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1. PRODUCT INFORMATION 1-1
1.1 SPECIFICATIONS 1-1
1.2 MACHINE CONFIGURATION 1-2
1.2.1 COPIER 1-2
1.3 GUIDANCE FOR THOSE WHO ARE FAMILIAR WITH PREDECESSOR PRODUCTS 1-5
1.4 OVERVIEW 1-6
1.4.1 COMPONENT LAYOUT 1-6
1.4.2 PAPER PATH 1-8
1.4.3 DRIVE LAYOUT 1-9
2. INSTALLATION 2-1
2.1 INSTALLATION REQUIREMENTS 2-1
2.1.1 ENVIRONMENT 2-2
2.1.2 MACHINE LEVEL 2-2
2.1.3 MINIMUM SPACE REQUIREMENTS 2-3
2.1.4 POWER REQUIREMENTS 2-3
2.2 INSTALLATION FLOW CHART 2-4
2.3 MAIN MACHINE INSTALLATION 2-5
2.3.1 ACCESSORY CHECK 2-5
2.3.2 INSTALLATION PROCEDURE 2-7
Preliminary Procedures 2-7
PCDU (Photoconductor and Development Unit) 2-10
Toner Bottle 2-13
Paper Trays 2-13
Initialize TD Sensor and Developer 2-14
Set Paper Size for Paper Trays 2-14
Electrical Total Counter 2-14
Exposure Glass Cleaner 2-15
Settings Relevant to the Service Contract 2-15
Data Overwrite Security 2-16
HDD Encryption 2-17
App 2 Me Setting (SP model only) 2-18
2.3.3 MOVING THE MACHINE 2-19
2.3.4 TRANSPORTING THE MACHINE 2-19
2.4 PAPER FEED UNIT INSTALLATION (D580) 2-20
2.4.1 ACCESSORY CHECK 2-20
2.4.2 INSTALLATION PROCEDURE 2-20
2.5 2000-SHEET LCT INSTALLATION (D581) 2-23
2.5.1 ACCESSORY CHECK 2-23
2.5.2 INSTALLATION PROCEDURE 2-23
2.6 1200-SHEET LCT INSTALLATION (D631) 2-26
2.6.1 COMPONENT CHECK 2-26
2.6.2 INSTALLATION PROCEDURE 2-27
2.7 ARDF INSTALLATION (D630) 2-29
2.7.1 COMPONENT CHECK 2-29
2.7.2 INSTALLATION PROCEDURE 2-29
2.8 1-BIN TRAY UNIT INSTALLATION (D632) 2-33
2.8.1 COMPONENT CHECK 2-33
2.8.2 INSTALLATION PROCEDURE 2-34
2.9 BRIDGE UNIT INSTALLATION (D634) 2-36
2.9.1 COMPONENT CHECK 2-36
2.9.2 INSTALLATION PROCEDURE 2-37
2.10 3000/2000-SHEET (BOOKLET) FINISHER (D636/D637) 2-41
2.10.1 ACCESSORY CHECK 2-41
2.10.2 INSTALLATION PROCEDURE 2-42
Support Tray Installation 2-45
2.11 PUNCH UNIT INSTALLATION (D570) 2-46
2.11.1 COMPONENT CHECK 2-46
2.11.2 INSTALLATION PROCEDURE 2-47
2.12 PLATEN COVER (D593) 2-52
2.13 1000-SHEET FINISHER (D588) 2-53
2.13.1 ACCESSORY CHECK 2-53
2.13.2 INSTALLATION PROCEDURE 2-54
2.14 SIDE TRAY (D635) 2-57
2.14.1 COMPONENT CHECK 2-57
2.14.2 INSTALLATION PROCEDURE 2-58
2.15 INTERNAL SHIFT TRAY (D633) 2-62
2.15.1 COMPONENT CHECK 2-62
2.15.2 INSTALLATION PROCEDURE 2-62
Rev. 04/23/2012
2.16 KEY COUNTER INSTALLATION 2-64
2.16.1 INSTALLATION PROCEDURE 2-64
2.17 KEY COUNTER INTERFACE UNIT INSTALLATION 2-66
2.17.1 INSTALLATION PROCEDURE 2-66
2.18 TRAY HEATER 2-68
2.18.1 INSTALLATION PROCEDURE 2-68
2.19 TRAY HEATER (OPTIONAL PAPER FEED UNIT) 2-70
2.19.1 COMPONENT CHECK 2-70
2.19.2 INSTALLATION PROCEDURE 2-71
For installing the tray heater in the D580 (Two-tray paper feed unit) . 2-71 For installing the tray heater in the D581 (LCT) 2-73
2.20 HDD INSTALLATION (D640-11) 2-76
