Page 1
D095+/M077+
SERVICE MANUAL
Page 2
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Page 3
The Service Manual contains information
regarding service techniques, procedures,
Untrained and uncertified users utilizing
WARNING
processes and spare parts of office equipment
distributed by Ricoh Americas Corporation.
Users of this manual should be either service
trained or certified by successfully completing a
Ricoh Technical Training Program.
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Americas Corporation
Page 4
REV. NO.
DATE
COMMENTS
*
04/2013
Original Printing
LEGEND
PRODUCT
CODE
D095+ Pro C901s/GA+ Pro C901s/GA+ Pro C901s/GA+
M077+ Pro C901/GA+ Pro C901/GA+ Pro C901/GA+
**NOTE: GA+ refers to Graphic Arts+
LANIER RICOH SAVIN
DOCUMENTATION HISTORY
COMPANY
Page 5
D095+/M077+
TABLE OF CONTENTS
1. PRODUCT INFORMATION ......................................................... 1-1
1.1 SPECIFICATIONS ..................................................................................... 1-1
1.2 MACHINE CONFIGURATION ................................................................... 1-2
1.2.1 PRINTER M077+ .............................................................................. 1-2
1.2.2 COPIER D095+ ................................................................................ 1-4
1.3 OVERVIEW ................................................................................................ 1-6
1.3.1 MACHINE L AYOUT .......................................................................... 1-6
1.3.2 PAPER PATH ................................................................................... 1-7
Printer (M077+) model ......................................................................... 1-7
Copier (D095+) model .......................................................................... 1-8
1.3.3 FAN LOCATION ............................................................................... 1-9
1.4 GUIDANCE FOR THOSE WHO ARE FAMILIAR WITH PREDECESSOR
PRODUCTS ................................................................................................... 1-12
2. INSTALLATION .......................................................................... 2-1
2.1 INSTALLATION REQUIREMENTS ............................................................ 2-1
2.1.1 OPERATING ENVIRONMENT ......................................................... 2-1
2.1.2 MACHINE LEVEL ............................................................................. 2-2
2.1.3 MINIMUM SPACE REQUIREMENTS ............................................... 2-2
2.1.4 DIMENSIONS ................................................................................... 2-3
Side View with Finisher SR5000 (B830) or SR5020 (D434)................. 2-3
Side View with Ring Binder RB5000 (D392) ........................................ 2-4
Side View with Perfect Binder GB5000 (D391) .................................... 2-5
Side View with High Capacity Stacker SK5000 (D364) ........................ 2-6
2.1.5 POWER REQUIREMENTS .............................................................. 2-7
Input voltage level ................................................................................ 2-7
Required Breaker ................................................................................. 2-7
Main Power Switch ............................................................................... 2-7
Operation Switch .................................................................................. 2-7
2.1.6 CORRECT PROCEDURE TO TURN OFF THE POWER ................. 2-8
Shut the Fiery Controller Down First .................................................... 2-8
Then Shut Down the Machine .............................................................. 2-8
2.2 BEFORE YOU BEGIN... ............................................................................ 2-9
2.2.1 OVERVIEW OF OPTIONAL PERIPHERALS ................................... 2-9
SM i D095+/M077+
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Optional Peripherals Configuration for Printer M077+ .......................... 2-9
Optional Peripherals Configuration for Copier D095+ ........................ 2-11
2.3 MAINFRAME ........................................................................................... 2-13
2.3.1 ACCESSORIES .............................................................................. 2-13
2.3.2 INSTALLATION .............................................................................. 2-18
Rating Voltage for Peripherals ........................................................... 2-18
External Tape and Packing Material .................................................. 2-19
Leveling the Mainframe ...................................................................... 2-20
Internal Tape and Packing Mater i al .................................................... 2-21
Install the Toner Bottles...................................................................... 2-23
Installing the Operation Panel Unit ..................................................... 2-24
Keytop Adjustment ............................................................................. 2-25
Attaching the Ground Plate ................................................................ 2-26
Installing the Attention Light ............................................................... 2-26
Connecting the Upper and Lower Tray Heaters ................................. 2-27
Connecting the LCT-MF (D095+ only) ............................................... 2-29
Testing the Breaker Switch and Attaching the Caution Decal ............ 2-38
Connecting to the Controller ............................................................... 2-39
Turn on the Machine Power ............................................................... 2-40
Controller Selection ............................................................................ 2-40
Fiery Language Selection ................................................................... 2-40
Fiery Controller Settings ..................................................................... 2-41
Paper Library Data ............................................................................. 2-44
TCRU Setting ..................................................................................... 2-45
Load the Paper Trays ......................................................................... 2-45
Print an SMC Report .......................................................................... 2-45
Checking the Print Quality .................................................................. 2-46
Make a Test Color Print (D095+ only) ................................................ 2-49
ACC (Automatic Color Calibration) Adjustment (D095+ only) ............ 2-49
Color Registration Procedure for MUSIC ........................................... 2-51
2.3.3 REAR CONTROLLER BOX REMOVAL ......................................... 2-51
Rear Controller Box Removal ............................................................. 2-51
2.4 A3/11"X17" TRAY UNIT TK5000 (B331).................................................. 2-55
2.4.1 ACCESSORIES .............................................................................. 2-55
2.4.2 INSTALLATION .............................................................................. 2-56
2.5 RING BINDER (D392) INSTALLATION ................................................... 2-59
2.5.1 ACCESSORIES .............................................................................. 2-59
2.5.2 BEFORE YOU BEGIN .................................................................... 2-60
2.5.3 INSTALLATION PROCEDURE ...................................................... 2-60
D095+/M077+ ii SM
Page 7
Remove All Shipping Materials .......................................................... 2-60
Prepare the Finisher fo r Docki ng ........................................................ 2-62
Prepare the Mainframe or other peripheral for Docking ..................... 2-63
Dock the Finisher to the Upstream Unit ............................................. 2-63
Install the Shoes and Level the Finisher............................................. 2-66
Peripheral Height Adjustment ............................................................. 2-66
Attach Ring Supply Level Indicator .................................................... 2-67
Test the Breaker Switch ..................................................................... 2-68
2.5.4 CENTERING PAPER IN THE PAPER PATH ................................. 2-68
Checking and Correcting Side-to-Side Registration ........................... 2-69
Checking and Correcting Skew .......................................................... 2-71
2.5.5 AFTER INSTALLATION .................................................................. 2-74
2.6 PERFECT BINDER (D391) INSTALLATION ........................................... 2-76
2.6.1 DOCKING THE PERFECT BINDER ............................................... 2-76
Before Docking ................................................................................... 2-76
Docking Procedure ............................................................................. 2-77
Peripheral Height Adjustment ............................................................. 2-79
2.6.2 FILLING BOOKBINDER GLUE SUPPLY UNIT .............................. 2-80
Handling and Storing the Glue Pellet Supply ..................................... 2-82
2.6.3 TESTING THE BREAKER SWITCH ............................................... 2-82
2.7 HIGH CAPACITY STACKER SK5010 (D447) .......................................... 2-84
2.7.1 ACCESSORIES .............................................................................. 2-84
2.7.2 INSTALLATION .............................................................................. 2-86
Shipping Tapes .................................................................................. 2-86
Paper Guide, Sponge Strip, Grou nd Pl ate ......................................... 2-87
Docking .............................................................................................. 2-88
Lock Hasps ........................................................................................ 2-90
Height Adjustment .............................................................................. 2-91
Power Cord, Breaker Switch Test ...................................................... 2-92
Check for Skew and Correct Side-to-Side Registration ...................... 2-93
Docking: Downstream ........................................................................ 2-93
Roll-Away Cart (D456) ....................................................................... 2-94
2.8 BRIDGE UNIT BU5000 (D379) ................................................................ 2-96
2.8.1 ACCESSORY CHECK .................................................................... 2-96
2.8.2 INSTALLATION .............................................................................. 2-97
Horizontal Bridge Unit ........................................................................ 2-97
Vertical Bridge Unit .......................................................................... 2-102
2.9 LCIT RT5050 (D532) ............................................................................. 2-106
2.9.1 ACCESSORY CHECK .................................................................. 2-106
SM iii D095+/M077+
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2.9.2 INSTALLATION PROCEDURE FOR PRINTER (M077+) ............. 2-107
Naming for double LCT units ............................................................ 2-107
Preparing for Installation .................................................................. 2-108
Installation for only one LCT unit ...................................................... 2-109
Installation for two LCT units ............................................................ 2-113
2.9.3 INSTALLATION PROCEDURE FOR COPIER (D095+) ............... 2-118
Preparing for Installation .................................................................. 2-118
Installation for two LCT units ............................................................ 2-119
2.10 LCIT RT5030 (D452) ........................................................................ 2-124
2.10.1 ACCESSORIES ........................................................................ 2-124
2.10.2 INSTALLATION ........................................................................ 2-125
Tapes, Retainers .............................................................................. 2-125
Docking ............................................................................................ 2-126
Height Adjustment ............................................................................ 2-127
2.10.3 IMAGE POSITION SENSOR, PAPER REGISTRATION
ADJUSTMENT ....................................................................................... 2-128
2.10.4 LCIT (D452) TRAY HEATERS .................................................. 2-128
Accessories ...................................................................................... 2-128
Installation ........................................................................................ 2-129
2.11 MULTI BYPASS TRAY (B833) ......................................................... 2-132
2.11.1 ACCESSORIES ........................................................................ 2-132
2.11.2 INSTALLATION ........................................................................ 2-132
2.12 COVER INTERPOSER TRAY CI5010 (B835) ................................. 2-136
2.12.1 ACCESSORIES ........................................................................ 2-136
2.12.2 INSTALLATION ........................................................................ 2-137
Setting up the Unit and Docking to the Mainframe ........................... 2-137
Docking the Next Peripheral Device ................................................. 2-141
Mounting the Tray Unit ..................................................................... 2-142
Peripheral Height Adjustment ........................................................... 2-144
Docking the Cover Interposer Tray B835 ......................................... 2-145
Z-Fold Unit B660 to Cover Interposer Tray B835 ............................. 2-146
Finisher B830 to Cover Interposer Tray B835 .................................. 2-146
Firmware Update .............................................................................. 2-147
2.13 Z-FOLDING UNIT ZF4000 (B660) ................................................... 2-148
2.13.1 ACCESSORY CHECK .............................................................. 2-148
2.13.2 INSTALLATION ........................................................................ 2-150
Unpacking ........................................................................................ 2-150
Attaching the Brackets ..................................................................... 2-151
Preparing for Docking ....................................................................... 2-152
D095+/M077+ iv SM
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Testing the Breaker .......................................................................... 2-154
Docking the Z-Folding Unit to the Cover Interposer Tray or Mainframe
......................................................................................................... 2-154
Connecting the Z-Folding Unit B660 ................................................ 2-156
Connecting the Peripheral to the Z-Folding Unit B660 ..................... 2-158
2.14 BOOKLET FINISHER SR5020 (D434) ............................................. 2-159
2.14.1 ACCESSORIES ........................................................................ 2-159
2.14.2 INSTALLATION ........................................................................ 2-160
Tapes, Retainers, Shipping Plates ................................................... 2-160
Ground Plate, Sponge Strip ............................................................. 2-163
