x6 7

13 Step Screw 2

- Decal Sheet 1

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Mail Bin (M413)

Installation Procedure

1. Open the right door.

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2. Installation

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2. Operation panel [A] ( x 2, x 1, x 2, USB x 1)

3. Remove the following:

• Screw caps [A]

• Top right cover [B] ( x 2)

• Top rear cover [C] ( x 2)

Mail Bin (M413)

4. Remove the paper exit cover [A] ( x 1).

5. Remove the top right stay [B] ( x 3).

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2. Installation

6. Install the mail bin solenoid [A] ( x 1: M3x8).

7. Connect the harness [B] and then clamp the harness with the four clamps.

8. Reinstall the top right stay [A] ( x 3).

9. Install the guide plate [B] ( x 2: M3x6).

10. Install the paper exit cover [C] ( x1).

11. Install the two step screws [D].

12. Remove the rear cover [A] ( x1).

13. Remove the top cover [B] of the mail bin unit.

14. Remove the front cover [C] ( x1).

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Mail Bin (M413)

• The front cover is connected to the mail bin unit with the harnesses. It is not necessary to
disconnect the harnesses from the front cover. However, take care not to break or disconnect
the harnesses during this installation procedure.

15. Install the mail bin unit [A] on the machine as shown above.

16. Attach the front hold bracket [A] and rear hold bracket [B] ( x 2 each).

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2. Installation

17. Release the harness [A] from the machine ( x 1).

18. Connect the harness [A] to the main board of the mail bin unit ( x 1).

19. Reinstall the top rear cover ( x 2)

20. Install the right stay [A] ( x 1).

21. Reinstall the top, front and rear covers of the mail bin unit ( x 2).

22. Reinstall the operation panel and connection cover ( x 2).

23. Close the right door.

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24. Install the tray [A] in each bin of the mail bin unit [B].

25. Plug in and turn on the machine.

26. Check the operation of the mail bin unit.

Mail Bin (M413)

87

2. Installation

Anti-Condensation Heater

• This option is provided as a service part.

Component Check

No. Description Q'ty

1 Tray heater 1

2 On-standby decal 1 (-90) or 2 (-91)

3 Harness 2 (For D579) 1

4 Harness 1 (For D580/D581) 1

5 Screw M4 x 10 2

- Installation procedure 1

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Installation Procedure

• Unplug the machine power cord before starting the following procedure.

• Do the following procedure not to damage any harnesses.

• Check that any harnesses are not damaged nor pinched after installation.

For installing the tray heater in the main machine

Anti-Condensation Heater

1. Remove trays 1 and 2 from the machine.

2. Remove the connector cover [A] ( x 1).

3. Connect the connector [B] of the heater to the connector of the main machine.

4. Install the heater [C] inside the machine ( x 1)

5. Reassemble the machine.

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2. Installation

For installing the tray heater in D580

1. Rear cover [A] ( x 6)

2. Pull out the two trays in the optional paper feed unit.

3. Install the tray heater [B] in the optional paper feed unit ( x 1).

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Anti-Condensation Heater

4. Remove the two securing brackets [C] ( x 1 each), and then the rear cover [D] of the optional
paper feed unit ( x 2).

5. Remove the harness cover bracket [E] ( x 1).

6. Pull out tray 2 from the mainframe.

7. Replace the shoulder screw [F] with the washer screw [G], using securing bracket [H] ( x 1).

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2. Installation

8. Connect the harness [I] to the connector [J] of the tray heater.

9. Route the harness [I] as shown and clamp it with four clamps ( x 4).

10. Connect the harness [I] to the connector [K] of the mainframe.

11. Reassemble the mainframe and optional paper feed unit.

For Installing the tray heater in D581

1. Remove the rear cover of the mainframe ( step 1 in "For Installing the Tray Heater in D580").

2. Pull out the LCT drawer.

• If the right tray comes out with the left tray, push the right tray into the LCT.

3. Left tray [A] ( x 2)

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4. Remove the right tray [B] while pressing down the stopper [C].

Anti-Condensation Heater

• When reinstalling the right tray, set the right tray on the guide rail and carefully push the tray
in, making sure to keep the tray level.