2.20.1 COMPONENT CHECK 2-76
2.20.2 INSTALLATION PROCEDURE 2-77
After Installing the HDD 2-78
2.21 COPY DATA SECURITY UNIT (B829) 2-79
2.21.1 COMPONENT CHECK 2-79
2.21.2 INSTALLATION PROCEDURE 2-80
User Tool Setting 2-81
Check All Connections 2-82
2.22 BROWSER UNIT TYPE I 2-83
2.22.1 INSTALLATION PROCEDURE 2-83
2.22.2 UPDATE PROCEDURE 2-85
2.23 CARD READER BRACKET TYPE C3352 (D593) 2-87
2.23.1 COMPONENT CHECK 2-87
2.23.2 INSTALLATION PROCEDURE 2-88
2.34 FAX CONNECTION UNIT TYPE A (D629-31) (REMOTE FAX) 2-94
3. PREVENTIVE MAINTENANCE 3-1
3.1 PM TABLES 3-1
4. REPLACEMENT AND ADJUSTMENT 4-1
4.1 GENERAL CAUTIONS 4-1
4.1.1 LASER UNIT 4-1
4.1.2 USED TONER 4-1
4.2 SPECIAL TOOLS AND LUBRICANTS 4-2
4.2.1 SPECIAL TOOLS 4-2
4.2.2 LUBRICANTS 4-2
4.3 EXTERIOR COVERS 4-3
4.3.1 FRONT DOOR, UPPER AND LOWER INNER COVER 4-3
SM iii D129/D130
Rev. 09/11/2012
Upper Inner Cover 4-3
Lower Inner Cover 4-3
4.3.2 LEFT COVER 4-4
4.3.3 REAR COVER 4-4
4.3.4 RIGHT REAR COVER 4-5
4.3.5 FRONT RIGHT COVER 4-6
4.3.6 OPERATION PANEL & LCD 4-6
4.3.7 PAPER EXIT COVER 4-10
4.3.8 INNER TRAY 4-11
4.4 SCANNER 4-12
4.4.1 EXPOSURE GLASS 4-12
4.4.2 SCANNER EXTERIOR PANELS AND OPERATION PANEL 4-12
Operation panel 4-12
Scanner left cover 4-12
Scanner right cover 4-13
Scanner front cover 4-13
Scanner rear cover 4-13
4.4.3 LENS BLOCK ASSEMBLY 4-14
When reassembling 4-15
4.4.4 ORIGINAL SIZE SENSOR 4-15
4.4.5 EXPOSURE LAMP 4-17
Chromaticity rank adjustment 4-18
4.4.6 SCANNER HP SENSOR/PLATEN COVER SENSOR. 4-20
Scanner HP Sensor 4-20
Platen Cover Sensor 4-21
4.4.7 SCANNER MOTOR 4-22
4.4.8 SCANNER MOTOR DRIVE BOARD 4-24
4.4.9 FRONT SCANNER WIRE 4-24
Reassembling the Front Scanner Wire. 4-26
4.4.10 REAR SCANNER WIRE 4-29
Reassembling the Rear Scanner Wire 4-30
4.5 LASER UNIT 4-31
4.5.1 CAUTION DECAL LOCATIONS 4-31
4.5.2 LASER UNIT 4-31
4.5.3 POLYGON MIRROR MOTOR 4-33
4.5.4 LASER SYNCHRONIZATION DETECTOR 4-33
4.5.5 LD UNIT 4-34
Laser Beam Pitch Adjustment 4-34
D129/D130 iv SM
4.6 PCDU 4-37
4.6.1 PCDU (PHOTOCONDUCTOR AND DEVELOPMENT UNIT) 4-37
Reinstallation 4-37
4.6.2 DRUM 4-38
Re-installation 4-39
4.6.3 PICK-OFF PAWLS 4-40
Pick-off Pawl Position Adjustment 4-40
4.6.4 CHARGE ROLLER AND CLEANING ROLLER 4-41
4.6.5 DRUM CLEANING BLADE 4-42
Re-installation 4-42
4.6.6 ID SENSOR 4-43
4.7 DEVELOPMENT 4-44
4.7.1 DEVELOPMENT FILTER 4-44
4.7.2 DEVELOPMENT ROLLER 4-44
Cleaning Procedure 4-45
4.7.3 DEVELOPER 4-46
4.7.4 TD SENSOR 4-49
4.8 TRANSFER 4-50
4.8.1 TRANSFER BELT UNIT 4-50
4.8.2 TRANSFER BELT 4-51
4.8.3 TONER OVERFLOW SENSOR 4-53
4.8.4 TRANSFER BELT CLEANING BLADE/TONER OVERFLOW SENSOR 4-53
Transfer Belt Cleaning Blade 4-53
Toner Overflow Sensor 4-54
4.9 PAPER FEED 4-55
4.9.1 PAPER FEED UNIT 4-55
Tray 1 and Tray 2 4-55
4.9.2 PICK-UP, FEED AND SEPARATION ROLLERS 4-56