Booklet Tray, Shift Tray .................................................................... 2-164
Docking ............................................................................................ 2-165
Height Adjustment ............................................................................ 2-167
Power Cord, Breaker Switch Test .................................................... 2-168
Auxiliary Trays .................................................................................. 2-169
Check for Skew and Correct Side-to-Side Registration .................... 2-170
2.14.3 PUNCH UNIT PU5020 NA, EU, SC (D449-17, -27, -28) .......... 2-170
Accessories ...................................................................................... 2-170
2.14.4 INSTALLATION ........................................................................ 2-171
2.15 TRIMMER UNIT TR5020 (D455) ..................................................... 2-179
2.15.1 ACCESSORIES ........................................................................ 2-179
2.15.2 INSTALLATION ........................................................................ 2-180
Tapes, Stopper Plate ....................................................................... 2-180
Output Tray ...................................................................................... 2-181
Ground Plate .................................................................................... 2-182
Preparing the Booklet Finisher (D434) for Docking .......................... 2-182
Docking ............................................................................................ 2-184
2.16 FINISHER SR5000 (B830) ............................................................... 2-186
2.16.1 ACCESSORIES ........................................................................ 2-186
Finisher SR5000 B830 Accessories ................................................. 2-186
2.16.2 FINISHER INSTALLATION....................................................... 2-187
Removing tape and shipping retainers ............................................. 2-187
Preparing before Docking ................................................................. 2-188
Docking the Finisher B830 ............................................................... 2-191
Connecting the Finisher B830 .......................................................... 2-192
Peripheral Height Adjustment ........................................................... 2-194
Support Tray .................................................................................... 2-194
2.17 PUNCH UNIT PU5000 (B831) ......................................................... 2-195
2.17.1 ACCESSORIES ........................................................................ 2-195
SM v D095+/M077+
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2.17.2 INSTALLATION ........................................................................ 2-196
2.18 COOLING FAN UNIT TYPE 5000 (B831) ........................................ 2-200
2.18.1 COMPONENT CHECK ............................................................. 2-200
2.18.2 INSTALLATION PROCEDURE ................................................ 2-201
2.19 BUFFER PASS UNIT TYPE 5000 (M379) ....................................... 2-206
2.19.1 ACCESSORY CHECK .............................................................. 2-206
2.19.2 INSTALLATION ........................................................................ 2-207
Unpacking ........................................................................................ 2-207
Preparing for Docking ....................................................................... 2-208
Docking the Buffer Pass Unit to the Mainframe ................................ 2-208
Removing the Shipping Brackets ..................................................... 2-210
Connecting the Other Per i pher al t o the Bu ff e r Pass Unit ................. 2-211
2.20 FUSER UNIT AIR SEPARATOR TYPE C901 (M390)...................... 2-212
2.20.1 ACCESSORY CHECK .............................................................. 2-212
2.20.2 INSTALLATION ........................................................................ 2-213
Before Installation ............................................................................ 2-213
Installation Procedure....................................................................... 2-214
2.21 SKEW AND SIDE-TO-SIDE ADJUSTMENT .................................... 2-222
2.21.1 SKEW AND SIDE-TO-SIDE REGISTRATION .......................... 2-222
Overview .......................................................................................... 2-222
Checking Side-to-Si de R eg i str ati on ................................................. 2-225
Correcting Side-to-Side Registration ................................................ 2-227
Detecting Paper Skew ...................................................................... 2-229
Correcting Skew ............................................................................... 2-231
2.22 OPTIONAL COUNTER INTERFACE UNIT TYPE A (B870) ............ 2-234
2.22.1 COMPONENT LIST .................................................................. 2-234
2.22.2 INSTALLATION ........................................................................ 2-234
2.23 MFP OPTION ................................................................................... 2-237
2.23.1 VM CARD TYPE F (D377-04): D095+ ONLY ........................... 2-237
Installation Procedure....................................................................... 2-237
3. PREVENTIVE MAINTENANCE ................................................... 3-1
3.1 PM COUNTER ........................................................................................... 3-1
3.1.1 INITIALIZING PM PARTS ................................................................. 3-1
3.1.2 DISPLAYING THE PM COUNTER ................................................... 3-3
3.1.3 PM PARTS SCREEN DETAILS ........................................................ 3-4
All PM Parts list: Main Menu ................................................................ 3-4
Number button submenu ...................................................................... 3-5
Parts list for PM yield indicator ............................................................. 3-6
3.2 P M TABLES ............................................................................................... 3-7
D095+/M077+ vi SM
Page 11
4. REPLACEMENT AND ADJUSTMENT ........................................ 4-1
4.1 GENERAL CAUTIONS .............................................................................. 4-1
4.1.1 REAR CONTROLLER BOX .............................................................. 4-1
4.1.2 DRUM ............................................................................................... 4-1
4.1.3 PCDU ................................................................................................ 4-2
4.1.4 IMAGE TRANSFER BELT UNIT ....................................................... 4-2
4.1.5 SCANNER UNI T (D095+ ONLY) ...................................................... 4-2
4.1.6 LASER UNIT ..................................................................................... 4-2
4.1.7 DEVELOPMENT ............................................................................... 4-3
4.1.8 CLEANING ....................................................................................... 4-3
4.1.9 FUSING UNI T ................................................................................... 4-3
4.1.10 PAPER FEED ............................................................................... 4-3
4.1.11 WASTE TONER ........................................................................... 4-4
4.1.12 FIERY CONTROLLER .................................................................. 4-4
4.2 SPECIAL TOOLS AND LUBRICANTS ...................................................... 4-5
4.2.1 SPECIAL TOOLS.............................................................................. 4-5
4.2.2 LUBRICANTS ................................................................................... 4-5
4.3 IMAGE ADJUSTMENT .............................................................................. 4-6
4.3.1 SCANNING (D095+ ONLY) .............................................................. 4-6
Scanner sub-scan magnification .......................................................... 4-6
Scanner leading edge and side-to-side registration ............................. 4-6
4.3.2 ADF (D095+ ONLY) .......................................................................... 4-7
ADF side-to-side and leading edge registration ................................... 4-7
4.3.3 COLOR I MAGE CHECK ................................................................... 4-8
Checking Procedure ............................................................................. 4-8
Recovery Procedure ............................................................................ 4-8
4.3.4 COLOR RE GISTRATION CHECK .................................................... 4-9
Checking Procedure for Printer (M077+) model ................................... 4-9
Checking Procedure for Copier (D095+) model ................................... 4-9
Recovery Procedure ............................................................................ 4-9
4.3.5 RULED LINE CHECK ..................................................................... 4-10
Checking Procedure for Printer (M077+) ............................................ 4-10
Checking Procedure for Copier (D095+) model ................................. 4-11
Recovery Procedure .......................................................................... 4-11
4.3.6 IMAGE SHIFT CHECK BETWEEN THE 1ST AND 2ND PAGES ... 4-12
Checking Procedure ........................................................................... 4-12
Adjustment Procedure ........................................................................ 4-14
Adjustable User SP List...................................................................... 4-15
4.3.7 IMAGE SKEW CHECK ................................................................... 4-15
SM vii D095+/M077+
Page 12
Checking Procedure ........................................................................... 4-16
Adjustment Procedure ........................................................................ 4-17
4.4 EXT ERIOR COVERS .............................................................................. 4-18
4.4.1 FRONT DOOR ................................................................................ 4-18
Left Front Door ................................................................................... 4-18
Right Front Door ................................................................................. 4-18
4.4.2 LEFT COVER ................................................................................. 4-19
4.4.3 RIGHT COVER ............................................................................... 4-19
4.4.4 FRONT TOP COVER ..................................................................... 4-20
4.4.5 REAR TOP COVER ........................................................................ 4-21
4.4.6 REAR UPPER AND LOWER COVERS .......................................... 4-21
Rear Upper Cover .............................................................................. 4-21
Rear Lower Right Cover ..................................................................... 4-21
Rear Lower Left Cover ....................................................................... 4-21
4.4.7 OPERATION PANEL ARM ............................................................. 4-22
4.4.8 OPERATION PANEL ...................................................................... 4-23
4.4.9 OPU ................................................................................................ 4-24
4.4.10 MAIN KEY, SUB KEY AND APPLICATION KEY BOARD, AND LCD
UNIT 4-25
When reinstalling the application key board ....................................... 4-26
Inverter Fuse ...................................................................................... 4-26
4.4.11 TOUCH PANEL POSITION ADJUSTMENT ............................... 4-27
4.4.12 REAR CONTROLLER BOX ........................................................ 4-28
Opening the rear controller box .......................................................... 4-28
Detaching the rear controller box ....................................................... 4-28
4.5 LA SER UNIT ............................................................................................ 4-31
4.5.1 CAUTION DECALS ........................................................................ 4-32
View from the top of the printer .......................................................... 4-32
View from the rear of the printer ......................................................... 4-33
4.5.2 LD SAFETY SWITCHES ................................................................ 4-34
4.5.3 LASER UNIT ................................................................................... 4-35
Reinstallation ...................................................................................... 4-36
4.5.4 POLYGON MOTOR ........................................................................ 4-41
4.5.5 POLYGON MOTOR DRIVE BOARD .............................................. 4-42
4.5.6 LD UNITS ....................................................................................... 4-44
When installing a new LD unit ............................................................ 4-45
4.5.7 LASER SYNCHRONIZING DETECTOR ........................................ 4-49
4.6 T ONER HOPPER .................................................................................... 4-50
4.6.1 TONER BOTTLES .......................................................................... 4-50
D095+/M077+ viii SM
Page 13
Cleaning Requirement........................................................................ 4-50
4.6.2 TONER HOPPER COVER ............................................................. 4-51
4.6.3 TONER HOPPER DOOR SWITCH ................................................ 4-52
4.6.4 RFID BOARD .................................................................................. 4-52
4.6.5 TONER BOTTLE MOTOR .............................................................. 4-53
Lubricating the toner bottle motor gears ............................................. 4-54
4.6.6 SUB-HOPPER UNIT ....................................................................... 4-57
Lubrication for the sub-hopper gears ................................................. 4-59
After installing new sub-hopper unit ................................................... 4-60
4.6.7 TONER SUPPLY CLUTCH ............................................................. 4-61
4.6.8 TONER PUMP CLUTCH ................................................................ 4-62
4.6.9 TONER END SENSOR ................................................................... 4-63
4.6.10 TONER SUPPLY MOTOR .......................................................... 4-64
4.6.11 WASTE TONER TRANSPORT MOTOR 1 ................................. 4-65
4.6.12 WASTE TONER TRANSPORT MOTOR 2 AND SENSOR ........ 4-66
4.7 IMAGE CREATION .................................................................................. 4-67
4.7.1 CHARGE CO RONA UNIT .............................................................. 4-67
After installing a new charge corona unit............................................ 4-67
4.7.2 DRUM CLEANI NG UNIT ................................................................ 4-68
Cleaning Requirement at PM Replacement ....................................... 4-71
When installing a new drum cleaning unit .......................................... 4-71
After installing a new drum cleaning unit ............................................ 4-72
4.7.3 DRUM LUBRICA NT BLADE ........................................................... 4-72
After installing a new drum lubricant blade ......................................... 4-72
