Model Pro C901S/Pro C901 Machine Code: D095/M077 Field Service Manual
Model Pro C901S/Pro C901 Machine Code: D095/M077 Field Service Manual
17 September, 2010
Safety, Conventions, Trademarks
Conventions
Screw
Connector
E-ring
C-ring
Harness clamp
The notations "SEF" and "LEF" describe the direction of paper feed. The arrows indicate the direction of
paper feed.
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.
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• Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable
data and to prevent damage to the machine
• This information provides tips and advice about how to best service the machine.
In the SP tables, the finishers are referred to by number (1, 2, 3), and some devices that appear in the SP
tables are not supported overseas:
For your safety, please read this manual carefully before you use this product. Keep this manual handy for
future reference.
Safety Information
Always obey the following safety precautions when using this product.
Safety During Operation
In this manual, the following important symbols and notations are used.
Switches and Symbols
Where symbols are used on or near switches on machines for Europe and other areas, the meaning of
each symbol conforms with IEC60417.
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Responsibilities of the Customer Engineer
Customer Engineer
Maintenance shall be done only by trained customer engineers who have completed service training for
the machine and all optional devices designed for use with the machine.
• Work carefully when lifting or moving the machine. If the machine is heavy, two or more customer
engineers may be required to prevent injuries (muscle strains, spinal injuries, etc.) or damage to the
machine if it is dropped or tipped over.
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• Personnel moving or working around the machine should always wear proper clothing and footwear.
Never wear loose fitting clothing or accessories (neckties, loose sweaters, bracelets, etc.) or casual
footwear (slippers, sandals, etc.) when lifting or moving the machine.
• Always unplug the power cord from the power source before you move the product. Before you move
the product, arrange the power cord so it will not fall under the product.
Power
• Always disconnect the power plug before doing any maintenance procedure. After switching off the
machine, power is still supplied to the main machine and other devices. To prevent electrical shock,
switch the machine off, wait for a few seconds, then unplug the machine from the power source.
• Before you do any checks or adjustments after turning the machine off, work carefully to avoid injury.
After removing covers or opening the machine to do checks or adjustments, never touch electrical
components or moving parts (gears, timing belts, etc.).
• After turning the machine on with any cover removed, keep your hands away from electrical
components and moving parts. Never touch the cover of the fusing unit, gears, timing belts, etc.
• After installation, maintenance, or adjustment, always check the operation of the machine to make
sure that it is operating normally. This ensures that all shipping materials, protective materials, wires
and tags, metal brackets, etc., removed for installation, have been removed and that no tools remain
inside the machine. This also ensures that all release interlock switches have been restored to normal
operation.
• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to
lubricate moving parts while the machine is operating.
• An excessive amount of ozone can build up around machines. Make sure the room where the machine
is to be installed is well ventilated and spacious. Good ventilation is especially important when the
machine is used heavily.
• To avoid possible build-up of ozone, locate this machine in a large well ventilated room that has an
air turnover of more than 30m3/hr/person.
Special Tools
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• For special adjustments, use only the special tools and lubricants described in the service manual.
Using tools incorrectly, or using tools that could damage parts, could damage the machine or cause
injuries.
During Maintenance
General
Safety Devices
• Never remove any safety device unless it requires replacement. Always replace safety devices
immediately.
• Never do any procedure that defeats the function of any safety device. Modification or removal of a
safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of
the machine to ensure that it is operating normally and safely after removal and replacement of any
safety device.
• For replacements, use only the correct fuses or circuit breakers rated for use with the machine. Using
replacement devices not designed for use with the machine could lead to a fire and personal injuries.
Organic Cleaners
• During preventive maintenance, never use any organic cleaners (alcohol, etc.) other than those
described in the service manual.
• Make sure the room is well ventilated before using any organic cleaner. Use organic solvents in small
amounts to avoid breathing the fumes and becoming nauseous.
• Switch the machine off, unplug it, and allow it to cool before doing preventive maintenance. To avoid
fire or explosion, never use an organic cleaner near any part that generates heat.
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• Wash your hands thoroughly after cleaning parts with an organic cleaner to contamination of food,
drinks, etc. which could cause illness.
