Ricoh MP C6502SP Field Service Manual
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Ricoh MP C6502SP Field Service Manual

Ricoh MP C6502SP Field Service Manual

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Table of Contents

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Model CH-C1
Machine Code:
D135/D136/D137/D138
Field Service Manual
23 May, 2014

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Summary of Contents for Ricoh MP C6502SP

  • Page 1 Model CH-C1 Machine Code: D135/D136/D137/D138 Field Service Manual 23 May, 2014...

  • Page 3: Revision History

    Revision History Version Revision Date Revision History V1.00 2013.05.13 V2.00 2014.03.20 See page 1 "Revision History (V2.00)" . V3.00 2014.05.23 See page 4 "Revision History (V3.00)" . Revision History (V2.00) Chapter Items 2. Installation Main machine (Pro) Main machine (Office) Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) Finisher SR4110 (D707) Punch Unit PU5000 (B831)
  • Page 4 Chapter Items 5. Troubleshooting Adjustments Required for Improved Glossiness (Pro C5110S/ C5100S Only) Adjustments Required for Improved Glossiness (MP C8002SP/MP C6502SP) Margin adjustment Image Quality_Definitions of abnormal images Color spots (189mm/40mm pitch) White spots White spots with toner cores White, fish-shape stains Vertical streaks caused by contact with the toner adhering to the guide plate Roller marks...
  • Page 5 Chapter Items 5. Troubleshooting Stains in the area 76mm from the trailing edge Stains on the side edges of paper Blocking on the Paper Output Tray Streaks made by Paper Edges Grainy image Uneven image density on textured paper(Pro C5110S/C5100S Only) Small granular toner fixation (Pro C5110S/C5100S Only) Too Much Weight/Abnormal Noise on Pulling Out/Pushing In the...

  • Page 6: Revision History (V3.00)

    Chapter Items 5. Troubleshooting Proof tray detected to be full too soon Envelopes are not fed Toner rubbing off along the fold line SR4090/SR4100: Corner stapling: stapling failure/stack failure/ large misalignment SR4090/SR4100: 1st sheet of stapled stack misaligned SR4090/SR4100: Paper jam caused by the shift tray unexpectedly staying up or down SR4090/SR4100: Problem with paper stacked on the shift tray SR4100: How to improve center-folding accuracy...
  • Page 7 Chapter Items 3. Preventive Maintenance PM Parts Settings PM Counter Display: All PM Parts list: Main Menu 4. Replacement and adjustment Toner Supply Unit: Sub Hopper Unit replacement / adjustment procedure Scanner Unit: Important Notice for Scanner Heater Installation PCDU: Important notice of the newly replaced drum Image Transfer Belt Unit: Lubrication after replacement ITB Cleaning Unit: Brush when applying the lubricant powder or yellow toner...
  • Page 8 Chapter Items 5. Troubleshooting Self-Diagnostic Mode Service Call 101-195: SC187 table Jam Detection (Sensor locations) Troubleshooting for 2~3mm pitch banding Troubleshooting for White spots appear in Winter environment Troubleshooting for scratch mark Troubleshooting streaks caused by damaged fusing belt Troubleshooting fuzzy line in originating in cyan drum Troubleshooting “Shock-jitter”...

  • Page 9: Important Safety Notices

    Important Safety Notices Prevention of Physical Injury 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier 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.

  • Page 10: Safety And Ecological Notes For Disposal

    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.

  • Page 11: Warnings, Cautions, Notes

    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.

  • Page 12: Symbols, Abbreviations And Trademarks

    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 Short Edge Feed Long Edge Feed [A] Short Edge Feed (SEF) [B] Long Edge Feed (LEF) Trademarks ®...
  • Page 13 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.

  • Page 14: Table Of Contents

    TABLE OF CONTENTS Revision History..............................1 Revision History (V2.00)..........................1 Revision History (V3.00)..........................4 Important Safety Notices........................... 7 Prevention of Physical Injury.......................... 7 Health Safety Conditions..........................7 Observance of Electrical Safety Standards....................7 Safety and Ecological Notes for Disposal....................8 Laser Safety..............................8 Warnings, Cautions, Notes...........................9 Symbols, Abbreviations and Trademarks......................
  • Page 15 Dimensions..............................61 D137/D138............................61 D135/D136............................62 Power Requirements............................ 62 Input voltage level (D137/D138)....................62 Input voltage level (D135/D136)....................63 Main Machine Installation..........................64 Special Tools and Lubricants........................64 D137/D138............................64 D135/D136............................65 Installation Flow Chart..........................66 Accessory Check............................67 D137/D138............................67 D135/D136............................69 Installation Procedure (D137/D138).......................
  • Page 16 Attaching the ITB Separation Lever....................118 Attaching the Service Pocket......................123 Storing the Supply Port Cap of the Developer................125 Storing the Factory SP Sheet......................125 Attaching the decals......................... 125 Machine Level Adjustment....................... 127 Installing the Securing Bracket to Prevent the Power Cord from Falling Off........129 How to Set the Toner Cartridge.......................130 ACC (Automatic Color Calibration) Adjustment................
  • Page 17 Component Check.............................195 Installation Procedure..........................196 Cooling Fan Unit Type M2 (D770)......................202 Component Check.............................202 Common Installation Procedure for Finisher SR4090 / Booklet Finisher SR4100 and Finisher SR4110 ..................................203 Installation Procedure for Finisher SR4090/ Booklet FinisherSR4100..........212 Installation Procedure for Finisher SR4110.....................218 Information for Cooling Fan Unit Type M2.....................231 Copy Tray Type M2 (D744)........................
  • Page 18 Proof Tray Auxiliary Plate.........................291 Detecting Paper Skew........................291 Correcting Skew..........................292 Checking Side-to-Side Registration....................294 Correcting Side-to-Side Registration....................294 Mail Box CS4010 (D708) (D135/D136 Only)..................296 Accessories..............................296 Installation Procedure..........................296 Cover Interposer Tray CI4010 (D711).......................302 Accessories..............................302 Installation Procedure..........................303 Cover Interposer Tray CI4020 (D712).......................320 Accessories..............................
  • Page 19 Accessories............................376 Installation............................377 Image Adjustments: Side-to-side registration..................383 A3/11"x17" Tray Unit Type M2 (D749)....................384 Component List............................384 Installation..............................385 Copy Connector Type 3260 (B328)......................392 Accessory Check............................392 Preparation..............................392 Installation..............................393 Tab Sheet Holder Type M2 (D750)......................399 Accessories..............................399 Installation..............................
  • Page 20 Browser Unit Type M2 (D719)........................425 Accessories..............................425 Installation Procedure..........................425 Do the following steps if the customer is using the Ricoh JavaScript connected to a Web application developed by Operius/RiDP..................427 Optional Counter Interface Unit Type A (B870)..................428 Component Check.............................428 Installation Procedure..........................428...
  • Page 21 3. Preventive Maintenance Preventive Maintenance Tables........................451 Image Quality Standards..........................452 Resolution..............................452 Color shift..............................452 Magnification ratio error margin......................453 Magnification ratio error margin deviation.....................453 Pitch error margin............................453 Perpendicularity............................454 Linearity..............................454 Parallelism..............................454 Missing Image Area (D135/D136)....................... 455 Missing Image Area (D137/D138)....................... 456 Margin position............................
  • Page 22 Estimated Usage Rate/Estimated Remaining Days............... 470 Commissioning Status Report Print....................471 Initial Adjustment SP Lists..........................472 D137/D138............................. 472 D135/D136............................. 476 Cleaning Points.............................. 479 Scanner..............................479 Exposure Glass, ADF Exposure Glass, Reflective Plate, 1st Mirror, 2nd Mirror, 3rd Mirror, Original Size Sensors........................479 Laser Unit..............................481 Toner shield glass..........................
  • Page 23 Relay Sensor............................. 494 Paper Dust Collection Unit....................... 495 Duplex................................ 497 Heat Pipe Roller..........................497 Heat Pipe Drive Roller........................497 Paper Exit Roller (Drive/Idle)......................498 Inverter Feed Out Roller (Drive/Idle)....................500 Inverter Exit Roller (Drive/Idle)......................501 Paper Exit Relay Roller (Drive/Idle)....................502 Inverter Feed In Roller (Drive/Idle)....................504 Exit Transport Guide Plate (Upper/Middle/Left)................
  • Page 24 Right Middle Upper Cover (D135/D136)..................527 Right Middle Rear Cover (D137/D138)..................528 Right Middle Rear Cover (D135/D136)..................529 Right Lower Cover..........................530 Left Cover..............................532 Left Middle Cover..........................532 Left Lower Cover..........................535 Rear Cover..............................537 Rear middle cover..........................537 Rear Lower Cover..........................538 Upper Cover.............................. 539 Upper Front Cover (D137/D138)....................
  • Page 25 Checking the magnification......................562 Platen Adjustment..........................562 ADF Cover..............................563 ADF Front Cover..........................563 ADF Rear Cover..........................565 Feed Cover............................566 Original Feed Unit.............................566 Pick-up Roller / Transport Belt......................... 567 ADF Separation Roller..........................570 Original Registration Sensor........................571 Original Exit Sensor..........................572 ADF Control Board............................574 Separation Sensor / Skew Correction Sensor..................
  • Page 26 Layout (Boards)............................593 Drawer Unit Cover............................ 594 If the Drawer is Locked........................595 DUB (Drawer Unit Board).........................600 Paper Separation AC Power Pack......................600 Fusing Web Control Board-Drawer (D137/D138 only)..............601 Curled Cord............................... 602 Drawer Unit Connector..........................604 Drawer Unit Set Sensor..........................606 Drawer Unit Lock Sensor.......................... 606 Drawer Unit Handle Sensor........................
  • Page 27 Toner Cartridge Guide..........................633 Toner Supply Motor (KCMY)........................636 Scanner Unit..............................638 Exposure Glass............................638 ADF Exposure Glass / Gap Sheet (D135/D136)................639 How to Remove the ADF Exposure Glass/Gap Sheet..............639 How to Attach the ADF Exposure Glass/Gap Sheet..............640 Modification Procedure for Original Transport..................642 Replacing Parts of the ADF......................
  • Page 28 Laser Unit..............................672 Before Replacement......................... 672 Replacement............................672 How to Distinguish between the CK Laser Unit and YM Laser Unit..........674 Notes on Installation of a New Laser Unit..................676 Adjustment after Laser Unit Replacement..................676 Laser Unit Cooling Fan (Left / Right)....................... 677 PCDU................................680 Faceplate..............................
  • Page 29 Lubrication after replacement......................724 ID/MUSIC Sensors...........................725 ITB HP Sensor............................726 PTR Separation Sensor..........................726 ITB Lift (YMC) Sensor..........................727 Image Transfer Roller (K).......................... 728 Image Transfer Roller (YMC)........................729 ITB Bias Roller............................731 Transfer Power Pack/Separation Power Pack..................736 TDRB (Transfer Drive Relay Board)......................737 Anti-condensation Heater.........................738 PTR Separation Motor..........................739 AC Transfer Power Pack (D137/D138 Only)..................
  • Page 30 Fusing Unit Cover............................768 Fusing Front / Rear Cover....................... 768 Entrance Drawer Cover........................768 Exit Drawer Cover..........................769 Fusing Upper Cover......................... 770 Separation Unit..........................770 Fusing Unit Plate............................772 IH Coil Unit..............................775 Fusing Cleaning Web Unit (D137/D138 Only)................... 777 Fusing Cleaning Web (D137/D138 Only)...................
  • Page 31 PTB Fans..............................815 PTB Sensor..............................816 PTB Unit Set Sensor........................... 817 Tandem Tray..............................818 Left Tandem Tray / Right Tandem Tray....................818 Feed Roller, Pick-up Roller and Separation Roller................. 820 Paper Feed Unit for Tray 1........................821 Rear Fence Home Position Sensor / Left Tray Paper Sensor..............825 Rear Fence Return Sensor.........................826 Paper Height Sensors 1, 2, 3 / Tray Down Sensor / Right Tray Set Sensor........828 Rear End Fence Closed Sensor........................
  • Page 32 By-pass Tray Unit Separation......................855 By-pass Pick-up Roller / By-pass Feed Roller / By-pass Separation Roller........856 By-pass Tray Paper End Sensor....................... 857 By-pass Paper Width Sensor........................858 By-pass Paper Length Sensor........................859 By-pass Tray Lower Limit Sensor......................860 By-pass Tray Lift Motor..........................860 By-pass Tray Upper Limit Sensor / By-pass Paper Feed Sensor............
  • Page 33 Inverter Feed-in Sensor..........................897 Inverter Feed-out Sensor...........................899 Inverter Junction Gate Home Position Sensor..................900 Inverter Junction Gate Motor........................900 Duplex Inverter Solenoid.......................... 901 Paper Exit Left Guide Plate Sensor......................902 Paper Exit Upper Guide Plate Sensor......................903 Duplex Unit..............................904 Purge Relay Sensor / Duplex Invert Sensor....................904 Duplex Invert Solenoid..........................905 Duplex Unit Entrance Sensor........................906 Duplex Unit Sensor 1..........................
  • Page 34 Main Boards / HDD Unit..........................926 Layout................................. 926 Controller Board............................927 When installing the New Controller Board..................929 HDD Unit..............................930 After Installing the New HDD Unit....................931 Disposal of HDD Unit........................931 Reinstallation............................. 931 BCU................................932 NVRAM Replacement Procedure......................933 NVRAM on the Controller Board....................933 NVRAM (EEPROM) on the BCU.....................
  • Page 35 Drawer Unit (Front)...........................953 Drawer Unit (Rear)........................... 954 Drum Motor (KCMY) / Drum Encoder Sensor (KCMY)................ 954 Removing the Drive Exhaust Fan and the Potential Sensor Board..........958 Drum HP Sensor (D137/D138 only)......................960 Drum Cleaning Motor (KCMY)........................960 Removing the Drive Exhaust Fan and the Potential Sensor Board..........962 Development Motor (KCMY)........................
  • Page 36 Fusing Exit Exhaust Fan..........................998 Fusing Pressure Roller Exhaust Fan (D137/D138 only)............... 998 Heat Pipe Panel Exhaust Fan......................... 1000 Heat Pipe Panel Intake Fan........................1001 PTR Fusing Exhaust Fan...........................1003 ITB Motor Cooling Fan...........................1004 Ozone Exhaust Fan..........................1005 Duplex Exhaust Fans (Front / Middle / Rear)..................1006 IH Coil Power Cooling Fan........................
  • Page 37 SC300 (Engine: Charge, Development)....................1052 SC300 (Engine: Development)......................1062 Service Call 400-498..........................1075 SC400 (Engine: Around the Drum)....................... 1075 SC300/400 (Engine: Transfer/Separation, Cleaning etc.).............. 1080 Service Call 501-595..........................1107 SC500 (Engine: Paper transport 1: Paper Feed, Duplex, Transport)..........1107 SC500 (Engine: Paper Transport 2: Fusing, etc.)................1132 SC500 (Engine: Paper Transport 3: Feed, Duplex, Transport, Fusing)..........1156 SC500 (Engine: Others).........................1163 Service Call 620-689..........................
  • Page 38 Finisher SR4110 (D707).......................1333 Multi Folding Unit FD4000 (D615):.................... 1334 Mail Box CS4010 (D708)......................1336 Cover Interposer Tray CI4010 (D711)..................1337 Cover Interposer Tray CI4020 (D712)..................1337 Decurl Unit DU5020........................1338 Buffer Pass Unit Type 5020 (D751).....................1339 Plockmatic Bookletmaker.......................1340 GBC Stream Punch........................1340 Sensor Locations.............................
  • Page 39 Adjustment Procedure........................1364 Adjustment 007: Adjustments Required for Improved Glossiness............1365 Overview............................1365 Adjustments Required for Improved Glossiness (Pro C5110S /Pro C5100S)......1365 Adjustments Required for Improved Glossiness (MP C8002SP/MP C6502SP).....1366 Adjustment 008: Margin Adjustment....................1366 Overview............................1366 Margin adjustment......................... 1367 Adjustment 009: Staple misalignment (3 mm or more) occurs............
  • Page 40 Troubleshooting for Blurred Image in 189mm Pitch (OPC Drum Circumference)....1408 Troubleshooting fuzzy line in originating in cyan drum (Pro C5110S/Pro C5100S).....1409 Troubleshooting Roller marks......................1411 Troubleshooting for 2-3mm pitch banding.................. 1416 Troubleshooting for Banding Caused by the PCDU (Pro C5110S/Pro C5100S)....1418 Troubleshooting for “shock-jitter”...
  • Page 41 Troubleshooting for Envelopes Are Wrinkled................1466 Troubleshooting for Feed Direction Limitations Applied on Certain Types of Envelopes..1466 Paper Transport 003: Twining Jams......................1467 Troubleshooting for Twining Jams in the Lower Part of the Fusing Unit Caused by Insufficient Margins............................1467 Other Problems............................1470 Other 001: Drawer Unit.........................1470 Drawer Unit Lock Motor Emergency....................
  • Page 42 Cause.............................. 1503 Solution............................1503 Procedure............................1503 Problems Related to Peripheral Devices....................1507 Peripherals 001: Buffer Pass Unit Type 5020..................1507 Troubleshooting for Fan Noise Is Large..................1507 Peripherals 002: Finisher SR4090/SR4100..................1507 Troubleshooting for Proof Tray Detected to Be Full Too Soon........... 1507 Troubleshooting for Envelopes Are Not Fed................1508 Troubleshooting for toner rubbing off along the fold line............
  • Page 43 Option Board............................1548 IEEE1284 (B5955710)........................ 1548 Copy connector (B5815710)...................... 1549 Wireless Lan: 11n (D1645230)....................1550 Giga-Ethenet Board (D7306036)....................1550 6. Energy Saving Energy Saving............................. 1553 Energy Save............................1553 If the Energy Saver button is pressed during machine operation..........1553 Energy Saver Timer..........................1555 Paper Save..............................

  • Page 45: Product Information

    1. Product Information Product Overview Component Layout 1. ADF 11. Fusing Unit 2. Scanner Unit 12. Exit Transport 3. Laser Unit 13. Exit Inverter Transport 4. PCDU 14. Duplex Transport 5. Bypass Unit 15. Vertical Transport 6. ITB Unit 16. Tray 1 (Tandem Tray) 7.

  • Page 46: Paper Path

    1. Product Information 9. PTR Unit 19. Purge Tray 10. PTB Unit Paper Path 1. ADF Transport 2. Bypass Transport 3. LCIT Transport 4. Duplex Transport 5. Simplex Transport...

  • Page 47: Drive Layout

    Product Overview Drive Layout Front View 10. Cleaning Web Drive Motor : Cartridge Drive Motor : Toner Supply Transport Coil Motor 2. PTR Lift Motor 11. Cleaning Web Contact Motor 3. Registaration Motor 12. Duplex Transport Motor 4. Duplex Exit Motor 13.
  • Page 48 1. Product Information 7. Roller Shift Motor 2 16. Belt Smoothing Roller Contact Motor 8. Roller Shift Motor 1 17. Fusing Motor 9. Duplex Inverter Motor Rear View 1.Scanner Carriage Motor 14. Used Toner Bottle Collection Motor 2. Exit Motor (ADF) 15.
  • Page 49 Product Overview 4. Tray Lift Motor (ADF) 17. Bottom Plate Lift Motor : For Tray 2 : For Tray 3 5. Feed Motor (ADF) 18. Feed Motor : For Tray 2 : For Tray 3 6. Entrance Motor (ADF) 19. Transport Motor : For Tray 2 : For Tray 3 7.

  • Page 50: Machine Codes And Peripherals Configuration

    1. Product Information Machine Codes and Peripherals Configuration D137/D138 (Pro Models) Item Machine Code Call out D703-17 (NA/EU/AP) Finisher SR4090 [14] D703-21(CHN) D704-17 (NA/EU/AP) Booklet Finisher SR4100 [12] D704-21 (CHN) Output Jogger Unit Type M2 D705-01 [13] Punch Unit PU3060 NA D706-00 Punch Unit PU3060 EU D706-01...
  • Page 51 Machine Codes and Peripherals Configuration Item Machine Code Call out Copy Tray Type M2 D744-01 D709-17 (NA/TWN) LCIT RT4020 D709-27 (EU/AP/CHN) 8 1/2" x 14" Paper Size Tray Type M2 D745-17 LCIT RT4030 D710-17 Cover Interposer Tray CI4010 D711-17 [15] Cover Interposer Tray CI4020 D712-17 A3/11"x17"...
  • Page 52 1. Product Information Item Machine Code Call out ® Unicode Font Package for SAP 100 License B869-03 SD Card for Fonts Type D D641-54 Copy Data Security Unit Type G D640-41 File Format Converter Type E D377-04 IEEE1284 Interface Board Type A B679-17 IEEE802.11a/g/n Unit Type M2 D164-01...
  • Page 53 Machine Codes and Peripherals Configuration D135/D136 (Office Models) Item Machine Code Call out D703-17 (NA/EU/AP) Finisher SR4090 [13] D703-21 (CHN) D704-17 (NA/EU/AP) Booklet Finisher SR4100 [11] D704-21 (CHN) Output Jogger Unit Type M2 D705-01 [12] Punch Unit PU3060 NA D706-00 D706-01 (EU/AP) Punch Unit PU3060 EU D706-03 (CHN)
  • Page 54 1. Product Information Item Machine Code Call out Copy Tray Type M2 D744-01 D709-17 (EU) LCIT RT4020 D709-27 (NA/AP/CHN) 8 1/2" x 14" Paper Size Tray Type M2 D745-17 LCIT RT4030 D710-17 Cover Interposer Tray CI4010 D711-17 Cover Interposer Tray CI4020 D712-17 A3/11"x17"...
  • Page 55 Machine Codes and Peripherals Configuration Item Machine Code Call out D719-10 (NA) Postscript3 Unit Type M2 D719-11 (EU) D719-12 (AP) D719-15 (NA) IPDS Unit Type M2 D719-16 (EU) D719-17 (AP) ® Unicode Font Package for SAP 1 License B869-01 ® Unicode Font Package for SAP 10 License B869-02...

  • Page 56: Specifications

    1. Product Information Specifications See "Appendices" for the following information: • General Specifications • Supported Paper Sizes • Software Accessories • Optional Equipment...

  • Page 57: Guidance For Those Who Are Familiar With Predecessor Products

    Guidance for Those Who are Familiar with Predecessor Products Guidance for Those Who are Familiar with Predecessor Products New features of D137/D138 and D135/D136 Developed Image Quality Items Description D137/D138 D135/D136 The CH-C1 series adopts new chemical New Chemical toner in order to enhance image quality Toner and meet the demand of higher image quality in commercial printers.

  • Page 58: Improvement Of The Scratch Mark Issue

    1. Product Information Items Description D137/D138 D135/D136 CH-C1 Pro supports DEMS in order to adjust the toner adhesion and banding. When the gap between development roller and OPC drum changes, color DEMS (3*) inconsistency will occur due to changes in toner adhesion. CH-C1 Pro supports DEMS in order to adjust the toner adhesion.

  • Page 59: Developed Printing Quality Of Textured Paper

    Guidance for Those Who are Familiar with Predecessor Products Developed Printing Quality of Textured Paper Items Description D137/D138 D135/D136 In order to improve printing quality on textured media, CH-C1 Pro uses AC AC transfer transfer. This can increase toner transfer to the media by generating better adherence between toner and ITB.

  • Page 60: Controller Features

    1. Product Information Items Description D137/D138 D135/D136 Toner cartridge replacement during Toner Replacement machine operation Controller features Items Description D137/D138 D135/D136 Capture of part of the controller and Capturing log engine log contents onto an SD card (operation possible from the LCD)

  • Page 61: Installation

    2. Installation Installation Requirements • Install the machine in a safe place to maintain security. • Make sure that the operation instructions are kept at the customer's hand. Environment Temperature Range: 10°C to 32°C (50°F to 90°F) Humidity Range: 15% to 80% RH Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight.) Ventilation:...

  • Page 62: Minimum Space Requirements

    2. Installation 1. Avoid areas exposed to sudden temperature changes: 1) Areas directly exposed to cool air from an air conditioner. 2) Areas directly exposed to heat from a heater. 2. Do not place the machine where it will be exposed to corrosive gases. 3.

  • Page 63: Dimensions

    Installation Requirements Dimensions D137/D138...

  • Page 64: D135/D136

    2. Installation D135/D136 Power Requirements • Make sure that the wall outlet is near the main machine and easily accessible. Make sure the plug is firmly inserted in the outlet. • Avoid multi-wiring. • Be sure to ground the machine. •...

  • Page 65: Input Voltage Level (D135/D136)

    Installation Requirements Destination Model Power supply voltage Rated current consumption D137 220 to 240V 12 to 10A D138 220 to 240V 12 to 10A D137 220 to 240V 12 to 10A D138 220 to 240V 12 to 10A Input voltage level (D135/D136) Destination Model Power supply voltage...

  • Page 66: Main Machine Installation

    2. Installation Main Machine Installation Special Tools and Lubricants D137/D138 The following special tools should be prepared for maintenance of this model in the field: Unique or Common: U: Unique for this model C: Common with listed Item Part Number Description Q’ty Unique or Common...

  • Page 67: D135/D136

    Main Machine Installation D135/D136 The following special tools should be prepared for maintenance of this model in the field: Unique or Common: U: Unique for this model C: Common with listed Item Part Number Description Q’ty Unique or Common D0159501 ZINC STEARATE C (*1) D0159500...

  • Page 68: Installation Flow Chart

    2. Installation Installation Flow Chart...

  • Page 69: Accessory Check

    Main Machine Installation Accessory Check D137/D138 Q’ty Description D137 D138 PCU Pocket Developer Funnel Tube Type Lamp Operation Panel Arm Upper Cover Operation Panel Arm Cover Operation Panel Rear Cover Operation Panel Arm Screw Cover Tapping Screw - 3 x 6 Printing Sample Paper (White, 100 sheets) Decal - ADF Paper Set...
  • Page 70 2. Installation Q’ty Description D137 D138 Sheet - Logo (NA Only) Decal - Caution: ADF Paper Set Sheet - Exposure Glass Power Supply Cord Sheet - Application : Multi Language Sheet - Pro Sheet - Scanner Protection Sheet - Safety (EU Only) Decal - EMC Address (EU Only) Sheet - TEL Name (CHN Only) Guarantee (CHN Only)

  • Page 71: D135/D136

    Main Machine Installation D135/D136 Q’ty Description D135 D136 PCU Pocket Developer Funnel Decal - Paper Size...
  • Page 72 2. Installation Q’ty Description D135 D136 Decal - Paper Set Direction Decal - Function : Multi Language Decal - ADF Paper Set Leveling Shoes Cloth - DF Exposure Glass Cloth Holder Development Cap Rivet - Dia5 Logotype Plate (NA/EU/AP/TWN Only) Sheet - Logo (NA/EU/AP/TWN Only) Decal - Caution: ADF Paper Set Decal - Paper Feed (NA/CHN Only)
  • Page 73 Main Machine Installation Q’ty Description D135 D136 CD-ROM-Driver CD-ROM-OI (NA/AP/TWN Only) CD-ROM-OI (EU Only) Sheet - EULA Sheet: 20 languages Seal - Caution: 20 languages Operation Instructions Sheet - Security Password...

  • Page 74: Installation Procedure (D137/D138)

    2. Installation Installation Procedure (D137/D138) 1. Unpack the machine and remove all the wrapping. 2. Place the machine at the installation site. 3. Remove all filament tape from the machine. 4. Open the tandem tray [A] and remove the filament tape at the duplex unit [B]. 5.
  • Page 75 Main Machine Installation 6. Open the ADF [A] and release the lever to open the white board. Then remove the protection sheet. 7. Remove the power cable from paper tray 2. 8. Remove the operation panel from paper tray 3.

  • Page 76: Removing The Retainers Of The Charge Roller Units (C, M, K)

    2. Installation Removing the Retainers of the Charge Roller Units (C, M, K) The shipping retainers [A] must be removed from the charge roller units (C, M, K). • These retainers is not included in the Yellow (Y) charge roller unit. 1.
  • Page 77 Main Machine Installation • Make sure to hold down the lock lever ([A] in the photo below) when you pull out the unit. (The unit is locked in place by this lever). 2. Close the drawer unit. • When you push the unit back in to the machine, you can close the guide plate [A] of the paper exit and duplex unit.
  • Page 78 2. Installation 3. Remove the ITB cleaning intake fan [A] together with the duct ( x 1). 4. Open the front cover of the toner supply unit [A]. 5. Remove the fixing screws of the toner supply unit [A] ( x 3).
  • Page 79 Main Machine Installation 6. Pull out the toner supply unit [A]. 7. Remove the toner supply unit [A]. ( x2) 8. Remove the filament tape [A] from the faceplate.
  • Page 80 2. Installation 9. Remove the screws fixing the face plate ( x6). 10. Remove the handles. 11. Attach the handles and pull out the units slowly and evenly.
  • Page 81 Main Machine Installation 12. Hold the grips and remove the face plate. 13. Remove all filament tapes [A] of Magenta and Cyan units.
  • Page 82 2. Installation 14. Unlock the lever [A] and pull out the PCDU [B] from the machine. 15. Place the PCDU [A] on the PCU stand [B]. 16. Remove the charge roller unit and place it on a clean, flat, and level surface with the roller facing up ( x2).
  • Page 83 Main Machine Installation • Make sure that the surface is flat and level. 17. Remove the filament tape [A] and retainers [B] from both ends of the charge roller unit. 18. Reattach the charger roller unit and PCDU, and then attach the face plate. •...

  • Page 84: Attaching The Itb Separation Lever

    2. Installation [A]: The locking lever is properly fit into the hole in the machine frame. [B]: The locking lever is not properly fit into the hole in the machine frame. Attaching the ITB Separation Lever When unpacking the machine, the ITB separation lever is not yet attached to the correct location. During machine installation, you must install the lever.
  • Page 85 Main Machine Installation 2. Drawer unit cover [A] ( x 7*) * D137/D138 use TCRU screws 3. Close the drawer unit • After removing the drawer unit cover, when the drawer unit is returned to the machine, you can close the guide plate [A] of the paper exit and duplex unit.
  • Page 86 2. Installation • When the drawer unit is pushed back into the machine, it is locked in place by the lock lever [A]. (Make sure to hold down this lever whenever pulling out the unit). 4. ITB cleaning intake fan [A] along with the duct ( x 1*). * D137/D138 use TCRU screws 5.
  • Page 87 Main Machine Installation 6. Remove the fixing screws of the toner supply unit [A] ( x 3*). * D137/D138 use TCRU screws 7. Slide the toner supply unit [A] to the front.
  • Page 88 2. Installation 8. Attach the ITB separation lever [A] horizontally from the right side of the machine. 9. Turn the ITB separation lever [A] clockwise until it is vertical.

  • Page 89: Operation Panel Attachment

    Main Machine Installation 10. Return the toner supply unit to the machine and secure it with the screws. 11. Attach the ITB cleaning intake fan and drawer unit cover Operation Panel Attachment 1. In order to easily remove the right middle upper cover [A], remove the fixing screws on the left side of the rear middle cover [B] ( x 2).
  • Page 90 2. Installation • Check the position of the hooks in the photo below before removing. 3. Attach the arm stay [A] for the operation panel ( x 5).
  • Page 91 Main Machine Installation 4. Attach the operation panel arm ( x 5, x 3). • Position the hook of the operation panel arm [A] over the arm stay [B].
  • Page 92 2. Installation 5. Open the by-pass tray unit and attach the arm cover [A] ( x 2). 6. Attach the screw covers [B] on the arm cover [A]. 7. Attach the operation panel [A] to fit the hook of the operation panel arm [B].
  • Page 93 Main Machine Installation 8. Secure the operation panel [A] ( x 4, x 3). 9. Attach the rear cover [A] ( x 3) and the screw cover [B].
  • Page 94 2. Installation 10. Attach the arm upper cover [A] ( x 2) and the screw covers [B]. 11. Remove the protection sheet [A].

  • Page 95: Operator Call Light Attachment

    Main Machine Installation Operator Call Light Attachment 1. Connect the machine and operation call light [A] ( x 1). 2. Fold back the harness [A] and clamp it. 3. Attach the operation call light [A] ( x 3).

  • Page 96: Attaching The Service Pocket

    2. Installation • When attaching the operator call light, be careful not to pinch the harness. Fix the light after it was confirmed visually from the front and back. Attaching the Service Pocket When Attaching to the Machine 1. Attach the service pocket [A] for the funnel/PCU holder to the left lower (rear) (rivet x 2). Put the funnel [B], PCU holder [C] and Development roller/Drum rotation tools into the service pocket.
  • Page 97 Main Machine Installation When Attaching to the Finisher • Finisher SR4090/ Booklet Finisher SR4100: Attach to the following locations. Rear side (upper): Operating instructions [A] Rear side (lower): Funnel/ PCU holder [B] • Finisher SR4110: Attach to the following locations. Rear side (upper): Operating instructions [A] Rear side (lower): Funnel/ PCU holder [B]...

  • Page 98: Storing The Supply Port Caps For The Developer

    2. Installation Storing the Supply Port Caps for the Developer TCRU/ORU Contracts When a TCRU/ORU user removes the PCDU from the machine, they must use the caps (x 4) to prevent developer spill. When installing the machine, attach the caps [A] to the clamping position shown below.

  • Page 99: Storing The Factory Sp Sheet

    Main Machine Installation Storing the Factory SP Sheet On a newly delivered machine, the factory SP sheet is located on the exposure glass. Open the tandem tray [A], and remove the paper cassette decal [B]. Confirm that the factory SP sheet [C] is stored inside.
  • Page 100 2. Installation • [B]: ADF caution decal for CHN • [C]: ADF caution decal for other countries 2. Attach the ADF caution decal to the position [A] on the ADF. 3. Attach the ADF paper set decal [A] in the indentation in the ADF.

  • Page 101: Machine Level Adjustment

    Main Machine Installation 4. According to the paper that will be used by the customer, select and attach the following decals to the 1st tray, 2nd tray and 3rd tray. RTB 155 Attach a protective sheet to the tandem tray. •...
  • Page 102 2. Installation 1. Place the four shoes [A] below the bolts [B] under each corner of the machine. 2. Turn the nuts [B] to lower the bolt until the bolts reach the leveling shoes [A]. Example below: Front side • Use a wrench to raise or lower the nuts. 3.

  • Page 103: Installing The Securing Bracket To Prevent The Power Cord From Falling Off

    Main Machine Installation • When the left side of the machine is lower: Lower the nuts of the left side of the machine (front and rear) to lift the left side of the machine. 5. Open the ADF, and then place the level [A] along the side. 6.