Tray 1 and Tray 2 4-56
4.9.3 TRAY LIFT MOTOR 4-57
4.9.4 RELAY, TRAY LIFT, PAPER END AND PAPER FEED SENSORS 4-58 Tray 1 and Tray 2 4-58
4.9.5 REGISTRATION SENSOR 4-59
Reinstall the registration sensor 4-60
4.10 FUSING 4-61
4.10.1 FUSING UNIT 4-61
4.10.2 WEB ROLLER UNIT 4-62
4.10.3 BRAKE PAD 4-62
4.10.4 WEB HOLDER ROLLER AND WEB ROLLERS 4-63
Installing a new web holder roller 4-65
Installing new web rollers 4-65
4.10.5 PRESSURE ROLLER CLEANING ROLLER 4-66
4.10.6 THERMOSTATS 4-67
4.10.7 THERMISTOR 4-68
4.10.8 HOT ROLLER STRIPPERS 4-69
4.10.9 FUSING LAMPS 4-70
4.10.10 HOT ROLLER AND PRESSURE ROLLER 4-71
4.11 PAPER EXIT 4-72
4.11.1 PAPER EXIT UNIT 4-72
4.11.2 FUSING EXIT, PAPER OVERFLOW, AND PAPER EXIT SENSORS 4-73
4.11.3 JUNCTION JAM SENSOR 4-73
4.11.4 PAPER EXIT MOTOR 4-74
4.12 DUPLEX 4-75
4.12.1 DUPLEX UNIT 4-75
4.12.2 RIGHT DOOR COVER 4-77
4.12.3 DUPLEX DOOR SENSOR 4-77
4.12.4 DUPLEX ENTRANCE SENSOR 4-78
4.12.5 DUPLEX EXIT SENSOR 4-79
4.12.6 DUPLEX/BY-PASS MOTOR 4-81
4.12.7 DUPLEX INVERTER MOTOR 4-82
4.13 BY-PASS 4-84
4.13.1 BY-PASS PAPER SIZE SENSOR/BY-PASS PAPER LENGTH SENSOR 4-84
When reinstalling the by-pass paper size sensor 4-86
4.13.2 BY-PASS PAPER END SENSOR 4-87
4.13.3 BY-PASS PICK-UP, FEED AND SEPARATION ROLLER, TORQUE LIMITER 4-87
4.13.4 BY-PASS FEED CLUTCH 4-88
4.14 DRIVE AREA 4-89
4.14.1 PAPER FEED CLUTCH 4-89
Tray 1 and Tray 2 4-89
4.14.2 DEVELOPMENT PADDLE MOTOR 4-90
4.14.3 TRANSFER/DEVELOPMENT MOTOR 4-90
4.14.4 DRUM MOTOR 4-91
4.14.5 FUSING MOTOR 4-91
4.14.6 WEB MOTOR 4-92
4.14.7 PAPER FEED MOTOR 4-92
4.14.8 TRANSFER BELT CONTACT MOTOR 4-93
4.14.9 REGISTRATION MOTOR. 4-93
4.14.10 TONER SUPPLY MOTOR 4-94
4.15 ELECTRICAL COMPONENTS 4-95
4.15.1 CONTROLLER UNIT 4-95
4.15.2 HDD UNIT 4-96
Before Replacing the HDD Unit 4-96
Replacement Procedure 4-96
After installing the new HDD unit 4-97
4.15.3 CONTROLLER BOARD 4-98
Before Replacing the Controller Board in the Model without HDD 4-98
Replacement Procedure 4-98
When Installing the New Controller Board 4-100
4.15.4 AFTER INSTALLING THE CONTROLLER BOARD 4-101
4.15.5 MOTHER BOARD 4-101
4.15.6 BCU 4-103
When installing the new BCU 4-104
4.15.7 IPU 4-104
4.15.8 IOB 4-105
When installing a new IOB 4-105
4.15.9 PSU 4-105
4.15.10 HIGH VOLTAGE POWER SUPPLY 4-106
4.15.11 FUSING EXHAUST FAN 4-106
When installing the fusing exhaust fan 4-106
4.15.12 CONTROLLER FAN 4-107
When installing the controller fan 4-107
4.15.13 NVRAM ON THE BCU BOARD 4-108
Replacement procedure for the NVRAM on the BCU Board 4-108
4.16 COPY ADJUSTMENTS: PRINTING/SCANNING 4-109
4.16.1 OVERVIEW 4-109
4.16.2 PRINTING 4-109
Registration - Leading Edge/Side-to-Side 4-109
Blank Margin 4-111
Main Scan Magnification 4-112
Parallelogram Image Adjustment 4-112
SM vii D129/D130
4.16.3 SCANNING 4-114