4.7.4 DRUM CLEANI NG GEARS ............................................................ 4-73
After installing new drum cleaning gears ............................................ 4-73
4.7.5 DRUM LUBRICA NT BAR AND DRUM LUBRICANT BRUSH ROLLER
4-74
After installing a new drum lubricant bar and drum lubricant brush roller
........................................................................................................... 4-75
4.7.6 DRUM CLEANI NG BLADE ............................................................. 4-76
After installing a new drum cleaning blade ......................................... 4-76
4.7.7 DRUM CLEANI NG BRUSH ROLLER ............................................. 4-77
After installing a new drum cleaning brush roller ................................ 4-77
4.7.8 DRUM UNIT .................................................................................... 4-78
Reassembling the Drum Unit ............................................................. 4-78
Cleaning Requirement at PM Replacement ....................................... 4-79
After installing a new drum unit .......................................................... 4-80
4.7.9 LUBRICATING THE DRUM ............................................................ 4-81
SM ix D095+/M077+
Page 14
Reinstallation ...................................................................................... 4-81
4.7.10 QUENCHING LAMP ................................................................... 4-82
4.7.11 DRUM MOTOR ........................................................................... 4-82
4.7.12 DRUM CLEANING MOTOR ....................................................... 4-83
4.7.13 DRUM POTENTIAL SENSOR .................................................... 4-83
Cleaning Requirement........................................................................ 4-84
4.7.14 POTENTIAL SENSOR HVPS ..................................................... 4-85
4.7.15 DUST SHIELD GLASS ............................................................... 4-86
When reinstalling the dust shield glass .............................................. 4-86
4.7.16 ERASE LAMP SHIELD GLASS .................................................. 4-87
Cleaning Requirement........................................................................ 4-87
4.7.17 DEVELOPMENT UNIT ............................................................... 4-87
Before removal ................................................................................... 4-88
Removal procedure ............................................................................ 4-89
Reassembling the Development Unit ................................................. 4-90
After installing the new development unit ........................................... 4-91
4.7.18 DEVELOPER .............................................................................. 4-91
Removal ............................................................................................. 4-91
Installation .......................................................................................... 4-94
If the developer removal or installation fails ....................................... 4-97
4.7.19 TD SENSOR ............................................................................... 4-98
After installing a new TD sensor ......................................................... 4-99
4.7.20 DEVELOPMENT MOTOR .......................................................... 4-99
4.7.21 DEVELOPMENT FAN .............................................................. 4-100
4.7.22 CHARGE CLEANING MOTOR ................................................. 4-100
4.8 IMAGE TRANSFER ............................................................................... 4-101
4.8.1 ITB (IMAGE TRANSFER BELT) UNIT DRAWER ......................... 4-101
Normal Slide-out Position ................................................................. 4-101
Full Slide-out Position....................................................................... 4-102
4.8.2 IT B CL EANING UNIT .................................................................... 4-103
ITB Lubrication ................................................................................. 4-104
After installing a new ITB cleaning unit............................................. 4-105
4.8.3 ITB FAN CLEANING PROCEDURE ............................................. 4-105
4.8.4 ITB CLEANING AND ITB LUBRICANT BLADES.......................... 4-106
After installing a new ITB cleaning blade.......................................... 4-106
4.8.5 ITB LUBRICANT BRUSH ROLLER AND LUBRICANT BAR ........ 4-106
After installing a new ITB lubricant brush roller or ITB lubricant bar . 4-107
4.8.6 ITB CLEANING BRUSH ROLLER ................................................ 4-108
After installing a new ITB cleaning brush roller ................................ 4-108
D095+/M077+ x SM
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4.8.7 IMAGE TRANSFER BELT ............................................................ 4-109
When installing a new image transfer belt ........................................ 4-111
After installing a new image transfer belt.......................................... 4-111
4.8.8 ID/MUSIC SENSORS ................................................................... 4-112
After installing new ID/MUSIC sensors............................................. 4-112
4.8.9 ITB DRIVE MOTOR ...................................................................... 4-113
4.8.10 ITB MOTOR ROTATION SENSORS ........................................ 4-113
Reinstalling the ITB motor rotation sensors ...................................... 4-115
4.8.11 BELT SPEED SENSOR ........................................................... 4-115
When reinstalling the encoder roller with the encoder unit ............... 4-116
4.8.12 ITB BLACK AND COLOR LIFT MOTORS ................................ 4-117
4.8.13 ITB BLACK AND COLOR LIFT SENSORS .............................. 4-118
4.8.14 FRONT AND REAR BELT OVERRUN SENSORS ................... 4-119
4.8.15 BELT CENTERING SENSOR ................................................... 4-120
4.8.16 IMAGE TRANSFER ROLLERS ................................................ 4-122
After installing new image transfer rollers......................................... 4-122
4.8.17 ITB BIAS ROLLER .................................................................... 4-123
After installing a new ITB bias roller ................................................. 4-124
4.8.18 ITB CLEANING MOTOR........................................................... 4-124
4.8.19 ITB CLEANING UNIT SET SENSOR ....................................... 4-125
4.8.20 BELT CENTERING ROLLER SENSOR ................................... 4-126
4.8.21 BELT CENTERING ROLLER MOTOR ..................................... 4-127
4.8.22 TRB (TRANSFER RELAY BOARD) ......................................... 4-128
4.8.23 TRANSFER HVPS .................................................................... 4-129
4.9 PAPER REGISTRATION ....................................................................... 4-131
4.9.1 REGIST RATION UNIT DRAWER ................................................. 4-131
Pulling out the registration unit drawer ............................................. 4-131
Removing the registration unit drawer .............................................. 4-131
Reinstalling the regist ration unit drawer ........................................... 4-132
4.9.2 INNER REGISTRATION COVER ................................................. 4-133
4.9.3 LCT ENTRANCE SENSOR .......................................................... 4-133
4.9.4 REGISTRATION TIMING SENSOR ............................................. 4-134
4.9.5 REGIST RATION ENTRANCE SENSOR ...................................... 4-134
4.9.6 DOUBLE-FEED SENSOR ............................................................ 4-135
Double-Feed Sensor: R ec ept or ........................................................ 4-135
Double-Feed Sensor: LED ............................................................... 4-136
4.9.7 CIS (CONTACT IMAGE SENSOR) UNIT ..................................... 4-137
After installing a new CIS unit .......................................................... 4-138
4.9.8 PAPER DUST TRAY .................................................................... 4-139
SM xi D095+/M077+
Page 16
Cleaning Requirement...................................................................... 4-140
4.9.9 SHIFT ROLLER UNIT ................................................................... 4-140
4.9.10 SHIFT ROLL ER UNIT MOTOR ................................................ 4-143
4.9.11 SHIFT ROLLER HP SENSOR .................................................. 4-144
4.9.12 REGISTRATION GATE LIFT SENSOR .................................... 4-144
4.9.13 PTR TIMING SENSOR ............................................................. 4-145
4.9.14 REGISTRATION TIMING MOTOR ........................................... 4-146
4.9.15 REGISTRATION GATE MOTOR .............................................. 4-147
4.9.16 REGISTRATION ENTRANCE MOTOR .................................... 4-148
4.9.17 SHIFT ROLLER MOTOR .......................................................... 4-150
4.9.18 DUPLEX TRANSPORT MOTOR 2 ........................................... 4-151
4.9.19 PTR TIMING MOTOR ............................................................... 4-153
4.9.20 DUPLEX TRANSPORT SENSOR 3 AND 4 .............................. 4-154
Duplex Transport Sensor 3 .............................................................. 4-154
Duplex Transport Sensor 4 .............................................................. 4-154
4.9.21 PTR MOTOR ............................................................................ 4-155
4.9.22 SEPARATION HVPS ................................................................ 4-156
4.9.23 PTR LIF T MOTOR .................................................................... 4-157
4.9.24 PTR LIFT SENSOR .................................................................. 4-158
4.9.25 RCB .......................................................................................... 4-159
4.10 PAPER TRANSFER ......................................................................... 4-160
4.10.1 PTR (PAPER TRANSFER ROLLER) UNIT .............................. 4-160
After installing a new paper transfer roller unit ................................. 4-160
4.10.2 PTR ENTRANCE MYLAR CLEANING PROCEDURE ............. 4-161
Cleaning Requirement...................................................................... 4-161
4.10.3 PTR LUBRICANT BAR ............................................................. 4-161
After installing a new PTR lubricant bar ........................................... 4-162
4.10.4 PTR LUBRICANT BRUSH ROLLER ........................................ 4-162
After installing a new PTR lubricant brush roller ............................... 4-163
4.10.5 PTR DISCHARGE PLATE ........................................................ 4-163
After installing a new PTR discharge plate ....................................... 4-163
4.10.6 PAPER TRANSFER ROLLER .................................................. 4-163
After installing a new paper transfer roller ........................................ 4-164
4.10.7 PTR CLEANING BLADE .......................................................... 4-165
After installing a new PTR cleaning blade ........................................ 4-165
4.10.8 PTR CLEANING BRUSH ROLLER .......................................... 4-165
After installing a new PTR cleaning brush roller ............................... 4-165
4.11 PAPER FEED AND TRANSPORT ................................................... 4-166
4.11.1 TANDEM TRAY (TRAY 1) ........................................................ 4-166
D095+/M077+ xii SM
Page 17
When reinstalling the right tandem tray ............................................ 4-167
4.11.2 UNIVERSAL TRAY (TRAY 2) ................................................... 4-167
4.11.3 PAPER FEED UNIT 1 AND 2 ................................................... 4-168
4.11.4 PICK-UP, FEED AND SEPARATION ROLLERS ..................... 4-169
4.11.5 PAPER FEED, PAPER END, TRAY LIFT SENSOR ................ 4-170
4.11.6 REAR FENCE RETURN SENSOR ........................................... 4-170
4.11.7 REAR FENCE HP SENSOR ..................................................... 4-171
4.11.8 RIGHT TRAY PAPER SENSOR ............................................... 4-171
4.11.9 BOTTOM PLATE LIFT WIRE ................................................... 4-172
Re-installation .................................................................................. 4-173
4.11.10 2ND TRAY PAPER SIZE SWITCH ......................................... 4-174
4.11.11 PAPER FEED AND GRIP MOTORS ...................................... 4-174
1st Paper Feed and Grip Motor ........................................................ 4-174
2nd Paper Feed and Grip Motor ....................................................... 4-176
4.11.12 VERTICAL RELAY MOTOR ................................................... 4-177
4.11.13 TRAY LIFT MOTORS ............................................................. 4-178
1st tray Lift Motor ............................................................................. 4-178
2nd tray Lift Motor ............................................................................ 4-179
4.12 FUSING ............................................................................................ 4-180
4.12.1 FUSING UNIT ........................................................................... 4-180
When reinstalling the fusing unit ...................................................... 4-182
After installing a new fusing unit ....................................................... 4-182
4.12.2 FUSING UNIT DRAWER .......................................................... 4-183
Pulling out the fusing unit drawer ..................................................... 4-183
Removing the fusing unit drawer ...................................................... 4-183
4.12.3 FUSING FRONT COVER ......................................................... 4-184
4.12.4 FUSING REAR COVER ........................................................... 4-185
4.12.5 FUSING UPPER FRAME ......................................................... 4-185
4.12.6 FUSING CLEANING UNIT........................................................ 4-186
After installing a new fusing cleaning unit ......................................... 4-187
4.12.7 CLEANING WEB ...................................................................... 4-187
When reinstalling the cleaning web .................................................. 4-189
4.12.8 FUSING LAMPS ....................................................................... 4-191
Heating Roller Fusing Lamps ........................................................... 4-191
Pressure Roller Fusing Lamp ........................................................... 4-193
When reinstalling the fusing lamps ................................................... 4-195
4.12.9 FUSING BELT STRIPPER PLATE ........................................... 4-196
4.12.10 PARTS IN THE FUSING BELT ASSEMBLY .......................... 4-197
Fusing Belt Assembly ....................................................................... 4-197
SM xiii D095+/M077+
Page 18
Fusing Belt Tension Roller ............................................................... 4-199
Hot Roller Gear ................................................................................ 4-200
Fusing Belt ....................................................................................... 4-200
Hot Roller and Heating Roller ........................................................... 4-201
Fusing Belt Tension Roller Bushing ................................................. 4-202
4.12.11 HEATING ROLLER THERMISTOR ........................................ 4-203
After installing a new heating roller thermistor .................................. 4-203