  • Page 104: How To Set The Toner Cartridge

    2. Installation • D137/D138 machines have two power cords. Install a securing bracket for each power cord. How to Set the Toner Cartridge • Be careful when setting the toner cartridges because the toner cartridges have different shapes, and the cartridge may be damaged if you try to force a cartridge into the wrong place. The position of the toner cartridges is Y, M, C, K from the left.
  • Page 105 Main Machine Installation 2. Unpack the new toner cartridge. 3. Reverse the toner cartridge and shake 5-6 times while grasping both ends. 4. Set each color toner cartridge. Push the toner cartridge until it locks into place. • Make sure to remove the retainer before installing the K toner catridge.

  • Page 106: Executing Dems

    2. Installation Executing DEMS Execute DEMS (SP3-040-001) to correct uneven image density. ACC (Automatic Color Calibration) Adjustment 1. Check that there are no clamps or other parts that you forgot to remove. Then, plug the power cord into the power source. 2.

  • Page 107: Checking The Copy Image With Color Chart

    Main Machine Installation Checking the copy image with color chart If you want to install any options, install them using the installation procedure before doing the procedure below. 1. Switch the machine to copier mode. 2. Make sure that there is A3 or DLT paper in one of the trays. 3.
  • Page 108 2. Installation 5. Turn the machine main power ON. 6. Make sure that the data version of the SD card is newer than the data version of the flash ROM on the controller. If it is not, store the latest data version of the Paper Library onto an SD card. •...

  • Page 109: Installation Procedure (D135/D136)

    Main Machine Installation Adjustment Setting for SP mode SD slot Skilled Operators Custom Back up Slot on operation panel paper Restore Slot on operation panel Library Back up Upper slot Saved paper Yes: Restore Lower slot Library SP5-711-002 How to back up and restore Custom paper library/Saved paper library in Adjustment Settings for Skilled Operators 1.
  • Page 110 2. Installation 4. Open the tandem tray [A] and remove the filament tape at the duplex unit [B]. 5. Remove the filament tape and the cushion at the ADF.
  • Page 111 Main Machine Installation 6. Open the ADF [A] and release the lever to open the white board. Then remove the protection sheet. 7. Remove the power cable from paper tray 2.

  • Page 112: Removing The Retainers Of The Charge Roller Units (C, M, K)

    2. Installation 8. Remove the protection sheet Removing the Retainers of the Charge Roller Units (C, M, K) The shipping retainers [A] must be removed from the charge roller units (C, M, K). • These retainers is not included in the charge roller unit Y.
  • Page 113 Main Machine Installation 1. Pull out the drawer unit and remove its cover [A] ( x7). • Make sure to hold down the lock lever ([A] in the photo below) when you pull out the unit. (The unit is locked in place by this lever).
  • Page 114 2. Installation 2. Close the drawer unit. • When you push the unit back in to the machine, you can close the guide plate [A] of the paper exit and duplex unit. 3. Remove the ITB cleaning intake fan [A] together with the duct ( x 1). 4.
  • Page 115 Main Machine Installation 5. Remove the fixing screws of the toner supply unit [A] ( x 3). 6. Pull out the toner supply unit [A].
  • Page 116 2. Installation 7. Remove the toner supply unit [A]. ( x2) 8. Remove the filament tape [A] from the faceplate. 9. Remove the screws fixing the face plate. ( x6) 10. Remove the handles.
  • Page 117 Main Machine Installation 11. Attach the handles and pull out the units slowly and evenly. 12. Hold the grips and remove the face plate. 13. Remove all filament tape [A] of Magenta and Cyan units.
  • Page 118 2. Installation 14. Unlock the lever [A] and pull out the PCDU [B] from the machine. 15. Place the PCDU [A] on the PCU stand [B].
  • Page 119 Main Machine Installation 16. Remove the charge roller unit and place it on a clean, flat surface with the roller facing up ( x2). • Make sure that the surface is flat and level. 17. Remove the filament tapes [A] and retainers [B] from both ends of the charge roller unit. 18.

  • Page 120: Attaching The Itb Separation Lever

    2. Installation • After attaching the face plate, check the status of the locking levers again by looking through the holes as shown. [A]: The locking lever is properly fit in the hole in the machine frame. [B]: The locking lever is not properly fit in the hole in the machine frame. Attaching the ITB Separation Lever When unpacking the machine, the ITB separation lever is not yet attached to the correct location.
  • Page 121 Main Machine Installation 2. Drawer unit cover [A] ( x 7) 3. Close the drawer unit • After removing the drawer unit cover, when the drawer unit is returned to the machine, you can close the guide plate [A] of the paper exit and duplex unit.
  • Page 122 2. Installation • When the drawer unit is pushed back into the machine, it is locked in place by the lock lever [A]. (Make sure to hold down this lever whenever pulling out the unit). 4. ITB cleaning intake fan [A] along with the duct ( x 1). 5.
  • Page 123 Main Machine Installation 6. Remove the fixing screws of the toner supply unit [A] ( x 3). 7. Slide the toner supply unit [A] to the front.
  • Page 124 2. Installation 8. Attach the ITB separation lever [A] horizontally from the right side of the machine. 9. Turn the ITB separation lever [A] clockwise until it is vertical.

  • Page 125: Attaching The Service Pocket

    Main Machine Installation 10. Return the toner supply unit to the machine and secure it with the screws. 11. Attach the ITB cleaning intake fan and drawer unit cover Attaching the Service Pocket When Attaching to the Machine 1. Attach the service pocket [A] for the funnel/PCU holder to the left lower (rear) (rivet x 2). Put the funnel [B], PCU holder [C], Development roller/Drum rotation tools and development caps into the service pocket.
  • Page 126 2. Installation • Finisher SR4110: Attach to the following locations. Rear side (upper): Operating instructions [A] Rear side (lower): Funnel/ PCU holder [B]...

  • Page 127: Storing The Supply Port Cap Of The Developer

    Main Machine Installation Storing the Supply Port Cap of the Developer Store the caps [A] (x 4) in the service pocket for the operating instructions. Use them during maintenance if needed. Storing the Factory SP Sheet On a newly delivered machine, the factory SP sheet is located on the exposure glass. Open the tandem tray [A], and remove the paper cassette decal [B].
  • Page 128 2. Installation • [B]: ADF caution decal for CHN • [C]: ADF caution decal for other countries 2. Attach the ADF caution decal to the position [A] on the ADF. 3. Attach the ADF paper set decal [A] in the indentation in the ADF.

  • Page 129: Machine Level Adjustment

    Main Machine Installation 4. According to the paper set by customer, select and attach the following decals to the 1st tray, 2nd tray and 3rd tray. RTB 155 Attach a protective sheet to the tandem tray. • Paper brand can be written on the blank space. Machine Level Adjustment When installing the main machine, make the machine level.
  • Page 130 2. Installation 1. Place the four shoes [A] below the bolts [B] under each corner of the machine. 2. Turn the nuts [B] to lower the bolt until the bolts reaches to the leveling shoes [A]. Example below: Front side •...

  • Page 131: Installing The Securing Bracket To Prevent The Power Cord From Falling Off

    Main Machine Installation • When the left side of the machine is lower: Lower the nuts of the left side of the machine (front and rear) to lift the left side of the machine. 5. Open the ADF, and then place the level [A] along the side. 6.

  • Page 132: How To Set The Toner Cartridge

    2. Installation • D135/D136 machines have two power cords. Install a securing bracket for each power cord. How to Set the Toner Cartridge • Be careful when setting the toner cartridges because the toner cartridges have different shapes, and the cartridge may be damaged if you try to force a cartridge into the wrong place. The position of the toner cartridges is Y, M, C, K from the left.

  • Page 133: Acc (Automatic Color Calibration) Adjustment

    Main Machine Installation 2. Unpack the new toner cartridge. 3. Reverse the toner cartridge and shake 5-6 times while grasping both ends. 4. Set each color toner cartridge. Push the toner cartridge until it locks into place. ACC (Automatic Color Calibration) Adjustment 1.

  • Page 134: Checking The Copy Image With The Color Chart

    2. Installation Checking the copy image with the color chart If you want to install any options, install them using the installation procedure before doing the procedure below. 1. Switch the machine to copier mode. 2. Make sure that there is A3 or DLT paper in one of the trays. 3.
  • Page 135 Main Machine Installation • If encryption is enabled after data has been stored on the disk, or of the encryption key is changed, this process can take up to three and a half hours or more. The machine cannot be operated while data is being encrypted. Once the encryption process begins, it cannot be stopped.
  • Page 136 2. Installation Installation Procedure 1. Connect the network cable if it needs to be connected. 2. Turn on the main power switch. 3. Go into the SP mode and push “EXECUTE” in SP5-878-001. 4. Exit the SP mode and turn off the operation switch. Then turn off the main power switch. 5.
  • Page 137 Main Machine Installation The icon [2] is lit when there is no temporary data to be overwritten. HDD Encryption Before You Begin the Procedure: 1. Make sure that the following settings (1) to (3) are not at the factory default settings. (1) Supervisor login password (2) Administrator login name (3) Administrator login password...
  • Page 138 2. Installation 6. Select the data to be carried over to the hard disk and not be reset. To carry all of the data over to the hard disk, select [All Data]. To carry over only the machine settings data, select [File System Data Only]. To reset all of the data, select [Format All Data].
  • Page 139 Main Machine Installation 8. Press [Exit] to remove the following message. 9. Press [Exit] again. 10. Press the [User Tools/Counter] key. • After step 10, the initial operation display appears as below. However, HDD data encryption has not been completed at this moment. Step 11 and step 12 should be performed in order to encrypt the HDD data.
  • Page 140 2. Installation 11. Turn the main power switch off and on. 12. "Memory Conversion complete. Turn the man power switch off" is displayed as below. Then turn the main power switch off and on. 13. Then initial operation display appears again. After this step, HDD data encryption has already been completed.
  • Page 141 Main Machine Installation Check the Encryption Settings 1. Press the [User tools/Counter] key. 2. Press [System Settings]. 3. Press [Administrator Tools]. 4. Press [Machine Data Encryption Settings].
  • Page 142 2. Installation 5. Please confirm whether the encryption has been completed or not on this display. Print the encryption key Use the following procedure to print the key again if it has been lost or misplaced. 1. Press the [User tools/Counter] key. 2.

  • Page 143: Moving The Machine

    Main Machine Installation Encryption key sample The encryption key is printed out as a sheet of paper like the example shown above. Please instruct the customer to keep it in a safe place. Moving the Machine Moving the SR4090/SR4100 finishers D137/D138 RTB 25 1.
  • Page 144 2. Installation the machine at the places marked with red rectangles below, and then lift the machine slightly to get over the uneven surface. • When you move the machine, face the left or right side of the machine toward the direction of movement.

  • Page 145: D135/D136

    Main Machine Installation D135/D136 1. Turn off the main power switch, and then unplug the power cable from the main machine. 2. Close all the doors and trays that are openable and closable, and then secure them in place with shipping tape.
  • Page 146 2. Installation...

  • Page 147: Finisher Sr4090 (D703) /Booklet Finisher Sr4100 (D704)

    Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) Accessory Check Check the quantity and condition of the accessories against the following list. Q’ty Description SR4090 SR4100 Lower output tray Shift Auxiliary Tray (use only when the Multi-Folding Unit FD4000 is installed.) Proof Auxiliary Tray Cushion (with double-sided tape)

  • Page 148: Installation Procedure

    2. Installation Installation Procedure • Always switch the machine off and unplug the machine before doing the following procedure. 1. Unpack the finisher and remove all tapes and packing materials from the finisher. 2. Open the front door [A], and then remove all tapes and packing materials from the inside of the finisher.
  • Page 149 Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) 4. Remove the upper bracket with the red tag attached [A] ( x 2). 5. Remove the lower bracket with the red tag attached [A] ( x 2). 6. Install the docking bracket [A] on the finisher. ( x 2; M3 x 6 )
  • Page 150 2. Installation 7. Attach the Cover: Right Upper [A] to the finisher. ( x 2) • If the Cover Interposer Tray CI4010 (D711) is to be installed, DO NOT attach the Cover: Right Upper. 8. Install the ground plate [B] on the finisher. ( x 2; M3 x 6 )
  • Page 151 Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) 9. Attach the cushion [A] to the finisher. • Make sure that the cushion is placed within 0 to 1 mm from the edge of the cover. 10. Secure the docking bracket [A] with the screws in the center of each elliptical screw hole ( x 4; M4x20).
  • Page 152 2. Installation 11. Attach the Seal Coupling [A] to the left side of the copier. 12. Remove the connector cover [A] from the main machine. 13. Open the front door [A] of the finisher, and pull the lock lever [B]. ( x 1)
  • Page 153 Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) 14. Slowly push the finisher against the left side of the machine, keeping its front door open until the brackets go into their slots. 15. Push the lock lever [A], and then secure it ( x 1). 16.
  • Page 154 2. Installation 17. Close the front door of the finisher. 18. Install the upper output tray [A] ( x 1; M3 x 8). 19. Only for D704, install the lower output tray [A]. 20. Turn on the main power switch of the machine.

  • Page 155: Auxiliary Trays

    Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) 21. Check the finisher operation. 22. Print out five A3 or DLT sheets to the proof tray and check the side-to-side registration as follows: A3 sheets: Use the scale marks on the FRONT exit roller [B]. •...
  • Page 156 2. Installation • The trailing edges of excessively curled or Z-folded paper can activate the tray full sensors before the tray is actually full. • Once the "Exit Tray Full" message displays, the job cannot continue until some sheets are removed from the tray which is only partially full.
  • Page 157 Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) Proof Support Tray Install the proof support tray [A] on the proof tray when the trailing edges of paper are excessively curled.

  • Page 158: Output Jogger Unit Type M2 (D705)

    2. Installation Output Jogger Unit Type M2 (D705) This option is for the Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704) only. It jogs the sheets delivered to the finisher shift tray. Component Check Check the quantity and condition of the accessories against the following list. Description Jogger Unit Tapping Screws M3 x 6...
  • Page 159 Output Jogger Unit Type M2 (D705) 3. Use the flat head of a screwdriver to remove the left upper cover [A]. (hook x 3) 4. Rear cover [A] ( x 2)
  • Page 160 2. Installation 5. Open the clamp [A] to release the connector [B]. 6. Connect the connector to the upper left cover and close the clamp.. 7. Attach the rear cover [A] ( x 2)
  • Page 161 Output Jogger Unit Type M2 (D705) 8. Attach the jogger unit [A] to the finisher. ( x 2) • When you install the jogger unit, put the hooks of the frame of the jogger unit into the holes in the left and right sides of the finisher frame. 9.
  • Page 162 2. Installation 10. Reattach the jogger unit cover [A] to the jogger unit ( x 2).

  • Page 163: Punch Unit Pu3060 (D706)

    Punch Unit PU3060 (D706) Punch Unit PU3060 (D706) Accessory Check Check the quantity and condition of the accessories against the following list. Description Paper Chip Guide Hopper Bracket Punch Unit Slide Stay Registration Guide Plate Registration Sensor Bracket Punch Unit Punch Waste Hopper Stepper Motor Bracket Harness Connector Cable-PCB...

  • Page 164: Installation Procedure

    2. Installation Installation Procedure • Always switch the machine off and unplug the machine before doing the following procedure. 1. If the finisher is connected to the machine, disconnect it. 2. If the finisher is installed on the machine, remove it. 3.
  • Page 165 Punch Unit PU3060 (D706) 5. Open the front door [A], and then remove the punch hopper bracket [B]. ( x 2 ) 6. Pull out the stapling unit [A]. (Booklet Finisher SR4100 (D704) only) 7. Remove the inner upper cover [A] from the front side of the finisher. ( x 2)
  • Page 166 2. Installation • Disconnect the harness from the back side of the inner upper cover when you remove the inner upper cover. 8. Remove screw [A] of the transport guide plate from the rear side of the finisher. ( x 1 )
  • Page 167 Punch Unit PU3060 (D706) 9. Remove the transport guide plate [A]. 10. Install the punch unit slide stay [A] from the rear side of the finisher. 11. Fasten the punch unit slide stay. (Front side [A]: x 2, Rear side [B]: x 2) •...
  • Page 168 2. Installation • Rear side: 12. Insert the paper chip guide [A] into the finisher as shown below. 13. Install the paper chip guide. (Front side [A]: hook x 2, Rear side [B]: hook x 2, snap ring x 1)
  • Page 169 Punch Unit PU3060 (D706) • Hook the paper chip guide onto the front side of the finisher first, and then hook it onto the rear side of the finisher. • Front side: • Rear side: 14. Fasten the paper chip guide with an E-ring from the rear side of the finisher. (snap ring x 1)
  • Page 170 2. Installation • When fastening the paper chip guide with the snap ring, make sure the front side of the paper chip guide is hooked onto the small-diameter slot [A]. 15. Insert the hopper bracket [A] into the finisher as shown below.
  • Page 171 Punch Unit PU3060 (D706) 16. Hook the hopper bracket onto the frame [A] [B] of the finisher.
  • Page 172 2. Installation • Make sure the hooks [A] and [B] of the hopper bracket are also hooked onto the finisher.
  • Page 173 Punch Unit PU3060 (D706) 17. Fasten the hopper bracket [A]. ( x 2)
  • Page 174 2. Installation 18. Route the harness of the hopper bracket [A] inside the finisher as shown. 19. Route the harness of the hopper bracket to the rear side of the finisher. (locking edge saddle x 1, x 3) 20. Insert the registration guide plate [A] from the rear side of the finisher. •...
  • Page 175 Punch Unit PU3060 (D706) 21. Fasten the registration guide plate. (front side: x 1, rear side: x 1) • Front side: • Rear side:...
  • Page 176 2. Installation 22. Inert the registration sensor bracket from the rear side of the finisher. • Hook [A] of the registration sensor bracket into the slotted holes of the finisher. 23. Fasten the registration sensor bracket. (rear side: x 2)
  • Page 177 Punch Unit PU3060 (D706) 24. Inert the punch unit [A] from the rear side of the finisher. • Make sure the shaft [A] on the finisher is inserted into the punch unit [B].
  • Page 178 2. Installation • When inserting the punch unit, make sure the bracket [A] of the punch unit is in the right position as shown below. 25. Fasten the punch unit. (rear side: x 2)
  • Page 179 Punch Unit PU3060 (D706) • Make sure the bracket of the punch unit fits the embossed parts [A] on the finisher. 26. Install the stepper motor bracket [A] from the rear side of the finisher.
  • Page 180 2. Installation • Insert the hole [A] of the stepper motor bracket into the shaft [B] on the rear side of the finisher. • Make sure the rack [A] of the punch unit is engaging with the pinion [B] of the stepper motor bracket when you insert the stepper motor bracket.
  • Page 181 Punch Unit PU3060 (D706) 28. Connect the harness [A] of the registration sensor bracket to the harness [B] from the hopper bracket. ( x 1) 29. Connect the harness [A] of the registration sensor bracket to the harness [B] from the punch unit. x 1)
  • Page 182 2. Installation 30. Connect the harness connector cable provided with the punch unit to the main board [A] of the finisher. ( x 2) • The end that is split into two connectors must be connected to the main board. 31.
  • Page 183 Punch Unit PU3060 (D706) • Route the harness inside the I/F bracket [A] as shown below. 32. Connect the harness connector cable to the PCB [A] on the punch unit. ( x 3)
  • Page 184 2. Installation 33. Connect the harness [A] of the stepper motor bracket to the PCB [B] in the punch unit. ( x 3) 34. Connect the harness [A] of the registration sensor bracket to the PCB [B] in the punch unit. ( x 1) 35.
  • Page 185 Punch Unit PU3060 (D706) • When you clamp the harness in clamp [A], clamp the harness between the two binds [B]. • Route the harness [A] of the punch unit over the PCB as shown below. 36. Slide the punch waste hopper [A] into the finisher from the rear.
  • Page 186 2. Installation 37. Pull back the stapling unit. 38. Re-attach the covers, and then re-install the finisher on the main machine. ( page 145 "Finisher SR4090 (D703) /Booklet Finisher SR4100 (D704)") 39. Connect the finisher connector to the main machine. 40.

  • Page 187: Finisher Sr4110 (D707)

    Finisher SR4110 (D707) Finisher SR4110 (D707) Accessories Check the accessories and their quantities against this list. Description Q'ty Side Tray Sponge Strip Ground Plate Entrance Guide Plate Joint Bracket Shift Tray Support Plate Support Plate Pocket Tapping Screws – M3 x 6 Tapping Screws –...

  • Page 188: Installation Procedure

    2. Installation Spacer A spacer for correcting paper skew is attached to the bottom right of the finisher. [A]: Spacer for skew correction and side-to-side registration adjustment Installation Procedure • Turn the machine off and disconnect the machine power cord before you do this procedure. 1.
  • Page 189 Finisher SR4110 (D707) 3. Open the front door and remove the shipping retainers. 4. Remove the brackets, tags, and wires in this order: [A]> [B]> [C] ( x 2 each). 5. Be sure to remove the two sheets of paper [D]. 6.

  • Page 190: Docking The Finisher D707

    2. Installation 10. Insert the shift tray [A] into the grooves and fasten it. ( x 4; M3 x 8) Docking the Finisher D707 The Finisher (D707) is docked to one of the following: • Multi-Folding Unit FD4000 (D615) • Cover Interposer Tray CI4020 (D712) •...
  • Page 191 Finisher SR4110 (D707) 2. Dock the finisher. (See “Connecting the Finisher D707”) • Attach the black mylar [A] provided with the cover interposer tray accessories to the relay guide plate [B] of the Finisher D707. RTB 159 Delete this note Finisher D707 to Main Machine or Other Upstream Unit 1.

  • Page 192: Connecting The Finisher D707

    2. Installation 3. Attach the coupling seal [A] to the copier. 4. Dock the finisher. (See “Connecting the Finisher D707”) Connecting the Finisher D707 1. Open the front door of the finisher. 2. Pull out the locking lever [A]. ( x 1) 3.

  • Page 193: How To Use The Spacer To Correct Paper Skew

    Finisher SR4110 (D707) 9. Set the leveling shoes [A] (x4) under the feet. 10. Turn the nuts to adjust the height of the finisher until it is level. How to Use the Spacer to Correct Paper Skew A spacer for correcting paper skew is attached to the bottom right of the finisher.
  • Page 194 2. Installation [A] Spacer for skew correction and side-to-side registration adjustment 1. Check to see if the paper is skewed when it is exited from the machine. 2. If skew correction is required, dock the finisher to the copier using the M4x20 screws included with the finisher.
  • Page 195 Finisher SR4110 (D707) [C]: Finisher side [D]: Main machine (Mainframe) side [E]: Adjustable direction [A]: Screws (with spacer(s): M4 x 20, without spacer(s): M4 x 14) [B]: Joint Bracket [C]: Without spacer [D]: With 1-2 spacers [E]: Exterior Cover 3. If skew correction is NOT required, dock the finisher to the copier using the M4x14 screws included with the finisher.

  • Page 196: Sp Setting

    2. Installation [A]: Folding Unit [B]: Joint Bracket [C]: Screw (M4 x 20) [D}: Screw is too long and cannot be fully inserted SP Setting 1. Enter the SP mode. 2. Do SP5841-11 and enter the name of the staples used for corner stapling. •...

  • Page 197: Punch Unit Pu5000 (B831)

    Punch Unit PU5000 (B831) Punch Unit PU5000 (B831) Component Check Check the quantity and condition of the accessories in the box against the following list: Description Q'ty Punch Unit Punch Waste Collection Hopper Spacer (2 mm) Spacer (1 mm) Knob Step Screw Screw (M4 x 6) Black Screw (M3 x 10)

  • Page 198: Installation Procedure

    2. Installation Installation Procedure This punch unit is for the D707 finisher only. • Switch the machine off and unplug the machine before starting the following procedure. 1. If the finisher is connected to the main machine, disconnect it. 2. Open the front door and remove the rear cover ( x 2). 3.
  • Page 199 Punch Unit PU5000 (B831) 8. Behind the inner cover at [B] and [C], press the lock tab to the right to release the inner cover from the frame. 9. Remove the plastic knockouts [D]. 10. Remove the rear cover. ( x 2) 11.
  • Page 200 2. Installation 13. Position the 2 mm spacer [A] and attach the punch unit [B] ( x 2, M3 x 10). 14. Use one of the screws removed from the motor protector plate to fasten the remaining two spacers to the frame as shown. •...
  • Page 201 Punch Unit PU5000 (B831) 16. Remove the harness cover [A] ( x 2) and middle cover [B] ( x 2). 17. Install the sensor arm [A] ( x 1, small step screw (M3 x 4). Make sure that the sensor arm swings freely on the step screw.
  • Page 202 2. Installation 19. Connect the PCB harness connector [A] to CN135 of the finisher PCB and to CN600 of the punch unit PCB. 20. Connect the harness [B] to CN136 of the finisher PCB. 21. Connect the single end of the hopper full sensor connector cable [C] to the hopper full sensor on the arm ( x 1, x 2).
  • Page 203 Punch Unit PU5000 (B831) 23. Slide the punch waste collection hopper [A] into the finisher. 24. Reattach the inner cover and rear cover. 25. Close the front door and re-connect the finisher to the machine.

  • Page 204: Cooling Fan Unit Type M2 (D770)

    2. Installation Cooling Fan Unit Type M2 (D770) D135 RTB 146 New procedure • This option is to be installed to Finisher SR4090 (D703) or Booklet Finisher SR4100 (D704) or Finisher SR4110 (D707). • When installing this option to the Finisher SR4090 (D703) or Booklet Finisher SR4100 (D704), install it after installing the Output Jogger Unit Type M2 (D705).

  • Page 205: Common Installation Procedure For Finisher Sr4090 / Booklet Finisher Sr4100 And Finisher Sr4110

    Cooling Fan Unit Type M2 (D770) Common Installation Procedure for Finisher SR4090 / Booklet Finisher SR4100 and Finisher SR4110 • Always switch the machine off and unplug the machine before doing the following procedure. 1. Remove the left middle cover. ( page 532 "Left Middle Cover") 2.
  • Page 206 2. Installation 4. Attach the Wire Saddle: LWSM-0511A [B] (accessory #8) to the bracket [A]. 5. Connect the connectors [A] and [B] of the Harness: Fan: Separation (accessory #5) to the PCB:OKB.
  • Page 207 Cooling Fan Unit Type M2 (D770) 6. Lock harness [A] Harness: Fan: Separation (accessory #5) ( x 5).
  • Page 208 2. Installation 7. Connect the harness [A] Harness: Fan: Separation (accessory #5) clamped in step 6 to the connector [B] of Harness: Fan (accessory #6). 8. Disconnect the connector [A], then connect [A] to the connector [B] of the Harness: Fan (accessory #6) connected in step 7.
  • Page 209 Cooling Fan Unit Type M2 (D770) 9. Connect the remaining connector [A] of the Harness: Fan (accessory #6) to connector [B]. 10. Lock the Harness: Fan (accessory #6) with the clamp as shown.
  • Page 210 2. Installation 11. Disconnect connector [A]. • When disconnecting the white relay connector [B], make sure it remains connected to the connector attached to the purple harness [C]. If it remains connected to the connector attached to the red, white and black harnesses, harnesses could be connected falsely in the following steps.
  • Page 211 Cooling Fan Unit Type M2 (D770) • Harnesses [A] and [C] should be purple. • Harnesses [B] and [D] should be different colors. 13. Clamp the harness [A] with the clamp. 14. Attach the Left Middle Cover ( x 2) and Rear Middle Cover ( x 4). 15.
  • Page 212 2. Installation 16. Peel off the tapes from the Velcro [B] attached to the interface unit [A] (accessory #2). 17. Align the screw hole [C] against the surface of the cover [A], and attach the interface unit [B] with its Velcro against the surface of the cover.
  • Page 213 Cooling Fan Unit Type M2 (D770) 18. Attach the interface unit [A] to the lower left cover with M3X16 screw (accessory #3). 19. Connect connector [A] to the copier.

  • Page 214: Installation Procedure For Finisher Sr4090/ Booklet Finishersr4100

    2. Installation Installation Procedure for Finisher SR4090/ Booklet FinisherSR4100 1. Remove the cover [A] from the Output Jogger Unit Type M2 ( x 2). • The removed cover will not be used. 2. Remove the cover [A] from the Cooling Fan Assembly ( x4). Do not remove screw [B].
  • Page 215 Cooling Fan Unit Type M2 (D770) 4. Route the ends of the harness [B] through the hole [A] on the fan unit bracket. 5. Attach the bracket [A] by fastening the screw (M3X6; x1) to the hole [B] . Then, fix the ground wire [C] to the hole [D] with screw (M3X6;...
  • Page 216 2. Installation 6. Mount the fan unit [A] on the Output Jogger Unit Type M2 [B] ( x 4). • Screws #1 and #3 will fasten the fan unit, output jogger unit and copier. • Screws #2 and #4 will fasten the fan unit and output jogger unit. 7.
  • Page 217 Cooling Fan Unit Type M2 (D770) 8. Connect the harness of the fan unit ( x1). Clamp the harness with the clamps ( x 2). 9. Attach the cover [A] of the cooling fan unit ( x 2). Make sure the tabs on both sides of the cover [B] (colored in grey) lap over the plate (colored in green).
  • Page 218 2. Installation 10. Insert the 4 tabs [B] to the upper cover to attach the cover [A].
  • Page 219 Cooling Fan Unit Type M2 (D770) 11. Bind the interface unit harness [A] and clamp it with the Locking Wire Saddle CKN-13 [B] (accessory #4) as shown.

  • Page 220: Installation Procedure For Finisher Sr4110

    2. Installation • Depending on the number of options installed between the copier and Finisher SR4090/ SR4100, 3 pcs of Locking Wire Saddle CKN-13 might be needed to clamp the harness. Installation Procedure for Finisher SR4110 1. Remove the upper cover [A] from the Cooling Fan Assembly ( x2). 2.
  • Page 221 Cooling Fan Unit Type M2 (D770) 4. Release the 3 clamps attached to the cooling fan assembly. 5. Disconnect the connector. 6. Remove the bracket [A] ( x 2).
  • Page 222 2. Installation 7. Remove the rocker switches [B] and [C] from the bracket [A] removed in step 6 (connectors [D], [E] and [F]). 8. Remove the fan motor [A] from the bracket [B] ( x4, x1). 9. Remove the spring plate [B] ( x1) and the resistor harness [C] from the bracket [A].
  • Page 223 Cooling Fan Unit Type M2 (D770) 10. Assemble the fan motor [A] and bracket [B] (for Finisher SR4110) (accessory #10) ( x4). 11. Remove the knob screw [C] and snap ring [B] from the upper cover [A] removed from the cooling fan unit in step 1.
  • Page 224 2. Installation 12. Remove the air shield [B] from the upper cover [A]. 13. Remove the bracket [B] from the air shield [A] ( x2). 14. Assemble the air shield [A] and Upper Cover (for Finisher SR4110) [B] (accessory #12) with the snap ring and knob screw removed in step 11.
  • Page 225 Cooling Fan Unit Type M2 (D770) 15. Attach the spring plate [B] removed in step 9 to the Lower Cover (for Finisher SR4110) (accessory #11) [A] ( x1). 16. Prepare the following parts: • Rocker switches [A] and [B] • Harness removed in step 9 [C] •...
  • Page 226 2. Installation 17. Route the harnesses through the openings [D] and attach the rocker switches [B] and [C] to the lower cover of Finisher SR4110 [A]. • Attach the rocker switch [B] so that the white dot marking positions to the side indicated with the arrow in the photo below.
  • Page 227 Cooling Fan Unit Type M2 (D770) 19. Connect the connectors [A] and [B]. 20. Connect the 2 connectors [A] to the rocker switch [B]. 21. Remove the clamp [B] from the bracket [A] removed in step 7. Then attach the clamp [B] to the hole [C] on the lower cover of Finisher SR4110.
  • Page 228 2. Installation 22. Remove the jogger unit cover [A] from Finisher SR4110 ( x2). 23. Mount the fan motor unit on Finisher SR4110 by aligning the hooks [A] and [B] with the cutouts [C] and [D] ( x2).
  • Page 229 Cooling Fan Unit Type M2 (D770) 24. Attach the lower cover [A] assembled in step 21 by inserting the tabs [B] and [C] to the grooves [D] and [E] located under the cooling fan unit ( x2). • Grooves [D] and [E] refer to the wider groove (toward the upstream of the unit).
  • Page 230 2. Installation 25. Connect the connectors [A] and [B].
  • Page 231 Cooling Fan Unit Type M2 (D770) 26. Fix the harness [A] from the interface unit mounted on the copier in page 203 "Common Installation Procedure for Finisher SR4090 / Booklet Finisher SR4100 and Finisher SR4110" ( x 1 for ground wire [B], x 1 for bracket [C], x1 [D]).
  • Page 232 2. Installation 29. Bind the harness of the interface unit [A] and clamp it with Locking Wire Saddle CKN-13 [B] (accessory #4). • Depending on the number of options installed between the copier and Finisher SR4110, 3 pcs of Locking Wire Saddle CKN-13 might be needed to clamp the harness.

  • Page 233: Information For Cooling Fan Unit Type M2

    Cooling Fan Unit Type M2 (D770) Information for Cooling Fan Unit Type M2 Cooling Fan Unit Type M2 activates under the following condition. Mainframe Main Power Switch [A] of Cooling Fan Unit Type M2 Printing/Copying Ready status Active Inactive Inactive Inactive •...
  • Page 234 2. Installation 2: Min air volume...

  • Page 235: Copy Tray Type M2 (D744)

    Copy Tray Type M2 (D744) Copy Tray Type M2 (D744) Component Check Check the accessories and their quantities against this list. Description Q'ty COPY TRAY:EXIT:ASS'Y BRACKET:COOLING UNIT:ASS'Y COOLING UNIT:ASS'Y CLAMP:LWC-3A TAPPING SCREW:4X8 TAPPING SCREW:ROUND POINT:3X6 SCREW:M4X20 LEVER BRACKET:SENSOR:PAPER VOLUME SENSOR SPRING PLATE:SENSOR:EXIT PHOTOINTERRUPTOR:GP1A173LCS2F CLAMPS:WES-0507...