• Clean the floor completely after accidental spillage of silicone oil or other materials to prevent slippery
surfaces that could cause accidents leading to hand or leg injuries. Use dry rags to soak up spills.
Batteries
• Always replace a battery with the same type of battery prescribed for use. Replacing a battery with
any type other than the one prescribed for use could lead to an explosion.
• Never discard used batteries by mixing them with other trash. Remove them from the work site and
dispose of them in accordance with local laws and regulations regarding the disposal of such items.
Ozone Filters
• Always replace ozone filters as soon as their service life expires (as described in the service manual).
• An excessive amount of ozone can build up around machines that use ozone filters if they are not
replaced at the prescribed time. Excessive ozone could cause personnel working around the machine
to feel unwell.
• Always disconnect the all power plugs for the mainframe and other peripherals before doing any
maintenance procedure. After switching off the machine, power is still supplied to the main machine
and other devices. To prevent electrical shock, switch the machine off, wait for a few seconds, then
unplug the machine from the power source.
• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A
dirty plug can generate heat which could cause a fire.
• Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary.
A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or
personal injury from electrical shock.
• Check the length of the power cord between the machine and power supply. Make sure the power
cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.
• Make sure that the area around the power source is free of obstacles so the power cord can be
removed quickly in case of an emergency.
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• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on
the plug.
• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the cable.
• Always dispose of used items (developer, toner, toner cartridges, OPC drums, etc.) in accordance
with the local laws and regulations regarding the disposal of such items.
• To protect the environment, never dispose of this product or any kind of waste from consumables at
a household waste collection point. Dispose of these items at one of our dealers or at an authorized
collection site.
• Return used selenium drums to the service center for handling in accordance with company policy
regarding the recycling or disposal of such items.
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1) Something has spilled into the product.
2) Service or repair of the product is necessary.
3) The product cover has been damaged.
• Caution operators about removing paper fasteners around the machine. They should never allow
paper clips, staples, or any other small metallic objects to fall into the machine.
• Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling
toner on clothing or the hands.
• If toner is inhaled, immediately gargle with large amounts of cold water and move to a well ventilated
location. If there are signs of irritation or other problems, seek medical attention.
• If toner gets on the skin, wash immediately with soap and cold running water.
• If toner gets into the eyes, flush the eyes with cold running water or eye wash. If there are signs of
irritation or other problems, seek medical attention.
• If toner is swallowed, drink a large amount of cold water to dilute the ingested toner. If there are signs
of any problem, seek medical attention.
• If toner spills on clothing, wash the affected area immediately with soap and cold water. Never use
hot water! Hot water can cause toner to set and permanently stain fabric.
• Always store toner and developer supplies such as toner and developer packages, cartridges, and
bottles (including used toner and empty bottles and cartridges) out of the reach of children.
• Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not
exposed to direct sunlight.
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Toner Disposal
• Never attempt to incinerate toner, used toner, or empty toner containers (bottles or cartridges). Burning
toner can explode and scatter, causing serious burns.
• Always wrap used toner and empty toner bottles and cartridges in plastic bags to avoid spillage.
Follow the local laws and regulations regarding the disposal of such items.
• Dispose of used toner and toner cartridges at one of our dealers or at an authorized collection site.
Always dispose of used toner cartridges and toner bottles in accordance with the local laws and
regulations regarding the disposal of such items.
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Observance of Electrical Safety Standards
1. The machine and its peripherals must be installed and maintained by a customer service representative
who has completed the training course on those models.
2. The NVRAM on the system control board has a lithium battery which can explode if replaced
incorrectly. Replace the NVRAM only with an identical one. The manufacturer recommends replacing
the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance
with local regulations.
Laser Safety
The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units
in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite
equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser
chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and
laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
• Use of controls, or adjustment, or performance of procedures other than those specified in this manual
may result in hazardous radiation exposure.
• Turn off the main switch before attempting any of the procedures in the Laser Unit section. Laser beams
can seriously damage your eyes.
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Trademarks
• Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the
United States and /or other countries.
• PostScript® is a registered trademark of Adobe Systems, Incorporated.
• PCL® is a registered trademark of Hewlett-Packard Company.