4.12.12 HEATING ROLLER THERMOSTAT ....................................... 4-204
4.12.13 PRESSURE ROLLER STRIPPER PAWL UNIT ..................... 4-205
After installing a new pressure roller stripper pawl unit .................... 4-206
4.12.14 ACCORDION JAM SENSOR .................................................. 4-206
4.12.15 FUSING EXIT FRONT, CENTER AND REAR SENSOR ........ 4-207
Fusing Exit Front Sensor .................................................................. 4-207
Fusing Exit Center Sensor ............................................................... 4-207
Fusing Exit Rear Sensor .................................................................. 4-208
4.12.16 FRONT AND REAR PRESSURE ROLLER HP SENSORS.... 4-209
4.12.17 PRESSURE ROLLER ............................................................. 4-210
After installing a new pressure roller ................................................ 4-211
4.12.18 PRESSURE ROLLER THERMOSTAT ................................... 4-211
4.12.19 HOT ROLLER THERMISTOR ................................................ 4-212
4.12.20 FUSING BELT THERMISTOR ................................................ 4-213
4.12.21 CLEANING WEB MOTOR AND CLEANING WEB END SENSOR
4-214
4.12.22 FUSING MOTOR .................................................................... 4-216
4.12.23 PRESSURE ROLLER LIFT MOTOR ...................................... 4-217
4.13 PAPER TRANSPORT AND EXIT .................................................... 4-218
4.13.1 PTB (PAPER TRANSPORT BELT) UNIT ................................. 4-218
4.13.2 PAPER TRANSPORT BELT ..................................................... 4-219
4.13.3 PTB MOTOR ............................................................................ 4-220
4.13.4 PTB JAM SENSOR .................................................................. 4-220
4.13.5 PTB FAN 1 AND 2 .................................................................... 4-221
4.13.6 PAPER EXIT MOTOR .............................................................. 4-222
4.13.7 PAPER EXIT SENSOR ............................................................ 4-224
4.13.8 EXIT JUNCTION TIMING SENSOR ......................................... 4-225
4.13.9 INVERTER MOTOR ................................................................. 4-226
4.13.10 INVERTER MOTOR FAN ....................................................... 4-226
4.13.11 DUPLEX TRANSPORT MOTOR 1 ......................................... 4-227
4.13.12 SWITCHBACK MOTOR ......................................................... 4-228
4.13.13 DUPLEX TRANSPORT SENSOR 1 AND 2 ............................ 4-229
D095+/M077+ xiv SM
Page 19
Duplex transport sensor 1 ................................................................ 4-229
Duplex transport sensor 2 ................................................................ 4-230
4.13.14 SWITCHBACK SENSOR ........................................................ 4-231
4.13.15 SWITCHBACK LO WER SENSOR .......................................... 4-232
4.13.16 PTR UNIT COOLING FAN...................................................... 4-233
4.13.17 PDB (PAPER EXIT DRIVE BOARD) ...................................... 4-234
4.13.18 PAPER EXIT TRANSPORT MOTOR ..................................... 4-235
4.13.19 DE-CURLER UNIT ................................................................. 4-236
After installing a new de-curler unit .................................................. 4-237
4.13.20 DE-CURLER UNIT MOTOR ................................................... 4-238
4.13.21 DE-CURLER FEED MOTOR .................................................. 4-239
4.13.22 DE-CURLER UNIT HP AND LIMIT SENSOR ......................... 4-239
4.14 ELECTRICAL COMPONENTS ........................................................ 4-240
4.14.1 BOARD LOCATION .................................................................. 4-240
4.14.2 IOB 1 AND 2 ............................................................................. 4-240
IOB 1 ................................................................................................ 4-241
IOB 2 ................................................................................................ 4-241
4.14.3 IOB BRACKETS ....................................................................... 4-242
Opening out the IOB 1 Bracket ........................................................ 4-242
Opening out the IOB 2 Bracket ........................................................ 4-243
4.14.4 BCU .......................................................................................... 4-244
When reinstalling the BCU ............................................................... 4-244
When installing a new BCU .............................................................. 4-244
4.14.5 AC DRIVE BOARD ................................................................... 4-245
4.14.6 FIB (FINISHER INTERFACE BOARD) AND RB (RELAY BOARD)
4-246
4.14.7 PSU-G ...................................................................................... 4-247
4.14.8 CGB HVPS ............................................................................... 4-248
4.14.9 CONTROLLER NVRAM AND DIMM ........................................ 4-249
Before Controller NVRAM Removal ................................................. 4-249
Removal Procedure for Controller NVRAM ...................................... 4-250
After New NVRAM Installation ......................................................... 4-251
4.14.10 CONTROLLER BOARD ......................................................... 4-252
4.14.11 HDD ........................................................................................ 4-254
When installing new HDDs ............................................................... 4-255
Disposal of HDDs ............................................................................. 4-255
4.14.12 IPU .......................................................................................... 4-256
4.14.13 PSU-C .................................................................................... 4-257
4.14.14 CONTROLLER FANS ............................................................. 4-257
SM xv D095+/M077+
Page 20
Controller Fans 1 and 2 .................................................................... 4-257
Controller Fans 3 and 4 .................................................................... 4-258
4.14.15 PSU-EA1, EA2 AND -EB ........................................................ 4-258
4.15 FIERY CONTROLLER ..................................................................... 4-260
4.15.1 FIERY CONTROLLER LEFT AND RIGHT COVER .................. 4-260
4.15.2 FIERY CONTROLLER FRONT COVER ................................... 4-261
4.15.3 FIERY CONTROLLER TOP COVER AND OPERATION PANEL
BOARD 4-262
4.15.4 VIDEO BOARD ......................................................................... 4-263
4.15.5 FIERY CONTROLLER MOTHER BOARD, DIMM AND CPU ... 4-264
When reassembling ......................................................................... 4-265
4.15.6 FIERY CONTROLLER PSU ..................................................... 4-266
4.15.7 HDD UNIT................................................................................. 4-267
4.15.8 DVD DRIVE .............................................................................. 4-268
4.15.9 FIERY CONTROLLER FRONT FAN ........................................ 4-269
4.16 OTHERS .......................................................................................... 4-270
4.16.1 DUST FILTERS ........................................................................ 4-270
After installing a new dust filter ......................................................... 4-270
4.16.2 DEVELOPMENT FILTER ......................................................... 4-271
Cleaning Requirement...................................................................... 4-271
4.16.3 PSU FILTER ............................................................................. 4-271
Cleaning Requirement...................................................................... 4-271
4.16.4 CONTROLLER FILTER ............................................................ 4-272
Cleaning Requirement...................................................................... 4-272
4.16.5 OZONE FILTERS ..................................................................... 4-273
After installing new ozone filters ....................................................... 4-273
4.17 DOCUMENT FEEDER (D095+ ONLY) ............................................ 4-274
4.17.1 ADF UNIT ................................................................................. 4-274
4.17.2 ADF COVERS .......................................................................... 4-275
4.17.3 ADF ORIGINAL TRAY .............................................................. 4-276
Original Tray ..................................................................................... 4-276
Original Table Cover ........................................................................ 4-276
Bottom Plate ..................................................................................... 4-276
4.17.4 FEED UNIT AND SEPARATION ROLLE R ............................... 4-277
4.17.5 FEED BELT .............................................................................. 4-278
4.17.6 PICK-UP ROLLER .................................................................... 4-279
4.17.7 ADF SENSORS ........................................................................ 4-280
Entrance Sensor and Length Sensor ............................................... 4-280
Registration Sensor .......................................................................... 4-280
D095+/M077+ xvi SM
Page 21
Width Sensors .................................................................................. 4-281
Exit Sensor, Inverter Sensor ............................................................ 4-282
4.17.8 TRANSPORT BELT .................................................................. 4-283
4.17.9 ADF MOTORS .......................................................................... 4-284
Bottom Plate Motor, Pick-up Motor .................................................. 4-284
Feed-in, Transport, Fe ed-out Motors ............................................... 4-285
4.17.10 FEED-IN CLUTCH .................................................................. 4-286
4.18 SCANNER UNIT (D095+ ONLY) ...................................................... 4-288
4.18.1 EXPOSURE GLASS ................................................................. 4-288
4.18.2 OPTICS DUST FILTER ............................................................ 4-288
4.18.3 TOP FRONT COVER ............................................................... 4-289
4.18.4 TOP LEFT COVER ................................................................... 4-290
4.18.5 TOP RIGHT COVER ................................................................ 4-290
4.18.6 TOP REAR COVER .................................................................. 4-291
4.18.7 LENS BLOCK ........................................................................... 4-291
4.18.8 ORIGINAL SIZE SENSORS ..................................................... 4-292
4.18.9 EXPOSURE LAMPS ................................................................. 4-293
4.18.10 LAMP REGULATORS ............................................................ 4-294
4.18.11 SCANNER HP SENSOR ........................................................ 4-294
4.18.12 SCANNER MOTOR ................................................................ 4-295
4.18.13 SCANNER DRIVE WIRES...................................................... 4-295
Preparation ....................................................................................... 4-295
Front, Rear Scanner Drive Wires ..................................................... 4-296
Reinstallation .................................................................................... 4-297
4.18.14 MCU (MOTOR CONTROL UNIT) ........................................... 4-298
4.18.15 SIB (SCANNER INTERFACE BOARD) .................................. 4-299
4.19 LCT-MF (D095+ ONLY) ................................................................... 4-300
4.19.1 COVERS................................................................................... 4-300
4.19.2 INNER COVERS ...................................................................... 4-301
4.19.3 SIDE REGISTRATION ADJUSTMENT .................................... 4-302
4.19.4 TRAYS ...................................................................................... 4-303
4.19.5 SIDE FENCE ............................................................................ 4-304
Front Side Fence .............................................................................. 4-304
Rear Side Fence .............................................................................. 4-305
4.19.6 SIDE FENCE BLOWER ............................................................ 4-306
Front Side Fence Blower .................................................................. 4-306
Rear Side Fence Blower .................................................................. 4-306
4.19.7 LCT PAPER LENGTH SENSOR .............................................. 4-307
4.19.8 PAPER FEED UNIT .................................................................. 4-309
SM xvii D095+/M077+
Page 22
4.19.9 PAPER FEED, PICK-UP AND SEPARATION ROLLERS ........ 4-310
4.19.10 PAPER FEED, PAPER END AND PAPER LIFT SENSORS .. 4-312
Paper Lift Sensor ............................................................................. 4-312
Paper Feed and Paper End Sensors ............................................... 4-312
4.19.11 LCT EXI T MOTOR .................................................................. 4-313
4.19.12 LCT EXIT ROLLER CONTACT MOTOR ................................ 4-313
4.19.13 LCT VERTICAL TRANSPORT MOTOR ................................. 4-314
4.19.14 LCT HORIZONTAL RELAY MOTOR ...................................... 4-315
4.19.15 LCT PAPER FEED MOTOR, LCT GRIP MOTOR .................. 4-316
Reinstallation .................................................................................... 4-316
4.19.16 LCT LIFT MOTOR .................................................................. 4-317
4.19.17 LCT EXIT SENSOR ................................................................ 4-318
4.19.18 LCT PAPER EXIT ROLLER CONTACT SENSOR ................. 4-318
4.19.19 LCT VERTICAL TRANSPORT AND GRIP SENSORS ........... 4-319
4.19.20 PAPER HEIGHT, PAPER WIDTH SENSORS ........................ 4-321
Paper Height Sensors ...................................................................... 4-321
Paper Width Sensors ....................................................................... 4-321
4.19.21 MAIN BOARD ......................................................................... 4-322
5. SYSTEM MAINTENANCE ........................................................... 5-1
5.1 SERVICE PROGRAM MODE OPERATION .............................................. 5-1
5.1.1 SERVICE MODE LOCK/UNLOCK .................................................... 5-2
5.1.2 TO SWITCH TO THE APL (APPLICATION) WINDOW FOR TEST
PRINTING .................................................................................................. 5-2
5.1.3 USING THE SP MODE ..................................................................... 5-2
Direct Entry .......................................................................................... 5-2
Button Selection Entry .......................................................................... 5-3
5.1.4 SP MODE BUTTON SUMMARY ...................................................... 5-3
5.2 SERVICE PROGRAM TABLES ................................................................. 5-5
5.2.1 SP TABLES ...................................................................................... 5-5
5.2.2 SERVICE TABLE KEY ...................................................................... 5-5