  • Page 236: Installation Procedure

    2. Installation Description Q'ty TAPPING SCREW:ROUND POINT:3X6 Installation Procedure • Turn the machine off and disconnect the machine power cord before you do this procedure.
  • Page 237 Copy Tray Type M2 (D744) 1. Remove the rear middle cover. ( x 4) 2. Remove the left middle cover [A]. ( x 2) 3. Open the drawer unit [A]. 4. Attach the sheet [A] to the left side of the drawer unit.
  • Page 238 2. Installation • There are four cutouts in the sheet. • Align the left-most cutout with the corner [A] of the paper exit. 5. Attach the paper height sensor [A] and harness clamp [B] to the sensor bracket [C]. 6. Attach the actuator [F] to the actuator arm bracket [D]. 7.
  • Page 239 Copy Tray Type M2 (D744) 10. D135/D136 only: Remove the interface cable cover. ( x 1) 11. D135/D136 only: Attach the "CONNECTOR: 2-292246-2". ( x 2; M3 x 8) 12. Attach the PCB:OKB ( x 1)
  • Page 240 2. Installation 13. Attach the CLAMP:LWSM-0511A. 14. Connect the branched (divided) end of the HARNESS:EXIT:TRAY:COOLING UNIT:OKB to the PCB:OKB. 15. Bind the harness as shown in the photo. ( x 5)
  • Page 241 Copy Tray Type M2 (D744) 16. D135/D136 only: Connect the harness tied with a bind to the rear side of “CONNECTOR: 2-292246-2”. • If you leave this harness unconnected or connect it to the front side, SC534-02 (Duplex Exhaust Fan/Rear Lock) will occur. •...
  • Page 242 2. Installation • Connect the harness tied with a bind to the rear side of the peripheral interface port. • Reconnect the front side of the harness disconnected in the first step to the peripheral interface port. 17. Disconnect the harness [A]. 18.
  • Page 243 Copy Tray Type M2 (D744) • In this step, make sure to connect the purple harnesses to each other, and the black/white harnesses to each other. DO NOT connect harnesses of a different color. If the colors are different, SC534-02 (Duplex Exhaust Fan/Rear Lock) will occur. •...
  • Page 244 2. Installation • If you do not bind the harnesses, they may get caught on the left middle cover and trigger SC547-02 (Zero Cross Error). 20. Make four holes [A] in the left cover with a screwdriver. 21. Reattach the left upper cover. ( x2) 22.
  • Page 245 Copy Tray Type M2 (D744) 24. Attach the copy tray [A]. • Remove the packing material from the copy tray before attaching the tray.
  • Page 246 2. Installation 25. Install the cooling unit [A] on the cooling unit bracket [B]. (hook x2) 26. Fasten the cooling unit to the cooling unit bracket. ( x2; M3 x 6)
  • Page 247 Copy Tray Type M2 (D744) 27. Install the cooling unit bracket [A] on the left side of the main machine. ( x4; M4 x 20)
  • Page 248 2. Installation 28. Attach the cable clamp [A] provided with the copy tray to the main machine. Then route the harness as shown below. ( x 1) 29. D135/D136 only: Connect the interface cable of the cooling unit to the interface [A] whose cover you removed in Step 23.
  • Page 249 Copy Tray Type M2 (D744) • Align the lower side of the decal with the marker [A] on the main machine when you attach the decal to the main machine. 33. Turn the power switch [A] of the cooling fan ON.
  • Page 250 2. Installation • Always keep the power switch of the cooling fan ON. This is because the fan is installed prevent paper from sticking together and jamming during duplex printing due to undried toner. (The fan stops when the print/copy job is complete). •...

  • Page 251: Decurl Unit Du5020 (D727) (D137/D138 Only)

    Decurl Unit DU5020 (D727) (D137/D138 Only) Decurl Unit DU5020 (D727) (D137/D138 Only) • The decurl unit is top heavy and has an extremely narrow base. It can fall over easily. Work carefully to avoid knocking it over. • Do not set this unit upright until you are ready to install it and connect it to the side of the main machine.

  • Page 252: Installation Procedure

    2. Installation Installation Procedure • Make sure that the main machine is switched off and that its power cord is disconnected before doing the following procedure. 1. Remove the retainers [A]. ( x 4) • Keep the screws. They will be needed to reinstall the retainers after connecting the decurl unit with the main unit.
  • Page 253 Decurl Unit DU5020 (D727) (D137/D138 Only) 2. Loosen the screws [A] of the retainers. ( x 2) 3. Install the retainers on the decurl unit. ( x 4) Install the retainers [A] alternately on both sides of the decurl unit as shown below. •...
  • Page 254 2. Installation • Right side of the decurl unit 4. Fasten the screws [A] loosened in step 2. ( x 2) • Left side of the decurl unit • Right side of the decurl unit...
  • Page 255 Decurl Unit DU5020 (D727) (D137/D138 Only) 5. Open the front door. 6. Remove tapes and retainers. 7. Disassemble the paper guide for this peripheral unit [A]. ( x 2) 8. Attach the transparent mylar [B]. • [C]: 0 to 1 mm 9.
  • Page 256 2. Installation 11. Attach the paper guide [B]. ( x2; M3x6) 12. Attach the following to the main machine: • [A] Right joint bracket, marked "R" ( x2; M4x16) • [B] Left joint bracket, marked "L" ( x2; M4x16).
  • Page 257 Decurl Unit DU5020 (D727) (D137/D138 Only) 13. Remove the interface connector cover [A] from the main machine. 14. Open the front door [A]. 15. Remove the screw of the lock bar [B] ( x1). Keep this screw. 16. Remove the retainers installed in step 3. ( x4) 17.
  • Page 258 2. Installation 18. Push in the lock bar [A] and fasten it with the screw removed in step 15. ( x 1) 19. Reinstall the retainers [A] removed in step 16 as shown below. ( x 4) 20. Connect the I/F cable [A] of the decurl unit to the main machine.
  • Page 259 Decurl Unit DU5020 (D727) (D137/D138 Only) 21. Set the leveling shoes [A]. 22. Adjust the height of the unit and make sure that it is level. 23. Remove the paper guide of the downstream peripheral device. 24. Disassemble the paper guide [A]. ( x2) 25.

  • Page 260: Connect The Downstream Peripheral Device

    2. Installation • [C]: 0 to 1 mm • [D]: 0 to 1 mm • If the downstream peripheral device is Buffer Pass Unit Type 5020 (D751), don’t attach the black mylar. The mylar for the decurl unit is provided with the buffer pass unit. Connect the Downstream Peripheral Device If the down stream peripheral device is Finisher SR4090 (D703) or Booklet Finisher SR4100 (D704)
  • Page 261 Decurl Unit DU5020 (D727) (D137/D138 Only) If the downstream peripheral device is Cover Interposer Tray CI4010 (D711) or Cover Interposer Tray CI4020 (D712) 1. Install the small bracket [A] on the cover interposer tray [B]. ( x1) 2. Connect the downstream unit. If the downstream peripheral device does not have a connecting section (such as Buffer Pass Unit Type 5020 (D751)) 1.
  • Page 262 2. Installation 2. Remove the rear lower cover [A] of the decurl unit. ( x2) 3. Remove the connecting bracket [A].

  • Page 263: Paper Curl Adjustment When Decurl Unit Du5020 Connects With Finisher Sr4090 Or Booklet Finisher Sr4100

    Decurl Unit DU5020 (D727) (D137/D138 Only) 4. Connect the downstream unit. • When you remove the decurl unit, hold it in the lower half, lower than the middle. Paper curl adjustment when Decurl Unit DU5020 connects with Finisher SR4090 or Booklet Finisher SR4100 1.

  • Page 264: Buffer Pass Unit Type 5020 (D751) (D137/D138 Only)

    2. Installation Buffer Pass Unit Type 5020 (D751) (D137/ D138 Only) Accessory Check Description Q'ty Screws (M4 x 8) Screws (M4 x 16) Leveling Shoes Docking Bracket (L) Docking Bracket (R) Wide Mylar (50.0mm width) Narrow Mylar (35.5mm width) Sponge Strip Power Cord Ground Plate...

  • Page 265: Installation

    Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) Installation • The unit must be connected to a power source that is close to the unit and easily accessible. • Make sure that the main machine is switched off and that its power cord is disconnected before doing the following procedure.
  • Page 266 2. Installation Rating Manufacturer Type No. DC32V/5A IDEC CORP NRPS10-G5A DC6V/1.5A TYCO ELECTRONICS CORP miniSMDC150F 1. Remove all visible external tapes on the external surfaces. 2. Open the front door [A] and remove all visible tapes. • There are no tapes inside the unit. •...
  • Page 267 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) 4. Attach the ground plate [A]. ( x 2) 5. Remove the entrance guide [A]. ( x 2)

  • Page 268: 01: When Connecting The Buffer Pass Unit With The Mainframe

    2. Installation #01: When connecting the Buffer Pass Unit with the mainframe • If the Buffer Pass Unit is to be connected to the Decurl Unit DU5020 (D727), go to "#02: When connecting the Buffer Pass Unit with the Decurl Unit DU5020 (D727)". This section describes the procedure for attaching the Wide Mylar to the entrance guide that was removed in step 5.
  • Page 269 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) 2. Attach the Wide Mylar to the Upper entrance guide by aligning the edge [D] of the Mylar with the edge (1) of the guide plate, and edge [E] of the double stick tape with the edge (2) of the guide plate.
  • Page 270 2. Installation 3. Confirm the Wide Mylar is attached correctly to the Lower entrance guide as shown in the photo below. 1. Attach the entrance guide to the buffer pass unit. ( x 2) 2. Attach the right cover of the buffer pass unit. ( x 6) 3.
  • Page 271 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) 4. Attach the docking bracket Right [A] (accessories item #5) and docking bracket Left [B] (accessories item #4) to the main frame. ( x 2 each) 5. Remove the connector cover [A] from the mainframe.
  • Page 272 2. Installation 6. Open the front door, then pull out the locking lever [A]. ( x 1) 7. Push the buffer pass unit against the mainframe to dock the units. 8. Push the lock lever [A] and fasten it with the screw removed in step 6. ( x 1) 9.

  • Page 273: 02: When Connecting The Buffer Pass Unit With The Decurl Unit Du5020 (D727)

    Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) Go to page 276 "Common Procedure". #02: When connecting the Buffer Pass Unit with the Decurl Unit DU5020 (D727) This section describes the procedure for attaching the Wide Mylar to the entrance guide that was removed in step 5.
  • Page 274 2. Installation [A]: Upper entrance guide [B]: Lower entrance guide Attaching the Wide Mylar to the Upper entrance guide 1. Peel off the sheet from the double stick tape [C] on the Wide Mylar. 2. Attach the Wide Mylar to the Upper entrance guide by aligning the edge [D] of the Mylar with the edge (1) of the guide plate, and the shorter edge [E] of the Mylar with the edge (2) of the guide plate.
  • Page 275 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) Attaching the Wide Mylar to the Lower entrance guide 1. Peel off the sheet from the double stick tape [C] on the Wide Mylar. 2. Attach the Wide Mylar to the Lower entrance guide by aligning the edge [D] of the Mylar with the edge (1) of the guide plate, and edge [E] of the double stick tape with the edge (2) of the guide plate.
  • Page 276 2. Installation 1. Attach the entrance guide to the buffer pass unit. ( x 2) 2. Attach the right cover of the buffer pass unit. ( x 6) 3. Remove the rear upper cover [A] of the Decurl Unit. ( x 4) 4.
  • Page 277 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) 5. Remove the bracket [A] from the Decurl Unit. ( x 3) 6. Attach the docking bracket Right [A] (accessories item #5) and docking bracket Left [B] (accessories item #4) to the paper exit side of the Decurl Unit. ( x2 each)

  • Page 278: Common Procedure

    2. Installation 7. Connect the I/F cable of the Decurl Unit to the socket [A] of the mainframe. Then connect the Buffer Pass Unit with the Decurl Unit similarly to steps 4 through 6 of page 266 "#01: When connecting the Buffer Pass Unit with the mainframe".
  • Page 279 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) 2. Remove the 2 screws [A] on the front side of clamping bracket [D]. 3. Turn the Kc5 lever [B] counter clockwise and pull out the buffer pass unit drawer [C]. 4. Remove the clamping bracket [D]. ( x 2) 5.
  • Page 280 2. Installation 8. Attach the docking bracket [A] of the downstream unit to the left side of the buffer pass unit. (Illustration below is an example showing the bracket for SR4110.) 9. Attach the Narrow Mylar [A] (35.5mm, accessories item #7) to the entrance guide of the downstream unit (for example, the SR4110) by referring to the procedure described on the following page.
  • Page 281 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) Attaching the Narrow Mylar to the Upper entrance guide 1. Peel off the sheet from the double stick tape [A] on the Narrow Mylar. 2. Attach the Narrow Mylar to the Upper entrance guide by aligning the edge [B] of the double stick tape with the edge (1) of the guide plate, and the edge [C] of the double stick tape with the edge (2) of the guide plate.
  • Page 282 2. Installation 3. Confirm the Narrow Mylar is attached correctly to the Lower entrance guide as shown in the photo below. 1. Dock the downstream unit to the buffer pass unit. 2. Connect the power cord [A] provided with the buffer pass unit to the power inlet on the buffer pass unit.
  • Page 283 Buffer Pass Unit Type 5020 (D751) (D137/D138 Only) • Make sure the power cords are plugged to the wall socket in the above order. Otherwise, the buffer pass unit will not be recognized by the mainframe when turning on the power in the following step, and cause a paper jam in the buffer pass unit.

  • Page 284: Multi-Folding Unit Fd4000 (D615)

    2. Installation Multi-Folding Unit FD4000 (D615) Accessories Check the quantity and condition of the accessories in the box against the following illustration and list. Description Q'ty Joint Bracket Paper Guide – Long (for D135/D136/D137/D138) Paper Guide – Short (for D131/D132/D133) Proof Tray Auxiliary Plate - Bottom Ground Plate Screws 3x6...

  • Page 285: Installation

    Multi-Folding Unit FD4000 (D615) Installation • The unit must be connected to a power source that is close to the unit and easily accessible. • Make sure that the main machine is switched off and that its power cord is disconnected before doing the following procedure.

  • Page 286: Paper Guide, Sponge Strip

    2. Installation Paper Guide, Sponge Strip 1. Fasten the joint bracket [A] to the left side of the upstream unit. ( x4; M4x20) 2. Fasten the joint bracket provided with the downstream device to the left side of the multi-folding unit, if a downstream device is going to be installed.
  • Page 287 Multi-Folding Unit FD4000 (D615) • Use the screws provided with the downstream device. 3. Select the long paper guide for the installation. • Two paper guides are provided. • The short paper guide is for another machine (D131/D132/D133). • If the upstream peripheral device is the Decurl Unit DU5020 (D727), attach the black mylar provided with the cover interposer tray or decurl unit to this paper guide.

  • Page 288: Ground Plate

    2. Installation Ground Plate 1. Attach the ground plate [A] to the lower right edge of the unit. ( x2; M3x6) Docking Do the step 8 to 12, only if the upstream unit is the Cover Interposer Tray CI4020 (D712). 1.
  • Page 289 Multi-Folding Unit FD4000 (D615) 4. Slowly push the unit [C] against the left side of the upstream unit (or main machine) so that the lock bar is directly and squarely under the arms of the joint bracket. 5. Pull out the lock bar so it slides up into the notches in the arms on both ends of the joint bracket [D]. 6.

  • Page 290: Power Cord

    2. Installation 9. Use a short screwdriver to loosen bracket [A] ( x2). 10. Fasten the bracket to the upstream unit at [B] ( x1). 11. Tighten the screws ( x3). 12. Re-attach the rear covers. Power Cord 1. Insert the power cord socket [A] into the power connection point. •...

  • Page 291: Height Adjustment

    Multi-Folding Unit FD4000 (D615) 2. Plug in the power cord for the Multi-Folding Unit into an AC wall outlet. 3. Disconnect the power cord from the copier, and then press the main power switch. • This releases the charge remaining inside the machine. If you do not do this step, the copier will not recognize the Multi-Folding Unit and paper jams will occur.

  • Page 292: Removing Parts For The Cover Interposer Tray Ci4020 (D712)

    2. Installation Removing Parts for the Cover Interposer Tray CI4020 (D712) Three parts must be removed before the tray unit of the cover interposer tray can be mounted on top of the Multi Folding Unit. 1. Open the front door. •...

  • Page 293: Proof Tray Auxiliary Plate

    Multi-Folding Unit FD4000 (D615) Proof Tray Auxiliary Plate 1. Install the proof tray auxiliary plate. • Set the plate [A] in the center aligned with the diagonal groove. • The back should be flat against the end fence. 2. When the plate is not being used, open the front door and store the plate at [B] inside the inner cover.

  • Page 294: Correcting Skew

    2. Installation 2. If a peripheral unit is connected on the left side, disconnect it and pull it away. 3. Execute a straight-through run. 4. Check the scale where each sheet exits. • The rear scale is for DLT-size paper. •...
  • Page 295 Multi-Folding Unit FD4000 (D615) 3. Loosen the screws ( x4) of the joint bracket attached to the upstream unit. 4. Insert a spacer and tighten the screws. If the trailing edge of the paper is skewing toward the front of the machine, insert a spacer [A] under the rear end of the bracket and tighten the screws.

  • Page 296: Checking Side-To-Side Registration

    2. Installation Checking Side-to-Side Registration Do this procedure to confirm that the paper is centered in the paper path. 1. Make sure that the I/F cable of the unit is connected to the upstream unit. 2. Disconnect the unit to the left of the unit to be tested. 3.
  • Page 297 Multi-Folding Unit FD4000 (D615) 2. On the joint bracket attached to the upstream unit, loosen screws , and 3. Remove bracket [A] ( x1), rotate it 90 degrees, and re-fasten the screw. Changing the position of this bracket aligns the oval cut-out horizontally and frees the joint bracket so it can slide from side to side.

  • Page 298: Mail Box Cs4010 (D708) (D135/D136 Only)

    2. Installation Mail Box CS4010 (D708) (D135/D136 Only) The Mail Box CS4010 is installed on the Finisher SR4090 or Booklet Finisher SR4100. It cannot be installed with the Cover Interposer Tray CI4010. (Either the mailbox or cover interposer tray can be installed on top of the finisher, but not both.) Accessories Check the accessories and their quantities against this list.
  • Page 299 Mail Box CS4010 (D708) (D135/D136 Only) • Move the mailbox carefully. It is easy to cause damage to the corner leaf plate [B]. 2. If the Cover Interposer Tray CI4010 is installed on the Finisher SR4090 or Booklet Finisher SR4100, remove it. •...
  • Page 300 2. Installation • Open the front door [A] of the finisher, and pull the lock lever [B]. ( x 1) • Remove the finisher from the main machine. 4. Remove the top cover [A] from the finisher ( x 2).
  • Page 301 Mail Box CS4010 (D708) (D135/D136 Only) 5. Install the finisher on the main machine. • Slowly push the finisher against the left side of the machine, keeping its front door open until the brackets go into their slots. • Push the lock lever [A], and then secure it ( x 1).
  • Page 302 2. Installation • Connect the finisher connector [A] to the machine. 6. Attach the guide plate [A] to the top of the finisher ( x 2, M3 x 8).
  • Page 303 Mail Box CS4010 (D708) (D135/D136 Only) 7. Attach the mailbox [A] to the top of the finisher ( x 4, M3 x 8). 8. Attach the 9 trays [B] to the mailbox. 9. Give the decals [C] to the customer. The customer will write on these and attach them at the correct location.

  • Page 304: Cover Interposer Tray Ci4010 (D711)

    2. Installation Cover Interposer Tray CI4010 (D711) Cover Interposer Tray CI4010 (D711) is for installation on the Finisher SR4090 (D703)/Booklet Finisher SR4100 (D704) only and not on Finisher SR4110 (D707). Cover Interposer Tray CI4010 (D711) inserts cover or slip sheets into copied or printed outputs. Accessories Check the accessories and their quantities against this list.

  • Page 305: Installation Procedure

    Cover Interposer Tray CI4010 (D711) Description Q'ty GUIDE PLATE:CONNECTING:LOWER Installation Procedure • Always switch the machine off and unplug the machine before doing the following procedure. 1. Remove all tape and retainers from the cover interposer tray.
  • Page 306 2. Installation 2. If the finisher is connected to the main machine, disconnect it. • Disconnect the finisher connector [A] from the main machine. • Open the front door [A] of the finisher, and pull the lock lever [B]. ( x 1)
  • Page 307 Cover Interposer Tray CI4010 (D711) • Disconnect the finisher from the main machine. 3. Remove the front joint bracket [A] and rear joint bracket [B]. ( x 4)
  • Page 308 2. Installation 4. Remove the cover [A] from the finisher. 5. Remove the docking bracket [A] from the finisher. ( x 2) Also see RTB 130...
  • Page 309 Cover Interposer Tray CI4010 (D711) 6. If the "Decurler Unit DU5020 (D727)" or "Buffer Pass Unit Type 5020 (D751)" is included in the configuration, the original guide plate [A] must be replaced with "GUIDE PLATE: CONNECTING: LOWER" (item#19 of accessories). •...
  • Page 310 2. Installation 2) Remove the guide plate [A] ( x 2). The original guide plate will no longer be used and does not have to be stored. 3) Attach the new guide plate [A] (item#19 of accessories) to the frame of the cover interposer ( x 2).
  • Page 311 Cover Interposer Tray CI4010 (D711) 8. Install the shoulder screws from inside the finisher. ( x 2; shoulder screws) • Front side [A]: ( x 1) • Rear side [B]: ( x 1) 9. Open the finisher front door, and then install the cover interposer tray [A] on the finisher.
  • Page 312 2. Installation • Make sure the cover interposer tray is set on the shoulder screws installed in step 7. 10. Fasten the cover interposer tray on the finisher. ( x 1; M3 x 6) 11. Install the 4 screws in the front door of the finisher. ( x 4; M4 x 8)
  • Page 313 Cover Interposer Tray CI4010 (D711) 12. Install the bottom front cover extension [A] on the front door. ( x 2; screws installed in step 10) 13. Install the top front cover extension [A] on the front door. ( x 2; screws installed in step 10)
  • Page 314 2. Installation 14. Install the rear cover extension [A] on the right side of the finisher. ( x 2; M3 x 6) 15. Remove the ground plate [A] from the finisher. ( x 2)
  • Page 315 Cover Interposer Tray CI4010 (D711) 16. Install the ground plate [A] provided with the cover interposer tray. ( x 2; M3 x 6) 17. Install the ground plate [A] removed in step 14. ( x 2; screws removed in step 15) 18.
  • Page 316 2. Installation 19. Temporary tighten the screw [A] at the front side of the finisher. ( x 1; M4 x 16) 20. Install the right front corner plate [A], and fasten the screw installed in step 18. ( x 1; M4 x 16) 21.
  • Page 317 Cover Interposer Tray CI4010 (D711) 22. Install the right rear cover plate [A], and fasten the screws installed in step 20. ( x 2; M4 x 16) 23. Attach the cushion [A] to the finisher.
  • Page 318 2. Installation 24. Open the front door of the finisher, and pull the lock lever [A]. ( x 1) • Keep the screw that you removed. 25. Install the front joint bracket [A]. ( x 2; M4 x 14) 26. Install the rear joint bracket [B]. ( x 2; M4 x 14)
  • Page 319 Cover Interposer Tray CI4010 (D711) 27. Attach the gasket seals [A] and [B].
  • Page 320 2. Installation 28. Slowly push the finisher with cover interposer tray against the left side of the machine, keeping its front door open until the brackets go into their slots. 29. Push the lock lever [A], and then secure it. ( x 1; screw removed in step 23). 30.
  • Page 321 Cover Interposer Tray CI4010 (D711) 32. Enter the [System Settings]. 33. Set the [Interposer] for the [Front Cover Sheet Tray], [Back Cover Sheet Tray], and [Designation Sheet 2 Tray] of the [Tray Paper Settings].

  • Page 322: Cover Interposer Tray Ci4020 (D712)

    2. Installation Cover Interposer Tray CI4020 (D712) Cover Interposer Tray CI4020 (D712) is for installation on the Finisher SR4110 (D707) only and not on Finisher SR4090 (D703)/Booklet Finisher SR4100 (D704). Cover Interposer Tray CI4020 (D712) inserts cover or slip sheets into copied or printed outputs. Accessories Check the quantity and condition of the accessories in the box against the following list.

  • Page 323: Installation Procedure

    Cover Interposer Tray CI4020 (D712) Installation Procedure Setting up the Unit and Docking to the Copier • Unplug the power cord before starting the following procedure. 1. Remove all the tape and shipping materials from the tray unit [A]. 2. Remove cover [A].
  • Page 324 2. Installation 3. Remove all tape and shipping materials from the transport unit [B]. 4. Remove the interface connector cover [A]. 5. Attach the rear docking bracket [B] ( x2; M4x14). 6. Attach the front docking bracket [C] ( x2; M4x14). 7.
  • Page 325 Cover Interposer Tray CI4020 (D712) 12. Open the front door of the cover interposer tray. 13. Pull out the locking lever [A]. 14. Align the finisher [B] with the joint brackets [C], then slowly push the finisher onto the brackets. 15.

  • Page 326: Docking The Next Peripheral Device

    2. Installation 20. Close the front door. Docking the Next Peripheral Device The next peripheral device to the left of the cover interposer tray must be installed before you can mount the tray unit on top of the transport unit of the cover interposer tray. •...
  • Page 327 Cover Interposer Tray CI4020 (D712) 4. Attach the knob screw [D] ( x1). 5. Connect the harness connectors [E] ( 6. Reattach the rear cover. 7. Remove the front inner cover [A] from the dual-tray unit ( x2). 8. Fasten the tray unit to the top of the transport unit with the knob screws [B] ( x2; M4x8). 9.
  • Page 328 2. Installation 11. Re-attach the front inner cover [B] (removed at step 7 above). 12. Position the tray unit front door [C] so that its hinges match the posts on the frame of the tray unit. 13. Hold the lower L-pin [D] as shown, insert it halfway, push it up, then rotate it into its groove. 14.
  • Page 329 Cover Interposer Tray CI4020 (D712) 17. Turn the nuts to adjust the height of the cover interposer until it is level.

  • Page 330: Lcit Rt4020 (D709)

    2. Installation LCIT RT4020 (D709) Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Stay Rail Tapping screws – M3 x 6 Tapping screws – M4 x 14 Shoulder screws Decal: caution chart: paper set direction Decal: LED Installation Procedure •...
  • Page 331 LCIT RT4020 (D709) 2. Remove the paper entrance cover [A] from the main machine. ( x 2) 3. Install the stay [A] on the main machine. (M3 x 6; x 2)
  • Page 332 2. Installation 4. Remove the connector cover [A] from the main machine. 5. Install the rail [A] on the right side of the main machine. (M4 x 14; x 2)
  • Page 333 LCIT RT4020 (D709) • The rail must be standing on the floor. If the screw holes on the LCT are too high or too low, and do not overlap the vertical screw slots in the rail, the rubber feet of the rail must be adjusted.
  • Page 334 2. Installation 8. Open the top right cover [A]. 9. Right cover [A] ( x2) 10. Fasten the rail to the LCT. (shoulder screws; x 2)
  • Page 335 LCIT RT4020 (D709) • When you fasten the rail to the LCT, the screw holes [B] of the rail need to be in the same position as the screw holes [A] of the LCT. 11. Reattach the right cover, and then connect the plug [A] of the LCT power connector to the side of the machine.
  • Page 336 2. Installation 12. Prepare the Decal: caution chart: paper set direction [A]. 13. Open the top right cover and attach the decal as shown below. Select one of the decals according to the paper that will be used by the customer.
  • Page 337 LCIT RT4020 (D709) • Paper type, brand, etc can be written on the blank space. 14. Attach a decal to the front. D137/D138: Attach the Decal: LED supplied with the LCIT. D135/D136: Attach a blank sheet on the paper size decal supplied with the main machine.

  • Page 338: Adjustment For The Rubber Foot Positions On The Rail

    2. Installation 15. Plug in the machine and turn it on. • To move down the paper tray, cover the photosensor with your left hand and press the bottom plate operation button [A]. Adjustment for the Rubber Foot Positions on the Rail The rail must be standing on the floor.
  • Page 339 LCIT RT4020 (D709) 2. The slotted screw holes in the rail for attaching the rail to the LCT have a tolerance for the height (-/+ 2 mm). If you can install the rail within -/+ 2 mm in height, you do not need to do the following steps.

  • Page 340: Lcit (D709) Tray Heater

    2. Installation • When changing the rubber foot position, remove the rail bracket [A]. ( x 4). After changing the rubber foot position, reinstall the rail bracket. LCIT (D709) Tray Heater Accessories Check the accessories against the list below.

  • Page 341: Installation

    LCIT RT4020 (D709) Description Q'ty Heater: 15W Heater Harness Harness clamp Harness clamp Tapping Screw:4x6 Tapping Screw:4x8 Tapping Screw - M3x6 Screw: Polished Round/Spring:M4x8 Screw: Polished Round/Spring:M3x8 Installation 1. Open the top right cover [A].
  • Page 342 2. Installation 2. To move down the paper tray, cover the photosensor with your left hand and press the bottom plate operation button [A]. 3. Remove the side fences [A]. ( x 4)
  • Page 343 LCIT RT4020 (D709) 4. Close the top right cover to move the paper tray upward. (The paper tray stops in about 30 seconds.) 5. Switch the machine off and unplug the machine. 6. Disconnect the LCT power connector from the machine. 7.
  • Page 344 2. Installation 9. Release the LCT from the main machine. ( x 2) 10. Slide the LCT [A] against the main machine, and then remove it from the rail [B]. 11. Top right cover [A] ( x1)
  • Page 345 LCIT RT4020 (D709) 12. Top left cover [A] ( x2) 13. Rear left cover [A] ( x2) 14. Rear cover [A] ( x2)
  • Page 346 2. Installation 15. Left cover [A] ( x2) 16. Remove the bottom bracket [A]. ( x 3)
  • Page 347 LCIT RT4020 (D709) 17. Attach the clamp [A] on the undersurface of the LCT. ( x 1) 18. Attach the clamp [A] on the undersurface of the LCT. ( x 1)
  • Page 348 2. Installation 19. Attach the three clamps [A] on the front side of the LCT. ( x 3) 20. Install the tray heater [A] in the LCT. (M4 x 6; x 2) 21. Route the heater harness to the right side of the LCT as shown below. ( x 1)
  • Page 349 LCIT RT4020 (D709) 22. Clamp the harness routed from the left side of the LCT. ( x 1) 23. Install the heater bracket [A] in the LCT. (M4 x 8; x 2) 24. Connect the heater bracket [A] and heater harness [B]. ( x 1)
  • Page 350 2. Installation 25. Route the heater harness and heater bracket [A] as shown below. ( x 3) 26. Attach the ground wire [A] to the LCT. (M4 x 8; x 1) 27. Remove the heater harness cover [A] from the rear cover ( x 2).
  • Page 351 LCIT RT4020 (D709) 28. Reattach the following covers. • Left cover • Rear cover • Rear left cover • Top left cover • Top right cover When attaching the rear cover, pass the heater harness through the hole where the heater harness cover was.
  • Page 352 2. Installation 32. Attach the rear lower cover of the main machine. 33. Set the LCT [A] on the rail [B], and then slide it towards the main machine. 34. Install the LCT on the main machine.
  • Page 353 LCIT RT4020 (D709) 35. Open the top right cover, and then fasten the rail to the LCT. (shoulder screws; x 2) • When you fasten the rail to the LCT, the screw holes [B] of the rail needs to be in the same position as the screw holes [A] of the LCT.

  • Page 354: Image Adjustments: Side-To-Side Registration

    2. Installation 36. Reattach the right cover. ( x 2) 37. Remove the cover of the main machine. 38. Connect the heater bracket to the main machine. 39. Reattach the cover of the main machine. 40. Connect the LCT power connector to the main machine, and then turn on the main power. 41.
  • Page 355 LCIT RT4020 (D709) 5. Exit the SP mode.

  • Page 356: 1/2" X 14" Paper Size Tray Type M2 (D745)

    2. Installation 8 1/2" x 14" Paper Size Tray Type M2 (D745) Component List Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Cover B4/LG frame Bottom plate extension Rear bracket Front bracket Harness clamp Tapping screws - M4x8 Tapping bind screws - M4x8...

  • Page 357: Installation Procedure

    8 1/2" x 14" Paper Size Tray Type M2 (D745) Installation Procedure 1. Open the upper right cover [A]. 2. Move down the paper tray, cover the photosensor with your left hand and press the bottom plate operation button [A]. 3.
  • Page 358 2. Installation 4. Close the upper right cover [A] to move the paper tray up. (The paper tray stops in about 30 seconds.) 5. Switch the machine off and unplug the machine. 6. Disconnect the LCT power connector from the machine. 7.
  • Page 359 8 1/2" x 14" Paper Size Tray Type M2 (D745) 10. Remove the following covers. ( page 328 "LCIT RT4020 (D709)") • Upper right cover • Upper left cover • Rear left cover • Rear cover • Left cover 11. Remove the lower limit sensor bracket [A]. ( x 1, x 1) 12.
  • Page 360 2. Installation 13. Pull the sensor connector wire removed in step 11 through the hole [A] from the left side of the LCT. 14. Release the sensor connector wire from the clamp [B]. 15. Put the sensor connector wire to the right side of the LCT through the hole [A]. 16.
  • Page 361 8 1/2" x 14" Paper Size Tray Type M2 (D745) 17. Attach the harness clamp to the rear of the plate [A]. Use this clamp to hold the sensor connector wire. 18. Reattach the following covers. • Left cover • Rear cover •...
  • Page 362 2. Installation 20. Attach the right stay [A] below. ( x 2) 21. Attach the front bracket [A] with the beveled corner down. ( x 2)
  • Page 363 8 1/2" x 14" Paper Size Tray Type M2 (D745) • If the brackets are not easy to install, lift the bottom plate with your hand. 22. Attach the rear bracket [B] with the beveled corner down. ( x 2) 23.
  • Page 364 2. Installation 25. Attach the right cover [B]. ( x 2) 26. Attach the upper right cover [A] provided with the 8 1/2" x 14" Paper Size Tray Type M2. ( x 1) 27. Install the LCT on the main machine. ( page 328 "LCIT RT4020 (D709)") 28.

  • Page 365: Lcit Rt4030 (D710)

    LCIT RT4030 (D710) LCIT RT4030 (D710) Accessory Check Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Shoes Upper Joint Brackets Lower Joint Bracket Tapping screws – M4 x 8 Stay Decal: caution chart: paper set direction Decal: LED Decal: transport: cover Decal: misfeed removal: manual feed: 250...
  • Page 366 2. Installation 1. Remove all tape and retainers from the LCT. 2. Open the front door [A] and paper tray unit [B], and remove all tape and retainers from the LCT. 3. Remove the paper entrance cover [A] from the main machine. ( x 2)
  • Page 367 LCIT RT4030 (D710) 4. Install the stay [A] on the main machine. (M4 x 8; x 2) • Set the embossed side of the stay against the main machine.
  • Page 368 2. Installation 5. Remove the connector cover [A] and LCT connecting cover [B]. 6. Install the upper joint brackets [A] and [B].
  • Page 369 LCIT RT4030 (D710) 7. Install the lower joint brackets [A]. 8. Remove the ground plate [A]. ( x 2)
  • Page 370 2. Installation 9. Change the orientation of the ground plate, and then install it as shown below. ( x 2) 10. Open the front cover [A]. 11. Remove the screw [B] and release the lock plate [C]. (M4 x 8; x 1) 12.
  • Page 371 LCIT RT4030 (D710) 13. Reattach the left corner plate [A]. (M4 x 8; x 1) 14. Set the leveling shoes [A]. (front left, front right, rear left, rear right side of the LCT) 15. Connect the LCIT I/F cable [A] to the main machine.
  • Page 372 2. Installation 16. Open the by-pass tray unit [A]. • Push down the lever [A] when opening the by-pass unit. 17. Prepare the caution decal [A] provided with the LCT.
  • Page 373 LCIT RT4030 (D710) 18. Attach the caution decal to [A] on the by-pass tray unit. • [B]: 2mm • [C]: 2mm 19. Prepare the sponge decal [A] provided with the LCT.
  • Page 374 2. Installation 20. Attach the sponge decal to [A] on the exit cover. • Attach the sponge decal [A] on the corner of the exit cover. • [B]: 50 mm • [C]: 65 mm...
  • Page 375 LCIT RT4030 (D710) 21. Prepare the Decal: caution chart: paper set direction [A]. 22. Draw out the paper tray and attach the decal [A] on the top of the front door. Select one of the decals according to the paper that will be used by the customer. •...