• Ethernet® is a registered trademark of Xerox Corporation.
• PowerPC® is a registered trademark of International Business Machines Corporation.
• 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.
Fuse Caution
This controller uses a double pole fuse. Be careful when you do maintenance on the Fiery Controller after
the fuse circuit has been opened.
Batteries
WARNING:
• Always replace a battery with the same type of battery prescribed for use. Replacing a battery with
any type other than the one prescribed for use could lead to an explosion.
• Never discard used batteries by mixing them with other trash. Remove them from the work site and
dispose of them in accordance with local laws and regulations regarding the disposal of such items.
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TABLE OF CONTENTS
Safety, Conventions, Trademarks......................................................................................................................1
Conventions....................................................................................................................................................1
Warnings, Cautions, Notes...........................................................................................................................1
Commonly Used Terms..................................................................................................................................2
General Safety Instructions............................................................................................................................2
Responsibilities of the Customer Engineer....................................................................................................3
Before Installation, Maintenance..................................................................................................................3
During Maintenance......................................................................................................................................5
After Installation, Servicing............................................................................................................................7
Special Safety Instructions for Toner.............................................................................................................8
Safety Instructions for this Machine...............................................................................................................9
Safety Instructions for Fiery Controller.......................................................................................................11
1. Product Information
Specifications....................................................................................................................................................27
Machine Configuration....................................................................................................................................28
Printer M077................................................................................................................................................28
Copier D095................................................................................................................................................30
Overview..........................................................................................................................................................33
Machine Layout...........................................................................................................................................33
Paper Path....................................................................................................................................................34
Fan Location.................................................................................................................................................36
Guidance for Those Who are Familiar with Predecessor Products..............................................................39
2. Installation
Installation Requirements.................................................................................................................................41
Operating Environment...............................................................................................................................41
Machine Level..............................................................................................................................................42
Minimum Space Requirements...................................................................................................................43
Dimensions...................................................................................................................................................44
Power Requirements....................................................................................................................................48
Correct Procedure to Turn Off the Power ..................................................................................................49
Before You Begin.............................................................................................................................................51
Overview of Optional Peripherals .............................................................................................................51
Mainframe........................................................................................................................................................56
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Accessories...................................................................................................................................................56
Installation....................................................................................................................................................60
Rear Controller Box Removal.....................................................................................................................98
A3/11"x17" Tray Unit TK5000 (B331).....................................................................................................103
Accessories................................................................................................................................................103
Installation..................................................................................................................................................103
Ring Binder (D392) Installation....................................................................................................................109
Accessories................................................................................................................................................109
Before You Begin.......................................................................................................................................110
Installation Procedure................................................................................................................................111
Centering Paper in the Paper Path...........................................................................................................121
After Installation.........................................................................................................................................127
Perfect Binder (D391) Installation................................................................................................................129
Docking the Perfect Binder.......................................................................................................................129
Filling Bookbinder Glue Supply Unit.......................................................................................................134
Testing the Breaker Switch........................................................................................................................136
High Capacity Stacker SK5010 (D447)....................................................................................................138
Accessories................................................................................................................................................138
Installation..................................................................................................................................................139
Bridge Unit BU5000 (D379)........................................................................................................................151
Accessory Check.......................................................................................................................................151
Installation..................................................................................................................................................152
LCIT RT5050 (D532)....................................................................................................................................164
Accessory Check.......................................................................................................................................164
Installation Procedure for Printer (M077)...............................................................................................165
Installation Procedure for Copier (D095)...............................................................................................178
LCIT RT5030 (D452)....................................................................................................................................186
Accessories................................................................................................................................................186
Installation..................................................................................................................................................187
Image Position Sensor, Paper Registration Adjustment..........................................................................190
LCIT (D452) Tray Heaters........................................................................................................................190
Multi Bypass Tray (B833).............................................................................................................................195
Accessories................................................................................................................................................195
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Installation..................................................................................................................................................195
Cover Interposer Tray CI5010 (B835).......................................................................................................200
Accessories................................................................................................................................................200
Installation..................................................................................................................................................201
Z-Folding Unit ZF4000 (B660)....................................................................................................................213
Accessory Check.......................................................................................................................................213
Installation..................................................................................................................................................214
Booklet Finisher SR5020 (D434).................................................................................................................225