5.2.3 ABBREVIATIONS FOR SP SERVICE TABLES ............................... 5-6
5.3 USING SP MODE .................................................................................... 5-12
5.3.1 CPM DOWN (SP1201) ................................................................... 5-12
SP1107-018: Low Temp On/Off ......................................................... 5-12
SP1201-001 and -002: Threshold Temperature for CPM Down ......... 5-12
SP1201-003 to -005: Low Temp.: CPM Down Rate ........................... 5-12
SP1201-006 to -011: CPM Down Rate and Mode Threshold Temp ... 5-13
SP1201-012 to -023: CPM Down Rate for Each Mode ...................... 5-13
5.3.2 USING THE DEBUG LOG .............................................................. 5-14
D095+/M077+ xviii SM
Page 23
Overview ............................................................................................ 5-14
Switching On and Setting Up Save Debug Log .................................. 5-15
Retrieving the Debug Log from the HDD ............................................ 5-19
Recording Errors Manually ................................................................. 5-19
Debug Log Codes .............................................................................. 5-20
5.3.3 PAPER LIBRARY ........................................................................... 5-20
5.4 TEST PATTERN PRINTING .................................................................... 5-21
5.4.1 PRINTING TEST PATTERN: SP2109 002 ..................................... 5-21
Test Pattern Table .............................................................................. 5-21
5.5 S MC LISTS .............................................................................................. 5-23
5.6 MEMORY ALL CLEAR: SP5801 .............................................................. 5-24
5.7 SOFTWARE AND SYSTEM SETTING RESET ....................................... 5-26
5.7.1 SO FTWARE RESET ....................................................................... 5-26
5.7.2 RESETTING THE SYSTEM ........................................................... 5-26
5.8 PM COUNTER ......................................................................................... 5-27
5.8.1 ACCESSING THE PM COUNTERS ............................................... 5-27
All PM Parts List ................................................................................. 5-28
Parts List for PM Yield Indicator ......................................................... 5-29
Parts Exceeding Target Yield ............................................................. 5-30
Counter Clear for Parts Exceeding Target Yield ................................ 5-30
Clear All PM Settings ......................................................................... 5-30
Counter List Print Out ......................................................................... 5-31
5.9 FIRMWARE UPDATE .............................................................................. 5-32
5.9.1 BEFORE YOU BEGIN... ................................................................. 5-32
5.9.2 FIRMWARE UPDATE PROCEDURE ............................................. 5-32
Operation Panel Update ..................................................................... 5-33
Engine Update ................................................................................... 5-34
5.9.3 VERIFYING THE FIRMWARE UPDATE ........................................ 5-34
Errors during Firmware Update .......................................................... 5-35
5.9.4 FIERY CONTROLLER SYSTEM UPDATE ..................................... 5-36
Fiery System Installation .................................................................... 5-36
Updating the Fiery Controller ............................................................. 5-40
6. TROUBLESHOOTING ................................................................ 6-1
6.1 PROGRAM DOWNLOAD .......................................................................... 6-1
6.1.1 OVERVIEW ...................................................................................... 6-1
6.1.2 RECOVE RY METHODS ................................................................... 6-1
6.1.3 DOWNLOAD ERROR CODES ......................................................... 6-2
6.2 SP ECIAL PROCEDURES.......................................................................... 6-8
6.2.1 SP3812 001 (DEVSETUP EXECUTE) ERRORS ............................. 6-8
SM xix D095+/M077+
Page 24
6.2.2 PROCES S CONTROL TROUBLESHOOTING ................................. 6-9
Summary of Process Control SC Codes .............................................. 6-9
Process Control Self-Check: SP3821 ................................................ 6-10
6.2.3 MUSIC ADJUSTMENT RESULT .................................................... 6-20
6.3 FIE RY CONTROLLER TROUBLESHOOTING ........................................ 6-20
6.4 SERVICE CALL CONDITI ONS ................................................................ 6-21
6.5 IMAGE PROBLEMS ................................................................................ 6-22
6.5.1 WHITE SPOT S ............................................................................... 6-22
Mylar at the PTR Timing Roller .......................................................... 6-22
Vertical Transport Path from Trays 1 and 2 ........................................ 6-23
Paper Path from the LCT-MF or Optional LCT ................................... 6-23
6.5.2 COLOR S POTS .............................................................................. 6-24
For Printer M077+ .............................................................................. 6-24
For Copier D095+ ............................................................................... 6-24
6.5.3 BLURRED IMAGE .......................................................................... 6-25
Blurred Image due to Ozone .............................................................. 6-25
6.5.4 BLURRED TEXT............................................................................. 6-25
How to Enable Toner Reductio n ........................................................ 6-26
Side Effect .......................................................................................... 6-26
6.5.5 WHITE LINES IN B/W MODE ......................................................... 6-26
6.5.6 VERTICAL WHITE LINE ................................................................. 6-26
Decision Flow ..................................................................................... 6-27
1. Countermeasure for Drum Problem ............................................... 6-27
2. Countermeasure for Fusing Belt Error............................................ 6-27
6.5.7 WHITE SCATTERED DOTS ........................................................... 6-28
Before doing countermeasures .......................................................... 6-28
Countermeasures ............................................................................... 6-29
6.5.8 BLACK SPOTS AT 125 MM INTERVAL ......................................... 6-29
6.5.9 FUSING PROBLEM ........................................................................ 6-30
Paper Wrinkles/ Worm Tracks ............................................................ 6-30
6.6 PAPER PROBLEMS ................................................................................ 6-31
6.6.1 CONSECUTIVE JAM 38 (C JAM) ................................................... 6-31
6.6.2 COLOR P APER AND PREPRINTED PAPER ................................ 6-32
6.6.3 SMALL SIZE PAPER ...................................................................... 6-32
6.6.4 DOUBLE FEED PROBLEM FROM LCT (MAIN AND OPTION) ..... 6-32
Changing the "Wide LCT Fan Duty Adjustment" (SP1920-xxx) ......... 6-33
Turning on the LCT Heater ................................................................. 6-33
Changing the upper limit of the paper stack in the LCT tray............... 6-34
6.6.5 NO PAPER FEED FROM LCT (MAIN AND OPTION) .................... 6-35
D095+/M077+ xx SM
Page 25
6.7 OPERATION PROBLEMS ....................................................................... 6-36
6.7.1 CLEARING SC 471, 475 OR 476 ................................................... 6-36
6.7.2 ITB CONDI TION CHECK ................................................................ 6-37
6.7.3 STAPLING ERROR FOR FINISHER SR5000 (B830) .................... 6-37
6.7.4 REAR CONTROLLER BOX CONNECTION ERROR ..................... 6-40
Problem Cause .................................................................................. 6-40
Possible Cause List ............................................................................ 6-41
Abnormal Image when CN412 or CN415 is Disconnected ................. 6-42
6.7.5 REMAINING TONER DETECTION ERROR .................................. 6-43
Cleaning Procedure fo r the Toner Supply Tube ................................. 6-43
6.7.6 OPERATION ERROR AFTER CONTRO LL ER SELECTION ......... 6-44
Recovery of "Please wait" for Printer Model ....................................... 6-44
Recovery of No Communication with Controller for Copier Model ..... 6-44
6.8 EL ECTRICAL COMPONENT DEFECTS ................................................. 6-45
6.8.1 BROWN FUSE CONDITIONS ........................................................ 6-45
PSU Type-EA1 ................................................................................... 6-45
PSU Type-EA2 ................................................................................... 6-45
PSU Type-EB ..................................................................................... 6-46
PSU Type-G ....................................................................................... 6-46
PSU Type-Controller .......................................................................... 6-46
6.9 JAM DETECTION .................................................................................... 6-47
6.9.1 PAPER JAM DISPLAY ................................................................... 6-47
Paper Size Code ................................................................................ 6-47
6.9.2 JAM CODES AND DISPLAY CODES ............................................. 6-48
Mainframe .......................................................................................... 6-48
Finisher SR5000 (B830) ..................................................................... 6-55
Cover Interposer Tray C I5010 (B835) ................................................ 6-57
Booklet Finisher SR5020 (D434) ........................................................ 6-59
Z-folding Unit ZF4000 (B660) ............................................................. 6-62
Trimmer Unit TR5020 (D455) ............................................................. 6-63
High Capacity Stacker SK5000 (D447) .............................................. 6-64
Perfect Binder (D391) ......................................................................... 6-68
Ring Binder RB5000 (D392) ............................................................... 6-71
Buffer Pass Unit (M379) ..................................................................... 6-73
LCT-MF or LCIT RT5020 (D532) ....................................................... 6-75
SM xxi D095+/M077+
Page 26
Page 27
READ THIS FIRST
Safety, Conventions, Trademarks
Conventions
Symbol What it means
Core Tech Manual
Screw
Connector
E-ring
C-ring
Harness clamp
The notations "SEF" a nd "LEF" describe the direction of paper feed. The arrows indicate the
direction of paper feed.
Warnings, Cautions, Notes
In this manual, the following i mp ortant symbols and notations are used.
§ A Warning indicates a potentially hazardou s sit uation. Failure to obey a Warning could
result in death or serious injury.
§ A Caut ion indicates a potentially hazardous situation. Failure t o obey a Caution could
result in minor or moderat e injur y or damage to the machine or ot her property.
§ Obey these guidelines to avoid problems such as m isfeeds, damage to originals, lo s s of
valuable data and to prev ent damage to the machine
Page 28
§ This information provides tips and advice about how to best service the machine.
Commonly Used Terms
In the SP tables, the finish ers are referred t o by number (1, 2, 3), and some dev ices that appear i n
the SP tables ar e not s upported overseas:
Z-Fold This refers to the Z-Folding unit.
ITB Image Transfer Belt
PTR Paper Trans fer Roller
PTB Paper Transport Belt
General Safety Instructions
For your safety, please read this manual carefully before you use this product. Keep this manu al
handy for future reference.
Safety Information
Always obey the following s afety precautions when usin g t his product.
Safety During Operation
In this manual, the following i mp or tant symbols and notations are used.
Switches and Symbols
Where symbols are used on or near sw it ches on machines for Europe a nd other areas, the
meaning of each symbol conf orms with IEC60417.
Page 29
Responsibilitie s of the Cust om er E ngine er
Customer Engineer
Maintenance shall be done only by trained custome r engineers who have complete d s ervice
training for the machine a nd al l opt i onal devices designed for use w ith t he machine.
Reference Material for Maintenance
§ Maintenance shal l be do ne using the special tools and procedures prescribe d for
maintenance of the machine described in the reference materials (service ma nuals, technical
bulletins, operating instructions, and safety guidelines for customer engineers) .
§ Use only consumable s upplies and replacement parts designed for us e of the machine.
Before Installation, Maintenance
Shipping and Moving the Machine
§ Work carefully w hen l if ting or moving the machine. I f the machine is heavy, two or more
customer engineers may be required to prevent inju ries (muscle strains, sp inal injuri e s ,
etc.) or damage to the machin e i f it is dropped or tipped over.
§ Personnel moving or wor king around the machine should always wear proper clothing
and footwear. Never wear loose f it t ing clothing or accessories (neckties, loose sweaters,
bracelets, etc.) or casual footwear (slippers, sandals, etc.) when lifting or moving the
machine.
§ Always unplug the power cor d from the power source befor e you move the product.
Before you move the product, arrange the power cord so it w il l not fall under the product.
Power
§ Always disconnect the power plug before doing any ma int enance procedure. After
switching off the mac hi ne, power is still supplied to t he m ai n m achine and other devices.
To prevent electrical shock, switch the mach ine o ff, wait for a few seconds, t hen unplug
the machine from the power sour c e.
§ Before you do any checks or adjustments after t ur ni ng t he machine off, work c arefully to
avoid injury. After re mov in g c overs or opening the machine to do checks or adjustments,
never touch electrical components or moving parts (gears, timing belts, etc.).
§ After turning the mach ine on with any cover removed, ke ep your hands away from
electrical components and moving parts. Never touch the cov er of the f using unit, gears,
timing belts, etc.
Page 30
Installation, Disassembly, and Adjustments
§ After installatio n, mainte nance, or adj ustment, alway s check the operati on of the mach ine
to make sure that it is operating normally. This ensures that all shipping mater ials,
protective materials, wires and tags, met al brackets, etc., r emov ed f or installation, have
been removed and that no tools r emain inside the machine. This also ensures that all
release interlock switch es have been restored to nor ma l operation.
§ Never use your fingers to chec k m oving parts causing spurious noise. Nev er 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 ventilate d and spacious. Good vent ilati on i s
especially important w hen the machine is used heavily.
§ To avoid possible build-up of ozone, locate this ma chine in a large well ventila t ed r oom
that has an air turnover of more than 30m3/hr/person.