  • Page 376: How To Disconnect The Lcit From The Main Machine

    2. Installation D137/D138: Attach the Decal: LED supplied with the LCIT. D135/D136: Attach a blank sheet on the paper size decal supplied with the main machine. 24. Plug in the machine and turn it on. How to disconnect the LCIT from the main machine 1.
  • Page 377 LCIT RT4030 (D710) 2. Disconnect the LCIT from the main machine while pressing the lock bracket [D] in the direction indicated with the arrow. • Lock bracket [D] is located at the rear side of the LCIT frame [E].

  • Page 378: Lcit (D710) Tray Heater

    2. Installation LCIT (D710) Tray Heater Accessories Check the accessories against the list below.

  • Page 379: Installation

    LCIT RT4030 (D710) Description Q'ty Heater: 15W Heater Harness Intermediate Harness Harness Clamp Tapping Screw:4x8 Tapping Screw - M3x6 Screw: Polished Round/Spring:M4x8 Screw: Polished Round/Spring:M3x8 Installation • Always switch the machine off and unplug the machine before doing the following procedure. •...
  • Page 380 2. Installation 2. Right rear cover [A] ( x4) 3. Left rear cover [A]...
  • Page 381 LCIT RT4030 (D710) 4. Connect the heater [A], intermediate harness [B], heater harness [C]. ( x 3) 5. Pull out the paper tray, and then install the heater [A]. ( x 3)
  • Page 382 2. Installation 6. Route the harness with the clamp [A] as shown below, and then attach it to the rear side of the LCT. x 3) 7. Attach the clamp [A] to the rear side of the LCT. 8. Clamp the heater harness. ( x 1)
  • Page 383 LCIT RT4030 (D710) 9. Attach the ground wire [A] to the LCT. (M4 x 8; x 3) 10. Remove the LCT bracket [A]. ( x 2) 11. Attach the heater bracket [A]. ( x 2)
  • Page 384 2. Installation 12. Reattach the exterior covers. 13. Remove the rear lower cover of the main machine. 14. Fix the heater bracket [A]. ( x 2) 15. Attach the heater harness [A] and ground wire [B]. ( x 1, x 1) To attach the ground wire, remove the screw and replace it with the polished round screw M3.

  • Page 385: Image Adjustments: Side-To-Side Registration

    LCIT RT4030 (D710) 16. Attach the rear lower cover of the main machine. Image Adjustments: Side-to-side registration 1. Use the Trimming Area Pattern (SP2-109-003, No. 14) to print the test pattern. 2. Go to SP1-003-007 (Side-to-Side Reg: LCT). 3. Load paper (A4 LEF) in the LCT tray, and then copy a couple of sheets. 4.

  • Page 386: A3/11"X17" Tray Unit Type M2 (D749)

    2. Installation A3/11"x17" Tray Unit Type M2 (D749) Component List Check the quantity and condition of the accessories in the box against the following illustration and list. Description Q'ty Screw – M3 x 4 Tapping screws –M3 x 6 Screw – M3 x 6 Pin Bracket Harness Paper Size Decal...

  • Page 387: Installation

    A3/11"x17" Tray Unit Type M2 (D749) Installation • The unit must be connected to a power source that is close to the unit and easily accessible. • Make sure that the main machine is switched off and that its power cord is disconnected before doing the following procedures.
  • Page 388 2. Installation 5. Remove the fences and adjust their positions for the paper to be loaded: [F] Side fence ( x1) [G] Back fence ( x1) [H] End fence ( x1)
  • Page 389 A3/11"x17" Tray Unit Type M2 (D749) 6. Reattach the front panel. ( x10) 7. Open the front doors. 8. Pull out the tandem feed tray [A] and remove the paper cassette decal [B]. 9. Remove the factory SP sheet [A] and SD card holder [B]. •...
  • Page 390 2. Installation 11. Remove the left tandem tray [A] (left rail: x 2 (M3 x 8), right rail: x 3 (M3 x 10)). 12. From the left tandem tray, remove the front cover [A] ( x 2).
  • Page 391 A3/11"x17" Tray Unit Type M2 (D749) 13. Pull out the right tandem tray [A] then remove it ( x2). 14. Insert the short connector [A] into the socket inside the machine [B]. ( x1) • Hold the connector as shown in the illustration.
  • Page 392 2. Installation 15. Using the screw provided in the accessories, attach the pin bracket [A] to the center rail. ( x2) 16. Using the screws provided in the accessories for the right rail and left rail, install the tray [B] on the right rail [C], center rail [D], and left rail [E].
  • Page 393 A3/11"x17" Tray Unit Type M2 (D749) • Make sure that bosses [A] (two each on the left/right rails) pass through the holes in the tray. If you close the tray without doing this, it will be impossible to open the tray. 17.

  • Page 394: Copy Connector Type 3260 (B328)

    2. Installation Copy Connector Type 3260 (B328) Accessory Check Check the quantity and condition of the accessories in the box against the following illustration and list. Description Q’ty Copy Connector Board B328 Repeater Hub 1394 Ferrite Core Power Repeater Cable Coupling Interface Cable 1394 Keytop for V-C1 (Not used) Keytop (Not Used)

  • Page 395: Installation

    Copy Connector Type 3260 (B328) • Measure the distance between the machines to be connected. Determine the number of cables and repeater hubs that are necessary based on the distance measured between the machines. Power Repeater Hubs Distance Interface Cables Required Required Less than 9.0 m (Less than 29.5 ft) 9.0 to 13.5 m (29.5 to 112.5 ft.)
  • Page 396 2. Installation 2. Remove the controller box cover. ( x 4) 3. Remove the cover [A] of Slot A. ( x 2)
  • Page 397 Copy Connector Type 3260 (B328) 4. Install the Copier Connection Kit Board B328 [A] in Slot A and fasten it. ( x 2) 5. Connect the power repeater cable [A] to CN525 [B] on the controller board. 6. Connect the other end of the power repeater cable [A] to CN4 [C] on the copy connector board.
  • Page 398 2. Installation • Pass the power repeater cable [A] under the harness [D] on the controller board when you connect it to the copy connector board. 7. Connect the end of the interface cable [B] to the copy connector board [A]. 8.
  • Page 399 Copy Connector Type 3260 (B328) 9. Connect the other end of the interface cable [A] and repeater hub [B]. 10. Repeat Steps 1 to 9 to install the connector kit on the second machine. 11. Connect the interface cable [A] from the second machine to the repeater hub [B].
  • Page 400 2. Installation • Measure the distance between the machines to be connected. Determine the number of cables and repeater hubs that are necessary based on the distance measured between the machines. ( page 392 "Preparation") 12. Reattach the covers.

  • Page 401: Tab Sheet Holder Type M2 (D750)

    Tab Sheet Holder Type M2 (D750) Tab Sheet Holder Type M2 (D750) The tab sheet holder can installed in trays 2 and 3, and allows the user to load tab stock. Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Tab Sheet Holder...
  • Page 402 2. Installation 2. Check that the paper tray is not being used, and then pull the tray carefully out until it stops. 3. Install the tab sheet holder on the end fence of the paper tray. • When the tab sheet holder is installed correctly, you can hear a clicking noise.
  • Page 403 Tab Sheet Holder Type M2 (D750) • [A]: End fence • [B]: Tab sheet holder 4. Load tab stock in the paper tray. • Load tab stock so that the side with the tab faces the tab sheet holder. 5. Adjust the end fence position so that the tab sheet holder will fit the tab stock. 6.
  • Page 404 2. Installation...

  • Page 405: Ieee802.11A/G/N Unit Type M2 (D164)

    IEEE802.11a/g/n Unit Type M2 (D164) IEEE802.11a/g/n Unit Type M2 (D164) Component List Check the quantity and condition of the accessories in the box against the following list. Description Q'ty IEEE802.11a/g/n Unit Velcro Fasteners Clamps • Don’t disassemble the IEEE802.11a/g/n Unit. When you need to replace the IEEE802.11a/g/n board, replace the entire IEEE802.11a/g/n Unit.
  • Page 406 2. Installation • To prevent damage to the controller box, always work carefully. Never put your hand or a tool into the box when you remove the controller box or install an option. • To prevent damage to the circuits on the boards, always touch a metal surface to remove static charge from your hands before you handle a board.
  • Page 407 IEEE802.11a/g/n Unit Type M2 (D164) • ANT1. Antenna 1 [A] transmits and receives. It must be installed on the rear middle side of the main machine. (The core on the Antenna 1 cable is black.) • ANT2. Antenna 2 [B] only receives. It is installed on the rear right corner of the machine. (The core on the Antenna 2 cable is white.) 5.

  • Page 408: User Tool Settings For Ieee 802.11A/G/N

    2. Installation • Make sure that the cables are not slack. Keep them wired tightly along the covers. 10. Turn on the main machine. 11. Make sure that the machine can recognize the option.: User Tools > Printer Features > List/Test Print >...
  • Page 409 IEEE802.11a/g/n Unit Type M2 (D164) 4. Set the “Communication Mode“. 5. Enter the “SSID setting”. (The setting is case sensitive.) 6. Set the “Ad-hoc Channel”. You need this setting when Ad Hoc Mode is selected. The allowed range for the channel settings may vary for different countries. •...

  • Page 410: Sp Mode Settings For Ieee 802.11 Wireless Lan

    2. Installation SP Mode Settings for IEEE 802.11 Wireless LAN The following SP commands and UP modes can be set for IEEE 802.11 SP No. Name Function 5840 Channel MAX Sets the maximum range of the channel settings for the country. 5840 Sets the minimum range of the channels settings allowed for your Channel MIN...

  • Page 411: Bluetooth Interface Unit Type D (D566)

    Bluetooth Interface Unit Type D (D566) Bluetooth Interface Unit Type D (D566) Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q'ty Bluetooth Module CD-ROM Installation Procedure • Turn off the power of the main unit when connecting the Bluetooth unit. Do not attach or remove the Bluetooth unit while the power of the main unit is turned on.
  • Page 412 2. Installation 2. Make sure that the machine can recognize the option.: User Tools > Printer Features > List/Test Print > Configuration Page...

  • Page 413: Ieee1284 Interface Board Type A (B679)

    IEEE1284 Interface Board Type A (B679) IEEE1284 Interface Board Type A (B679) Component List Check the quantity and condition of the accessories in the box against the following list. Description Q'ty PCB Unit Installation Procedure • Unplug the main machine power cord before you do the following procedure. •...
  • Page 414 2. Installation 2. Insert the IEEE1284 interface board into the I/F slot and fasten it with the screws. ( x 2) 3. Turn on the main machine. 4. Make sure that the machine can recognize the option.: User Tools > Printer Features > List/Test Print >...

  • Page 415: File Format Converter Type E (D377)

    File Format Converter Type E (D377) File Format Converter Type E (D377) Component List Check the quantity and condition of the accessories in the box against the following list. Description Q'ty PCB Unit Installation Procedure • Unplug the main machine power cord before you do the following procedure. •...
  • Page 416 2. Installation 2. Insert the file format converter into the I/F slot and fasten it with the screws. ( x 2) 3. Turn on the main machine. 4. Make sure that the machine can recognize the option.: User Tools > Printer Features > List/Test Print >...

  • Page 417: Sd Card For Netware Printing Type M2 (D719)

    SD card for NetWare printing Type M2 (D719) SD card for NetWare printing Type M2 (D719) Component List Check the quantity and condition of the accessories in the box against the following list. Description Q'ty SD Card Installation Procedure • Unplug the main machine power cord before you do the following procedure. 1.
  • Page 418 2. Installation 2. Insert the SD card (SD card for NetWare printing) in SD slot 2 (lower) [A] with its label face towards the front of the machine. Then push it slowly into SD slot 2 (lower) until you hear a click. 3.

  • Page 419: Ocr Unit Type M2 (D166)

    OCR Unit Type M2 (D166) OCR Unit Type M2 (D166) OCR unit allows you to use the searchable PDF function with the scanner application. Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q’ty SD Card...

  • Page 420: Installation Procedure

    2. Installation • The machine embeds the text information of the scanned document after scanning the originals (after the originals are ejected from the ADF). Therefore, you can remove the originals from the exposure glass or ADF. • You can use other applications such as copy and printer while the machine embeds the text information of the scanned document.
  • Page 421 OCR Unit Type M2 (D166) 5. When the display tells you that the execution is completed, press [Exit]. • If the execution failed, the display tells you that the execution failed. • If the execution failed, do the following. Check if the SD card is already used. Turn off the main power switch, and do steps 1 to 5 again.

  • Page 422: Restoration Procedure

    2. Installation • You can switch the searchable PDF function on and off in the [OCR Settings] screen after installing the OCR unit. • If you want to use the searchable PDF function, select [On] for [OCR Settings]. (Default: [Off]) Restoration Procedure When you install the OCR Unit Type M2, the searchable PDF function is saved on the HDD and the SD card ID is saved in NVRAM.

  • Page 423: Postscript3 Unit Type M2 (D719)

    Postscript3 Unit Type M2 (D719) Postscript3 Unit Type M2 (D719) Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q’ty PostScript3 Emulation SD Card Decal Installation Procedure • Unplug the main machine power cord before you do the following procedure. 1.
  • Page 424 2. Installation 3. Perform the SD Card Appli Move. ( page 446 "SD Card Appli Move") • After the SD Card Aplli Move is completed, do the following procedure. 1. Remove the SD Card from SD slot 2 (lower). 2. Attach the SD-card slot cover, and then turn on the machine ( x 1) 3.

  • Page 425: Ipds Unit Type M2 (D719)

    IPDS Unit Type M2 (D719) IPDS Unit Type M2 (D719) Accessories Check the quantity and condition of the accessories in the box against the following list. Description Q'ty IPDS Emulation SD Card Decal Installation Procedure • Unplug the main machine power cord before you do the following procedure. 1.
  • Page 426 2. Installation 3. Perform the SD Card Appli Move. ( page 446 "SD Card Appli Move") • After the SD Card Aplli Move is completed, do the following procedure. 1. Remove the SD Card from SD slot 2 (lower). 2. Attach the SD-card slot cover, and then turn on the machine ( x 1) 3.

  • Page 427: Browser Unit Type M2 (D719)

    Browser Unit Type M2 (D719) Browser Unit Type M2 (D719) Accessories Description Q'ty SD Card Installation Procedure • Unplug the main machine power cord before you do the following procedure. 1. Turn the main switch OFF. 2. Remove the SD-card slot cover [A] from the SD Card slots. ( x 1) 3.
  • Page 428 2. Installation 4. Turn the main switch ON. 5. D135/D136: Press the “User Tools/Counter” key. D137/D138: Press the “User Tools” key. 6. On the touch panel, touch “Extended Feature settings”. 7. Touch “Extended Feature settings” in the Extended Feature Settings Menu. 8.

  • Page 429: Do The Following Steps If The Customer Is Using The Ricoh Javascript Connected To A Web Application Developed By Operius/Ridp

    Browser Unit Type M2 (D719) Do the following steps if the customer is using the Ricoh JavaScript connected to a Web application developed by Operius/RiDP. 1. Turn the main switch ON. 2. D135/D136: Press the “User Tools/Counter” key. D137/D138: Press the “User Tools” key.

  • Page 430: Optional Counter Interface Unit Type A (B870)

    2. Installation Optional Counter Interface Unit Type A (B870) Component Check Check the quantity and condition of the components against the following list. Description Q’ty Key Counter Interface Board Harness Tapping Screw: M3 x 6 Stud Stay Harness Clamp Band Installation Procedure •...
  • Page 431 Optional Counter Interface Unit Type A (B870) 3. Install the four stud stays on the controller box. 4. Install the optional counter interface board [A] on the four stud stays. 5. Release the extension harness (13-pin) [B] from the clamps [A] in the controller box. (...
  • Page 432 2. Installation 6. Connect the harness [A] to CN3 [B] on the optional counter interface board. ( x 1) 7. Route the harness [A] inside the controller box as shown below. ( x 3) 8. Remove the part [A] of the rear middle cover with a flathead screwdriver.
  • Page 433 Optional Counter Interface Unit Type A (B870) 9. Connect the harness from the optional counter device to CN4 [A] on the optional counter interface board through the cut off part of the right rear cover. ( x 1) 10. Reassemble the machine.

  • Page 434: Smart Card Reader Built-In Unit Type M2 (D739) (D135/D136 Only)

    2. Installation Smart Card Reader Built-in Unit Type M2 (D739) (D135/D136 Only) Component Check Description Q’ty IC Card Upper Cover IC Card Cover Sponge Cable Clamp Harness Clamp Front Upper Cover *1: Not used in this machine...

  • Page 435: Installation Procedure

    Smart Card Reader Built-in Unit Type M2 (D739) (D135/D136 Only) Installation Procedure • Unplug the main machine power cord before starting the following procedure. 1. Remove the following covers. ( page 522 "Outer Covers") • Upper front cover • Upper rear cover •...
  • Page 436 2. Installation 4. Remove the IC card cover [A] from the operation panel lower cover. 5. Attach the IC card R/W you want to install [A] on the operation panel lower cover.
  • Page 437 Smart Card Reader Built-in Unit Type M2 (D739) (D135/D136 Only) 6. Pass the USB cable through hole [A] from the back side of the operation panel lower cover, and then connect the USB cable [B] to the IC card R/W. 7.
  • Page 438 2. Installation 9. Install the IC card upper cover [B] on the IC card cover [A]. 10. Install the IC card cover [A] on the operation panel lower cover. 11. Route the USB cable [A] inside the right middle upper cover. ( x 3)
  • Page 439 Smart Card Reader Built-in Unit Type M2 (D739) (D135/D136 Only) 12. Route the USB cable [A] under the upper rear cover, and then pull it out to the rear side of the machine. 13. Hold the USB cable with the clamp [A]. ( x 1) 14.
  • Page 440 2. Installation 15. Attach the cable clamp [A] to the side surface of the controller box. 16. Hold the USB cable with the clamp [A]. ( x 1) 17. Reattach the rear middle cover. • When your reattach the rear middle cover [B], pull out the USB cable [A] to the outside as shown below.
  • Page 441 Smart Card Reader Built-in Unit Type M2 (D739) (D135/D136 Only) 18. Connect the USB cable [A] to the USB host interface. ( x 1) 19. Attach the cable clamps to the rear middle cover, and then route the USB cable. (...
  • Page 442 2. Installation 20. Reassemble the machine. 21. Turn on the main power switch. 22. Make sure that SP5-985-002 (Device Setting - On Board USB) is set to “1”.

  • Page 443: Dataoverwritesecurity Unit Type H (B869) (D135/D136 Only)

    DataOverwriteSecurity Unit Type H (B869) (D135/D136 Only) DataOverwriteSecurity Unit Type H (B869) (D135/D136 Only) Overview This option should be installed only for the customer who requires the CC certified Data Overwrite Security function. This option is for D135/D136 copiers (Office version) ONLY. The function of this option is completely the same as the Data Overwrite Security in Security Functions, which is standard on this machine.
  • Page 444 2. Installation 2. Insert the SD card (DataOverwriteSecurity Unit) in SD slot 1 (upper) [A] with its label face towards the front of the machine. Then push it slowly into SD slot 1 (upper) until you hear a click. 3. Install the application using SP5-878-001.

  • Page 445: Copy Data Security Unit Type G (D640)

    Copy Data Security Unit Type G (D640) Copy Data Security Unit Type G (D640) Component Check List Installation of this unit requires the following components. Other components included in this kit are not used for installation on this machine. Description Q’ty Copy data security unit board Screws...

  • Page 446: User Tool Setting

    2. Installation 3. Attach the copy data security unit board [A] to the IPU board bracket ( x 2). 4. Reassemble the machine. User Tool Setting 1. Plug in and turn on the main power switch. 2. Go into the User Tools mode, and select System Settings > Administrator Tools > Copy Data Security Option >...

  • Page 447: Check All Connections

    Copy Data Security Unit Type G (D640) 3. Exit User Tools. 4. Check the operation. • The machine will issue an SC165-00 error if the machine is powered on with the Copy Data Security Unit Board removed and the "Data Security for Copying" feature set to "ON". •...

  • Page 448: Sd Card Appli Move

    2. Installation 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. Be very careful when you do the SD Card Appli Move procedure: •...

  • Page 449: Undo Exec

    SD Card Appli Move • 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.

  • Page 450: Caution

    2. Installation • 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.
  • Page 451 SD Card Appli Move • Follow the procedure below to store the SD card from which you moved an application in the machine. • If the SD card is lost, it will be impossible to determine which application has been installed in the case of a machine failure.
  • Page 452 2. Installation 4. Set the SD card in the SD card holder.

  • Page 453: Preventive Maintenance

    3. Preventive Maintenance Preventive Maintenance Tables See "Appendices" for the following information: • Preventive Maintenance Items • Other Yield Parts...

  • Page 454: Image Quality Standards

    3. Preventive Maintenance Image Quality Standards Resolution Item Specification Chart Measuring method Copy (100%/ Ave 5.0 lines/mm or Book: S-5 Copy onto plain paper using Enlargement), Black more (revised) Auto Image Density/5 and White (1C) notches and then determine Min 4.5lines/mm or resolution.

  • Page 455: Magnification Ratio Error Margin

    Image Quality Standards Magnification ratio error margin Item Specification Chart Measuring method Engine, Main Scan, 0.75% or less Mono_CCD Copy the scale and compare Black and White (1C) it with the scale at 100 mm to see if it is within specification. Engine, Sub Scan, 0.50% or less Scale chart...

  • Page 456: Perpendicularity

    3. Preventive Maintenance Perpendicularity Item Specification Chart Measuring method Engine, Black and ±0.70mm/200mm or Measure with the full length Mono_CCD White(1C) less (90° ± 0.20°) and width of the image. Copy (100%), Black ±1.00mm/200mm or Scale chart and White (1C) less Linearity Item...

  • Page 457: Missing Image Area (D135/D136)

    Image Quality Standards Missing Image Area (D135/D136) Item Specification Chart Measuring method [Uncoated paper] Paper thickness 1 to 3: Since there is a variability of 5.0±1.5mm about 1 mm in the sizes of Paper thickness 4 to 8: sheets of paper, correct the 4.0+1.8/-1.2mm Engine (leading edge), size of the sheet before...

  • Page 458: Missing Image Area (D137/D138)

    3. Preventive Maintenance Item Specification Chart Measuring method [Uncoated paper] Paper thickness 1 to 3: Since there is a variability of 5.0±1.5mm about 1 mm in the sizes of Paper thickness 4 to 8: sheets of paper, correct the 4.0+1.8/-1.2mm Copy (leading edge), size of the sheet before Black and White(1C)
  • Page 459 Image Quality Standards Item Specification Chart Measuring method [Uncoated paper] Paper thickness 1 to 3: Since there is a variability of 5.0±1.5mm about 1 mm in the sizes of Paper thickness 4 to 8: sheets of paper, correct the 4.0±1.5mm Engine (leading edge), size of the sheet before Black and White(1C)
  • Page 460 3. Preventive Maintenance Item Specification Chart Measuring method [Uncoated paper] Paper thickness 1 to 3: Since there is a variability of 5.0±1.5mm about 1 mm in the sizes of Paper thickness 4 to 8: sheets of paper, correct the 4.0±1.5mm Copy (leading edge), size of the sheet before Black and White(1C)

  • Page 461: Margin Position

    Image Quality Standards Margin position Item Specification Chart Measuring method Engine (simplex), Main ±2.0 or less Mono_CCD Scan/Sub Scan, Black and White (1C) Engine (duplex), Main ±3.0 or less Scan, Black and White (1C) Engine (duplex), Sub ±4.0 or less Scan, Black and White (1C) 1st Side/2nd Side Positional Precision (Shift Length of 2nd Side Compared to...

  • Page 462: Paper Transfer Quality Standards

    3. Preventive Maintenance Paper Transfer Quality Standards Registration Exposure glass Item Specification Note Simplex (1st print side), 100% 0±2mm (Vertically and or reduction horizontally) Simplex (1st print side), 0±2mm × M mm (Vertically and M: Magnification ratio enlargement horizontally) Duplex (2nd print side), 100% 0±2mm (Vertically and or reduction horizontally)

  • Page 463: Skew

    Paper Transfer Quality Standards Item Specification Note Main Scan: 0±(2×M+3)mm Duplex (2nd print side), non-B6 M: Magnification ratio original, enlargement Sub Scan: 0±(2×M+2)mm Skew Exposure glass Item Specification Note Simplex, A4 SEF or larger*1 ±1.0mm/200mm or less Excluding paper longer than 12 Simplex, B5 SEF or smaller *2 ±1.0mm/100mm or less ×18inches.
  • Page 464 3. Preventive Maintenance Original Printed paper Specification Note Main Scan and Sub 2nd side, A3 to A5 B5 SEF or smaller Scan: ±4.0mm/ 200mm or less Main Scan and Sub 2nd side, A3 to A5 A3/DLT to A4/LT Scan: ±3.0mm/ 200mm or less...

  • Page 465: Pm Parts Settings

    PM Parts Settings PM Parts Settings PM Parts Replacement Procedure PM parts replacement procedure for this model is different from predecessor models. If the PM counter is reset in “PM parts display”, flag is set (SP3701-XXX) and initial process SPs are run automatically for the replaced part.
  • Page 466 3. Preventive Maintenance • If the counter for the Lubricant Bar is reset in SP7622-XX, make sure to set the flag in SP3701- XXX. Otherwise, the lubricant end detection (SP3810-XXX) will not be reset and the banner message indicating near-end will remain on the operation panel. PM part replacement procedure 1.

  • Page 467: Preparation Before Operation Check

    PM Parts Settings 8. Enter SP5-990-004 and check the counter values in the SMC logging data. Make sure that the PM counters for the replaced units are "0" in the PM parts display. If a PM counter for a unit that had been replaced does not display “0,” reset that counter in the procedure described above.

  • Page 468: Pm Counter Display

    3. Preventive Maintenance PM Counter Display The PM Counter main menu and submenu allow you to view the PM counts for both units and individual components. On the CH-C1, Estimated usage rate / Remaining days and Commissioning Status Report have been added to this menu.

  • Page 469: Opening The Pm Counter

    PM Counter Display Opening the PM Counter 1. Enter the SP mode. 2. Touch [PM Counter]. All PM Parts List. Displays all PM items (all PM items, not only PM units). Lists all PM items regardless of PM yield indicator settings. Parts list for PM yield indicator Displays on the items with their PM yield indicator settings set to "Yes".

  • Page 470: Pm Parts Screen Details

    3. Preventive Maintenance Estimated Usage Rate/Estimated Remain Days Displays the estimated usage rate (0 to 100%) and remaining days (255 to 0 days) of the PM items, in which the calculation is based on page counter value and running distance, allowing more accuracy in comparison to the conventional PM page counter.

  • Page 471: Number Button Submenu

    PM Counter Display Number Button Submenu Press any number button to open the submenu for a part. In the example below, the number button [001] #Development Unit was pressed. [A]: Clear current counter. Press to reset the selected PM counter (in this example 001 #Development Unit) to "0".

  • Page 472: Estimated Usage Rate/Estimated Remaining Days

    3. Preventive Maintenance • The # mark denotes a unit. • Items without the # (for example, 065 ITB) denote individual components. • An asterisk (*) will appear in the Exceed column [A] to show items that have exceeded their target PM yields.

  • Page 473: Commissioning Status Report Print

    PM Counter Display Calculation of Estimated remaining days (255 to 0 days) and Estimated usage rate (0 to 100%) • Calculation of estimated remaining days (255 to 0 days) Displays either the page counter (SP7-951-XXX) or the running distance (SP7952-XXX), whichever is smaller.

  • Page 474: Initial Adjustment Sp Lists

    3. Preventive Maintenance Initial Adjustment SP Lists D137 RTB 94 This section describes the following: Important notes on waste toner bottle counter reset • Automatic execution to be performed after replacement • SP that needs to be done manually after replacement •...
  • Page 475 Initial Adjustment SP Lists Auto/ Manual Parts list Adjustment SP SP description SP time Manual SP3-040-001 DEMS : DEMS Control 110 to Lubricant Bar Manual to 005 EXECUTE (Pro Only) 180s Lubricant SP3-040-001 DEMS : DEMS Control 110 to Manual Blade to 005 EXECUTE...
  • Page 476 3. Preventive Maintenance Auto/ Manual Parts list Adjustment SP SP description SP time Manual Dancing Control speed control Auto SP2-924-004 45 to 60s Belt of ITB+MUSIC Manual ProCon Image Auto SP3-011-002 Exe Density Pro Con 15 to 85s Transfer Belt Adjustment Unit Force Apply...
  • Page 477 Initial Adjustment SP Lists Auto/ Manual Parts list Adjustment SP SP description SP time Manual Dancing Control speed control Auto SP2-924-004 45 to 60s Belt of ITB+MUSIC ITB Cleaning Force Apply Unit Manual SP2-696-001 Lubricant Lubrication 180s Execute Dancing Control speed control Auto SP2-924-004...

  • Page 478: D135/D136

    3. Preventive Maintenance D135/D136 Auto/ Manual Parts list Adjustment SP Parts list SP time Manual SP3-030-0 Initial TD Sensor Initial setting Auto 01 to 006 Execute of TD sensor Developer Manual ProCon SP3-011-0 Auto Exe Density Pro Con 15 to 85s Adjustment Development Filter...
  • Page 479 Initial Adjustment SP Lists Auto/ Manual Parts list Adjustment SP Parts list SP time Manual Manual ProCon SP3-011-0 Auto Exe Density Pro Con 15 to 85s Adjustment OPC Drum SP2-111-0 Forced line Auto MUSIC Position SP2-924-0 Dancing Control speed control Auto 45 to 60s Belt...
  • Page 480 3. Preventive Maintenance Auto/ Manual Parts list Adjustment SP Parts list SP time Manual ITB drive shaft SP2-924-0 Dancing Control speed control Manual 45 to 60s gear Belt of ITB+MUSIC SP2-924-0 Dancing Control speed control Auto 45 to 60s Belt of ITB+MUSIC ITB Cleaning Force Apply...

  • Page 481: Cleaning Points

    Cleaning Points Cleaning Points Scanner Exposure Glass, ADF Exposure Glass, Reflective Plate, 1st Mirror, 2nd Mirror, 3rd Mirror, Original Size Sensors 1. Exposure glass ( page 638) 2. Clean the front and back of the exposure glass with a glass cleaner. 3.
  • Page 482 3. Preventive Maintenance • Do not touch the mirror, reflector, or light guide plate in the scanner carriage. 5. Clean the reflective plate [A] with a dry optical cloth. 6. Clean the 1st mirror [A], 2nd mirror [B] and 3rd mirror [C] with a dry optical cloth.

  • Page 483: Laser Unit

    Cleaning Points 7. Clean the original size sensors [A] with a dry cloth. Laser Unit Toner shield glass 1. Open the drawer unit [A] and remove the Toner Shield Glass Cleaning Tool [B].

  • Page 484: Developer

    3. Preventive Maintenance 2. Toner supply unit. ( page 624) 3. Insert the Toner Shield Glass Cleaning Tool [A] to the slot [B], and slide it back-and-forth about 5 times to clean the toner shield glass on the laser units. Do this procedure for all 4 colors. Developer Development Unit Do the following cleaning at 300k.

  • Page 485: Toner Supply

    Cleaning Points 3. Clean off the toner adhering around the unit with a dry cloth. Toner Supply Toner Supply Unit 1. Open the toner supply unit front cover [A]. 2. Remove the toner cartridge [A]. Clean the toner supply unit [B] with a damp cloth that has been wrung out.

  • Page 486: Itb Unit

    3. Preventive Maintenance Clean the sponge seal [C] of the supply port with a dry cloth. e.g.: Y • In order to prevent the scattering of toner, do not use a blower brush to clean. ITB Unit As shown below, there are seven parts to clean at a certain interval. 1.

  • Page 487: Rollers

    Cleaning Points 3. Pre-Transfer Roller 4. ITB Cleaning Blade Counter Roller 5. ITB Lubricant Blade Counter Roller 6. Back-up Roller 7. ITB Driven Roller Rollers Rollers need cleaning every 900k prints Transfer Belt (page 719 "ITB Replacement") With a dry cloth, wipe each roller. ID Sensor Clean the ID sensor every 600k prints.

  • Page 488: Fusing

    3. Preventive Maintenance With a damp cloth, wipe the ID sensor (three areas indicated below). Fusing Stripper Plate (Fusing / Pressure) Pull the fusing unit out and then raise the stripper unit to open it. With a dry cloth, wipe the circled area shown below. Fusing Stripper Plate: Clean the surface and the back.

  • Page 489: Fusing Entrance Guide

    Cleaning Points • Do not wipe too strongly. Fusing Entrance Guide Pull the fusing unit out. With a dry cloth, wipe the circled area shown below. Thermistor (Fusing Belt) Access the thermistor (Fusing Belt) (page 801 "Thermistor (Fusing Belt)") Wipe the circled area shown below.

  • Page 490: Thermistor (Hot Roller Shaft) (Proc5100S/5110S Only)

    3. Preventive Maintenance Thermistor (Hot Roller Shaft) (ProC5100S/5110S Only) Access the thermistor (hot roller shaft) (page 802 "Thermistor (Hot Roller Shaft)") With a dry cloth, wipe the circled area shown below. Thermopile Access the thermopile. (page 807 "Thermopile (Pressure Roller)") With a dry cloth, wipe the surface of the lens.

  • Page 491: Other

    Cleaning Points Other Development Intake Dust Filter 1. Access the development intake filter. ( page 996 "Development Intake Fans (KCMY)") 2. Clean the locations marked with a red circle below with some dry cloth. Pressure Roller Dust Filter (D137/D138 only) 1.

  • Page 492: Paper Feed

    3. Preventive Maintenance Paper Feed 1st to 4th Transport Roller (Drive/Idle) 1. Open the vertical transport door [A]. 2. Wipe the 1st to 4th feed roller (drive) with damp cloth. • [A]: 1st feed roller (drive) • [B]: 2nd feed roller (drive) •...