Accessories................................................................................................................................................225
Installation..................................................................................................................................................226
Punch Unit PU5020 NA, EU, SC (D449-17, -27, -28)........................................................................236
Installation..................................................................................................................................................238
Trimmer Unit TR5020 (D455)......................................................................................................................247
Accessories................................................................................................................................................247
Installation..................................................................................................................................................248
Finisher SR5000 (B830)...............................................................................................................................254
Accessories................................................................................................................................................254
Finisher Installation....................................................................................................................................255
Punch Unit PU5000 (B831).........................................................................................................................265
Accessories................................................................................................................................................265
Installation..................................................................................................................................................266
Cooling Fan Unit Type 5000 (B831)..........................................................................................................271
Component Check....................................................................................................................................271
Installation Procedure................................................................................................................................271
Buffer Pass Unit Type 5000 (M379)...........................................................................................................277
Accessory Check.......................................................................................................................................277
Installation..................................................................................................................................................278
Fuser Unit Air Separator Type C901 (M390)............................................................................................285
Accessory Check.......................................................................................................................................285
Installation..................................................................................................................................................286
Skew and Side-to-Side Adjustment..............................................................................................................296
Skew and Side-to-Side Registration........................................................................................................296
Optional Counter Interface Unit Type A (B870).........................................................................................308
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Component List..........................................................................................................................................308
Installation..................................................................................................................................................308
MFP Option....................................................................................................................................................312
VM Card Type F (D377-04): D095 only...............................................................................................312
3. Preventive Maintenance
PM Counter....................................................................................................................................................315
Initializing PM Parts...................................................................................................................................315
Displaying the PM Counter.......................................................................................................................316
PM Parts Screen Details............................................................................................................................317
PM Tables.......................................................................................................................................................320
4. Replacement and Adjustment
General Cautions..........................................................................................................................................321
Rear Controller Box ..................................................................................................................................321
Drum...........................................................................................................................................................321
PCDU..........................................................................................................................................................322
Image Transfer Belt Unit............................................................................................................................322
Scanner Unit (D095 only)........................................................................................................................322
Laser Unit....................................................................................................................................................322
Development..............................................................................................................................................322
Cleaning.....................................................................................................................................................323
Fusing Unit..................................................................................................................................................323
Paper Feed.................................................................................................................................................323
Waste Toner..............................................................................................................................................323
Fiery Controller..........................................................................................................................................324
Special Tools and Lubricants........................................................................................................................325
Special Tools..............................................................................................................................................325
Lubricants...................................................................................................................................................325
Image Adjustment..........................................................................................................................................326
Scanning (D095 only)..............................................................................................................................326
ADF (D095 only).......................................................................................................................................327
Color Image Check...................................................................................................................................328
Color Registration Check..........................................................................................................................329
Ruled Line Check.......................................................................................................................................330
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Image Shift Check between the 1st and 2nd Pages...............................................................................332
Image Skew Check...................................................................................................................................336
Exterior Covers...............................................................................................................................................339
Front Door..................................................................................................................................................339
Left Cover...................................................................................................................................................340
Right Cover................................................................................................................................................341
Front Top Cover.........................................................................................................................................341
Rear Top Cover ........................................................................................................................................342
Rear Upper and Lower Covers................................................................................................................343
Operation Panel Arm................................................................................................................................344
Operation Panel........................................................................................................................................345
OPU............................................................................................................................................................346
Main Key, Sub Key and Application Key Board, and LCD Unit...........................................................347
Touch Panel Position Adjustment..............................................................................................................349
Rear Controller Box...................................................................................................................................350
Laser Unit........................................................................................................................................................355
Caution Decals..........................................................................................................................................355
LD Safety Switches....................................................................................................................................359
Laser Unit ...................................................................................................................................................359
Polygon Motor...........................................................................................................................................365
Polygon Motor Drive Board.....................................................................................................................366