Registration: Platen Mode 4-114
Magnification 4-115
4.16.4 ADF 4-116
Registration 4-116
4.16.5 TOUCH SCREEN CALIBRATION 4-117
5. SERVICE TABLES 5-1
5.1 SERVICE PROGRAM MODE 5-1
5.1.1 SERVICE PROGRAM MODE OPERATION 5-1
Service Mode Lock/Unlock 5-1
5.1.2 SERVICE PROGRAM MODE TABLES 5-2
Service Table Key 5-2
5.2 SERVICE PROGRAM MODE TABLES 5-3
5.2.1 SP TABLES 5-3
5.3 MAIN SP TABLES-1 5-4
5.3.1 SP1-XXX: FEED 5-4
5.4 MAIN SP TABLES-2 5-13
5.4.1 SP2-XXX: DRUM 5-13
5.5 MAIN SP TABLES-3 5-18
5.5.1 SP3-XXX: PROCESS 5-18
5.6 MAIN SP TABLES-4 5-19
5.6.1 SP4-XXX: SCANNER 5-19
5.7 MAIN SP TABLES-5 5-41
5.7.1 SP5-XXX: MODE 5-41
5.8 MAIN SP TABLES-6 5-108
5.8.1 SP6-XXX: PERIPHERALS 5-108
5.9 MAIN SP TABLES-7 5-117
5.9.1 SP7-XXX: DATA LOG 5-117
5.10 MAIN SP TABLES-8 5-132
5.10.1 SP8-XXX: DATA LOG 2 5-132
5.11 MAIN SP TABLES-9 5-183
5.11.1 INPUT CHECK TABLE 5-183
Copier 5-183
Table 1: Paper Height Sensor 5-186
Table 2: Paper Size Switch 5-187
Table 3: Paper Size (By-pass Table) 5-188
APS Original Size Detection 5-189
3000/2000-Sheet (Booklet) Finisher (D636/D637) 5-190
D129/D130 viii SM
1000-Sheet Finisher (D588) 5-193
5.11.2 OUTPUT CHECK TABLE 5-194
Copier 5-194
1000-Sheet Finisher (D588) 5-199
3000 /2000-Sheet (Booklet) Finisher (D636/D637) 5-200
5.11.3 PRINTER SERVICE TABLES 5-202
SP1-XXX (Service Mode) 5-202
5.11.4 SCANNER SERVICE TABLES 5-210
SP1-xxx (System and Others) 5-210
SP2-XXX (Scanning-image quality) 5-211
5.12 UPDATING THE FIRMWARE 5-212
5.12.1 BEFORE YOU BEGIN 5-212
5.12.2 UPDATING FIRMWARE 5-213
Preparation 5-213
Updating Procedure 5-213
Error Messages 5-215
Firmware Update Error 5-215
Recovery after Power Loss 5-215
5.12.3 HANDLING FIRMWARE UPDATE ERRORS 5-216
Error Message Table 5-216
5.13 UPLOADING/DOWNLOADING NVRAM DATA 5-218
5.13.1 UPLOADING NVRAM DATA (SP5-824) 5-218
5.13.2 DOWNLOADING NVRAM DATA (SP5-825). 5-219
5.14 SELF-DIAGNOSTIC MODE 5-221
5.14.1 SELF-DIAGNOSTIC MODE AT POWER ON 5-221
5.14.2 SELF-DIAGNOSTIC TEST FLOW 5-222
5.14.3 DETAILED SELF-DIAGNOSTIC MODE 5-223
5.14.4 EXECUTING DETAILED SELF-DIAGNOSIS 5-223
5.15 USING THE DEBUG LOG 5-224
5.15.1 OVERVIEW 5-224
5.15.2 SWITCHING ON AND SETTING UP SAVE DEBUG LOG 5-224
4-Digit Entries for Keys 1 to 10 5-226
Key to Acronyms 5-227
Retrieving the Debug Log from the HDD 5-228
Recording Errors Manually 5-228
6. TROUBLESHOOTING 6-1
6.1 SERVICE CALL CONDITIONS 6-1
6.1.1 SUMMARY 6-1
SM ix D129/D130
6.1.2 SC CODE DESCRIPTIONS 6-2
SC Tables: SC1xx 6-3
SC Tables: SC2xx 6-6
SC Tables: SC3xx 6-8
SC Tables: SC4xx 6-11
SC Tables: SC5xx 6-12
SC Tables: SC6xx 6-21
SC Tables: SC7xx 6-30
SC Tables: SC8xx 6-42
SC Tables: SC9xx 6-65
6.2 ELECTRICAL COMPONENT DEFECTS 6-71
6.2.1 SENSORS 6-71
6.2.2 SWITCHES 6-75
6.3 BLOWN FUSE CONDITIONS 6-76
6.4 FUSES 6-77
D129/D130 x SM