  • Page 493: Registration Roller (Drive/Idle)

    Cleaning Points • [A]: 1st feed roller (idle) • [B]: 2nd feed roller (idle) • [C]: 3rd feed roller (idle) • [D]: 4th feed roller (idle) Registration Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Open the registration section and wipe the registration roller (drive/idle) with a damp cloth.

  • Page 494: Relay Roller (Drive/Idle)

    3. Preventive Maintenance • [A]: Registration roller (Drive) • [B]: Registration roller (Idle) Relay Roller (Drive/Idle) 1. Remove the registration unit. ( page 882) 2. Remove the relay unit. ( page 884) 3. Wipe the relay roller (drive) [A] with a damp cloth. 4.

  • Page 495: Bypass Relay Roller (Drive/Idle)

    Cleaning Points Bypass Relay Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Wipe the by-pass relay roller (drive/idle) with a damp cloth while rotating the joint [A]. • [B]: By-pass relay roller (Drive)

  • Page 496: Registration Sensor

    3. Preventive Maintenance • [C]: By-pass relay roller (Idle) Registration Sensor 1. Pull out the drawer unit [A]. 2. Open the registration section and clean the registration sensor [A] with a blower brush. Relay Sensor 1. Open the drawer unit cover [A].

  • Page 497: Paper Dust Collection Unit

    Cleaning Points 2. Clean the relay sensor [A] with a blower brush Paper Dust Collection Unit 1. Pull out the drawer unit [A].
  • Page 498 3. Preventive Maintenance 2. Remove the upper cover [A] of the paper dust collection unit. ( x2) 3. Remove the paper dust, and then wipe the dust collection unit [A] with a dry cloth. 4. Reattach the upper cover of the paper dust collection unit. 5.

  • Page 499: Duplex

    Cleaning Points • [B]: By-pass relay roller (Drive) • [C]: By-pass relay roller (Idle) Duplex Heat Pipe Roller 1. Remove the fusing unit. ( page 764) 2. Wipe the heat pipe roller [A] with a damp cloth. Heat Pipe Drive Roller 1.

  • Page 500: Paper Exit Roller (Drive/Idle)

    3. Preventive Maintenance Paper Exit Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Wipe the paper exit roller (drive) [A] with a damp cloth.
  • Page 501 Cleaning Points 3. Hold up the exit guide plate [A]. 4. Wipe the paper exit roller (idle) [A] with a damp cloth...

  • Page 502: Inverter Feed Out Roller (Drive/Idle)

    3. Preventive Maintenance Inverter Feed Out Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Open the paper exit feed guide plate [A]. 3. Wipe the inverter feed out roller (drive/idle) with a damp cloth.

  • Page 503: Inverter Exit Roller (Drive/Idle)

    Cleaning Points • [A]: Inverter feed out roller (Drive) • [B]: Inverter feed out roller (Idle) Inverter Exit Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Open the paper exit feed guide plate [A].

  • Page 504: Paper Exit Relay Roller (Drive/Idle)

    3. Preventive Maintenance 3. Wipe the inverter exit roller (drive/idle) with a damp cloth. • [A]: Inverter exit roller (Drive) • [B]: Inverter exit roller (Idle) Paper Exit Relay Roller (Drive/Idle) 1. Pull out the drawer unit [A].
  • Page 505 Cleaning Points 2. Hold up the exit guide plate [A]. 3. Wipe the paper exit relay roller (drive/idle) with a damp cloth. • [A]: Paper exit relay roller (Drive) • [B]: Paper exit relay roller (Idle)

  • Page 506: Inverter Feed In Roller (Drive/Idle)

    3. Preventive Maintenance Inverter Feed In Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Hold up the exit guide plate [A]. 3. Remove the fusing unit. ( page 764) 4. Remove the separation pawl (e-ring x 2). 5. Wipe the inverter feed roller (drive/idle) with a damp cloth.

  • Page 507: Exit Transport Guide Plate (Upper/Middle/Left)

    Cleaning Points • [A]: Inverter feed roller (Drive) • [B]: Inverter feed roller (Idle) Exit Transport Guide Plate (Upper/Middle/Left) 1. Pull out the drawer unit [A]. 2. Open the reverse guide plate [A].
  • Page 508 3. Preventive Maintenance 3. Open the paper exit feed guide plate. 4. Wipe the paper exit feed guide plate (left) [A] with a dry cloth. 5. Hold up the paper exit guide plate [A].

  • Page 509: Duplex Unit Roller 1St To 4Th (Drive/Idle)

    Cleaning Points 6. Wipe the paper exit feed guide plate (upper/middle) with a dry cloth. • [A]: Paper exit feed guide plate (Upper) • [B]: Paper exit feed guide plate (Middle) Duplex Unit Roller 1st to 4th (Drive/Idle) 1. Pull out the drawer unit [A]. 2.
  • Page 510 3. Preventive Maintenance 3. Wipe the duplex feed roller 1st to 4th (drive) and duplex feed roller 2nd to 4th (idle) with a damp cloth. • [A]: Duplex feed roller 1st (Drive) • [B]: Duplex feed roller 2nd (Drive) • [C]: Duplex feed roller 3rd (Drive) •...

  • Page 511: Duplex Exit Roller (Drive/Idle)

    Cleaning Points 5. Wipe the duplex feed roller 1st (idle) [A] with a damp cloth. Duplex Exit Roller (Drive/Idle) 1. Pull out the drawer unit [A]. 2. Push down the guide plate [A].

  • Page 512: Transport Guide Plate (Upper/Lower)

    3. Preventive Maintenance 3. Wipe the duplex exit roller (drive/idle) with a damp cloth. • [A]: Duplex exit roller (Drive) • [B]: Duplex exit roller (Idle) Transport Guide Plate (Upper/Lower) 1. Pull out the drawer unit [A].
  • Page 513 Cleaning Points 2. Push down the guide plate [A]. 3. Wipe the transport guide plate (upper/lower) with a damp cloth.

  • Page 514: Purge Guide Plate (Lower)

    3. Preventive Maintenance • [A]: Transport guide plate (Upper) • [B]: Transport guide plate (Lower) Purge Guide Plate (Lower) 1. Open the purge door [A]. 2. Move the purge guide plate (lower) [A] to the upright position. 3. Wipe the area [A] under the transport guide plate (lower) with a damp cloth.
  • Page 515 Cleaning Points...

  • Page 516: Lubrication Points

    3. Preventive Maintenance Lubrication Points Fusing Bearing (Hot Roller/Pressure Roller) Lubrication Detach the bearing (page 787 "Heating Roller, Fusing Roller, Fusing Belt") Use grease (Barrierta S552R) to lubricate the inner surface of the bearing. Rotate the inner surface of the bearing to check if the bearing can rotate smoothly. •...
  • Page 517 Lubrication Points Make sure that grease is applied to all the gears. [Left]: FLUOTRIBO MG Grease 4.0g [Right]: FLUOTRIBO MG Grease 1.5g • The max. and min. amount of grease you should use is shown below. [A]: Min. Amount [B]: Max. Amount...
  • Page 518 3. Preventive Maintenance [A]: Min. Amount [B]: Max. Amount...

  • Page 519: Replacement And Adjustment

    4. Replacement and Adjustment Notes on the Main Power Switch Push Switch The main power button of this machine has been changed to a push-button switch (push button) from the conventional rocker switch. The push switch has characteristics and specifications different from the rocker switch.

  • Page 520: Shutdown Method

    4. Replacement and Adjustment • Automatic restart deals with cases when you accidentally unplugged the AC power cord or unexpected power outages. By keeping the power flag ON, after the resumption of power, the machine will start up automatically. In rare cases, when you reconnect the AC power cord to a power outlet, the machine does not start automatically.

  • Page 521: Forced Shutdown

    Notes on the Main Power Switch When the shutdown is complete Main power LED: Off Operation panel LED: Off • How to start from shutdown • To start the machine, press the main power switch. However, if you press the main power switch between the beginning and the end of a shutdown, the machine will not start.

  • Page 522: Special Tools And Lubricants

    4. Replacement and Adjustment Special Tools and Lubricants D137/D138 The following special tools should be prepared for maintenance of this model in the field: Unique or Common: U: Unique for this model C: Common with listed Item Part Number Description Q’ty Unique or Common D0159501...
  • Page 523 Special Tools and Lubricants U: Unique for this model C: Common with listed Item Part Number Description Q’ty Unique or Common D0159501 ZINC STEARATE C (*1) D0159500 G104 YELLOW TONER C (*1) FLUOTRIBO MG GREASE : VSSG9002 C (*2) 100G B6455020 SD Card C(General)

  • Page 524: Outer Covers

    4. Replacement and Adjustment Outer Covers Right Cover Right Middle Front Cover (D137/D138) 1. LCT cover [A] ( x 2) 2. Screw covers [B] on the arm cover [A] of the operation panel 3. Arm cover [A] of the operation panel ( x 2)
  • Page 525 Outer Covers 4. Remove the fixing screws of the right middle front cover ( x 2) 5. Open the toner supply unit front cover [A] and by-pass tray unit [C]. Slide the right middle front cover [B] to the left. •...

  • Page 526: Right Middle Front Cover (D135/D136)

    4. Replacement and Adjustment Right Middle Front Cover (D135/D136) 1. LCT cover [A] ( x 2) 2. Remove the fixing screws of the right middle front cover [A] ( x 2)

  • Page 527: Right Middle Upper Cover (D137/D138)

    Outer Covers 3. Open the toner supply unit front cover [A] and by-pass tray unit [C]. Slide the right middle front cover [B] to the left. • Check the position of the hooks in the photo below before removing. Right Middle Upper Cover (D137/D138) 1.
  • Page 528 4. Replacement and Adjustment 2. Open the by-pass tray unit [A]. Remove the right middle upper cover [B], moving it downward ( x • Check the position of the hooks in the photo below before removing.

  • Page 529: Right Middle Upper Cover (D135/D136)

    Outer Covers Right Middle Upper Cover (D135/D136) 1. In order to easily remove the right middle upper cover [A], remove the fixing screws on the left side of the rear middle cover [B] ( x 2). 2. Open the by-pass tray unit [A]. Remove the right middle upper cover [B], moving it downward ( x •...

  • Page 530: Right Middle Rear Cover (D137/D138)

    4. Replacement and Adjustment Right Middle Rear Cover (D137/D138) 1. Right middle upper cover (D137/D138) ( page 525) 2. LCT cover [A] ( x 2) 3. Slide the right middle rear cover [A] to the left ( x 2) • Check the position of the hooks in the photo below before removing.

  • Page 531: Right Middle Rear Cover (D135/D136)

    Outer Covers Right Middle Rear Cover (D135/D136) 1. Right middle upper cover (D135/D136) ( page 527) 2. LCT cover [A] ( x 2) 3. Slide the right middle rear cover [A] to the left ( x 2)

  • Page 532: Right Lower Cover

    4. Replacement and Adjustment • Check the position of the hooks in the photo below before removing. Right Lower Cover 1. In order to easily remove the right lower cover [A], remove the fixing screws on the left side of the rear lower cover [B] ( x 2).
  • Page 533 Outer Covers 4. Open the vertical tranport door [A]. Remove the hooks (x 2) located on the upper side of the right lower cover [B], then remove by sliding downward. • Check the position of the hooks in the photo below before removing.

  • Page 534: Left Cover

    4. Replacement and Adjustment Left Cover Left Middle Cover 1. In order to easily remove the left middle cover [A], remove the fixing screws on the right side of the rear middle cover [B] and rear lower cover [C] ( x 3). 2.
  • Page 535 Outer Covers 3. Remove the left middle cover [A]. • Check the position of the hooks in the photo below before removing.
  • Page 536 4. Replacement and Adjustment Notes on left middle cover attachment • Attach the left middle cover to align the left middle cover [A] and the upper cover [B]. • Attach the hook [A] to fit location [B] on the machine. •...

  • Page 537: Left Lower Cover

    Outer Covers Left Lower Cover 1. Purge cover [A] (pin x 2) 2. Remove the fixing screws of the left lower cover( x 2).
  • Page 538 4. Replacement and Adjustment 3. While holding the right side of the left lower cover [A], remove it in a downward direction. • Check the position of the hooks in the photo below before removing.

  • Page 539: Rear Cover

    Outer Covers Rear Cover Rear middle cover 1. Remove the rear middle cover [A] by moving it upward ( x 4).

  • Page 540: Rear Lower Cover

    4. Replacement and Adjustment • Check the position of the hooks in the photo below before removing. Rear Lower Cover 1. Rear middle cover ( page 537) 2. Rear Lower Cover [A] ( x 4).

  • Page 541: Upper Cover

    Outer Covers • Check the position of the hooks in the photo below before removing. Upper Cover Upper Front Cover (D137/D138) 1. Open the ADF and remove the fixing screws of the upper front cover [A] ( x 2). 2. Lift the upper front cover [A] and slide it forward.

  • Page 542: Upper Front Cover (D135/D136)

    4. Replacement and Adjustment • Check the position of the hooks in the photo below before removing. Upper Front Cover (D135/D136) 1. Open the ADF and remove the fixing screws of the upper front cover [A] ( x 2).
  • Page 543 Outer Covers 2. Disconnect the left hook of the upper front cover [A]. 3. Slide the upper front cover [A] to the right. • Check the position of the hooks in the photo below before removing.

  • Page 544: Upper Rear Cover (Small)

    4. Replacement and Adjustment Upper Rear Cover (Small) 1. Open the ADF and remove the fixing screws of the upper rear cover (small) [A] ( x 2). Upper Left Cover/ Upper Right Cover 1. Upper front cover ( D137/D138: page 539, D135/D136: page 540) 2.
  • Page 545 Outer Covers • Check the position of the hooks in the photo below before removing. • Upper left cover • Upper right cover...
  • Page 546 4. Replacement and Adjustment...

  • Page 547: Operation Panel (D137/D138)

    Operation Panel (D137/D138) Operation Panel (D137/D138) Operation Panel 1. Remove the screw covers [A] on the back of the operation panel. Remove the arm upper cover [B] ( x 2). 2. Screw cover [A] and the rear cover [B] ( x 3) 3.

  • Page 548: Ldcd Board

    4. Replacement and Adjustment LDCD Board 1. Operation Panel ( page 545) 2. Rear cover [A] ( x 8) 3. Bracket [A] ( x 10)

  • Page 549: Opu Board / Opr Board

    Operation Panel (D137/D138) 4. LDCD board [A] ( x 4, x 1, x 2, flat cable x 2) OPU Board / OPR Board 1. Remove the connector and the clamp that is connected to the LDCD board [A] ( x 1, x 1, flat cable x 1).
  • Page 550 4. Replacement and Adjustment 2. Bracket [A] ( x 15, flat cable x 2) 3. OPU board ( x 4) 4. OPR board ( x 7)

  • Page 551: Lcd Board (Touch Panel Unit)

    Operation Panel (D137/D138) LCD Board (Touch Panel Unit) 1. Remove the connector and the clamp that is connected to the LDCD board [A] ( x 1, x 1, flat cable x 1). 2. Bracket [A] ( x 15, flat cable x 2)
  • Page 552 4. Replacement and Adjustment 3. LCD Board (Touch Panel Unit) [A] ( x 1)

  • Page 553: Operation Panel (D135/D136)

    Operation Panel (D135/D136) Operation Panel (D135/D136) Operation Panel 1. Upper right cover ( page 542 "Upper Left Cover/ Upper Right Cover") 2. Remove the fixing screws and connectors of the operating unit [A] ( x 2, x 2) 3. Slide the operation panel [A] and lower cover [B] forward. •...

  • Page 554: Touch Panel Calibration

    4. Replacement and Adjustment 4. Remove the operation panel [B] from the lower cover [A] ( x 5). Touch Panel Calibration 1. Operation Panel ( page 551) 2. Turn the operation panel (including the lower cover) [A] and remove the fixing screws ( x 2,).
  • Page 555 Operation Panel (D135/D136) 3. For tilt adjustment, loosen the screws in three places. 4. Lift the lower cover [B] to pivot the hooks [A] on the front side. Then align the cover [B] with the ribs [C].
  • Page 556 4. Replacement and Adjustment 1. Fix the ribs and lower cover with the screws you removed in step 2 ( x 2,). e.g.: right side 2. Tighten the screws in three places to fix the operation panel.

  • Page 557: Ldcd Board

    Operation Panel (D135/D136) LDCD Board 1. Operation Panel ( page 551) 2. Middle cover [A] ( x 6) 3. Bracket [A] ( x 5, x 1)

  • Page 558: Opu Board / Opr Board

    4. Replacement and Adjustment 4. LDCD board [A] ( x 4, x 2, flat cable x 1) OPU Board / OPR Board 1. LDCD board [A] along with the bracket ( x 6, x 2, flat cable x 5) 2. OPU board ( x 1) 3.

  • Page 559: Lcd Board (Touch Panel Unit)

    Operation Panel (D135/D136) LCD Board (Touch Panel Unit) 1. LDCD board [A] along with the bracket ( x 6, x 2, flat cable x 5) 2. LCD Board (Touch Panel Unit) [A]...

  • Page 560: Adf

    4. Replacement and Adjustment ADF Removal 1. Remove the rear middle cover [A] by moving it upward ( x 4). 2. Controller box cover [A] ( x 4). 3. Disconnect the interface cable [A] ( x 1, x 1) and CIS unit cable [B] ( x 1, x 1, x 4) from the rear of the machine.
  • Page 561 4. Open the ADF [A]. 5. Remove the fixing screws of the ADF ( x 2).

  • Page 562: Adjustment After Replacing The Adf

    4. Replacement and Adjustment 6. While holding the left and right sides of the ADF, lift up to remove it. • Because of the weight of the ADF, handle with care. Adjustment after Replacing the ADF CIS RGB Adjustment Enter the four-digit numeric values for RGB that are listed on the paper that comes with the ADF into the following SP.

  • Page 563: Checking The Horizontal Registration

    *The arrows indicate the direction of feed. 2. Copy the original and make sure that the position of the line [A] is within 0±1mm 3. If not within the standard, adjust with the SP modes. Checking the horizontal registration SP6-006-010 (ADF Adjustment L-Edge Regist (1-Pass): Front) SP6-006-011 (ADF Adjustment L-Edge Regist (1-Pass): Rear) 1.

  • Page 564: Checking The Magnification

    4. Replacement and Adjustment Checking the magnification SP6-017-001 (DF Magnification Adj.) 1. Copy the original and make sure that the length of the line [B] is within 100±1mm. 2. If not within the standard, adjust with the SP mode. Platen Adjustment 1.

  • Page 565: Adf Cover

    3. Close the ADF [A] slowly and paste the ADF and the white cover [B] with the magic tapes. ADF Cover ADF Front Cover 1. Open the feed cover [A].
  • Page 566 4. Replacement and Adjustment 2. Slide the ADF front cover [A] to the left ( x 2, hook x 4). • Check the position of the hooks in the photo below before removing.

  • Page 567: Adf Rear Cover

    ADF Rear Cover 1. Open the feed cover [A]. 2. Cover [A] ( x 1). 3. Lift off the rear cover [A] ( x 2, hook x 4). • Check the position of the hooks in the photo below before removing.

  • Page 568: Feed Cover

    4. Replacement and Adjustment Feed Cover 1. ADF front cover ( “ADF Front Cover” in page 563 "ADF Cover") 2. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 3. Feed cover [A] ( x 3, x 1) Original Feed Unit 1.

  • Page 569: Pick-Up Roller / Transport Belt

    2. Remove the snap-fit [A]. 3. Original feed unit [A] (Pull the original feed unit, remove the back side of the shaft. Then, remove the bushing in the foreground.) Pick-up Roller / Transport Belt 1. Original feed unit ( page 566) 2.
  • Page 570 4. Replacement and Adjustment • At re-assembly, make sure that the tab on the front guide plate [A] is above the pick-up roller [B]. 3. Pick-up roller cover [A] and pick-up roller [B] (snap-fit x 2, bushing x 2, one-way clutch x 1)
  • Page 571 4. Lift the left and right sides of the feed belt holder [A], then remove it. 5. Remove the feed belt [B] from the feed belt holder [A].

  • Page 572: Adf Separation Roller

    4. Replacement and Adjustment ADF Separation Roller 1. Open the feed cover. 2. Original feed unit ( page 566) 3. ADF separation roller cover [A]. 4. ADF separation roller [A] and torque limiter clutch [B] (snap-fit x 1)

  • Page 573: Original Registration Sensor

    Original Registration Sensor 1. Entrance lower guide [A] ( x 2). 2. Scanning guide plate [A] (hook x 1). 3. Original registration sensor [A] along with the bracket ( x 1, x 1).

  • Page 574: Original Exit Sensor

    4. Replacement and Adjustment 4. Original Registration Sensor [A] (hook x 4). Original Exit Sensor 1. Entrance lower guide [A] ( x 2).
  • Page 575 2. Scanning guide plate [A] (hook x 1). 3. Open the white cover [A]. 4. Remove the original exit sensor [B], which is mounted on the upper guide [A] ( x 6).

  • Page 576: Adf Control Board

    4. Replacement and Adjustment 5. Remove the original exit sensor [B] from the upper guide [A] ( x 1, x 1). ADF Control Board 1. ADF rear cover ( “ADF Rear Cover ” in page 563 "ADF Cover") 2. ADF control board [A] ( x 4, all...

  • Page 577: Separation Sensor / Skew Correction Sensor

    Separation Sensor / Skew Correction Sensor 1. Feed upper guide [A] in the feed cover ( x 3) 2. Remove the sensors along with the bracket [A] ( x 1)

  • Page 578: Original Width Sensor / Interval Sensor

    4. Replacement and Adjustment 3. Separation Sensor [A] and Skew Correction Sensor [B] ( x 1 each) Original Width Sensor / Interval Sensor 1. Feed cover ( “Feed Cover ” in page 563 "ADF Cover") 2. Guide plate [A] ( x 3) 3.

  • Page 579: B5 Width Sensor / A4 Width Sensor / Lg Width Sensor

    4. Remove the original width sensor guide plate [A] ( x 2), then remove the original width sensors (x 5) [B] ( x 1 each). B5 Width Sensor / A4 Width Sensor / LG Width Sensor 1. Raise the document tray [A], then remove the lower cover [B] ( x 4).

  • Page 580: Aps Feeler

    4. Replacement and Adjustment 2. B5 Width Sensor [A] ( x 1) 3. A4 Width Sensor [B] ( x 1) 4. LG Width Sensor[C] ( x 1) APS Feeler 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2.

  • Page 581: Adf Lift-Up Interlock Sw / Lift-Up Sensor

    ADF Lift-Up Interlock SW / Lift-Up Sensor 1. ADF Control Board ( page 574) 2. ADF lift-up interlock SW [A] along with the bracket ( x 3, x 2) 3. Lift-Up Sensor [A] along with the bracket ( x 1, x 1)

  • Page 582: Original Set Sensor

    4. Replacement and Adjustment Original Set Sensor 1. ADF front cover ( “ADF Front Cover” in page 563 "ADF Cover") 2. Remove the screw and raise the original tray [A]. 3. Original set sensor [A] ( x 1, x 1)

  • Page 583: A4 Lef/Lt Lef Sensor

    A4 LEF/LT LEF Sensor 1. ADF front cover ( “ADF Front Cover” in page 563 "ADF Cover") 2. Remove the screw and raise the original tray [A]. 3. A4 LEF/LT LEF Sensor [A] (hook x 1, x 1) Bottom Plate HP Sensor 1.

  • Page 584: Bottom Plate Position Sensor

    4. Replacement and Adjustment 4. Bottom plate HP sensor [A] ( x 1) Bottom Plate Position Sensor 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2. Original feed unit ( page 566) 3. Bottom plate position sensor [A] ( x 1)

  • Page 585: Adf Feed Cover Interlock Sw / Pick-Up Roller Hp Sensor

    ADF Feed Cover Interlock SW / Pick-up Roller HP Sensor 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2. Remove the ADF feed cover interlock SW [A] from the retaining bracket (snap-fit x 1, spring x 1, pin x 1).

  • Page 586: Adf Entrance Motor

    4. Replacement and Adjustment ADF Entrance Motor 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2. ADF entrance motor [A] along with the frame ( x 2, x 2, x 2, spring x 1, timing belt x 1) 3.

  • Page 587: Adf Scanning Motor

    ADF Scanning Motor 1. ADF entrance motor along with the frame ( page 584 "ADF Entrance Motor") 2. ADF read motor [A] along with the bracket ( x 2, x 1 , spring x 1, timing belt x 1) 3. ADF scanning motor [A] ( x 2) ADF Exit Motor 1.

  • Page 588: Adf Bottom Plate Lift Motor

    4. Replacement and Adjustment 3. ADF exit motor [A] ( x 3) ADF Bottom Plate Lift Motor 1. ADF entrance motor along with the frame ( page 584 "ADF Entrance Motor") 2. ADF bottom plate lift motor [A] ( x 2, x 1)

  • Page 589: Adf Pick-Up Roller Lift Motor / Adf Transport Motor

    ADF Pick-up Roller Lift Motor / ADF Transport Motor 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2. Frame (black) [A] ( x 3) 3. ADF pick-up roller lift motor [A] ( x 2, x 1, timing belt x 1)
  • Page 590 4. Replacement and Adjustment 4. ADF transport motor [A] along with the bracket ( x 2, x 1, timing belt x 1) 5. ADF transport motor [A] ( x 3)

  • Page 591: Adf Feed Motor

    ADF Feed Motor 1. ADF rear cover ( “ADF Rear Cover” in page 563 "ADF Cover") 2. Remove the fixing screws of the frame (black) [A] ( x 2). 3. ADF entrance motor along with the frame ( page 584 "ADF Entrance Motor") 4.

  • Page 592: Cis Unit

    4. Replacement and Adjustment CIS Unit 1. Original Feed Unit ( page 566) 2. ADF Separation Roller ( page 570) 3. ADF front cover ( “ADF Front Cover” in page 563 "ADF Cover") 4. Guide plate (large) [A] ( x 3) 5.
  • Page 593 6. Guide plate [A] ( x 1) 7. CIS unit [A] ( x 2, • To prevent scratches on the surface of the CIS glass, removal of the CIS unit must be done with the white cover [A] open.

  • Page 594: Drawer Unit

    4. Replacement and Adjustment Drawer Unit Layout (Motors) Drawer Unit (Front) To replace the motors on the front of the drawer unit, first remove the drawer unit cover. ( page 594 "Drawer Unit Cover") Replacement Part Name Remarks procedure Exit Motor page 612 Duplex Inverter Entrance Motor page 612...

  • Page 595: Drawer Unit (Rear)

    Drawer Unit Drawer Unit (Rear) Replacement Part Name Remarks procedure Exit Inverter Motor page 613 Cleaning Web Contact Motor page 617 D137/ D138 only Layout (Boards)

  • Page 596: Drawer Unit Cover

    4. Replacement and Adjustment Replacement Part Name Remarks procedure Paper Separation AC Power Pack page 600 page 600 Fusing Web Control Board-Drawer page 601 D137/ D138 only Drawer Unit Cover 1. Open the drawer unit [A]. 2. Drawer unit cover [A] ( x 7*)

  • Page 597: If The Drawer Is Locked

    Drawer Unit * D137/D138 use TCRU/ORU screws • After removing the drawer unit cover, when the drawer unit is returned to the machine, you can close the guide plate [A] of the paper exit and duplex unit. If the Drawer is Locked When the drawer is locked, deal with the problem depending on the symptom.
  • Page 598 4. Replacement and Adjustment 3. Remove the fixing screws of the left and right sides of the drawer unit cover [A] ( x 5). 4. Open the paper feed tray, then remove the fixing screw on the bottom of the drawer unit cover [A]. 5.
  • Page 599 Drawer Unit 6. Put a hand in the flapper handle [A] and pull the drawer unit cover [B] to the front. Then hold the guide plate [C] of the paper exit and duplex unit, and remove the drawer unit cover [A] in an upward direction.
  • Page 600 4. Replacement and Adjustment 8. Drawer unit lock motor block [A] ( x 1, snap-fit x 1, x 3, x 1 ) 9. Turn the lock shaft [A] clockwise to release the lock.
  • Page 601 Drawer Unit 10. Turn the paper transfer roller shaft [A] clockwise by using the link [B] to separate the paper transfer roller unit from the ITB. You can pull the drawer unit out. • When mounting the motor block, screw the motor in first. Then, assemble links [A], [B] and [C] as shown below.

  • Page 602: Dub (Drawer Unit Board)

    4. Replacement and Adjustment DUB (Drawer Unit Board) 1. Drawer unit cover ( page 594) 2. Registration unit ( page 882) 3. Paper transfer roller unit ( page 757) 4. DUB cover [A] ( x 1) 5. DUB [A] ( x 6, all Paper Separation AC Power Pack 1.

  • Page 603: Fusing Web Control Board-Drawer (D137/D138 Only)

    Drawer Unit 3. Paper separation AC power pack [A] ( x 5, all Fusing Web Control Board-Drawer (D137/D138 only) 1. Paper transfer roller unit ( page 757) 2. Cover [A] ( x 2, hook x 2)

  • Page 604: Curled Cord

    4. Replacement and Adjustment 3. Fusing web control board-drawer [A] ( x 1, all x 4) Curled Cord 1. Drawer unit cover ( page 594) 2. Registration unit ( page 882) 3. Relay unit ( page 884) 4. Paper transfer roller unit ( page 757) 5.
  • Page 605 Drawer Unit • When mounting the curled cord, fit the fixing material in the hole on the rear of the machine. 6. Remove the left and right clamps fixing the curled cord [A]. 7. DUB cover [A] ( x 1)

  • Page 606: Drawer Unit Connector

    4. Replacement and Adjustment 8. Curled cord ( x 2, x 2) Drawer Unit Connector 1. In order to facilitate the work, pull the drawer unit out half way, then press the release levers (one on the left side and one on the right side, shown by the red arrows) and pull the drawer unit [A] out fully.
  • Page 607 Drawer Unit • In a low-temperature environment (below 15°C), the tension of the curled cord may be reduced. So, do not pull the drawer unit out for a long time, or the curled cord will be deformed and will not curl up again when you try to slide the drawer unit back in. As a guide, every 30 minutes, push the drawer unit back to the half-way position.

  • Page 608: Drawer Unit Set Sensor

    4. Replacement and Adjustment Drawer Unit Set Sensor 1. IOB along with the bracket, located on the back side of the machine ( page 940 "When removing the motors that are behind the IOB") 2. Drawer unit set sensor [A] ( x 1) Drawer Unit Lock Sensor 1.
  • Page 609 Drawer Unit • In a low-temperature environment (below 15°C), the tension of the curled cord may be reduced. So, do not pull the drawer unit out for a long time, or the curled cord will be deformed and will not curl up again when you try to slide the drawer unit back in. As a guide, every 30 minutes, push the drawer unit back to the half-way position.

  • Page 610: Drawer Unit Handle Sensor

    4. Replacement and Adjustment Drawer Unit Handle Sensor 1. Drawer unit cover ( page 594) 2. Right cover [A] and left cover [B] ( x 2 each) 3. Middle cover ( x 5) 4. Drawer unit handle sensor [A] ( x 1)

  • Page 611: Drawer Unit Lock Motor

    Drawer Unit Drawer Unit Lock Motor 1. Drawer unit cover ( page 594) 2. Drawer unit lock motor cover [A] ( x 3) 3. Drawer unit lock motor block [A] ( x 1, snap-fit x 1, x 3, x 1 )
  • Page 612 4. Replacement and Adjustment • When mounting the motor block, screw the motor in first. Then, assemble links [A], [B] and [C] as shown below. There is also a diagram embossed on the motor cover to help you to install the links correctly.

  • Page 613: Registration Motor

    Drawer Unit 5. Take off the gears, and remove the drawer unit lock motor [A] ( x 2) Registration Motor 1. Drawer unit cover ( page 594) 2. Registration motor [A] ( x 2, x 1, timing belt x 1)

  • Page 614: Exit Motor

    4. Replacement and Adjustment Exit Motor 1. Drawer unit cover ( page 594) 2. Exit motor [A] ( x 2, x 1, timing belt x 1) Duplex Inverter Entrance Motor 1. Drawer unit cover ( page 594)

  • Page 615: Exit Inverter Motor

    Drawer Unit 2. Duplex inverter entrance motor [A] ( x 2, x 1, timing belt x 1) Exit Inverter Motor 1. In order to facilitate the work, pull the drawer unit out half way, then press the release levers (one on the left side and one on the right side, shown by the red arrows) and pull the drawer unit [A] out fully.

  • Page 616: Duplex Transport Motor

    4. Replacement and Adjustment • In a low-temperature environment (below 15°C), the tension of the curled cord may be reduced. So, do not pull the drawer unit out for a long time, or the curled cord will be deformed and will not curl up again when you try to slide the drawer unit back in. As a guide, every 30 minutes, push the drawer unit back to the half-way position.

  • Page 617: Duplex Exit Motor

    Drawer Unit Duplex Exit Motor 1. Drawer unit cover ( page 594) 2. Duplex exit motor [A] ( x 2, x 1, timing belt x 1)

  • Page 618: Cleaning Web Motor (D137/D138 Only)

    4. Replacement and Adjustment Cleaning Web Motor (D137/D138 only) 1. Drawer unit cover ( page 594) 2. Cleaning Web Motor block [A] (torsion spring x 1, x 1, x 1) 3. Cleaning Web Motor [A] along with the bracket ( x 2) 4.

  • Page 619: Cleaning Web Contact Motor (D137/D138 Only)

    Drawer Unit Cleaning Web Contact Motor (D137/D138 only) 1. In order to facilitate the work, pull the drawer unit out half way, then press the release levers (one on the left side and one on the right side, shown by the red arrows) and pull the drawer unit [A] out fully.

  • Page 620: Fusing Heat Pipe Cooling Fan

    4. Replacement and Adjustment 3. Cleaning Web Contact Motor [A] ( x 2, x 1, x 1) Fusing Heat Pipe Cooling Fan 1. Drawer unit cover ( page 594) 2. Disconnect the connector, clamp, etc., in order to remove the duct together with the fusing heat pipe cooling fan [A].
  • Page 621 Drawer Unit 3. Fusing heat pipe cooling fan [A] along with the duct ( x 3, x 3, hook x 2) 4. Fusing heat pipe cooling fan [A]...

  • Page 622: Ih Coil Cooling Fan

    4. Replacement and Adjustment IH Coil Cooling Fan 1. Drawer unit cover ( page 594) 2. Disconnect the connector, clamp, etc., in order to remove the duct together with the IH coil cooling fan [A]. 3. IH coil cooling fan [A] along with the duct ( x 3, x 3, hook x 2) 4.