Special Tools
§ Use only standard too ls approv ed for machine ma intenanc e.
§ For special adjustment s, u se only the specia l tools and l ubricant s des cribed in the serv ice
manual. Using tools incorr ectly, or using tools that could damage p art s, cou ld damage t he
machine or cause injuries.
During Maintenance
General
§ Before you begin a maintenance procedure:
§ 1. Switch the machine off.
§ 2. Disconnect the all power plugs from the power sour ce.
§ 3. All ow t he m achine to cool for at least 10 minute s.
§ Avoid touching the components inside the machine that are labeled as hot surfaces.
Page 31
Safety Devices
§ Never remove any safety device unless it requires repl acement. Always replace safety
devices immediately.
§ Never do any procedure t hat def eats the function of any safety device. Modification or
removal of a safety device ( fuse, switch, etc.) could lead to a fire an d per s onal injury.
Always test the operation of the mach ine to ensure t hat it is operating nor mally 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 replace ment dev ices not des ign ed f or use w it h the mach ine c oul d lead t o
a fire and personal injuries.
Organic Cleaners
§ During preventive maint en ance, nev er us e any orga nic clea ners ( alco hol, 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 breathi ng t he f umes 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.
§ Wash your ha nds t horoughly after clean ing parts with an or ganic cleaner to
contamination of food, drinks, etc. which could cause illness.
§ Clean the floor completely af t er ac cidental spillage of silicone oil or other mate r ials to
prevent slippery surfaces that could cause accidents leading to hand or leg inj ur ies. Use
dry rags to soak up spills.
Batteries
1. Always replace a bat t er y with the same type of battery pr es cr ibe d for use. Replacing a
battery with any type other t han the one prescribed for use could lea d to an explosion.
2. Never discard used bat t eries by mixing them with other trash. Remove them from the
work site and dispose of them in accordance with local laws and r egulations regarding
the disposal of such items.
Page 32
Ozone Filters
1. Always replace ozone filters as soon as their serv ice life expires (as describe d in the
service manual).
2. An excessive amount of ozone can build up around machines that use ozone filters if
they are not replaced at the prescr i bed t ime. Excessive oz one c ould c ause personnel
working around the machi ne t o feel unwell.
Power Plug and Power Cord
1. Always disconnect t he all power plugs for the mainfr am e and other peripherals befor e
doing any maintenance pr ocedure. After switching off the machine, power is still supplied
to the main machine and other devices. To prevent electrical shoc k, swit ch t he machine
off, wait for a few secon ds, then unplug the machine from the power source.
2. Always check the pow er plug and make sure that it is free o f dust and lint. Clean it if
necessary. A dirty plug can generate heat which could cause a fire.
3. Inspect the length of the power cord for cuts or ot her damage. Replace the po w er cor d if
necessary. A fray ed or ot herwise damaged power c ord can cause a short circuit which
could lead to a fire or personal in jury from electrical shock.
4. Check the length o f the power cord between the machin e and power supply. Make sure
the power cord is not coiled or w rapped around any object such as a t able l eg. Coiling t he
power cord can cause excessiv e heat to build up and could cau se a f ire.
5. Make sure that t he ar ea around the power source is free of obstacles so the pow er c ord
can be removed quickly in case of an emergency.
6. Make sure that the power cord is gro unded (eart hed) at t he power source w ith the ground
wire on the plug.
7. Connect the power cor d directly into the power so ur ce. Never use an extension cor d.
8. When you disconnect the power plug from the power source, alway s pull on the plug, not
the cable.
Page 33
After Insta lla tion, Servicing
Disposal of Used Items
1. Never incinerate used toner or toner cartridg es.
2. Toner or toner cartridges thrown into a fire can ignite or explode and cau se ser ious in jury.
At the work site, always car ef ul ly wrap used toner and toner cartr idges with plastic bags
to avoid spillage before di spos al or removal.
§ Always dispose of used items ( developer, toner, toner cartridges, OPC drums, etc.) in
accordance with the local laws and regulations regar ding the disposal of such items.
§ To protect the environment, never dispose of this pr oduc t 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 authorize d collection site.
§ Return used selenium drums to the service center for hand li ng i n accordance with
company policy regar di ng the recycling or disposal of such items.
Points to Confirm with Operators
At the end of installat ion o r a s er vice call, instruct the user about use of the machine. Emphasize
the following points.
§ Show operators how to remove jammed pap er and troubleshoot other minor problems by
following the procedures d escr ibed in the operating instruc t io ns .
§ Point out the parts inside the machine that should never be touched or att empted to remove.
§ Confirm that operators know how to store and dispose of consumables.
§ Make sure that all operat ors have access to an operat ing ins t r uct i on manual for the machine.
§ Confirm that operators have read and understood all the safety instructio ns described in the
operating instructions.
§ Demonstrate how to tur n of f the power a nd disconne ct the power plug (by pulling t he plug, not
the cord) if any of the following ev ents occur:
1) Something has spilled i nt o t he pr oduct.
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 clip s, staples, or any other smal l metallic objects t o fa ll int o t he machine.
Page 34
Special Safety Instruct ions for Toner
Accidental Physical Expo su re
§ Work carefully w hen remov ing paper jams or replac ing toner bot tles or car tridges to av oid
spilling toner on clothing or the hands.
§ If toner is inhaled, immedi at ely gargle with large amounts of cold water and mov e t o a
well ventilated location. If there are signs of irritat i on or other problems, seek medical
attention.
§ If toner gets on the skin, w ash immediately with soap and co ld running water.
§ If toner gets into the eyes, flush t h e eyes with cold running w ater or eye w ash. If there are
signs of irritation or other problems, seek medica l attention.
§ If toner is swallowed, drink a large amount of cold wat er t o dilute t he ingested toner. If
there are signs of any pro blem, seek medical attention.
§ If toner spills on clothing, w ash t he affected area im me di ately with soap and cold water.
Never use hot water! Hot water can cause toner to set and perm anently stain fabric.
Handling and Storing Toner
§ Toner, used toner, and developer are extremely flammable.
§ Never store toner, developer, toner cartridges, or toner bottles (including empty toner
bottles or cartridges) in a locat io n where they will be exposed to high temperature or an
open flame.
§ Do not use the cleaner to suc k spil le d toner (including used toner). Sucked toner may
cause firing or explosion due to electrical contact f lic ker ing inside the cleaner.However, it
is possible to use the cleaner designed for dust explosion-proof purpose. If toner is
spilled over the floor, sweep up spilled toner slowly and clean remainder wit h wet cloth.
§ Always store toner and developer supplies such as toner and developer packa ges,
cartridges, and bottles (in cluding used toner and empty bottles and cartridges) out of the
reach of children.
§ Always store fresh toner supp lies or empt y bottles or c artridges in a coo l, dry location t hat
is not exposed to direct sunlight .
Page 35
Toner Disposal
§ Never attempt to incinerat e t oner, used toner, or em pt y toner containers (bott l es or
cartridges). Burning toner can explo de and scatter, causing serious burns.
§ Always wrap used toner and empty toner bottles and car t r idges in plastic bags to av oid
spillage. Follow the loca l laws and regulations regarding the disposal of such items.
§ Dispose of used toner and toner car t r idge s at one of our dealers or at an aut horized
collection site. Always dispose of used toner cartridges and toner bottles in accordance
with the local laws and regulat ion s r egar ding the disposal of such items.
Safety Instructions for this Machine
Prevention of Physical Injury
§ Before disassembl ing or asse mbling p art s of the machine and p eripher als, ma ke sure that t he
machine and peripheral power cords are unplugged.
§ The plug should be near the machine and easily accessible.
§ Note that some components of the machine a nd t he paper tray unit are supplied with
electrical voltage even if the main power switch is t ur ned off.
§ If any adjustment or opera tion chec k has to be made with exterior cov ers of f or open while the
main switch is turned on, keep hands away from elect r if ied or mechanically driven
components.
§ If the [S tart] key is pressed bef or e t he machine completes the war m-up period (the [Start] key
starts blinking red and green), keep hands away from the mechanical a nd t he electrical
components as the machine starts making copies as soon as the warm-up period is
completed.
§ The inside and the met al parts of the fusing unit become extre m ely hot while the machine is
operating. Be careful to avoid touching those components with your bare hand s .
§ Keep the machine away from flammable liquids, gases, and aerosols. A fire or an explosion
might occur.
Health Safety Conditions
1. Never operate t he machine without the ozone f ilters installed.
2. Always rep lace the ozone filters with the sp ec i f ied t ypes at the proper intervals.
3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it
may cause temporary eye disc o mfort. Try to remove w ith ey e dro p s or flush wit h w ater as fir st
aid. If unsuccessful, get medical attention.
Page 36
Observance of Electrical Safety Standards
§ The machine and its peripherals must be installed and maintained by a customer service
representative who has completed the training course on those models.
§ The NVRAM on the system control board has a lithi um b at t er y which can explode if replac ed
incorrectly. Replace the NVRAM only with an identical on e. The manufacturer r ecommends
replacing the entire NVRA M . Do not rec harge or burn this battery. Used NVRAM must be
handled in accordance wit h local regulations.
Safety and Ecological Notes for Disposal
§ Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed
to an open flame.
§ Dispose of used toner, developer, and org anic photoconductors in acc ordance with local
regulations. (These are n on-toxic supplies.)
§ Dispose of replaced parts in accorda nce with local regulations.
§ When keeping used lithium batteries in order to dispose of them later, do not put more than
100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to
chemical reactions and he at buil d-up.
§ The danger of explosion exists if a battery of this type is incorrectly replaced.
§ Replace only with the sa m e or an equivalent type recommended by the manufacturer.
Discard used batteries in ac cor dance with the manufacturer 's inst ructio ns.
Laser Safety
The Center for Devices and Rad iological Health (CD RH) prohibit s the r epa ir of laser-base d optica l
units in the field. The optical hous ing unit can only be r epaire d in a factory or at a location with the
requisite equipment. The laser subsystem is r eplaceable in the field by a qualif ied Customer
Engineer. The laser cha ssis is not repairable in t he f ield. Customer engineers ar e t her ef or e
directed to return all chassis an d laser subsystems to the factor y or service depot when
replacement of the optica l subs ystem is required.
§ Use of controls, or adjustme nt , or performance of procedur es ot her t han those specified
in this manual may result in haz ar dous r adiation exposure.
§ Turn of f the ma in switch b efore att empting any of the proce dures in the Laser Un it section .
Laser beams can seriousl y damage your eyes.
Page 37
Trademarks
§ Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in
the United States and /or other countries.
®
§ PostScript
§ PCL
®
§ Ethernet
§ PowerPC
is a registered trademark of Ado be Systems, Incorporated.
is a registered trademark of Hewlett-Packard Com pany.
®
is a registered trademark of Xerox Corporation.
®
is a registered trademark of International Business Machines Corpor at ion.
§ Other product names used herein are for ident ificat ion pur poses on ly and may be trademar ks
of their respective companies. We disc laim any and all rights inv olved with those marks.
Safety Instructions for Fi ery Controller
Fuse Caution
This controller uses a dou ble p ole fuse. Be careful when y ou do maintenance on the Fiery
Controller after the fus e c i r cuit has been opened.
§ Double Pole/ Neutral Fusing
Batteries
IWARNING:
§ Always replace a battery with the same t ype of battery prescribed for use. Replac ing a battery
with any type other than the one pr escr ibed for use could lead to an expl osion.
§ Never discard used batteries by mixing them with other trash. Remove them from the work
site and dispose of them in accord anc e wit h local la w s and regu lations r egar ding t he disposal
of such items.