LD Units.......................................................................................................................................................368
Laser Synchronizing Detector...................................................................................................................373
Toner Hopper.................................................................................................................................................375
Toner Bottles..............................................................................................................................................375
Toner Hopper Cover.................................................................................................................................376
Toner Hopper Door Switch.......................................................................................................................377
RFID Board.................................................................................................................................................378
Toner Bottle Motor....................................................................................................................................379
Sub-Hopper Unit.......................................................................................................................................383
Toner Supply Clutch..................................................................................................................................387
Toner Pump Clutch....................................................................................................................................389
Toner End Sensor......................................................................................................................................390
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Toner Supply Motor..................................................................................................................................390
Waste Toner Transport Motor 1..............................................................................................................391
Waste Toner Transport Motor 2 and Sensor..........................................................................................393
Image Creation..............................................................................................................................................396
Charge Corona Unit.................................................................................................................................396
Drum Cleaning Unit...................................................................................................................................396
Drum Lubricant Blade................................................................................................................................399
Drum Cleaning Gears...............................................................................................................................400
Drum Lubricant Bar and Drum Lubricant Brush Roller............................................................................400
Drum Cleaning Blade................................................................................................................................402
Drum Cleaning Brush Roller......................................................................................................................403
Drum Unit...................................................................................................................................................404
Lubricating the Drum.................................................................................................................................407
Quenching Lamp.......................................................................................................................................408
Drum Motor...............................................................................................................................................408
Drum Cleaning Motor...............................................................................................................................409
Drum Potential Sensor...............................................................................................................................410
Potential Sensor HVPS..............................................................................................................................412
Dust Shield Glass.......................................................................................................................................413
Erase Lamp Shield Glass..........................................................................................................................414
Development Unit......................................................................................................................................415
Developer..................................................................................................................................................419
TD Sensor...................................................................................................................................................426
Development Motor..................................................................................................................................428
Development Fan......................................................................................................................................428
Charge Cleaning Motor...........................................................................................................................429
Image Transfer...............................................................................................................................................430
ITB (Image Transfer Belt) Unit Drawer.....................................................................................................430
ITB Cleaning Unit.......................................................................................................................................432
ITB Fan Cleaning Procedure.....................................................................................................................435
ITB Cleaning and ITB Lubricant Blades....................................................................................................436
ITB Lubricant Brush Roller and Lubricant Bar..........................................................................................436
ITB Cleaning Brush Roller.........................................................................................................................438
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Image Transfer Belt....................................................................................................................................439
ID/MUSIC Sensors...................................................................................................................................442
ITB Drive Motor.........................................................................................................................................444
ITB Motor Rotation Sensors......................................................................................................................444
Belt Speed Sensor.....................................................................................................................................446
ITB Black and Color Lift Motors................................................................................................................448
ITB Black and Color Lift Sensors...............................................................................................................450
Front and Rear Belt Overrun Sensors .....................................................................................................450
Belt Centering Sensor ...............................................................................................................................451
Image Transfer Rollers ..............................................................................................................................453
ITB Bias Roller............................................................................................................................................454
ITB Cleaning Motor...................................................................................................................................456
ITB Cleaning Unit Set Sensor....................................................................................................................457
Belt Centering Roller Sensor.....................................................................................................................457
Belt Centering Roller Motor......................................................................................................................458
TRB (Transfer Relay Board).......................................................................................................................459
Transfer HVPS............................................................................................................................................460
Paper Registration .........................................................................................................................................463
Registration Unit Drawer...........................................................................................................................463
Inner Registration Cover...........................................................................................................................465
LCT Entrance Sensor.................................................................................................................................465
Registration Timing Sensor........................................................................................................................466
Registration Entrance Sensor....................................................................................................................467
Double-Feed Sensor.................................................................................................................................468
CIS (Contact Image Sensor) Unit.............................................................................................................470
Paper Dust Tray.........................................................................................................................................473
Shift Roller Unit..........................................................................................................................................474
Shift Roller Unit Motor...............................................................................................................................477
Shift Roller HP Sensor................................................................................................................................479
Registration Gate Lift Sensor.....................................................................................................................479
PTR Timing Sensor.....................................................................................................................................480
Registration Timing Motor.........................................................................................................................481
Registration Gate Motor...........................................................................................................................482
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