  • Page 623: Fusing Pressure Roller Intake Fan (D137/D138 Only)

    Drawer Unit Fusing Pressure Roller Intake Fan (D137/D138 only) 1. Drawer unit cover ( page 594) 2. Fusing unit ( page 764) 3. Inner cover [A] ( x 2, x 1) 4. Disconnect the connector, clamp, etc., of the duct [A] for the fusing heat pipe cooling fan and IH coil cooling fan.
  • Page 624 4. Replacement and Adjustment 5. Duct [A] for the fusing heat pipe cooling fan and IH coil cooling fan ( x 2, x 3, hook x 4 (On the left side, there is a hook on the top and bottom.)) 6.
  • Page 625 Drawer Unit...

  • Page 626: Toner Supply Unit

    4. Replacement and Adjustment Toner Supply Unit Toner Supply Unit Front Cover 1. Open the toner supply unit front cover [A]. 2. Remove the toner supply unit front cover [A] by sliding it to the left, fastener x 1). Toner Supply Unit 1.
  • Page 627 Toner Supply Unit * D137/D138 use TCRU/ORU screws 3. Open the toner supply unit front cover [A]. 4. Remove the fixing screws of the toner supply unit [A] ( x 3*).
  • Page 628 4. Replacement and Adjustment * D137/D138 use TCRU/ORU screws 5. Slide the toner supply unit [A] to the front. 6. Pull out the toner supply unit [A], and remove it from the slide rail with the handles on the left and right ( x 2*).

  • Page 629: Id Chip Connector Board (Kcmy)

    Toner Supply Unit * D137/D138 use TCRU/ORU screws • When attaching the toner supply unit to the machine, the hooks of the toner supply unit should be fit into the holes in the slide rails. ID Chip Connector Board (KCMY) 1.

  • Page 630: Toner Supply Unit Inner Cover

    4. Replacement and Adjustment 3. ID chip connector board [A] ( x 2, x 1). Toner Supply Unit Inner Cover 1. Toner supply unit front cover ( page 624) 2. Drawer unit cover ( page 594) 3. ITB cleaning intake fan [A] along with the duct ( x 1*). * D137/D138 use TCRU/ORU screws...

  • Page 631: Sub Hopper Unit (Kcmy)

    Toner Supply Unit 4. Toner supply unit inner cover [A] ( x 4). Sub Hopper Unit (KCMY) 1. Toner supply unit inner cover ( page 628) 2. CMY: Sub Hopper Unit [A] ( x 2 each, all e.g.: Y 3. K: Disconnect all the connectors and clamps connected to the sub hopper unit [A] and toner supply board (TSB) [B] ( x 2).
  • Page 632 4. Replacement and Adjustment Sub hopper unit [A] ( x 2) • When installing the sub hopper unit, take care not to tuck the toner fall prevention sheet [A] attached to the toner supply unit. [B]: Normal state [C]: Toner fall prevention sheet is tucked...

  • Page 633: Adjustment After Sub Hopper Unit (Kcmy) Replacement

    Toner Supply Unit Adjustment after Sub Hopper Unit (KCMY) replacement After replacing the Sub Hopper Unit, you have to execute Density Adjustment Process Control. 1. Turn on the main power switch with the by-pass tray unit [A] or the vertical transport door [B] open. 2.

  • Page 634: Toner End Sensor (Kcmy)

    4. Replacement and Adjustment 4. Confirm that SP3-012-001 (ProCon OK? > History:Latest) shows “11111111”. Toner End Sensor (KCMY) 1. Sub Hopper Unit ( page 629) 2. Toner end sensor [A] ( x 1, x 1) Sub Hopper Motor (KCMY) 1. Sub Hopper Unit ( page 629) 2.

  • Page 635: Toner Cartridge Guide

    Toner Supply Unit Toner Cartridge Guide 1. Toner supply unit inner cover ( page 628) 2. Drawer unit cover ( page 594) 3. ITB cleaning intake fan [A] along with the duct ( x 1*). * D137/D138 use TCRU/ORU screws 4.
  • Page 636 4. Replacement and Adjustment * D137/D138 use TCRU/ORU screws 5. Slide forward the toner supply unit [A]. 6. Toner cartridge [A]...
  • Page 637 Toner Supply Unit 7. Toner cartridge guide [A] ( x 8) • When installing, tighten the screws on the bottom while holding from the top as shown below.

  • Page 638: Toner Supply Motor (Kcmy)

    4. Replacement and Adjustment Toner Supply Motor (KCMY) 1. Toner cartridge guide ( page 633) 2. Remove the ID chip connector cover [B] from the back of the toner supply unit [A]. e.g.: Y 3. Toner supply motor [A] along with the bracket ( x 3, x 1, x 3) •...
  • Page 639 Toner Supply Unit 4. Toner supply motor [A] ( x 2) e.g.: Y...

  • Page 640: Scanner Unit

    4. Replacement and Adjustment Scanner Unit Exposure Glass 1. Rear scale [A] ( x 3) 2. Glass cover [A] ( x 2) 3. Exposure glass [A]...

  • Page 641: Adf Exposure Glass / Gap Sheet (D135/D136)

    Scanner Unit • When attaching the glass cover, ensure that the glass cover is not riding on the upper front cover or the upper rear small cover. ADF Exposure Glass / Gap Sheet (D135/D136) • The document transport system of the ADF is different between D135/D136 and D137/D138. D135/D136 uses a new non-contact transport system, so the glass replacement procedure is changed accordingly.

  • Page 642: How To Attach The Adf Exposure Glass/Gap Sheet

    4. Replacement and Adjustment How to Attach the ADF Exposure Glass/Gap Sheet 1. Clean the place to attach the exposure glass seal on the exposure glass bracket with alcohol. 2. Attach the exposure glass seal* [C] along the marking [B] on the exposure glass bracket [A]. * The tip of the seal is cut at an angle.
  • Page 643 Scanner Unit • Attach the ADF exposure glass, so that the marking [A] is on the upper left. 5. Attach in the order of exposure glass, glass cover and rear scale. 6. Clean the ADF exposure glass with a dry cloth. 7.

  • Page 644: Modification Procedure For Original Transport

    4. Replacement and Adjustment *The tip of the seal is cut at an angle. Its tip faces the front [B]. • When replacing an ADF exposure glass, replace with a new exposure glass seal and a gap sheet as well. •...
  • Page 645 Scanner Unit 3. Scanning guide plate [A] (hook x 1). • Scanning guide plate for non-contact transport: the following areas are black [A]. • Scanning guide plate for contact transport (part number: D6833350): the following areas are white [B]. 4. Attach the scanning guide plate for contact transport [A] (hook x 1). 5.

  • Page 646: Removing The Scanner Parts

    4. Replacement and Adjustment 6. Enter the SP mode, set "98" at SP4-688-002 (Scan Image Density Adjustment 1-pass). Removing the Scanner Parts 1. Exposure glass ( page 638) 2. Remove the gap sheet (black) [A] from the ADF exposure glass [B]. 3.
  • Page 647 Scanner Unit 3. Original size sensors [A] ( x 2) and the sensor cradle [B] ( x 2) 4. IDB [A] ( x 2, x 2)

  • Page 648: Adjustment After Replacing The Lens Block

    4. Replacement and Adjustment 5. Lens Block [A] ( x 4, x 3) Adjustment after Replacing the Lens Block SP4-008-001: Sub Scan Magnification Adj ( ”Sub Scan Magnification Adjustment” in page 669 "Magnification and Registration Adjustment") SP4-010-001: Sub Scan Registration Adj ( ”Sub Scan Registration Adjustment”...
  • Page 649 Scanner Unit • Do not touch the mirror, reflector, or light guide plate in the scanner carriage. 4. Exposure lamp (LED) [A] ( x 2, x 1) • When attaching the exposure lamp, put the harness in the hook.

  • Page 650: Scanner Drive Motor

    4. Replacement and Adjustment Scanner Drive Motor 1. Upper right cover ( page 542 "Upper Left Cover/ Upper Right Cover") • In the case of D135/D136, also remove the operation panel. ( page 551 "Operation Panel") 2. Pull out the toner supply unit. ( page 624) 3.
  • Page 651 Scanner Unit 4. Scanner drive motor [A] along with the bracket ( x 3, x 1, spring x 1, timing belt x 1) 5. Motor bracket [A] ( x 2) 6. Motor cushion [A] ( x 2)

  • Page 652: Scanner Hp Sensor

    4. Replacement and Adjustment • When attaching the motor, make sure that the timing belt does not come off. Slide the motor a few times. Screw the motor into place while the spring is pulled. Scanner HP Sensor 1. Exposure glass ( page 638) 2.

  • Page 653: Df Position Sensor

    Scanner Unit DF Position Sensor 1. ADF ( page 558) 2. Upper rear small cover [A] ( x 2) 3. Operator call light [A] ( x 3, x 1)
  • Page 654 4. Replacement and Adjustment • The operatior call light is not attached to D135/D136, so this step is not required. 4. Upper rear cover [A] ( x 2) 5. DF position sensor [A] ( x 1, x 1, spring plate x 1)

  • Page 655: Sio Board

    Scanner Unit SIO Board 1. Upper rear small cover [A] ( x 2) 2. Slide the upper right cover [A] toward the rear. 3. Remove the fixing screws on the right side of the rear middle cover [A] ( x 2).
  • Page 656 4. Replacement and Adjustment 4. Open the by-pass tray unit, then remove the right middle cover [A] ( x 1). 5. SIO board [A] ( x 5, x 5) • The 5 screws for the SIO board are accessed from holes in the right frame of the machine.

  • Page 657: Scanner Unit

    Scanner Unit Scanner Unit 1. Upper left cover/ upper right cover ( page 542 "Upper Left Cover/ Upper Right Cover") • In the case of D135/D136, also remove the operation panel. ( page 551 "Operation Panel") 2. Rear middle cover [A] ( x 4) 3.
  • Page 658 4. Replacement and Adjustment 4. Disconnect the interface cable [A] from the rear of the machine ( x 1, x 1, x 2, bind x 1). • When connecting the scanner cable, do not forget to attach the bind. As shown in the pictures below, the binding position should be in the middle of the cable.
  • Page 659 Scanner Unit 5. Remove the interface cable [A] through the right side [B] of the machine ( x 3). 6. Disconnect the connector of the scanner unit [A] ( x 2). 7. Fixing screws on the left side stay [A] ( x 2)
  • Page 660 4. Replacement and Adjustment 8. Fixing screws on the right side stay [A] ( x 3) • For steps 7-8 in the procedure described above, in the case of D135/D136, remove the operation panel bracket [A] ( x 7). 9. D137/D138: Scanner unit [A] ( x 4)
  • Page 661 Scanner Unit D135/D136: Scanner unit [A] ( x 4) 10. Hold the handles at the left and right, and remove the scanner unit [A] from the machine.

  • Page 662: Scanner Wire

    4. Replacement and Adjustment Scanner Wire Preparation for Replacing a Scanner Wire 1. Exposure glass ( page 638) 2. Left stay [A] and right stay [B] ( x 5 each) 3. Front frame [A] ( x 7)

  • Page 663: Replacing The Scanner Wire

    Scanner Unit Replacing the Scanner Wire 1. Move the 1st sacanner carriage [B] to a position where the screw [A] of the bracket can be seen. 2. Remove the springs of the tension brackets (rear: [A] / front: [B]).
  • Page 664 4. Replacement and Adjustment 3. Loosen the fixing screws of the tension brackets (rear: [A] / front: [B]). 4. Remove the retaining brackets (rear: [A] / front [B]) from the wire ( x 1 each).

  • Page 665: Preparation For Reassembling The Scanner Wire

    Scanner Unit 5. Remove the tip and the rear end of the wire (rear / front). 6. Unscrew the wire pulleys (rear: [A] / front [B]) and drive pulley [C]. Remove the wire pulleys from the shaft. 7. Remove the rear and front wires. Preparation for Reassembling the Scanner Wire 1.

  • Page 666: Reassembling The Scanner Wire

    4. Replacement and Adjustment 2. Place the beads on the middle of the wire in the groove. [B] 3. Attach tape across the pulley to temporarily hold the wires in place. [C] Reassembling the Scanner Wire 1. Remove the 1st scanner carriage from the scanner unit. 2.

  • Page 667: Installing The Scanner Heater

    Scanner Unit • If replacing anything other than the wire, adjust SP4-010-001 (Sub Scan Registration Adj). Installing the Scanner Heater Accessories Check the accessories against the list below. Description Q'ty Heater...

  • Page 668: Installation

    4. Replacement and Adjustment Description Q'ty Tapping Screw - M3x6 • The part number for the scanner heater is the same across all models except the D135-17. See the table below. Also see D137 RTB 119 Model Area Voltage Part number D135-17 120 to 127V B2291678...
  • Page 669 Scanner Unit 4. Pass the scanner heater [A] under the 2nd carriage [B]. Then put the connector [C] from the left side of the scanner unit [D]. 5. Attach the scanner heater [A] ( x 2).
  • Page 670 4. Replacement and Adjustment • The screw on the left side of the scanner heater is accessed from the scanner frame. 6. Connect the connector [A] of the scanner heater to the machine ( x 1, x 2).

  • Page 671: Magnification And Registration Adjustment

    Scanner Unit Magnification and Registration Adjustment Sub Scan Magnification Adjustment Measuring Tool 150 mm scale Adjustment Method Copy the scale and check that the length of the 100 mm scale on the copy is the same as the original, within the standard value (±0.8%) for a 100 mm scale. It should be measured 10 minutes after the copy has been fed out.

  • Page 672: Main Scan Registration Adjustment

    4. Replacement and Adjustment Adjustment Procedure 1. Enter SP mode. 2. Select SP4-010. The image is moved downward by increasing the adjustment value. The image is moved upward by decreasing the adjustment value. Main Scan Registration Adjustment Measuring Tool C4 chart Adjustment Method Copy the C4 chart.

  • Page 673: Laser Unit

    Laser Unit Laser Unit Before You Begin • This laser unit employs 80 laser beams produced by a Class III LD with a wavelength of 772 to 792 nm and intensity of 1.4 mW (40 beams). Direct exposure to the eyes could cause permanent blindness.

  • Page 674: Laser Unit

    4. Replacement and Adjustment D135/D136 only Laser Unit • Each laser unit is composed of two laser diode assemblies. Before Replacement 1. Plug in the power cord, and then turn ON the main power switch. 2. Reset the motors for skew adjustment to the zero point with the following SPs:. •...
  • Page 675 Laser Unit 3. For the Laser unit (CK) [A], remove the stay [B] first. ( x 1) 4. Remove the connectors from the laser unit [A]. ( x 4; includes a USB connector) e.g.: CK 5. Laser unit [A] ( x 4) e.g.: CK...

  • Page 676: How To Distinguish Between The Ck Laser Unit And Ym Laser Unit

    4. Replacement and Adjustment 6. Grasp the handles on the left and right, and lift out the laser unit. How to Distinguish between the CK Laser Unit and YM Laser Unit CK Laser Unit Bar code label [A]: White characters on black background Bottom center [B]: No screws...
  • Page 677 Laser Unit YM Laser Unit Bar code label [A]: Black characters on white background Center bottom [B]: A pentagonal protrusion is screwed in...

  • Page 678: Notes On Installation Of A New Laser Unit

    4. Replacement and Adjustment Notes on Installation of a New Laser Unit The polygon mirror of the new laser unit is protected by fall prevention materials. Therefore, when installing the unit in the machine, it is necessary to remove the materials 1.

  • Page 679: Laser Unit Cooling Fan (Left / Right)

    Laser Unit • During the download of the correction values, you can turn off the power, or open the door. • If an SC or a display of "failure" occurs, you can run the download again after turning the power OFF and ON. 3.
  • Page 680 4. Replacement and Adjustment 4. Laser unit cooling fan [A] (hook x 2) • It is also possible to leave the bracket on the machine side, and remove the laser unit cooling fan [A] only.
  • Page 681 Laser Unit...

  • Page 682: Pcdu

    4. Replacement and Adjustment PCDU Faceplate 1. Toner supply unit ( page 624) 2. Turn the transfer belt release lever counterclockwise and remove the fixing screws of the faceplate ( x 6*). * D137/D138 use TCRU/ORU screws 3. Take off the handles. 4.

  • Page 683: Pcdu

    PCDU 5. Remove the faceplate with the grips. • Do not close the drawer unit with the faceplate removed, because there is a risk of damage to the paper transfer roller unit. PCDU 1. Faceplate ( page 680) 2. Unlock the lever [A] and pull out the PCDU [B] from the machine.
  • Page 684 4. Replacement and Adjustment 3. Place the PCDU [A] on the cradle [B] that was laid down on paper in advance. • When installing the PCDU, ensure that the locking lever is fit in the hole of the machine frame. [A]: The locking lever is properly fit in the hole in the machine frame.

  • Page 685: Charge Roller Unit

    PCDU • After installing the faceplate, check the status of the locking levers again by looking through the holes as shown below. The levers should be straight, as shown above [A], and not at an angle [B]. However, some force is required to attach the faceplate, and this could knock the levers out of their horizontal alignment.

  • Page 686: Drum Cleaning Unit Removal

    4. Replacement and Adjustment * D137/D138 use TCRU/ORU screws • After removing the charge roller unit, place it on a clean, flat surface with the roller facing up. Drum Cleaning Unit Removal 1. PCDU ( page 681) 2. Front faceplace [A] ( x 3*)
  • Page 687 PCDU * D137/D138 use TCRU/ORU screws 3. Spopper [A] at the rear ( x 1*) * D137/D138 use a TCRU/ORU screw 4. Slide the bracket [A] to the rear.
  • Page 688 4. Replacement and Adjustment 5. Drum cleaning unit [A] ( x 1) • When installing the drum cleaning unit, ensure that it (the front side) is fit into the grooves of the development unit.
  • Page 689 PCDU • After removing the cleaning unit, lubricant and toner streaks [B] remain on the surface of the OPC drum [A]. This will cause stains on the charge roller. Therefore, rotate the OPC drum in the direction of the arrow [C] before you install the new drum cleaning unit. •...

  • Page 690: Notes On Replacing The Drum Cleaning Unit And Drum Cleaning Blade

    4. Replacement and Adjustment Notes on Replacing the Drum Cleaning Unit and Drum Cleaning Blade Do not replace the drum cleaning unit or the drum cleaning blade at the same time as the following parts. • ITB • ITB Cleaning Unit •...

  • Page 691: Opc Drum

    PCDU 4. Replace the above five parts 5. Run SP2-696-001 (Force Apply Lubricant Execute) manually OPC Drum 1. Charge roller unit ( page 683) 2. Drum cleaning unit ( page 684) 3. To remove the drum [A], move it to the front side (to the left as shown above), then pull it out from the rear side (the right side as shown above).
  • Page 692 4. Replacement and Adjustment • Use the blower brush (D0747690) when applying lubricant powder (zinc stearate) to the OPC drum. 2. Lay the protective sheet (black) [B] that had been wrapped around the new OPC drum on the development unit [A].
  • Page 693 PCDU 3. Attach the new OPC drum [A] and remove the protective sheet (black) [B] from the bottom. • The surface of a newly replaced drum needs to be lubricated. In the lubrication process where the drum is manually rotated, the two tools [A] function to fix the shaft so that the drum rotates precisely on its axis.

  • Page 694: Drum Cleaning Unit Internal Components

    4. Replacement and Adjustment Drum Cleaning Unit Internal Components Separation of the Lubrication Unit and Cleaning Unit 1. Drum cleaning unit ( page 684) 2. Front cover [B] of the cleaning unit [A] ( x 1)
  • Page 695 PCDU 3. Remove the following five gears (gear [A]: x 1). 4. Rear cover [A] ( x 1)

  • Page 696: Lubrication Unit

    4. Replacement and Adjustment 5. Remove the fixing screw on the rear side and separate into cleaning unit [A] and lubrication unit [B]. • When installing the cleaning unit and the lubrication unit, ensure that the shaft of the cleaning unit is fit into the hole in the vibration plate [A].
  • Page 697 PCDU • When assembling, position the lubricant blade on the earth plate [A] of the lubrication unit. 3. Joint at the rear side [A] 4. Cover [A] ( x 2)
  • Page 698 4. Replacement and Adjustment 5. Lubricant bar [A] 6. Bearing with the side seal (front) [A], bearing with the side seal (rear) [B] and lubrication roller [C]...
  • Page 699 PCDU • When installing a new lubricant bar, a new lubrication roller must be installed. • When installing the lubrication roller, ensure that the roller is fit into the groove of the lubrication unit 7. Remove the side seal (front) [A] and the side seal (rear) [B] from the bearings.

  • Page 700: Cleaning Unit

    4. Replacement and Adjustment Cleaning Unit 1. Separate the lubrication unit and cleaning unit ( page 692 "Drum Cleaning Unit Internal Components") 2. Drum cleaning blade [A] ( x 2) 3. Remove the side seal (rear) [A] and the side seal (front) [B] from the cleaning unit.

  • Page 701: Assembling The Cleaning Unit And Lubrication Unit With New Seals

    PCDU Assembling the Cleaning Unit and Lubrication Unit with New Seals • Replace the cleaning blade, lubrication blade and side seals as a set. 1. Assemble the cleaning unit and the lubrication unit. ( page 692 "Drum Cleaning Unit Internal Components") 2.
  • Page 702 4. Replacement and Adjustment 4. After attaching the side seals (x 2 each) on the cleaning unit and the lubrication unit, apply the lubricant powder (D0159501) (zinc stearate) with a brush on the side seals [A]. e.g. (enlarged): cleaning unit 5.
  • Page 703 PCDU • Use the blower brush (D0747690) when applying lubricant powder (zinc stearate) and yellow toner in Step 4 and 5.

  • Page 704: Development Unit

    4. Replacement and Adjustment Development Unit Development Unit 1. PCDU ( page 681) 2. Charge roller unit ( page 683) 3. Drum cleaning unit ( page 684) 4. OPC drum ( page 689) 5. Development unit [A] • D137/D138: After you take this part out of the machine and put it back, or replace it with a new one, carry out SP3-040-001 to SP3-040-005 (DEMS: Execute).
  • Page 705 Development Unit • When carrying the developing unit, do not hold the frame [A]. The frame may become bent or broken if load is applied to it. • When installing the new development unit, attach the color identification seals [A] that come with the unit to the supply port.

  • Page 706: Development Filter

    4. Replacement and Adjustment Development Filter 1. Filter cover [A] from the right side. 2. Filter cover [A]...

  • Page 707: Removing Old Developer

    Development Unit Removing Old Developer General Replacing the developer without completely removing old developer causes the machine to operate in a condition in which the applied toner density value is lower than the actual value. This happens because the toner density sensor (TD sensor) initialization process (SP3-030-001 to 006), which is performed when replacing the developer, always sets back the toner density readings to the prescribed standard value 7.0% regardless of the actual toner density, e.g.
  • Page 708 4. Replacement and Adjustment SP No. Color SP 3-200-002 SP 3-200-003 SP 3-200-004 If the toner density is 7%±0.5, skip the following procedures and go to PART 2. If the toner density is not 7%±0.5 (7.5% or higher), continue this procedure. 2.

  • Page 709: Part 2: Developer Removal Procedure

    Development Unit • Changed value “0” supplies toner in constant supply mode. Table 3-2 Toner Supply Rate SP No. Color Default Change to SP 3-440-001 SP 3-440-002 SP 3-440-003 SP 3-440-004 4. Select test pattern “26” from SP2-109-003 and specify the color in SP2-109-005. Table 4 Test Pattern Settings SP No.
  • Page 710 4. Replacement and Adjustment • When carrying the developing unit, do not hold the frame. It may become bent or broken if load is applied to the frame. 3. Remove the old developer while turning the screw [B] clockwise, using the special tool [A]. 4.
  • Page 711 Development Unit 5. Repeat until the developer does not come out of the supply port 6. Tilt the development unit towards the development roller. The developer in the unit is gathered at the development roller side. 7. Once again, dump the developer until there is no adhesion around the development roller [A]. 8.

  • Page 712: Adding New Developer

    4. Replacement and Adjustment • If you are in an environment where use of a vacuum cleaner is not possible, make sure that all old developer is removed from the center of the development roller until about 1cm from the edge [A].

  • Page 713: Adding New Developer (Summary)

    Development Unit Adding New Developer (Summary) Adding New Developer and Adjustment 1. Turn off the power. 2. Toner supply unit ( page 624) 3. Turn on the machine. 4. Attach the funnel [A] to the the supply port [B] of the development unit.
  • Page 714 4. Replacement and Adjustment • Protrusion [A] at the bottom of the funnel is the stopper. Make sure that the protrusion is inserted securely into the slot at the back side of the supply port [B] of the development unit. 5.
  • Page 715 Development Unit 6. Enter SP mode and execute SP3-024-00x (Developer Fill). See the table below. Filling Developer SP Description 3-024-001 Developer Fill :Exe Execute: ALL 3-024-002 Developer Fill :Exe Execute: COL 3-024-003 Developer Fill :Exe Execute: K 3-024-004 Developer Fill :Exe Execute: C 3-024-005 Developer Fill :Exe Execute: M 3-024-006...
  • Page 716 4. Replacement and Adjustment • Execution time for filling developer is 60 seconds as the default. The time interval for execution can be adjusted. If more time is needed to empty the developer pack, increase the time interval with SP3-024-11 (Developer Fill: Exe Drive Time Upper Limit). •...
  • Page 717 Development Unit Code Meaning Comment Conditions Recovery Procedure Even the results display of SP3025 shows success, developer may remain in the funnel. In this case, implement the following output checks in order to fill the remaining developer. • Set to ON “1” at SP5-805-068 (Output Check Used Toner Bottle Motor).
  • Page 718 4. Replacement and Adjustment Code Meaning Comment Conditions Recovery Procedure Deal with this in the following order. Before • Turn off the main power. Removing the execution, TD • Remove the PCDU and remove the developer in sensor output developer in the PCDU. EM, if the develope was above...
  • Page 719 Development Unit Code Meaning Comment Conditions Recovery Procedure By-pass tray cover opened, waste toner Deal with this in the following order. When the front cover situation on the • Enter SP mode and execute Forced opened, the left happend SP3-024-00x (Developer Fill). abort machine was when filling the...

  • Page 720: Image Transfer Belt Unit

    4. Replacement and Adjustment Image Transfer Belt Unit ITB Unit Removal Faceplate (page 680 "Faceplate") ITB Cleaning Unit (page 746 "ITB Cleaning Unit") Bracket [A] ( x2) Pull the drawer unit. Then pull the ITB Unit [A] out to detach it. •...

  • Page 721: Itb Replacement

    Image Transfer Belt Unit • When you remove or install the ITB unit, be sure not to let the transfer belt touch the drawer unit. • Be sure to place the ITB unit on a flat surface. • Execute SP2924-004 after you remove and re-install the ITB unit. ITB Replacement Before you start: •...
  • Page 722 4. Replacement and Adjustment Both side brackets [A], [B] ( x2 each, Spring x2) Anti-toner-scatterring cover [A] ( x2)
  • Page 723 Image Transfer Belt Unit Stay [A] on the left side ( x2) Stay [A] on the right side. ( x3)
  • Page 724 4. Replacement and Adjustment Bracket with ID Sensors [A]. ( x1, Center stay [A] ( x1)
  • Page 725 Image Transfer Belt Unit Hold the frames [A] of the encoder roller and pull them towards you. Tension roller [A] ( x1, Bracket x1) Pull the transfer belt [A] upward to remove it. • Be sure to install the new transfer belt with the number at the rear of the machine (the lower side in the picture below).

  • Page 726: Lubrication After Replacement

    4. Replacement and Adjustment • After the replacement, some procedures need to be done. See “Lubrication after replacement” described below. Lubrication after replacement Turn on the machine. Enter the SP mode and push the PM parts counter reset button in the PM Parts display. Replace Image Transfer Belt.

  • Page 727: Id/Music Sensors

    Image Transfer Belt Unit Keep the drawer unit open, and then turn the machine main power ON. • The automatic adjustment will not be performed when the machine is turned ON, since the drawer unit is pulled out/opened. Enter the SP mode and choose SP2-696-001 (Force Apply Lubricant Execute). Push [Execute] on the operation panel and then push the drawer unit into the machine.

  • Page 728: Itb Hp Sensor

    4. Replacement and Adjustment ITB HP Sensor Detach the ID sensor from the bracket. (page 725 "ID/MUSIC Sensors") Cover [A] ( x1, Hook x3) ITB HP Sensor [A] ( x2, PTR Separation Sensor Transfer Belt (page 719 "ITB Replacement")

  • Page 729: Itb Lift (Ymc) Sensor

    Image Transfer Belt Unit Bracket with PTR separation sensor [A] ( x2) Detach the PTR separation sensor [A] from the bracket [A]. (Hook, ITB Lift (YMC) Sensor Transfer Belt (page 719 "ITB Replacement") Rotate the cam [A] and make its widest part point to the bearing (“image transfer roller rises up”...

  • Page 730: Image Transfer Roller (K)

    4. Replacement and Adjustment • Be sure to re-rotate the cam and drop the image transfer roller down after the replacement. ITB Lift (YMC) Sensor ( x1, Hook) Image Transfer Roller (K) Transfer Belt (page 719 "ITB Replacement") Raise the lever [A]. •...

  • Page 731: Image Transfer Roller (Ymc)

    Image Transfer Belt Unit “ x1” that fixes the image transfer roller (K) [A] Slide the image transfer roller (K) [A] towards you and remove it. Image Transfer Roller (YMC) Transfer Belt (page 719 "ITB Replacement")
  • Page 732 4. Replacement and Adjustment Rotate the cams and make the wider parts [A] [B] point to the bearing (“rise up” state). • Be sure to re-rotate the cam and drop the image transfer roller down after the replacement. “ x1” that fixes the image transfer roller (C) [A]...

  • Page 733: Itb Bias Roller

    Image Transfer Belt Unit Slide the image transfer roller (C) [A] to the rear side and remove it. Remove the image transfer roller (M), (Y) as in the previous step. ITB Bias Roller Transfer Belt (page 719 "ITB Replacement") PTR Separation Sensor Bracket [A] ( x2, x 1)
  • Page 734 4. Replacement and Adjustment Actuator [A] ( Separate the drawer bracket [A] from the drawer ( x3). Harness Guide [A] and Bracket [B] ( x5, Grounding Plate x1)
  • Page 735 Image Transfer Belt Unit Re-attach the drawer bracket [A] ( x3) • Be sure not to pinch the harness when you re-attach the drawer bracket.
  • Page 736 4. Replacement and Adjustment Loosen the motor bracket [A] ( x2, Spring x1). Then remove the belt [B]. Pulley [A] ( x1)
  • Page 737 Image Transfer Belt Unit Bearing Bracket [A] ( x2, Bearing x1) Drop the ITB bias roller [A] down and remove the parallel pin [B]. Pull the ITB bias roller [A] upward and release its lower end to remove it. • Each side cam of the ITB bias roller must be attached in the correct direction. Re-attach these cams, directing each cam’s widest part inward.

  • Page 738: Transfer Power Pack/Separation Power Pack

    4. Replacement and Adjustment Transfer Power Pack/Separation Power Pack Transfer Belt (page 719 "ITB Replacement")

  • Page 739: Tdrb (Transfer Drive Relay Board)

    Image Transfer Belt Unit Bracket [A] ( x2) Transfer Power Pack/Separation Power Pack [A] ( x6, all) TDRB (Transfer Drive Relay Board) Transfer Belt (page 719 "ITB Replacement") Image Transfer Roller (C) (page 729 "Image Transfer Roller (YMC)")

  • Page 740: Anti-Condensation Heater

    4. Replacement and Adjustment Bracket [A] ( x2) TDRB [A] ( x4, all) Anti-condensation Heater Transfer Belt (page 719 "ITB Replacement")

  • Page 741: Ptr Separation Motor

    Image Transfer Belt Unit Detach the bracket with the drawer connector [A] from the ITB unit. ( x3) Disconnect the white connector and push the red connector into the back of the ITB frame. Detach the heater from the ITB unit. ( x2) PTR Separation Motor ITB Unit (page 718 "ITB Unit...

  • Page 742: Ac Transfer Power Pack (D137/D138 Only)

    4. Replacement and Adjustment Bracket with the PTR separation motor [A] (Spring x1, x2, Belt x1) Separate the bracket [A] and the PTR separation motor [B] ( x2, Detach the vibration-proof pad [A] from the motor. ( x2) AC Transfer Power Pack (D137/D138 Only) Image Transfer Roller (C) (page 729 "Image Transfer Roller (YMC)")

  • Page 743: Itb Motor

    Image Transfer Belt Unit AC Transfer Power Pack [A] ( x6, all) ITB Motor ITB Unit (page 718 "ITB Unit Removal") ITB Motor [A] ( x4, ITB Drive Shaft Gear / Encoder Sensor Transfer Belt (page 719 "ITB Replacement")
  • Page 744 4. Replacement and Adjustment Motor Bracket [A] ( x4, Housing [A] ( x4) • Do not remove only the housing [A]. Remove it [A] with the gear.
  • Page 745 Image Transfer Belt Unit Detach the ITB drive shaft gear [A] from the housing • Be sure to handle the gear carefully not to break the encoder [A]. • To prevent breaking the encoder [A] when you install the ITB drive shaft gear, remove the ITB drive shaft encoder sensor from the housing first.

  • Page 746: Itb Driven Shaft Encoder Sensor

    4. Replacement and Adjustment Disconnect the harness from the housing to detach the ITB drive shaft encoder sensor [A]. ITB Driven Shaft Encoder Sensor ITB Unit (page 718 "ITB Unit Removal") ITB Driven Shaft Encoder Sensor [A] (Pin x2,...
  • Page 747 Image Transfer Belt Unit...

  • Page 748: Itb Cleaning Unit

    4. Replacement and Adjustment ITB Cleaning Unit Before you start replacement of the ITB cleaning unit or its components (ITB cleaning blade / Lubricant bar / ITB lubricant blade): 1. Clear the counter for the ITB in PM counter mode (or use SP mode to turn SP3701-093 or 094 “0 1”) 2.

  • Page 749: Itb Cleaning Blade

    ITB Cleaning Unit ITB Cleaning Blade • ITB cleaning blade, ITB lubricant brush and ITB lubricant bar must be replaced together as a set. ITB Cleaning Unit (page 746 "ITB Cleaning Unit") ITB Cleaning Blade [A] ( x2) • Be sure to use a brush to apply yellow toner (D0149500) evenly on the lined faces of the new ITB blade before the installment as shown below.

  • Page 750: Itb Lubricant Brush

    4. Replacement and Adjustment • Use the blower brush (D0747690) when applying yellow toner to the new ITB blade. ITB Lubricant Brush • ITB cleaning blade, ITB lubricant brush and ITB lubricant bar must be replaced together as a set. ITB Cleaning Unit (page 746 "ITB Cleaning Unit")
  • Page 751 ITB Cleaning Unit Rotate the lock lever [A] in the arrowed direction as shown below. Lock lever [A] ( x1) Snap ring [A] x1, Gear x1 [B], Belt x1 [C], Bearing [D]...