Page 38
Page 39
PRODUCT INFORM ATION
REVISION HISTORY
Page Date Added/Updated/New
None
Page 40
Page 41
Product
1. PRODUCT INFORM ATI ON
1.1 SPECIFICATIONS
See "Appendices" for the f oll ow ing information:
§ Specifications
Specifications
Information
SM 1-1 D095+/M077+
Page 42
Machine Configuration
1.2 MACHINE CONFIGURATION
1.2.1 PRINTER M077+
No. Item
Machine
Code
1 Mainframe M077+ 90 ppm
Common with G178
2 Multi-Bypass Tray BY5000 B833
Alternate paper feed source
Unique
LCIT RT5050 D532
B832 or D532
3
Common with G178
LCIT RT5000 B832
B832 or D532
Child option for use when installing
4 - Bridge Unit BU50 00 D379
two LCTs (D532)
Unique
5 LCIT RT5050 D532
2nd LCT
Comments
6 Buffer Pass Unit Type 5000 M379 Common with G178
Cover Interposer Tray CI5010
7
(Transport Un it )
8 Cover Interposer Tray (Tray Unit) B835
9 Z-Folding Un it B660
D095+/M077+ 1-2 SM
B835
Common with G178
Inserts cover sheet s ( 2 t r ays).
Common with G178
Z-Folds large sheets
Page 43
Machine Configuration
Product
No. Item
Comments
Code
10 Transit Pass Unit Type GB5000 D391 Common with D059/D060/D061
Common with D059/D060/D061
D391 is required.
11 Perfect Binder G B5000*1 D391
Only one of these (D391, D39 2 or
D447) can be installed.
Common with D059/D060/D061
Machine
12 Ring Binder RB5000*1 D392
Only one of these (D391, D39 2 or
D447) can be installed.
Two stackers can be installed.
13 High Capacity Stacker SK5000 D447
Only one of these (D391, D39 2 or
D447) can be installed.
Common with G178
14 Finisher SR5000 B830
Corner stapling, edge stapling
Information
15 - Punch Unit PU5000 B831
Common with G178
Child option for Finisher B830
Common with D059/D060/D061
16 Finisher SR5020 D434
Booklet stapling, corn er stapling, edge
stapling
Common with D059/D060/D061
17 - Punch Unit PU 5020 B449
Child option for Finisher D434
18 Trimmer Unit TR5020 D455 Common with D059/D060/D061
19 - Tab Sheet Holder Ty pe3260 B499 Common with G178
20 - A3/1 1"x 17" T ray Unit TK5000 B331 Common with G178
Fuser Unit Air Separator Type
21
M390 Unique
C901
1
: Neither Perfect Binder ( D39 1) nor R ing Binder (D392) can be installed in the M078 or D097
*
model.
SM 1-3 D095+/M077+
Page 44
Machine Configuration
1.2.2 COPIER D095+
No. Item
1 Mainframe D095+ 90 cpm/ ppm
2 LCT-MF D095+
3 - Bridge Unit BU50 00 D379
4 Multi-Bypass Tray BY5000 B833
5 LCIT RT5050 D532 Unique
6 Buffer Pass Unit Type 5000 M379 Common with AG-C1
Cover Interposer Tray CI5010
7
(Transport Un it )
8 Cover Interposer Tray ( Tray Unit) B835
Machine
Code
B835
Comments
The A D F and Scanner are built into
this LCT.
Child option for use when installing
optional LCT (D532)
Common with AG-C1
Alternate paper feed source
Common with AG-C1
Inserts cover sheet s ( 2 t r ays).
9 Z-Folding Un it B660
10 Transit Pass Unit Type GB5000 D391 Common with D059/D060/D061
11 Perfect Binder G B5000*1 D391
D095+/M077+ 1-4 SM
Common with AG-C1
Z-Folds large sheets
Common with D059/D060/D061
D391 is required.
Only one of these (D391, D39 2 or
D447) can be installed.
Page 45
Machine Configuration
Product
Booklet stapling, corn er stapling, edge
No. Item
Machine
Code
12 Ring Binder RB5000*1 D392
13 High Capacity Stacker SK5000 D447
14 Finisher SR5000 B830
15 - Punch Unit PU5000 B831
16 Finisher SR5020 D434
Comments
Common with D059/D060/D061
Only one of these (D391, D39 2 or
D447) can be installed.
Two stackers can be installed.
Only one of these (D391, D39 2 or
D447) can be installed.
Common with G178
Corner stapling, edge stapling
Common with G178
Child option for Finisher B830
Common with D059/D060/D061
Information
stapling
Common with D059/D060/D061
17 - Punch Unit PU 5020 B449
Child option for Finisher D434
18 Trimmer Unit TR5020 D455 Common with D059/D060/D061
19 - Tab Sheet Holder Ty pe3260 B499 Common with AG-C1
20 - A3/1 1"x 17" T ray Unit TK5000 B331 Common with AG-C1
Fuser Unit Air Separator Type
21
M390 Unique
C901
1
: Neither Perfect Binder ( D39 1) nor R ing Binder (D392) can be installed in the M078 or D097
*
model.
SM 1-5 D095+/M077+
Page 46
Overview
1.3 OVERVIEW
1.3.1 MACHINE LAYOUT
1. Toner Hopper Unit
2. Operation Panel
3. Laser Unit
4. PCDU (Photoconductor and
Development Unit)
5. ITB (Image Transfer Belt) Unit
6. Registration Unit
7. Paper Feed Unit
8. Duplex Feed Path
9. Fusing Unit
10. Paper Exit Unit
D095+/M077+ 1-6 SM
Page 47
Product
1.3.2 PAPER PATH
Printer (M077+) model
Overview
Information
1. Paper Exit Path (for next per iph er al)
2. Paper T r ansport Path
3. Paper Entrance Path (from o pt ional LCT)
4. Bypass Tray Path
5. Paper Entrance Path (from o ptional 2nd
LCT)
6. Paper Feed Path (from optio nal t r ay 3
and 4)
7. Paper Feed Path (from tr ay 1 and 2)
8. Duplex Path
9. Switchback Path
10. Inverter Path
SM 1-7 D095+/M077+
Page 48
Overview
Copier (D095+) model
1. Paper Exit Path (for next per iph er al)
2. Paper Tr ansport Path
3. Paper Entrance Path (from L C T-MF)
4. DF Scanning Path
5. DF Scanning Path: Duplex S canning
6. Paper Tr ansport Path (from optio nal LCT)
7. Paper Feed Path (from tr ay 3 and 4)
8. Paper Feed Path (from tr ay 1 and 2)
9. Duplex Path
10. Switchback Path
11. Inverter Path
D095+/M077+ 1-8 SM
Page 49
Product
1.3.3 FAN LOCATION
Overview
Information
No. Description Air In / Out
1 Laser Unit MY In
2 Laser Unit KC In
3 Development CK Fan Out
4 Registration Fan Out
5 PTB Fan 2 Out
6 PTB Fan 1 Out
7 PTR Unit Cooling Fan Out
8 PTB Cooling Fan In
9 Paper Cooling Fan 3 In
10 ITB Fan In
SM 1-9 D095+/M077+
Page 50
Overview
No. Description Air In / Out
10 Development Fan In
11 Fusing Fan 4 Out
12 Fusing Fan 1 Out
13 Fusing Fan 2 Out
14 Fusing Fan 3 Out
15 Paper Cooling Fan 1 Out
16 Paper Cooling Fan 2 In
17 Exit Fan Out
18 Fusing Exhaust Fan 3 Out
19 Fusing Exhaust Fan 2 Out
20 Fusing Exhaust Fan 1 Out
21 PSU Fan5 In
D095+/M077+ 1-10 SM
Page 51
Product
No. Description Air In / Out
22 PSU Fan 4 In
23 Fusing Fan 6 Out
PSU Fan 3 Out
Overview
Information
24
PSU Fan 2 Out
PSU Fan 1 Out
25 Controller Fan4 In
26 Controller Fan3 In
Plotter Cooling Fan 1 Out
27
Plotter Cooling Fan 2 Out
Plotter Cooling Fan 3 Out
28 Controller Fan2 Out
29 Fusing Fan 5 In
30 Controller Fan1 Out
31 Ozone Fan Out
SM 1-11 D095+/M077+
Page 52
Guidance for Those Who are Familiar with Prede cessor Products
1.4 GUIDANCE FOR THOSE WHO ARE FAMILIAR WITH
PREDECESSOR PRODUCTS
The D095+ and M077+ are successor mo dels t o the D016 and G178. If y ou have experience w ith
the predecessor products, the following infor mati on will be of help when you read this m anual.
Different Points from Predecessor Products
D095+/M077+ D016/G178
Controller Standard external Fiery Stan dard em bedded Fiery
Toner Chemical toner/ Oil less Pulverized Toner
Max. Paper Thickness Simplex: 350 g/m2
Duplex: 350 g/m
2
Simplex: 350 g/m
Duplex: 220 g/m
2
2
Operation Panel New Operation Panel Com m on Panel with Katana
series
New TCRU Unit s Feed Rollers and Fusing Unit -
Energy Star Yes No
Longer Durability Max. Monthly: 350K
Life: 21,000K
Max. Monthly:240K
Life: 14,400K
Fusing Unit No Oil Cleaning System Oil Cleaning System
Fusing Unit Air
Optional Not available
Separation
Attention Light Yes No
New Peripherals 1. Booklet Finisher SR5020
-
2. Trimmer Unit TR5020
3. High Capacity St acker
SK5010
4. Fuser Unit Air Separator
Ty pe C901
Data Overwrite
Standard (Installed in SD slot 1) Optional
Security Unit
D095+/M077+ 1-12 SM
Page 53
INSTALLATION
REVISION HISTORY
Page Date Added/Updated/New
238 08/19/2014 Added DOSS (Data Overwrite Security System)
Page 54
Page 55
Installation Requirements
Installation
2. INSTALLATION
2.1 INSTALLATION REQUIRE MENTS
2.1.1 OPERATING ENVIRONMENT
1. Temperature Range
1. Recommended Temp.: 23°C (73.4°F)
2. Allowed Temp.: 10°C to 32°C (50°F to 90°F) – See the Note below
2. Humidity Range: 15% to 80% Rh
3. Ambient Illumination: Less than 1,500 l ux ( do not expose to direct sunlight or strong light.)
4. Ventilation: Air must be replaced a minimum of 3 times per hour
3
5. Ambient Dust: Less than 0.10 mg/m
§ If the machine is installed in a location where the ambient temperature is mor e than
30°C (86°F): (1) Do not run fu ll co lor printing longer than 2 hours, and (2) never turn
the main power switch off immediately after a long print job.
§ Leave the machine on so that the fans can expel the hot air fro m the machine and
cool the electronic components.
§ If this machine is to be used in a high temperature and hi gh humidity condition, t he
tray heater is required to g et t he proper pr int qual ity. Connect the tray heater harnes s
during the mainframe installation (
page 2-13 "Mainframe").
6. If the installation area has air-conditioners or heaters, put t he machine in a location that
SM 2-1 D095+/M077+
Page 56
Installation Requirements
agrees with these conditio ns :
1. Where there are no sudden temperature changes from low to high, or high to low.
2. Where it will not be dir ec t l y exposed to cool air from an air con ditioner in the summer.
3. Where it will not be dir ec t l y exposed to reflected heat from a heater in the winter
7. Do not put the machine where it will be exposed t o gases that can cause corrosion.
8. Do not install the machine at any location over 2,000 m (6,500 feet) abov e s ea level.
9. Put the mainframe on a strong and level surfa ce. The front and rear of the machine must be
less than 2.5 mm (0.1") away from level.
10. Do not put the machine where there co uld be strong vibrations.
11. Do not connect the machine to the same power source as other electr ical devices.
12. The machine can make an electro magnetic fie ld, and this can ca use inter ference w ith radio or
television reception.
2.1.2 MACHINE LEVEL
§ Front to rear: Less than 2. 5 m m (0. 1" ) aw ay from level
§ Right to left: Less than 5.0 mm (0.2") away from level
The machine feet can b e t ur ned to ad just th e m up or dow n, to ma ke th e machine l ev el. For det ai ls,
see the "Leveling the Main Machine" in the "page 2-13 "Mainframe"".
2.1.3 MINIMUM SPACE REQUIREMENTS
Put the mainframe near the pow er s our ce. Minimum clearance mu st be as s hown below. The
same amount of clearance is necessary when optional per ipheral devices are inst alled.