5. Install the tray heater [D] in the optional LCT ( x 1).

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2. Installation

6. Remove the two securing brackets [E] ( x 1 each), and the then rear cover [F] of the optional
LCT ( x 2).

7. Remove the harness cover bracket [G] ( x 1).

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8. Pull out tray 2 from the mainframe.

9. Replace the shoulder screw [7] with the washer screw [8], using the securing bracket [9] ( x 1).

10. Connect the harness [K] to the connector [L] of the tray heater.

11. Route the harness [K] as shown and clamp it with four clamps ( x 4).

12. Connect the harness [K] to the connector [M] of the mainframe.

13. Reassemble the mainframe and optional LCT.

14. Reassemble the mainframe and optional paper feed unit.

Anti-Condensation Heater

95

2. Installation

Controller Options

Overview

• Always touch a grounded surface to discharge static electricity from your hands before you handle
SD cards, printed circuit boards, or memory boards.

• If the VM card is installed, use the VM card as a target SD card.

This machine has I/F card slots for optional I/F connections and SD card slots applications.

After you install an option, check that the machine can recognize it (see "Check All Connections" at the
end of this section).

I/F Card Slots

SD Card Slots

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• Slot [A] is used for one of the optional I/F connections (only one can be installed): IEEE1284 or
IEEE802.11a/g (Wireless LAN).

• Slot [B] is used for Gigabit Ethernet.

• Slot [1] (upper) is used for optional applications (e.g.: Netware, PictBridge, IPDS unit, etc).

Controller Options

• Slot [2] (lower) is also used for installing applications, or for service only (for example, updating
the firmware).

SD Card Appli Move

Overview

The service program "SD Card Appli Move" (SP5-873) lets you move application programs from one
SD card to another SD card.

If more than one application is required, the applications must be moved to one SD card with SP5873-1
(Security Application, PictBridge, IPDS unit, etc.).

Be very careful when you do the SD Card Appli Move procedure:

• The data necessary for authentication is transferred with the application program from an SD card
to another SD card. Authentication fails if you try to use the SD card after you move the application
program from one card to another card.

• Do not use the SD card if it has been used before for other purposes. Normal operation is not
guaranteed when such an SD card is used.

• Remove the cover [A] ( x 2), and then keep the SD card in the place [B] after you move the
application program from one card to another card. This is done for the following reasons:

• The SD card can be the only proof that the user is licensed to use the application program.

• You may need to check the SD card and its data to solve a problem in the future.

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2. Installation

Move Exec

The menu "Move Exec" (SP5-873-001) lets you move application programs from the original SD card
to another SD card.

• Do not turn ON the write protect switch of the system SD card or application SD card on the
machine. If the write protect switch is ON, a download error (e.g. Error Code 44) occurs during a
firmware upgrade or application merge.

1. Turn the main switch off.

2. Make sure that a target SD card is in SD Card Slot 1 (upper). The application program is moved to
this SD card.

3. Insert the source SD card with the application program in SD Card Slot 2 (lower).The application
program is copied from this source SD card.

4. Turn the main switch on.

5. Start the SP mode.

6. Select SP5-873-001 "Move Exec".

7. Follow the messages shown on the operation panel.

8. Turn the main switch off.

9. Remove the source SD card from SD Card Slot 2 (lower).

10. Turn the main switch on.

11. Check that the application programs run normally.

Undo Exec

"Undo Exec" (SP5-873-002) lets you move back application programs from an SD card in SD Card
Slot 1 (upper) to the original SD card in SD Card Slot 2 (lower). You can use this program when, for
example, you have mistakenly copied some programs by using Move Exec (SP5-873-001).

• Do not turn ON the write protect switch of the system SD card or application SD card on the
machine. If the write protect switch is ON, a download error (e.g. Error Code 44) occurs during a
firmware upgrade or application merge.

1. Turn the main switch off.

2. Insert the original SD card in SD Card Slot 2 (lower). The application program is copied back into
this card.

3. Insert the SD card with the application program in SD Card Slot 1 (upper).The application program
is copied back from this SD card.

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4. Turn the main switch on.