  • Page 752: Itb Lubricant Bar

    4. Replacement and Adjustment [A] x1, Spacer [B] x1, Bearing [C] x1 ITB Lubricant Brush [A] ITB Lubricant Bar • ITB cleaning blade, ITB lubricant brush and ITB lubricant bar must be replaced together as a set. ITB Lubricant Brush (page 748 "ITB Lubricant Brush")

  • Page 753: Itb Lubricant Blade

    ITB Cleaning Unit Detach the ITB lubricant bar [A] from the ITB cleaning unit. ITB Lubricant Blade ITB Cleaning Unit (page 746 "ITB Cleaning Unit") ITB Lubricant Blade [A] ( x2) ITB Cleaning Unit Set Sensor Toner Supply Unit (page 624 "Toner Supply Unit")

  • Page 754: Itb Paper Dust Cleaning Brush Roller

    4. Replacement and Adjustment ITB Cleaning Unit Set Sensor [A] ( x1, Hook) ITB Paper Dust Cleaning Brush Roller ITB Cleaning Unit (page 746 "ITB Cleaning Unit") Rotate the lock lever [A] in the arrowed direction as shown below.
  • Page 755 ITB Cleaning Unit Lock lever [A] ( x1) Snap ring [A] x2, Gear x2 [B], Belt x1 [C], [D] x1, Gear [E] x1, Bearing [F] x1 Coupling [A] ( x1), Bearing [B] ( x1)
  • Page 756 4. Replacement and Adjustment Bearing [A] that has a sponge ITB Paper Dust Cleaning Brush Roller [A]...

  • Page 757: Lubrication After Replacement

    ITB Cleaning Unit Install the new cleaning brush roller and then use a brush to apply zinc stearate (D0149501) and yellow toner (D0149500) in a 40 ~ 50 mm area (shown below) of the installed cleaning brush roller. • Use the blower brush (D0747690) when applying zinc stearate and yellow toner to the cleaning brush roller.
  • Page 758 4. Replacement and Adjustment Lubrication starts (the operation takes 3 minutes). Turn the machine off when the lubrication finishes (the machine’s activity stops). Withdraw the drawer unit and rotate the blade release lever in order to make the cleaning blade contact the ITB Re-install the belt cleaning fan ( x1).

  • Page 759: Paper Transfer Roller Unit

    Paper Transfer Roller Unit Paper Transfer Roller Unit Paper Transfer Roller Unit Pull the drawer unit out. Drawer Unit Cover (page 594 "Drawer Unit Cover") Cover [A] ( x2, Remove the harnesses from the inner cover [A] (...
  • Page 760 4. Replacement and Adjustment Inner Cover [A] ( x3) Release the link plate [A] ( • When mounting the motor block, screw the motor in first. Then, assemble links [A], [B] and [C] as shown below. There is also a diagram embossed on the motor cover to help you to install the links correctly.
  • Page 761 Paper Transfer Roller Unit “Shoulder x2” on both sides of the paper transfer unit [A]...

  • Page 762: Paper Discharge Plate

    4. Replacement and Adjustment Paper Transfer Roller unit [A] ( Paper Discharge Plate Pull the drawer unit out. Paper Discharge Plate [A] ( x2) Paper Transfer Roller Pull the drawer unit out.
  • Page 763 Paper Transfer Roller Unit Paper Discharge Plate [A] ( x2) Lift the paper transfer roller [A] to remove it.

  • Page 764: Fusing Unit

    4. Replacement and Adjustment Fusing Unit Screw List The fusing unit has many types of screws. A screw list is shown below. In the procedures, the screw types used are shown as (A ) ~ (M ). • Example: Cover [A] (A x2) This means “the two screws that fixes cover [A] are A : SCREW:M3X6 listed below”.
  • Page 765 Fusing Unit E : HEXAGONAL BOLT:DOUBLE F : STEPPED SCREW:DIA5:M3X3.8 SCREW:M3X10 G : HEXAGON HEAD BOLT WITH H : STEPPED SCREW - M3 WASHER:M3X6 I : TAPPING SCREW:3X10 J : SCREW:GUIDE PLATE:ADF...

  • Page 766: Removing The Fusing Unit

    4. Replacement and Adjustment K : SCREW:M3X4 L : SCREW:CLAMP:FRONT M : TCRU/ORU SCREW M3 Removing the Fusing Unit Drawer Unit Cover (page 594 "Drawer Unit Cover")
  • Page 767 Fusing Unit Keep pressing in the locks [A] [B] and withdraw the drawer unit fully. Open the inner cover [A] (D x1)
  • Page 768 4. Replacement and Adjustment ”D x2” on the front side of the fusing unit [A]. Open the guide plate [A]. Raise the lever [A] to lift the inner guide plate [B] up.

  • Page 769: Fusing Heat Pipe

    Fusing Unit Hold the handgrips to detach the fusing unit [A]. Fusing Heat Pipe Fusing Unit (page 764 "Removing the Fusing Unit") Open the cover [A] and then remove the fusing heat pipe unit [B]. (D x2)

  • Page 770: Fusing Unit Cover

    4. Replacement and Adjustment Fusing Unit Cover Fusing Front / Rear Cover Fusing Unit (page 764 "Removing the Fusing Unit") Fusing Front Cover [A] (B x3) Fusing Rear Inner Cover [B] and Fusing Rear Cover [A]. (B x4) Entrance Drawer Cover Fusing Unit (page 764 "Removing the Fusing Unit")

  • Page 771: Exit Drawer Cover

    Fusing Unit Entrance Drawar Cover [A] (B x2) Exit Drawer Cover Fusing Unit (page 764 "Removing the Fusing Unit") Exit Drawer Cover [A] (B x2)

  • Page 772: Fusing Upper Cover

    4. Replacement and Adjustment Fusing Upper Cover Fusing Unit (page 764 "Removing the Fusing Unit") Fusing Upper Cover [A] (G x2, C x1) • Two types of screws are used to fasten the fusing upper cover. Refer to the diagram below to check each screw location.
  • Page 773 Fusing Unit Stoppers [B], [C] on Fusing Upper Cover [A] (M ×2) Open the separation unit [A].

  • Page 774: Fusing Unit Plate

    4. Replacement and Adjustment Separation Unit [A] (slide pins [B] [C] on both sides as shown below) Fusing Unit Plate Fusing Front Cover, Fusing Rear Cover, Entrance Drawer Cover, Exit Entracne Drawer Cover (page 768 "Fusing Unit Cover") Fusing Unit Plate [A] (A x5) In Pro C5100S/Pro C5110, you also need to remove “A x1”...
  • Page 775 Fusing Unit Drawer Connector [A], [B] (E x4)
  • Page 776 4. Replacement and Adjustment Rear plate [A] (A x5, B x1 x1, Harness Cover [B] x1) • Only [A] is B (HEXAGONAL BOLT:W/WASHER:M3X8). The others are A (SCREW:M3X6) in the picture below. In Pro C5100S/Pro C5110, you also need to remove “A x2” and the couplings [A], [B] shown below.

  • Page 777: Ih Coil Unit

    Fusing Unit • When re-attaching the harness cover, hook one of the harnesses on the tab (circled below) that is on the back of the harness cover as shown below. IH Coil Unit Fusing Front Cover, Fusing Rear Cover, Drawer Cover (page 768 "Fusing Unit Cover") Drawer Connector [A] (E x2)
  • Page 778 4. Replacement and Adjustment Spring [A], [B] A x2...

  • Page 779: Fusing Cleaning Web Unit (D137/D138 Only)

    Fusing Unit F x2 RTB 143 Note added after step 5 Disconnect the drawer connector [A] and [B]. IH Coil Unit [A] Fusing Cleaning Web Unit (D137/D138 Only) Fusing Heat Pipe (page 767 "Fusing Heat Pipe")
  • Page 780 4. Replacement and Adjustment Push the stopper [A] on the left side of the fusing cleaning web unit in the arrow direction as shown below. Raise the fusing cleaning web unit [A] as shown below to make it upright, and then remove it.

  • Page 781: Fusing Cleaning Web (D137/D138 Only)

    Fusing Unit Fusing Cleaning Web (D137/D138 Only) Fusing Cleaning Web Unit (page 777 "Fusing Cleaning Web Unit (D137/D138 Only)") Cover [A] (B x1, C x1) • See the picture below to make sure which screw is used in which location. •...
  • Page 782 4. Replacement and Adjustment Bracket [A] (A x4) Bracket [A] (A x3), and then the other screws (A x2).
  • Page 783 Fusing Unit Gears [A], [B], [C] and Bearings [D], [E] Gear [A] ( x1) and Bearing [B] ( x1) Bearing [A]...
  • Page 784 4. Replacement and Adjustment Bracket [A] (A x1) Gear [A] (loosen Hexagonal Socket x1) Bracket [A] (A x3)

  • Page 785: Fusing Belt Smoothing Roller (D137/D138 Only)

    Fusing Unit Feeler [A] (Spring x1) and Bearing [B] ( x1) Stay [A] (A x2) Fusing Cleaning Web [A] Fusing Belt Smoothing Roller (D137/D138 Only) Separation Unit (page 768 "Fusing Unit Cover")
  • Page 786 4. Replacement and Adjustment Remove the screw to release the stopper. (M x1) Raise the finger grips of the fusing belt smoothing roller [A] to hold them, and then slide and remove the fusing belt smoothing roller [A]. • Do not touch the side cams [B] [C] of the fusing belt smoothing roller [A]. The rim of the cams is greased.

  • Page 787: Fusing Belt Smoothing Roller Contact Sensor (Pro C5100S/Pro C5110S)

    Fusing Unit Fusing Belt Smoothing Roller Contact Sensor (Pro C5100S/Pro C5110S) Fusing Rear Cover (page 768 "Fusing Unit Cover") Fusing Belt Smoothing Roller Contact Sensor [A] (Hook, Separating the Fusing Unit Fusing Unit Plate (page 772 "Fusing Unit Plate")
  • Page 788 4. Replacement and Adjustment “H x1”and Bracket [A] (I x2) on the front side “H x1”, “I x2”, Bracket [A] on the rear side, and Connector [B]...

  • Page 789: Heating Roller, Fusing Roller, Fusing Belt

    Fusing Unit Separate the fusing unit into the upper part and the lower part. Heating Roller, Fusing Roller, Fusing Belt Separate the fusing unit into the upper part and the lower part. (page 785 "Separating the Fusing Unit") Turn the upper part [A] over.
  • Page 790 4. Replacement and Adjustment Gear [A] Bracket [A] (A x2)
  • Page 791 Fusing Unit “A x2 “and Bracket [A] (A x1) Rotation Sensor [A] (A x1, Spring [B] x1)
  • Page 792 4. Replacement and Adjustment Gear [A] ( x1, Washer x1) Brackets [A], [B] (J [C] x1, C-ring [D] x1, A x2)
  • Page 793 Fusing Unit Bracket [A] on the front side, and Grounding Plate [B] (A x2, K x1) • See the picture below to make sure which screw is used in which location. • [A]:K (SCREW:M3X4), Others: A (SCREW:M3X6)
  • Page 794 4. Replacement and Adjustment Bracket [A], [B] (L [C] x1, J [D] x1 , A x3, C-ring [E] x1) • Detach the bracket [A] and then the bracket [B]. C-ring [A] x1...
  • Page 795 Fusing Unit Entrance Stay [A] Detach the fusing belt unit from both side-frames. (Bearings [A], [B])

  • Page 796: Pressure Roller Stripper Plate

    4. Replacement and Adjustment Detach the hot roller [A] and the heating roller [B] from the fusing belt [C]. • When you detach the rollers and the belt from the frame, hold the ends of the hot roller shaft to lift it. Then move it above the heating roller to detach the whole thing (hot/heating rollers and fusing belt).
  • Page 797 Fusing Unit Release the springs on both sides of the pressure roller stripper plate [A].

  • Page 798: Fusing Lamp

    4. Replacement and Adjustment Raise and make the pressure roller stripper plate [A] upright to remove it. • The frame of the pressure roller stripper plate has C-cut holes. Fusing Lamp • In the procedure pictures below, the fusing unit is separated. But you need only to remove the fusing unit plate to remove or install the fusing lamp.
  • Page 799 Fusing Unit Harness Guide [A] (B x1) [A] x1 Bracket [A] (A x1)

  • Page 800: Pressure Roller

    4. Replacement and Adjustment Fusing Lamp [A] Pressure Roller Separate the fusing unit into the upper part and the lower part. (page 785 "Separating the Fusing Unit") Fusing Lamp (page 796 "Fusing Lamp") Gear [A] (C-ring [B] x1)
  • Page 801 Fusing Unit Detach the pressure roller fixing plates [A], [B] from the lower part. (A x3) Pressure Roller [A]...
  • Page 802 4. Replacement and Adjustment Pressure Roller Fixing Plates [A], [B] (C-ring [C] x1, Bearing [D] x2) • When re-installing the bearings on the pressure roller, pay attention to the direction of the bearings [A] (the brimmed part comes to the outside) as shown below (Diagram 1). •...

  • Page 803: Thermistor (Fusing Belt)

    Fusing Unit Diagram 2 Thermistor (Fusing Belt) Separate the fusing unit into the upper part and the lower part. (page 785 "Separating the Fusing Unit")

  • Page 804: Thermistor (Hot Roller Shaft)

    4. Replacement and Adjustment Bracket with Thermistor [A] (A x2) Thermistor (Fusing Belt) [A] (E x1, Thermistor (Hot Roller Shaft) Fusing Front Cover, Fusing Upper Cover (page 768 "Fusing Unit Cover")

  • Page 805: Heating Roller Rotation Sensor

    Fusing Unit Bracket with Thermistor (Hot Roller Shaft) [A] (A x1) Thermistor (Hot Roller Shaft) [A] (E x1, Heating Roller Rotation Sensor Fusing Rear Cover (page 768 "Fusing Unit Cover") Fusing Unit Plate (page 772 "Fusing Unit Plate")

  • Page 806: Pressure Roller Sensor (Rear)

    4. Replacement and Adjustment Bracket with Heating Roller Rotation Sensor [A] (A x1) Heating Roller Rotation Sensor [A] (Hook, Pressure Roller Sensor (Rear) Fusing Unit (page 764 "Removing the Fusing Unit") Turn the lower part [A] over.

  • Page 807: Pressure Roller Sensor (Front)

    Fusing Unit Bracket [A] with Pressure Roller Sensor (Rear) (A x1) Detach the fusing pressure roller sensor (rear) [A] from the bracket. (Hook, Pressure Roller Sensor (Front) Fusing Unit (page 764 "Removing the Fusing Unit") Turn the lower part [A] over.

  • Page 808: Hot Roller Nc Sensor

    4. Replacement and Adjustment Bracket [A] with Pressure Roller Sensor (Front) (A x1) Detach the pressure roller sensor (front) from the bracket. (Hook, Hot Roller NC Sensor Fusing Upper Cover (page 768 "Fusing Unit Cover") Hot Roller NC Sensor [A] (G x2,...

  • Page 809: Thermopile (Pressure Roller)

    Fusing Unit Thermopile (Pressure Roller) Separate the fusing unit into the upper part and the lower part. (page 785 "Separating the Fusing Unit") Bracket [A] (A x2) Harness Guide Cover [A] (B x1) Grounding Wire (B x1 [A] x 1)
  • Page 810 4. Replacement and Adjustment Harness Guide [A] (B x1) Bracket [A] (A x6) Bracket [A] with Thermopile (B x1)

  • Page 811: Thermostat (Pressure Roller)

    Fusing Unit Thermopile Cover [A] (Hook x3) Thermopile [A] ( Thermostat (Pressure Roller) Separate the fusing unit into the upper part and the lower part. (page 785 "Separating the Fusing Unit") See “Thermopile (Pressure Roller) Steps 1 to 7”. (page 807 "Thermopile (Pressure Roller)")

  • Page 812: Fusing Paper Feed Sensor

    4. Replacement and Adjustment Harness Guide [A] (G x1, C x1) • The left side screw is G ( HEXAGON HEAD BOLT WITH WASHER:M3X6), the right side screw is C ( STEPPED SCREW:M3) in the picture above. Themostat (Pressure Roller) [A] (B x2) Fusing Paper Feed Sensor Separate the fusing unit into the upper part and the lower part (page 785 "Separating the...

  • Page 813: Adjustment After Replacing The Fusing Paper Feed Sensor

    Fusing Unit Detach the fusing paper feed sensor [A] from the bracket [B]. ( x1) Fusing paper feed sensor [A] ( Adjustment after replacing the fusing paper feed sensor Do the following procedure after replacing the fusing paper feed sensor. Make sure the entire paper path is clear of paper.

  • Page 814: Cleaning Web Set Sensor

    4. Replacement and Adjustment Do SP1-134-001. Confirm the value in SP1-134-002 is in between 200 and 400. Reboot. Cleaning Web Set Sensor Fusing Unit (page 764 "Removing the Fusing Unit") Cleaning Web Set Sensor [A] ( x1, Hook) Cleaning Web End Sensor Fusing Unit (page 764 "Removing the Fusing Unit")

  • Page 815: Cleaning Web Contact Sensor

    Fusing Unit Cleaning Web End Sensor [A] ( x1, Hook) Cleaning Web Contact Sensor Fusing Unit (page 764 "Removing the Fusing Unit") Bracket [A] with Cleaning Web Contact Sensor ( x1) Cleaning Web Contact Sensor [A] ( x1, Hook)

  • Page 816: Paper Transport Belt Unit

    4. Replacement and Adjustment Paper Transport Belt Unit To replace the paper transport belt unit, first remove the fusing unit. ( page 764) Paper Transport Belt Unit 1. Inner cover [A] ( x 2) 2. Remove the springs and connector from the paper transport belt unit [A] (spring x 2, x 1).

  • Page 817: Paper Transport Belt

    Paper Transport Belt Unit Paper Transport Belt 1. Paper transport belt unit ( page 814) 2. Slide the paper transport belt [A] (x 2) to the left or right. PTB Fans 1. Paper transport belt unit ( page 814) 2. Disconnect the connectors of the PTB fans ( x 1 each).

  • Page 818: Ptb Sensor

    4. Replacement and Adjustment 3. After sliding the paper transport belts [A] to the left or right, remove the PTB fans [B] ( x 2 each). PTB Sensor 1. Paper transport belt unit ( page 814) 2. PTB sensor [A] ( x 1)

  • Page 819: Ptb Unit Set Sensor

    Paper Transport Belt Unit PTB Unit Set Sensor 1. Paper transport belt unit ( page 814) 2. PTB unit set sensor [A] ( x 1, x 1)

  • Page 820: Tandem Tray

    4. Replacement and Adjustment Tandem Tray Left Tandem Tray / Right Tandem Tray 1. Pull out paper tray 1 [A]. 2. Push the right tandem tray [A] into the machine. 3. Remove the left tandem tray [A] (M3 x 8; x 2 on the left side, M3 x 10; x 3 on the right side).
  • Page 821 Tandem Tray 4. Remove the front cover [A] from the left tandem tray ( x 2). 5. Pull out the right tandem tray [A] and remove the screws (TCRU/ORU x2).

  • Page 822: Feed Roller, Pick-Up Roller And Separation Roller

    4. Replacement and Adjustment Feed Roller, Pick-up Roller and Separation Roller 1. Pull out paper tray 1 [A]. 2. Right side of the tray [A] (TCRU/ORU x 2) 3. Pick-up roller [A] and feed roller [B] ( x 1)

  • Page 823: Paper Feed Unit For Tray 1

    Tandem Tray 4. Open the door of the vertical feed path and remove the separation roller [A] ( x 1). Paper Feed Unit for Tray 1 1. Right lower cover of the machine exterior ( page 530) 2. Pull out paper trays 1 and 2. 3.
  • Page 824 4. Replacement and Adjustment 4. Paper guide plate for tray 2 [A] ( x 1) 5. Paper feed unit for tray 2 [A] ( x 2, x 1)
  • Page 825 Tandem Tray 6. LED cover [A] ( x 2) 7. Vertical transport LED [B] along with the bracket ( x 1) 8. Relay cover [A] ( x 2,...
  • Page 826 4. Replacement and Adjustment 9. Paper guide plate for tray 1 [A] ( x 1) 10. Pull out the left side of the paper feed unit for tray 1 [A], and then remove it. ( x 2, (Remove the bracket [B] in order to remove the paper feed unit for tray 1 easily ( x 2))

  • Page 827: Rear Fence Home Position Sensor / Left Tray Paper Sensor

    Tandem Tray Rear Fence Home Position Sensor / Left Tray Paper Sensor 1. Pull out paper tray 1 [A]. 2. Side fence [A] ( x 1)

  • Page 828: Rear Fence Return Sensor

    4. Replacement and Adjustment 3. Cover [A] ( x 1) 4. Rear Fence Home Position Sensor [A] / Left Tray Paper Sensor [B] ( x 1 each, x 1 each) Rear Fence Return Sensor 1. Pull out paper tray 1 [A].
  • Page 829 Tandem Tray 2. Right side of the tray [A] (TCRU/ORU x 2) 3. Turn the bracket and remove the rear fence return sensor [A] ( x 1, x 1).

  • Page 830: Paper Height Sensors 1, 2, 3 / Tray Down Sensor / Right Tray Set Sensor

    4. Replacement and Adjustment Paper Height Sensors 1, 2, 3 / Tray Down Sensor / Right Tray Set Sensor 1. Right lower cover of the machine exterior ( page 530) 2. Pull out paper trays 1 and 2. 3. Right side of paper tray 1 [A] (TCRU/ORU x 2) 4.
  • Page 831 Tandem Tray 6. Paper feed unit for tray 2 [A] ( x 2, x 1) 7. LED cover [A] ( x 2) 8. Vertical transport LED [B] along with the bracket ( x 1)
  • Page 832 4. Replacement and Adjustment 9. Relay cover [A] ( x 2) 10. 5 sensors [A] along with the bracket, located inside the rear face of the machine ( x 3, each (front x 4, back x 1), x 2 each).

  • Page 833: Rear End Fence Closed Sensor

    Tandem Tray 11. Paper height sensors 1, 2, 3 [A], tray down sensor [B] and right tray set sensor [C] Rear End Fence Closed Sensor 1. Right lower cover of the machine exterior ( page 530) 2. Pull out paper trays 1 and 2. 3.
  • Page 834 4. Replacement and Adjustment 4. Vertical transport unit [A] ( x 2) 5. Paper guide plate [A] ( x 1) 6. Paper feed unit for tray 2 [A] ( x 2, x 1)
  • Page 835 Tandem Tray 7. LED cover [A] ( x 2) 8. Vertical transport LED [B] along with the bracket ( x 1) 9. Relay cover [A] ( x 2)

  • Page 836: End Fence Rear Solenoid

    4. Replacement and Adjustment 10. Rear End Fence Closed Sensor [A], located inside of the rear face of the machine ( x 1) End Fence Rear Solenoid 1. PSU1 / PSU2 along with the bracket, located on the back side of the machine ( page 944 "When removing the motors and sensors that are behind the PSU1/PSU2") 2.
  • Page 837 Tandem Tray 3. Relay cover ( page 831 "Rear End Fence Closed Sensor") 4. End fence rear solenoid [A] along with the bracket, located inside the rear face of the machine ( x 4) 5. Bracket [A] ( x 1, spring x 1)

  • Page 838: Left Tray Lock Solenoid

    4. Replacement and Adjustment 6. End fence rear solenoid [A] ( x 2) Left Tray Lock Solenoid 1. PSU1 / PSU2 along with the bracket, located inside the rear face of the machine ( page 944 "When removing the motors and sensors that are behind the PSU1/PSU2") 2.

  • Page 839: Rear Fence Drive Motor

    Tandem Tray Rear Fence Drive Motor 1. PFB along with the bracket, located on the back side of the machine ( page 941 "When removing the motors that are behind the PFB") 2. PSU1 / PSU2 along with the bracket, located on the back side of the machine ( page 944 "When removing the motors and sensors that are behind the PSU1/PSU2") 3.
  • Page 840 4. Replacement and Adjustment 2. PSU1 / PSU2 along with the bracket, located on the back side of the machine ( page 944 "When removing the motors and sensors that are behind the PSU1/PSU2") 3. 1st Tray Lift Motor ( x 3, x 1)

  • Page 841: Paper Feed Section (Tray 2-3 / Vertical Transport)

    Paper Feed Section (Tray 2-3 / Vertical Transport) Paper Feed Section (Tray 2-3 / Vertical Transport) Paper Tray 1. Pull out the paper tray [A]. Feed Roller, Pick-up Roller and Separation Roller 1. Pull out the paper tray. 2. Pick-up roller [A] and feed roller [B] (snap-fit x 1) e.g.: Tray 2...

  • Page 842: Paper Feed Unit

    4. Replacement and Adjustment 3. Separation roller [A] (snap-fit x 1) e.g.: Tray 2 Paper Feed Unit 1. Right lower cover of the machine exterior ( page 530 "Right Lower Cover") 2. Pull out paper tray 2 (in the case of the paper feed unit for tray 2).
  • Page 843 Paper Feed Section (Tray 2-3 / Vertical Transport) 3. Vertical transport unit [A] (snap-fit x 2) 4. Paper guide plate [A] (snap-fit x 1) 5. Paper feed unit for tray 2 [A] ( x 2, x 1)

  • Page 844: Pick-Up Solenoid

    4. Replacement and Adjustment • For tray 3, replace with the same procedure as for tray 2. Pick-up Solenoid 1. Paper feed unit ( page 840) 2. Pick-up solenoid [A] ( x 1, x 1) Transport Sensor 1. Paper feed unit ( page 840) 2.

  • Page 845: Paper Feed Sensor

    Paper Feed Section (Tray 2-3 / Vertical Transport) Paper Feed Sensor 1. Paper feed unit ( page 840) 2. Paper feed sensor [A] ( x 1, x 1) Paper Tray Upper Limit Sensor / Paper End Sensor 1. Paper feed unit ( page 840)

  • Page 846: Vertical Transport Led

    4. Replacement and Adjustment 2. Paper tray upper limit sensor [A] and paper end sensor [B] ( x 1 each, x 1 each) • When removing the paper end sensor, remove the hook from the opposite side of the photo above.
  • Page 847 Paper Feed Section (Tray 2-3 / Vertical Transport) 2. LED cover [A] ( x 2) 3. Remove the vertical transport LED [A] by lifting it upward ( x 1)

  • Page 848: Paper Size Sensors

    4. Replacement and Adjustment Paper Size Sensors 1. PSU1 / PSU2 along with the bracket, located on the back side of the machine ( page 944 "When removing the motors and sensors that are behind the PSU1/PSU2") 2. Disconnect two connectors [A] from the paper size sensors. 3.

  • Page 849: Paper Tray Lift Motor

    Paper Feed Section (Tray 2-3 / Vertical Transport) 3. Pull out the paper trays from the front side of the machine and remove the two paper tray set sensors [A]. Paper Tray Lift Motor 1. PFB along with the bracket, located on the back side of the machine ( page 941 "When removing the motors that are behind the PFB") 2.

  • Page 850: Tray Heater

    4. Replacement and Adjustment • This work must be done while the paper tray is pulled out. 5. Paper tray lift motor [A] ( x 3, x 1 each) e.g.: for paper tray 2 • For tray 3, replace with the same procedure as for tray 2. Tray Heater Upper Tray Heater 1.
  • Page 851 Paper Feed Section (Tray 2-3 / Vertical Transport) 3. Remove the fixing screws of the bracket for the upper tray heater [A] ( x 2). 4. Connector cover [A] ( x 1) 5. Upper tray heater [A] along with the bracket ( x 1, x 2).

  • Page 852: Lower Tray Heater

    4. Replacement and Adjustment 6. Upper tray heater [A] ( x 2 , x 1). Lower Tray Heater 1. Pull out the paper tray. 2. Remove the fixing screws of the bracket for the lower tray heater [A] ( x 3). 3.

  • Page 853: Tray Heater Setting

    Paper Feed Section (Tray 2-3 / Vertical Transport) 5. Lower tray heater [A] ( x 2) Tray Heater Setting Turn on the tray heater depending on the needs of the user. 1. Rear lower cover ( page 538) 2. Remove the clamp and connect the connectors to CN402 [B] and CN401 [C] on the AC drive board [A].
  • Page 854 4. Replacement and Adjustment...

  • Page 855: By-Pass Tray Unit (D137/D138)

    By-pass Tray Unit (D137/D138) By-pass Tray Unit (D137/D138) By-pass Tray Unit Removal 1. In order to easily remove the right middle upper cover [A], remove the fixing screws on the right side of the rear middle cover [B] ( x 2). 2.
  • Page 856 4. Replacement and Adjustment 4. Slide the right middle rear cover [A] to the left ( x 2) 5. By-pass Tray Unit [A] ( x 1, x 1)

  • Page 857: By-Pass Tray Unit Separation

    By-pass Tray Unit (D137/D138) By-pass Tray Unit Separation 1. Separate the paper feed unit [A] and bottom plate [B] of the by-pass tray unit ( x 2). 2. Remove the right arm [A] and separate the paper feed unit and bottom plate of the by-pass tray unit.

  • Page 858: By-Pass Pick-Up Roller / By-Pass Feed Roller / By-Pass Separation Roller

    4. Replacement and Adjustment By-pass Pick-up Roller / By-pass Feed Roller / By-pass Separation Roller 1. Open the by-pass tray [A]. 2. By-pass pick-up roller [A] (hook x 1) 3. Open the by-pass tray unit [A] and remove the paper feed unit cover [B] ( x 1).

  • Page 859: By-Pass Tray Paper End Sensor

    By-pass Tray Unit (D137/D138) 4. By-pass feed roller [A] ( x 1) 5. By-pass separation roller [A] from the back of the by-pass tray unit ( x 1) By-pass Tray Paper End Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2.

  • Page 860: By-Pass Paper Width Sensor

    4. Replacement and Adjustment 3. By-pass tray paper end sensor [A] along with the bracket ( x 1) 4. By-pass tray paper end sensor [A] ( x 1, x 1) By-pass Paper Width Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2.

  • Page 861: By-Pass Paper Length Sensor

    By-pass Tray Unit (D137/D138) 3. By-pass paper width sensor [A] (hook x 3, x 1) By-pass Paper Length Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2.

  • Page 862: By-Pass Tray Lower Limit Sensor

    4. Replacement and Adjustment By-pass Tray Lower Limit Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2. By-pass tray lower limit sensor [A] from the bottom plate ( x 1, hooks) By-pass Tray Lift Motor 1.
  • Page 863 By-pass Tray Unit (D137/D138) 3. Fixing screws of the by-pass tray lift motor block [A] ( x 3) 4. Stay [A] (including the shaft) for lifting the bottom plate ( x 1, x 2) 5. By-pass tray lift motor block [A] (spring x 1)
  • Page 864 4. Replacement and Adjustment • When reinstalling the motor, press the spring [B] to rotate the gear. It is easy to insert the shaft [A] for lifting the bottom plate. 6. By-pass tray lift motor [A] along with the bracket ( x 2) 7.

  • Page 865: By-Pass Tray Upper Limit Sensor / By-Pass Paper Feed Sensor

    By-pass Tray Unit (D137/D138) By-pass Tray Upper Limit Sensor / By-pass Paper Feed Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2. By-pass paper feed unit cover [A] ( x 1) 3.
  • Page 866 4. Replacement and Adjustment 4. Bracket [A] of the by-pass paper feed unit ( x 4, x 1) 5. Lift the bracket [A] to remove ( x 3).

  • Page 867: By-Pass Pick-Up Solenoid

    By-pass Tray Unit (D137/D138) 6. By-pass tray upper limit sensor [A] ( x 1, x 1) 7. By-pass paper feed sensor [B] ( x 1, x 1) By-pass Pick-up Solenoid 1. Bracket of the by-pass paper feed unit ( page 863 "By-pass Tray Upper Limit Sensor / By-pass Paper Feed Sensor") 2.

  • Page 868: By-Pass Tray Set Sensor

    4. Replacement and Adjustment By-pass Tray Set Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 853 "By-pass Tray Unit Removal") 2. By-pass tray set sensor [A] ( x 1) By-pass Tray LED Connector (Red) 1.
  • Page 869 By-pass Tray Unit (D137/D138) 2. By-pass tray LED connector (Red) [A] ( x 1, x 1)

  • Page 870: By-Pass Tray Unit (D135/D136)

    4. Replacement and Adjustment By-pass Tray Unit (D135/D136) By-pass Tray Unit Removal 1. In order to easily remove the right middle upper cover [A], remove the fixing screws on the right side of the rear middle cover [B] ( x 2). 2.
  • Page 871 By-pass Tray Unit (D135/D136) 4. Slide the right middle rear cover [A] to the left ( x 2) 5. By-pass Tray Unit [A] ( x 1, x 1, x 1)

  • Page 872: By-Pass Tray Unit Separation

    4. Replacement and Adjustment By-pass Tray Unit Separation 1. Separate the paper feed unit [A] and bottom plate [B] of the by-pass tray unit ( x 2). 2. Remove the left arm [A] and right arm [B], and then separate the paper feed unit and bottom plate of the by-pass tray unit.
  • Page 873 By-pass Tray Unit (D135/D136) 3. By-pass tray [A] from the bottom plate ( x 5) 4. Turn over the by-pass tray [A], then disconnect the connectors and clamps of the by-pass paper width sensor [B] / by-pass paper length sensor [C].

  • Page 874: By-Pass Pick-Up Roller / By-Pass Feed Roller / By-Pass Separation Roller

    4. Replacement and Adjustment By-pass Pick-up Roller / By-pass Feed Roller / By-pass Separation Roller 1. Open the by-pass tray [A]. 2. By-pass pick-up roller [A] (hook x 1). 3. Open the by-pass tray unit [A] and remove the paper feed unit cover [B] ( x 1). 4.

  • Page 875: By-Pass Tray Paper End Sensor

    By-pass Tray Unit (D135/D136) 5. By-pass separation roller [A] from the back of the by-pass tray unit ( x 1) By-pass Tray Paper End Sensor 1. Open the by-pass tray [A]. 2. Open the by-pass tray unit [A] and remove the paper feed unit cover [B] ( x 1)

  • Page 876: By-Pass Paper Width Sensor

    4. Replacement and Adjustment 3. By-pass tray paper end sensor [A] ( x 1) By-pass Paper Width Sensor 1. Open the by-pass tray [A]. 2. Remove the bottom plate [A] of the by-pass tray and turn it over ( x 5).

  • Page 877: By-Pass Paper Length Sensor

    By-pass Tray Unit (D135/D136) 3. By-pass paper width sensor [A] (hook x 2, x 1) By-pass Paper Length Sensor 1. Open the by-pass tray [A]. 2. Remove the bottom plate [A] of the by-pass tray and turn it over ( x 5).

  • Page 878: By-Pass Paper Feed Sensor

    4. Replacement and Adjustment 3. By-pass paper length sensor [A] ( x 1, hooks) By-pass Paper Feed Sensor 1. Separate the paper feed unit and bottom plate of the by-pass tray unit. ( page 868 "By-pass Tray Unit Removal") 2. Remove the fixing screws (x 7) and joints (x 2) of the by-pass paper feed unit [A] ( x 2)
  • Page 879 By-pass Tray Unit (D135/D136) 3. Remove the connectors and clamps, then take out the paper feed unit [A]. 4. By-pass paper feed unit cover [A] ( x 1)
  • Page 880 4. Replacement and Adjustment 5. Bracket [A] of the by-pass paper feed unit ( x 7, x 1) 6. Bracket [A] for the by-pass paper feed unit (by-pass pick-up roller, by-pass feed roller, spring x 1)

  • Page 881: By-Pass Pick-Up Solenoid

    By-pass Tray Unit (D135/D136) 7. Lift the bracket [A] to remove (all s, all 8. By-pass paper feed sensor [A] ( x 1, x 1) By-pass Pick-up Solenoid 1. Bracket of the by-pass paper feed unit ( page 876 "By-pass Paper Feed Sensor") 2.

  • Page 882: By-Pass Tray Led Connector (Red)

    4. Replacement and Adjustment By-pass Tray LED Connector (Red) 1. Open the by-pass tray unit and remove the LED cover [A] ( x 1). 2. By-pass tray LED connector (Red) [A] ( x 1, x 1)
  • Page 883 By-pass Tray Unit (D135/D136)

  • Page 884: Paper Relay And Registration Section

    4. Replacement and Adjustment Paper Relay and Registration Section Registration Unit 1. Drawer unit cover ( page 594) 2. In order to facilitate the work, press the release lever to fully open the drawer unit [A]. 3. Inner cover [A] ( x 2, x 1) 4.
  • Page 885 Paper Relay and Registration Section • When installing the motor, attach the timing belt. 5. Timing pulley [A] and positioning bracket [B] ( x 1, x 1)

  • Page 886: Relay Unit

    4. Replacement and Adjustment 6. Remove the registration unit [A] by sliding it to the left. Relay Unit 1. Registration unit ( page 882) 2. Duplex exit motor [A] along with the bracket ( x 3, timing belt x 1) •...
  • Page 887 Paper Relay and Registration Section 3. Joint [B] of the relay unit [A] from the bottom ( x 1) 4. Positioning bracket [B] of the relay unit [A] ( x 1) • When installing, the positioning pin [A] must be within the hole in the relay unit.

  • Page 888: Registration Sensor

    4. Replacement and Adjustment 5. Remove the relay unit [A] by sliding it to the left ( x 1, x 1). Registration Sensor 1. Open the drawer unit cover [A].
  • Page 889 Paper Relay and Registration Section 2. Registration unit cover [A] ( x 2) 3. Bracket [A] ( x 3) 4. Registration sensor [A] ( x 1)

  • Page 890: Paper Type Sensor

    4. Replacement and Adjustment Paper Type Sensor 1. Relay unit ( page 884) 1. Relay unit bracket where the paper type sensor [A] is located ( x 6) 2. Paper type sensor [A] ( x 1, x 1, x 1)

  • Page 891: Relay Sensor

    Paper Relay and Registration Section Relay Sensor 1. Open the drawer unit cover [A]. 2. Relay sensor [A] ( x 1, x 1) By-pass Tray Paper Type Sensor 1. Open the drawer unit cover [A].
  • Page 892 4. Replacement and Adjustment 2. Cover [A] ( x 2) 3. Bracket [A] ( x 2) 4. Turn over the bracket and remove the by-pass tray paper type sensor [A] ( x 1, x 1).
  • Page 893 Paper Relay and Registration Section...

  • Page 894: Paper Exit And Duplex Unit

    4. Replacement and Adjustment Paper Exit and Duplex Unit Paper Exit Unit 1. Drawer unit cover ( page 594) 2. Fusing unit ( page 764) 3. Remove the paper exit inner cover [A] ( x 1) and turn it over, then disconnect the connector [B]. 4.
  • Page 895 Paper Exit and Duplex Unit 6. Inverter exit motor [A] along with the bracket ( x 3) 7. Harness cover [A] ( x 1) 8. Motor assembly [A] along with the bracket ( x 4, x 3, timing belt x 1)

  • Page 896: Paper Exit Sensor

    4. Replacement and Adjustment 9. Paper exit unit [A] ( x 2, x 3) Paper Exit Sensor 1. Open the drawer unit. 2. Paper exit sensor [A] ( x 1, x 1)

  • Page 897: Paper Exit Relay Sensor

    Paper Exit and Duplex Unit Paper Exit Relay Sensor 1. Open the drawer unit. 2. Guide plate [A] ( x 4) 3. Paper exit relay sensor [A] ( x 1, x 1)

  • Page 898: Inverter Exit Sensor

    4. Replacement and Adjustment Inverter Exit Sensor 1. Fusing unit ( page 764) 2. Inverter exit sensor [A] ( x 1, x 1, x 1)

  • Page 899: Inverter Feed-In Sensor

    Paper Exit and Duplex Unit Inverter Feed-in Sensor 1. Paper exit unit ( page 892) 2. Guide plate [A] ( x 1, x 1) 3. Roller [A] ( x 1) 4. Guide plate [A] ( x 4)
  • Page 900 4. Replacement and Adjustment 5. Remove the guide [A] by sliding it to the right ( x 2, rib x 2). 6. Right side of the roller [A] ( x 1, Bearing x 1) 7. Inverter feed-in sensor [A] along with the bracket ( x 1, x 1)

  • Page 901: Inverter Feed-Out Sensor

    Paper Exit and Duplex Unit Inverter Feed-out Sensor 1. Paper exit unit ( page 892) 2. Inverter feed-out sensor [A] ( x 1, x 1)

  • Page 902: Inverter Junction Gate Home Position Sensor

    4. Replacement and Adjustment Inverter Junction Gate Home Position Sensor 1. Paper exit unit ( page 892) 2. Inverter junction gate home position sensor [A] ( x 1) Inverter Junction Gate Motor 1. Paper exit unit ( page 892) 2. Before removing the inverter junction gate motor [A] along with the bracket, remove the joint [B] and connctors.

  • Page 903: Duplex Inverter Solenoid

    Paper Exit and Duplex Unit 4. Inverter junction gate motor [A] ( x 2) Duplex Inverter Solenoid 1. Inverter junction gate motor ( page 900) 2. Duplex inverter solenoid [A] along with the bracket ( x 3)

  • Page 904: Paper Exit Left Guide Plate Sensor

    4. Replacement and Adjustment 3. Duplex inverter solenoid [A] ( x 2) Paper Exit Left Guide Plate Sensor 1. Paper exit unit ( page 892) 2. Paper exit left guide plate sensor [A] ( x 1)

  • Page 905: Paper Exit Upper Guide Plate Sensor

    Paper Exit and Duplex Unit Paper Exit Upper Guide Plate Sensor 1. Paper exit unit ( page 892) 2. Open the paper exit upper guide plate [A] and remove the paper exit upper guide plate sensor [B] x 1)

  • Page 906: Duplex Unit

    4. Replacement and Adjustment Duplex Unit Purge Relay Sensor / Duplex Invert Sensor 1. Paper purge unit ( page 917) 2. Duplex invert solenoid ( page 905) 3. Remove the fixing screws of the guide plate [A] ( x 2). 4.

  • Page 907: Duplex Invert Solenoid

    Duplex Unit 6. Duplex invert sensor [A] along with the bracket ( x 1, x 1) Duplex Invert Solenoid 1. Paper purge unit ( page 917) 2. Remove the springs of the duplex invert solenoid [A] (spring x 2).

  • Page 908: Duplex Unit Entrance Sensor

    4. Replacement and Adjustment 3. Duplex invert solenoid [A] ( x 2) RTB 95, D137 RTB 147 The step was modified. Duplex Unit Entrance Sensor 1. Fusing unit ( page 764) 2. Duplex unit entrance sensor [A] ( x 1, x 1)

  • Page 909: Duplex Unit Sensor 1

    Duplex Unit Duplex Unit Sensor 1 1. Fusing unit ( page 764) 2. Duplex unit sensor 1 [A] ( x 1, x 1) Duplex Unit Sensor 2 1. Fusing unit ( page 764) 2. Duplex unit sensor 2 [A] ( x 1, x 1)

  • Page 910: Duplex Unit Sensor 3

    4. Replacement and Adjustment Duplex Unit Sensor 3 1. Paper transport belt unit ( page 814) 2. Duplex unit sensor 3 [A] ( x 1, x 1) Duplex Unit Sensor 4 1. Edge detection unit ( page 913) 2. Duplex unit sensor 4 [A] ( x 1, x 1)

  • Page 911: Duplex Exit Sensor

    Duplex Unit Duplex Exit Sensor 1. Relay Unit ( page 884) 2. Duplex exit sensor [A] ( x 1, x 1) Horizontal Feed Guide Plate Open Sensor 1. Paper transport belt unit ( page 814) 2. Paper transfer roller unit ( page 757) 3.

  • Page 912: Roller Hp Sensor 1

    4. Replacement and Adjustment 4. Open the horizontal feed guide plate [A] and remove the cover [B] ( x 2). 5. Horizontal feed guide plate open sensor [A] Roller HP Sensor 1 1. Paper transport belt unit ( page 814) 2.

  • Page 913: Roller Hp Sensor 2

    Duplex Unit Roller HP Sensor 2 1. Paper transport belt unit ( page 814) 2. Paper transfer roller unit ( page 757) 3. Roller HP sensor 2 [A] ( x 1, x 1) • Roller HP sensor 2 and sensor shift HP switch are in close proximity. When you connect a harness to the roller HP sensor 2 or sensor shift HP switch after the replacement, be careful not to connect the harness to an incorrect sensor.
  • Page 914 4. Replacement and Adjustment 3. Drawer unit lock motor block ( page 595 "If the Drawer is Locked") 4. Sensor shift motor [A] along with the bracket ( x 2, x 1, x 1) 5. Sensor shift motor [A] ( x 2) •...

  • Page 915: Edge Detection Unit

    Duplex Unit Edge Detection Unit 1. Sensor shift motor ( page 911) 2. Remove the fixing screws of the edge detection unit [A] ( x 2). 3. Edge detection unit [A] ( x 2)

  • Page 916: Edge Detection Sensor

    4. Replacement and Adjustment Edge Detection Sensor 1. Edge detection unit ( page 913) 2. Edge detection sensor [A] ( x 2, x 1) Sensor Shift HP Switch 1. Edge detection unit ( page 913) 2. Sensor shift HP switch [A]...

  • Page 917: Roller Shift Motor 1 / Roller Shift Motor 2

    Duplex Unit • Roller HP sensor 2 and sensor shift HP switch are in close proximity. When you connect a harness to the roller HP sensor 2 or sensor shift HP switch after the replacement, be careful not to connect the harness to an incorrect sensor.
  • Page 918 4. Replacement and Adjustment 5. Open the horizontal feed guide plate [A] and remove the cover [B] ( x 2). 6. Roller shift motor 1 [A] / Roller shift motor 2 [B] ( x 2 each, timing belt x 1 each)

  • Page 919: Paper Purge Unit

    Paper Purge Unit Paper Purge Unit Paper Purge Unit 1. Open the drawer unit [A]. 2. Open the guide plate [A] and remove it upward ( x 1). 3. Cover [A] ( x 2).
  • Page 920 4. Replacement and Adjustment 4. Remove the fixing screw of the paper purge unit [A] ( x 1). 5. Paper purge unit [A] ( x 2)

  • Page 921: Pcb: Lsb

    Paper Purge Unit PCB: LSB 1. Left lower cover of the machine exterior ( page 535) 2. Purge door [A] (pin x 2) 3. Pull out the paper trays [A]. 4. Remove the fixing screws of the upper inner cover [A] ( x 3). 5.

  • Page 922: Push Switch

    4. Replacement and Adjustment 6. LSB [A] along with the bracket ( x 2). 7. LSB [A] ( x 2, x 1). Push Switch 1. LSB [A] along with the bracket ( page 919 "PCB: LSB") 2. Hold the sides of the push switch [A], remove by pulling ( x 1).

  • Page 923: Duplex Inverter Motor

    Paper Purge Unit Duplex Inverter Motor 1. Left lower cover of the machine exterior ( page 535) 2. Disconnect the connector of the duplex inverter motor [A]. 3. Pull out the drawer unit and remove the duplex inverter motor unit [A] ( x 1).

  • Page 924: Purged Paper Sensor

    4. Replacement and Adjustment 4. Duplex inverter motor [A] ( x 2, x 1, belt x 1). Purged Paper Sensor 1. Left lower cover of the machine exterior ( page 535) 2. Guide plate [A] ( x 2).

  • Page 925: Led: Connecter: Red

    Paper Purge Unit 3. Purged paper sensor [A] along with the bracket ( x 1, x 1). 4. Turn the bracket and remove the purged paper sensor [A] ( x 1). LED: Connecter: Red LEDs are mounted at three points in the paper purge unit.

  • Page 926: Upper Guide Plate Led / Purge Door Led

    4. Replacement and Adjustment Upper guide plate LED / Purge door LED 1. Upper inner cover ( page 919 "PCB: LSB") 2. Remove by pulling the upper guide plate LED [A] and the purge door LED [B] ( x 1 each). Lower guide plate LED 1.
  • Page 927 Paper Purge Unit 3. Remove by pulling the lower guide plate LED [A] ( x 1).

  • Page 928: Main Boards / Hdd Unit

    4. Replacement and Adjustment Main Boards / HDD Unit Layout To replace the electrical components on the back of the machine, first remove the outer cover. ( page 537 "Rear Cover")

  • Page 929: Controller Board

    Main Boards / HDD Unit Replacement Part Name Remarks procedure Combined High-Voltage Power Supply KC: front side, MC: page 947 Board (Charge / Development) rear side Controller Board page 927 HDD Unit page 930 Fusing Web Control Board-Main page 949 D137/D138 only Machine AC Drive Board...
  • Page 930 4. Replacement and Adjustment 2. Controller panel plate [A] ( x 4) 3. Controller board [A] ( x 7, x 4) • There are two types of controller boards, one for D138/D136 and one for D137/D135. Because there are different part numbers on these two controller boards, when replacing, check the parts catalog to make sure that you install the correct type.

  • Page 931: When Installing The New Controller Board

    Main Boards / HDD Unit When installing the New Controller Board There are two NVRAMs ([A] and [B]) on the controller board. The two NVRAMs are one set. NVRAM [A] is labeled "2M-1", and NVRAM [B] is labeled "2M-2". When replacing the controller board, remove the NVRAMs from the old controller board. Then install them at the same position on the new controller board.

  • Page 932: Hdd Unit

    4. Replacement and Adjustment • After reinstalling the ESA applications, print the SMC (SP-5-990-024/025 (SMC: SDK/ Application Info)). Then open the tandem tray [A] and remove the paper cassette decal [B]. Store the SMC sheet [C] and the SD card(s) [D] that was used to install the ESA application(s). HDD Unit The HDD contains two separate hard disks (160 Gigabytes each x2 = 320 Gigabytes).

  • Page 933: After Installing The New Hdd Unit

    Main Boards / HDD Unit After Installing the New HDD Unit 1. Do SP5-832-001 to format the hard disk. 2. Do SP5-853-001 to copy the preset stamp data from the firmware to the hard disk. 3. Do SP5-846-052 to copy back the address book to the hard disk from the SD card to which you havealready copied the address book data if possible.

  • Page 934: Bcu

    4. Replacement and Adjustment • The address book and document server documents (if needed) must be input again. • If the customer is using the Data Overwrite Security, the Data Encryption feature or OCR Scanned PDF, these applicationsmust be installed again. 1.

  • Page 935: Nvram Replacement Procedure

    Main Boards / HDD Unit 3. Turn on the main power switch and register the machine serial number onto the new BCU by entering the machine serial number in SP5-811-004 (Machine Serial / Set: BCU). • Inputting a wrong serial number will cause the machine to display SC995-001 (CPM set error).
  • Page 936 4. Replacement and Adjustment 2. Print out the SMC data (“ALL”) in SP5-990-001. 3. Turn off the main power switch. 4. Insert a blank SD card into slot #2, and then turn on the main power switch. 5. Upload the NVRAM data to the blank SD card in SP5-824-001 (NVRAM Data Upload). •...
  • Page 937 Main Boards / HDD Unit • There are two NVRAMs on the controller board as mentioned in page 929. Make sure to replace the two NVRAMs as a set. • NVRAMs [A] and [B] installed on the Controller Board at the factory are labeled "2M-1" and "2M-2"...
  • Page 938 4. Replacement and Adjustment • DO NOT insert the SD card containing the NVRAM data that you removed in Step 7 before turning on the main switch. • SC995-02 (Defective NVRAM) will appear when powering on the main power switch, but ignore this SC.

  • Page 939: Nvram (Eeprom) On The Bcu

    Main Boards / HDD Unit Procedure for D135/D136 (Office model) only Confirm the “Reception Settings” and “Send Settings” correspond with the notes took in Step 9. Correct the settings, if they are wrong. 23. Print out the SMC data (“ALL”) in SP5-990-001, and make sure that it matches with the SMC data printed out in Step 2 (except for the total counter value).

  • Page 940: Ipu

    4. Replacement and Adjustment • Setting the wrong area code will cause the system to display SC995-04(CPM Set Error). 10. Input the machine serial number according to the procedure instructed by your supervisor. • Inputting an incorrect serial number will cause the system to display SC195-00 (Serial Number Set Error).

  • Page 941: Iob

    Main Boards / HDD Unit 3. IPU_Main [A] ( x 3) 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2). 2. Open the controller box [A] ( x 2).

  • Page 942: When Removing The Motors That Are Behind The Iob

    4. Replacement and Adjustment 3. IOB [A] ( x 2, all When removing the motors that are behind the IOB 1. Disconnect all connectors on the IOB. 2. Remove the IOB [A] along with the bracket by sliding it to the right ( x 2). 1.

  • Page 943: When Removing The Motors That Are Behind The Pfb

    Main Boards / HDD Unit When removing the motors that are behind the PFB 1. Disconnect all connectors on the PFB. 2. Remove the PFB [A] along with the bracket by sliding it upwards ( x 2). IH Inverter 1. IH inverter [A] ( x 9, all...

  • Page 944: Ac Drive Board

    4. Replacement and Adjustment AC Drive Board 1. AC drive board [A] ( x 8, all Notes on Replacing the AC Drive Board Depending on the model and the destination, it is necessary to remove a connector or harness from the old board and install it on the new board.

  • Page 945: Psu1 / Psu2

    Main Boards / HDD Unit 2. Install the jumper harness and the connector on the new AC drive board. D135 for EU/AP/CHN 1. Remove the the jumper harness [B] at CN405 on the old AC drive board [A]. 2. Install the jumper harness on the new AC drive board. PSU1 / PSU2 1.

  • Page 946: When Removing The Motors And Sensors That Are Behind The Psu1/Psu2

    4. Replacement and Adjustment RTB 151 Caution when handling these boards 2. PSU1 [A] ( x 8, all 3. PSU2 [A] ( x 8, all When removing the motors and sensors that are behind the PSU1/PSU2 1. Disconnect all connectors on the PSU1/PSU2. 2.
  • Page 947 Main Boards / HDD Unit 3. Remove the fixing screws of the PTR fusing exhaust fan [A] ( x 3). 4. Remove the PSU1/PSU2 [A] along with the bracket (upper side: x 2, lower side: x 7).

  • Page 948: Potential Sensor Board

    4. Replacement and Adjustment Potential Sensor Board 1. Slide the drive exhaust fan [A] upward along with the duct ( x 3, x 1). 2. Harness guide [A] and the connectors of the potential sensor board ( x 2, x 3).

  • Page 949: Combined High-Voltage Power Supply Board (Charge / Development) (Kcmy)

    Main Boards / HDD Unit 3. Potential sensor board ( x 4) Combined High-Voltage Power Supply Board (Charge / Development) (KCMY) Combined High-Voltage Power Supply Board (KC) 1. Combined high-voltage power supply board (KC) [A] ( x 6, x 3)

  • Page 950: Combined High-Voltage Power Supply Board (My)

    4. Replacement and Adjustment Combined High-Voltage Power Supply Board (MY) 1. Remove the combined high-voltage power supply board (KC) [A] along with the bracket by sliding it toward the left ( x 4, x 3) 2. Remove the combined high-voltage power supply board (MY) [A] by sliding it upwards ( x 5, x 3).

  • Page 951: Fusing Web Control Board-Main Machine (D137/D138 Only)

    Main Boards / HDD Unit Fusing Web Control Board-Main Machine (D137/D138 only) 1. Fusing web control board -main machine [A] ( x 1, x 1) AC Drive Board Relay (D137/D138 only) 1. AC drive board relay [A] ( x 1, x 1)

  • Page 952: Motors And Sensors

    4. Replacement and Adjustment Motors and Sensors Layout (Motor) Rear of the Machine (Top) To replace the motors and sensors on the back of the machine, first remove the outer cover. ( page 537 "Rear Cover") Replacement Part Name Remarks procedure K, C, M, Y from the left Drum Cleaning Motor (KCMY)

  • Page 953: Rear Of The Machine (Middle)

    Motors and Sensors Replacement Part Name Remarks procedure K, C, M, Y from the left Drum Motor (KCMY) page 954 Y is located behind the potential sensor board. Rear of the Machine (Middle) To replace the motors and sensors on the back of the machine, first remove the outer cover. ( page 537 "Rear Cover") Replacement Part Name...

  • Page 954: Rear Of The Machine (Bottom)

    4. Replacement and Adjustment Replacement Part Name Remarks procedure Fusing Drive Motor page 974 Waste Toner Collection Motor page 976 D137/ D138 only Fusing Belt Smoothing Roller page 986 Located behind the fusing drive Contact Motor motor Located behind the duct of the Fusing Release Motor page 981 PTR fusing exhaust fan...

  • Page 955: Drawer Unit (Front)

    Motors and Sensors Replacement Part Name Remarks procedure 2nd Paper Feed Motor page 973 Located behind the PFB 3rd Paper Feed Motor page 973 Located behind the PFB 3rd Transport Motor page 973 Located behind the PFB Drawer Unit (Front) To replace the motors on the front of the drawer unit, first remove the drawer unit cover.

  • Page 956: Drawer Unit (Rear)

    4. Replacement and Adjustment Drawer Unit (Rear) Replacement Part Name Remarks procedure Exit Inverter Motor page 613 Cleaning Web Contact Motor page 617 D137/ D138 only Drum Motor (KCMY) / Drum Encoder Sensor (KCMY) • Insert a sheet of paper as shown below when removing the drum motor in Step 6. •...
  • Page 957 Motors and Sensors 1. Toner Supply Unit ( page 624) 2. Faceplate ( page 680) 3. Unlock the lever [A] and pull out the PCDU [B] from the machine. 4. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2).
  • Page 958 4. Replacement and Adjustment 5. Open the controller box [A] ( x 2). 6. Drum motor as a unit [A] ( x 4, x 2). e.g.: K • The following four screws located on the outside of the bracket were positioned on the bracket with a special jig.
  • Page 959 Motors and Sensors 7. Drum motor [A] ( x 1). • Removing or assembling the drum shaft and motor • The binding portion of the drum shaft [A] and the motor [B] must be maintained in a horizontal state so that excessive load is not put on the drum shaft. In order to avoid deformation of the fixing screw [C], use a box-type driver [D].

  • Page 960: Removing The Drive Exhaust Fan And The Potential Sensor Board

    4. Replacement and Adjustment • In the Pro version, there is a HP sensor and feeler mechanism on the drum motor. If you forget the feeler, the machine does not work, an SC (SC421-01(K) / SC421-02(C) / SC421-03(M) / SC421-04(Y)) occurs. 8.
  • Page 961 Motors and Sensors 2. Potential sensor board along with the bracket ( x 4) • Access to the drum motor (Y) [A] is possible.

  • Page 962: Drum Hp Sensor (D137/D138 Only)

    4. Replacement and Adjustment Drum HP Sensor (D137/D138 only) 1. Drum motor ( page 954) 2. Drum HP Sensors (x 2) [A] ( x 2 each, rivet x 2 each) Drum Cleaning Motor (KCMY) 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2).
  • Page 963 Motors and Sensors 2. Open the controller box [A] ( x 2). 3. Vertical transport LED [B] along with the bracket ( x 3, x 1). e.g.: K • The procedures for C and M are the same as for K.

  • Page 964: Removing The Drive Exhaust Fan And The Potential Sensor Board

    4. Replacement and Adjustment • For Y, it is necessary to remove the drive exhaust fan and potential sensor board before you can do step 3 above. ( page 962 "Removing the Drive Exhaust Fan and the Potential Sensor Board") Removing the Drive Exhaust Fan and the Potential Sensor Board 1.

  • Page 965: Development Motor (Kcmy)

    Motors and Sensors Development Motor (KCMY) 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2). 2. Open the controller box [A] ( x 2). 3. Development motor [A] ( x 4, x 1).
  • Page 966 4. Replacement and Adjustment • Do not loosen or remove screws [A], [B] and [C] in the photograph below. These screws are positioned with a special jig. Loosening the screws will affect the driving of the development unit and leads to the occurrence of an abnormal image. •...

  • Page 967: Removing The Drive Exhaust Fan And The Potential Sensor Board

    Motors and Sensors Removing the Drive Exhaust Fan and the Potential Sensor Board 1. Slide the drive exhaust fan [A] upward along with the duct ( x 3, x 1). 2. Potential sensor board along with the bracket ( x 4) •...

  • Page 968: Development Roller Hp Sensor (Kcmy)

    4. Replacement and Adjustment Development Roller HP Sensor (KCMY) 1. Drum motor ( page 954) 2. Development Roller HP Sensor [A] ( x 1, x 1) By-pass Feed Motor/Relay Motor 1. IOB along with the bracket, located on the back side of the machine ( page 940 "When removing the motors that are behind the IOB") 2.
  • Page 969 Motors and Sensors 3. By-pass feed motor [A] and relay motor [B] ( x 2, each)

  • Page 970: Ptr Motor / Ptr Encoder Sensor

    4. Replacement and Adjustment • When installing motors, attach the timing belt. PTR Motor / PTR Encoder Sensor 1. IOB along with the bracket, located on the back side of the machine ( page 940 "When removing the motors that are behind the IOB") 2.
  • Page 971 Motors and Sensors 3. PTR encoder sensors (x 2) [A] (rivet x 2 each, x 1 each) 4. PTR encoder sensor cover [A] ( x1) • When installing the PTR encoder sensor, put the sensor [A] on the cover [B] and fasten the sensor with rivets.

  • Page 972: Paper Feed Motor/Transport Motor

    4. Replacement and Adjustment Paper Feed Motor/Transport Motor 1st Paper Feed Motor/1st Transport Motor 1. IOB along with the bracket, located on the back side of the machine ( page 940 "When removing the motors that are behind the IOB") 2.

  • Page 973: Vertical Transport Motor

    Motors and Sensors • When installing motors, attach the timing belt. Vertical Transport Motor 1. PFB along with the bracket, located on the back side of the machine ( page 941 "When removing the motors that are behind the PFB") 2.
  • Page 974 4. Replacement and Adjustment 3. Vertical transport motor [A] ( x 2) • When installing motors, attach the timing belt.

  • Page 975: 2Nd Paper Feed Motor/2Nd Transport Motor, 3Rd Paper Feed Motor/3Rd Transport Motor.973

    Motors and Sensors 2nd Paper Feed Motor/2nd Transport Motor, 3rd Paper Feed Motor/3rd Transport Motor 1. PFB along with the bracket, located on the back side of the machine ( page 941 "When removing the motors that are behind the PFB") 2nd paper feed motor/2nd transport motor [A] and 3rd paper feed motor/3rd transport motor [B] are attached to one bracket.

  • Page 976: Fusing Drive Motor

    4. Replacement and Adjustment • When installing motors, attach the timing belt. Fusing Drive Motor 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2). 2. Open the controller box [A] ( x 2).
  • Page 977 Motors and Sensors 3. PTR fusing exhaust fan and the grounding plate [A] along with the duct D137/D138: x 6, x 2, D135/D136: x 6, x 1,...

  • Page 978: Waste Toner Collection Motor

    4. Replacement and Adjustment 4. Fusing drive motor [A] ( x 4, x 1). Waste Toner Collection Motor Removing the Waste Toner Collection Motor 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2).
  • Page 979 Motors and Sensors 2. Open the controller box [A] ( x 2). 3. PTR fusing exhaust fan and the grounding plate [A] along with the duct D137/D138: x 6, x 2, D135/D136: x 6, x 1,...
  • Page 980 4. Replacement and Adjustment 4. Fusing drive motor [A] along with the bracket ( x 5, x 1, x 2). • For D137/D138, in order to remove the fusing drive motor along with the bracket, you must remove the bracket of the fusing belt smoothing roller drive motor. ( page 979 "Removing the Fusing Belt Smoothing Roller Drive Motor and the Bracket")

  • Page 981: Removing The Fusing Belt Smoothing Roller Drive Motor And The Bracket

    Motors and Sensors 5. Waste toner collection motor [A] ( x 3, x 1) Removing the Fusing Belt Smoothing Roller Drive Motor and the Bracket 1. Fusing belt smoothing roller drive motor [A] ( x 4, x 1) 2. The bracket [A] of the fusing belt release roller drive motor ( x 3).

  • Page 982: Waste Toner Lock Sensor

    4. Replacement and Adjustment • Access to the bracket [A] of the fusing drive motor is possible. Waste Toner Lock Sensor 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2).

  • Page 983: Fusing Release Motor

    Motors and Sensors Fusing Release Motor 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2). 2. Open the controller box [A] ( x 2). 3. PTR fusing exhaust fan and the grounding plate [A] along with the duct D137/D138: x 6, x 2,...
  • Page 984 4. Replacement and Adjustment D135/D136: x 6, x 1, 4. Fusing release motor [A] ( x 3, x 1)

  • Page 985: Removing The Fusing Belt Smoothing Roller Drive Motor And The Bracket

    Motors and Sensors • For D137/D138, in order to remove the fusing release motor, you must remove the bracket of the fusing belt smoothing roller drive motor. ( page 983 "Removing the Fusing Belt Smoothing Roller Drive Motor and the Bracket") Removing the Fusing Belt Smoothing Roller Drive Motor and the Bracket 1.

  • Page 986: Fusing Belt Smoothing Roller Drive Motor (D137/D138 Only)

    4. Replacement and Adjustment • Access to the fusing release motor is possible. Fusing Belt Smoothing Roller Drive Motor (D137/D138 only) 1. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2).
  • Page 987 Motors and Sensors 3. PTR fusing exhaust fan and the grounding plate [A] along with the duct ( x 6, x 2, x 6) 4. Fusing belt smoothing roller drive motor [A] ( x 4, x 1)

  • Page 988: Fusing Belt Smoothing Roller Contact Motor (D137/D138 Only)

    4. Replacement and Adjustment Fusing Belt Smoothing Roller Contact Motor (D137/D138 only) 1. Fusing Release Motor ( page 981) 2. Fusing drive motor [A] along with the bracket ( x 5, x 1, x 2) 3. Fusing belt release roller contact motor [A] along with the bracket ( x 5, x 1) 4.
  • Page 989 Motors and Sensors...

  • Page 990: Fans And Filters

    4. Replacement and Adjustment Fans and Filters Layout (Fans) Main Machine (Rear)
  • Page 991 Fans and Filters Main Machine (Front)
  • Page 992 4. Replacement and Adjustment Drawer (Inside) Replacement Part Name Remarks procedure Heat Pipe Panel Intake Fan page 1001 Development Exhaust Fan (Right) page 994 Development Exhaust Fan (Left) page 994 Heat Pipe Panel Exhaust Fan page 1000 Fusing Exit Exhaust Fan page 998 Drive Exhaust Fan page 998...
  • Page 993 Fans and Filters Replacement Part Name Remarks procedure PSU Fan (Left) page 1010 IH Coil Power Cooling Fan page 1007 PSU Fan (Right) page 1010 ITB Motor Cooling Fan page 1004 ID Sensor Cleaning Fan page 1009 Laser Unit Cooling Fan (Left) page 677 Laser Unit Cooling Fan (Right) page 677...

  • Page 994: Layout (Filters)

    4. Replacement and Adjustment Layout (Filters) Replacement Part Name Remarks procedure Dust Filter (Large) page 1012 Ozone Filter (Large) page 1013 Deodorizing Filter (Small) page 1011 Dust Filter (Small) page 1012 Ozone Filter (Small) page 1013 Deodorizing Filter (Large) page 1011 Controller Exhaust Fan 1.

  • Page 995: Controller Intake Fan

    Fans and Filters Controller Intake Fan 1. Rear middle cover ( page 537) 2. Remove the retaining bracket [A] of the controller box which is located at the rear of the machine ( x 2). 3. Open the controller box [A] ( x 2).

  • Page 996: Development Exhaust Fans (Right / Left)

    4. Replacement and Adjustment 4. Controller intake fan [A] ( x 1, x 1) Development Exhaust Fans (Right / Left) 1. Rear middle cover ( page 537) 2. Disconnect the harness to remove the development exhaust fans [A] along with the duct ( each)
  • Page 997 Fans and Filters 3. Disconnect the left clamp to remove the development exhaust fan (right) [A] ( x 1). 4. Development exhaust fans (Right / Left) [A] along with the duct ( x 2 each) e.g.: Development exhaust fan (right)

  • Page 998: Development Intake Fans (Kcmy)

    4. Replacement and Adjustment 5. Remove the hooks and take out the development exhaust fans (right / left) [A] e.g.: Development exhaust fan (right) Development Intake Fans (KCMY) 1. Toner supply unit inner cover ( page 628) 2. Development intake fans (KCM) [A] ( x 2 each, x 1 each)
  • Page 999 Fans and Filters • Development intake fan (Y) [A] from the right side ( x 2, x 1) 3. Development intake fan ( x2, hook x 1)

  • Page 1000: Drive Exhaust Fan

    4. Replacement and Adjustment Drive Exhaust Fan 1. Rear middle cover ( page 537) 2. Drive exhaust fan [A] ( x 2, x 1) Fusing Exit Exhaust Fan 1. Rear middle cover ( page 537) 2. Fusing exit exhaust fan [A] ( x 2, x 1) Fusing Pressure Roller Exhaust Fan (D137/D138 only) 1.
  • Page 1001 Fans and Filters 4. Open the controller box [A] ( x 2). 5. Remove the PTR fusing exhaust fan [A] and the grounding plate along with the duct ( x 6, x 2, x 6). 6. Fusing pressure roller exhaust fan [A] along with the duct ( x 2, x 1)

  • Page 1002: Heat Pipe Panel Exhaust Fan

    4. Replacement and Adjustment 7. Fusing pressure roller exhaust fan [A] ( x 2, x 1) Heat Pipe Panel Exhaust Fan 1. Rear middle cover ( page 537) 2. Drive exhaust fan [A] along with the duct ( x 3) 3.

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