D095+/M077+ 2-2 SM
Page 57
Installation
2.1.4 DIMENSIONS
Installation Requirements
Side View with Finisher SR5000 (B830) or SR5020 (D434)
Mainframe: Printer M077+
*1: Including the top right cover
Mainframe: Copier D095+
1
: Including the top right cover
*
SM 2-3 D095+/M077+
Page 58
Installation Requirements
Side View with Ring Binder RB5000 (D392)
Mainframe: Printer M077+
1
*
: Including the top right cover
Mainframe: Copier D095+
1
: Including the top right cover
*
D095+/M077+ 2-4 SM
Page 59
Installation
Side View with Perfect Binder GB5000 (D391)
Mainframe: Printer M077+
1
*
: Including the top right cover
Mainframe: Copier D095+
Installation Requirements
1
: Including the top right cover
*
SM 2-5 D095+/M077+
Page 60
Installation Requirements
Side View with High Capacity Stacker SK5000 (D364)
Mainframe: Printer M077+
1
: Including the top right cover
*
Mainframe: Copier D095+
1
: Including the top right cover
*
D095+/M077+ 2-6 SM
Page 61
Installation Requirements
Installation
2.1.5 PO WE R RE Q UIREMENTS
§ Make sure that the wall ou t let is near t he mainframe and that you can get access to it
easily. Make sure the plug is tightly connected to the out let.
§ Do not connect more than one electrical device to the same power outlet.
§ Be sure to ground the machine.
§ Do not put objects on the pow er cor d.
Input voltage level
§ North America 208 to 240 V, 50/60 Hz: More than 24 A
§ Europe/Asia 220/230/240V, 50/60 Hz: More than 25 A
Permissible voltag e fl uct uation: ±10%
Required Breaker
The operating area where the machine is to be insta lle d must have a required breaker for t he
power line.
§ North America: Listed circ uit br eaker , r at ing:240V30A, double pole
§ Europe: Circuit breaker, r ating:240V30A, double po le
§ Do not turn off the main p ower switch when the power LED is lit or flashing. To prevent
damage to the hard dis k or memory, push the operation switch to turn the power off, then
do nothing until the power LED g oes off, and then tu r n t he ma in power switch off.
There are two power switc hes on t he machine:
Main Power Switch
This is located inside the front left cover of the machine. This switch must alw ays be on unless a
technician does work on t he m achine.
Operation Switch
This is located on the top-right si de of the operation panel. This is the switch th at t he customer
uses to turn the machine on and off.
SM 2-7 D095+/M077+
Page 62
Installation Requirements
2.1.6 CORRE CT P RO CE DURE TO TURN OFF THE POWER
Shut the Fiery Controller Down First
The Fiery controller must be s hut dow n before turning of f the power supply to the Fiery controller.
Therefore, turn off the Fier y contr oller first at the oper ation pa nel before tur ning of f the main pow er
switch of the machine.
Use the "Shut Down" butt on on t he operation panel to t ur n off the Fiery controller.
Do not turn off the main p ower switch of the mainfra me b ef or e shutting down the Fiery cont r oll er.
The shut down procedure for the Fiery controller is described below.
§ Press the "Fiery" tab on the operation panel.
§ Press the "Restar t Fiery" button on the operation p anel.
§ Press the "Shut Down" button on the operation panel.
The shutdown can be also done with the Service Me nu of the Fiery controller. If you have
mistakenly tur ned off the machine first, use the "Service Menu" of the F iery controller.
§ Press the button [A] (M enu) on the operation pan el of the Fiery controller.
§ Select "Shut Down System" with the button [B].
Then Shut Down the Machine
§ Push the operation sw it ch to turn the power off
§ When the power LED goes off, turn the main power switch off.
§ Do not turn off the ma in power switch when the power LED is lit or flashing.
D095+/M077+ 2-8 SM
Page 63
Installation
2.2 BEFORE YOU BEGIN...
2.2.1 OVERVIEW OF OPTIONAL PERIPHERALS
Optional Peripherals Configuration for Printer M077+
Before You Begin...
There are many periphera ls av ailable for this machine. Install them in this order:
§ Mainframe (M077+)
§ Multi Bypass Tray BY5000 (B833)
§ This unit must be installed on the LCIT RT5050 (D532) before the LCT is docked to
the mainframe.
§ LCIT R T5050 (D532) or LCIT RT5030 (D452)
§ Bridge Unit BU5000 ( D3 79)
§ This unit is required o nly when two LCITs RT5050 are installed at t he same time.
Otherwise, it is not required.
§ LCIT R T5050 (D532)
§ Buffer Pass Unit Type 5000 (M379)
§ Cover Interposer Tray CI5010 ( B835: T ransport Unit)
§ Cover Interposer Tray ( B835: Tray Unit)
§ The Transport Unit (base) of the Cover Interposer Tray is narrow and ca nnot f ully
support its tray unit . Part of the tray unit must rest on top of the Z-folding unit (or the
next peripheral device installed to the left o f t he cover interposer).
§ To prevent the Cover Interposer Tray from falling, always install the next peripheral
device in line before inst alling the tray unit "8" of the Cov er I nt er poser Tr ay.
§ Z-Folding Unit ZF400 0 ( B660)
1. This unit cannot be installed in the same line as the High Capacit y Stacker SK5010
SM 2-9 D095+/M077+
Page 64
Before You Begin...
(D447) if two stacker units are to be insta lled in the mainframe.
§ Transit Pass Unit Type GB5000 (D391)
§ This unit is a child option f or t he Perfect Binder GB5000. This is required when t he
Perfect Binder GB5000 is installed in the mainframe.
One of the following u nits can be installed in the same line.
§ 1 1: Perfect Binder GB500 0 ( D39 1)
§ 12: Ring Binder RB5000 ( D39 2)
§ 13: High Capacity Stacker SK5010 (D447),
§ Perfect Binder GB50 00 ( D 391)
§ Ring Binder RB5000 (D392)
§ High Capacity St acker SK5010 (D447)
§ Two "High Capacity Stacker SK5 010 (D447)" units can be installed with the
mainframe at the same time.
§ If two stacker units are to be installed in t he mainframe, Z-Folding Unit ZF4000
(B660) cannot be installed in the same line as the tw o stacker units.
§ Finisher SR5000 (B830)
§ Punch Unit PU 5000 (B831)
§ For Finisher SR5000 (B8 30) only
§ Finisher SR5020 ( D43 4)
§ Punch Unit PU 5020 (B449)
§ For Finisher SR5020 (D434) only
§ Trimm er Un it TR5020 (D455)
§ This unit requires the Fini s her S R5020 (D434).
Other Options
These remaining options can be installed at any time and in any order.
§ Tab Sheet Holder Type3260 (B499)
§ Option for tandem tr ay
§ A3/11"x17" T ray Unit TK5000 (B331)
§ Option for tandem tr ay
§ Fuser Unit Air Separat or Type C901 (M390)
§ Cooling Fan Unit T ype 5000 (not shown)
§ Option for Finisher SR500 0 ( B830) only
§ Optional Counter I nt er fac e Unit Type A ( not shown)
§ VM Card Type F (not shown)
D095+/M077+ 2-10 SM
Page 65
Before You Begin...
Installation
Optional Peripherals Configuration for Copier D095+
There are many periphera ls av ailable for this machine. Install them in this order:
§ Mainframe (D095+)
§ LCT-MF (D095+)
§ V er t ical and Horizontal Bri dge U nit BU5000 (D379)
§ This unit is required only when the optional LCIT RT5050 is installed. Otherwise, it is
not required.
§ Multi Bypass Tray BY5000 (B833)
§ This unit must be installed on the LCIT RT5050 (D532) before the LCT is docked to
the LCT-MF.
§ LCIT R T5050 (D532)
§ Buffer Pass Unit Type 5000 (M379)
§ Cover Interposer Tray CI5010 ( B835: T ransport Unit and Tray)
§ Cover Interposer Tray ( B835: Tray Unit)
§ The "Transport Unit (base)" of the "Cov er I nterposer Tray" is narrow and cann ot ful ly
support its tray unit . Part of the tray unit must rest on top of the Z-folding unit (or the
next peripheral device installed to the left o f t he cover interposer).
§ To prevent the "Cover Interposer Tray" from falling, always install the n ext per i pheral
device in line before inst alling the tray unit "8" of the "Cover Interposer Tray".
§ Z-Folding Unit ZF400 0 ( B660)
§ This unit cannot be installed in the same line as t he High Capacity Stacker SK 5010
(D447) if two stacker units are to be insta ll ed i n t he ma inframe.
§ Transit Pass Unit Type GB5000 (D391)
SM 2-11 D095+/M077+
Page 66
Before You Begin...
§ This unit is a child option f or t he Perfect Binder GB5000. This is required when t he
Perfect Binder GB5000 is installed in the mainframe.
One of the following units can be installed in the same line.
1. 11: Perfect Binder G B5000 (D391)
2. 12: Ring Binder RB5000 (D392)
3. 13: High Capacity Stacker SK5010 (D447) ,
§ Perfect Binder GB50 00 ( D 391)
§ Ring Binder RB5000 (D392)
§ High Capacity St acker SK5010 (D447)
§ T wo "High Capacity Stacker SK5010 (D447)" units can be i nstalled with the
mainframe at the same time.
§ I If two stacker units are to be installed i n t he mainframe, Z-Folding Unit ZF4000
(B660) cannot be installed in the same line as the tw o stacker units.
§ Finisher SR5000 (B830)
§ Punch Unit PU 5000 (B831)
1. For Finisher SR5000 (B830) only
§ Finisher SR5020 ( D43 4)
§ Punch Unit PU 5020 (B449)
§ For Finisher SR5020 (D434) only
§ Trimm er Un it TR5020 (D455)
1. This unit requires the Finisher SR5020 (D43 4) .
Other Options
These remaining options can be installed at any time and in any order.
§ Tab Sheet Holder Type3260 (B499)
§ Option for tandem tr ay
§ A3/11"x17" T ray Unit TK5000 (B331)
1. Option for tandem tray
§ Fuser Unit Air Separat or Type C901 (M390)
§ Cooling Fan Unit T ype 5000 (not shown)
§ Option for Finisher SR5000 (B830) only
§ Optional Counter I nt er fac e Unit Type A ( not shown)
§ VM Card Type F (not shown)
D095+/M077+ 2-12 SM
Page 67
Installation
2.3 MAINFRAME
2.3.1 ACCESSORIES
Check the accessories an d their quantities against this l ist .
Mainframe
No. Figure-1 Description Q'ty
1 Sponge Strip 1
2 IF Connector Cover 1
3 Original Exit Tray 1
4 Leveling Shoe 4
5 Screw: M4x16 2
6 Screw: M4x8 6
7 Screw: M4x20 2
8 Washer Screw: M4x8 1
9 Stud Screw 2
10 Upper Pin 2
SM 2-13 D095+/M077+
Page 68
Mainframe
No. Figure-1 Description Q'ty
11 Lower Pin 2
12 Decal for Face-up 1
13 Washer (for Grand Cable of LCT-MF) 1
14 Decal for Paper Loading 2
15 Decal for Paper Tray 1
16 Decal for Scale 2
17 Decal for Paper Size 1
D095+/M077+ 2-14 SM
Page 69
Mainframe
Installation
No. Figure-2 Description Q'ty
1 Decal for Paper Loading 2
2 Brand Logo Plate (only for EU model) 5
3 Decal for Paper Size 1
4 Grease Dispenser 1
5 Heater Guide 1
6 Top Right Cover (LCT-MF) 1
7 Support T r ay for Finisher SR5000 (B8 30) 1
8 Shift Tr ay for Finisher SR5000 (B830) 1
9 Wrench 1
SM 2-15 D095+/M077+
Page 70
Mainframe
No. Figure-3 Description Q'ty
1 Screw: M4x8 2
2 Screw: M3x6 2
3 Bind Screw: M4x8 4
4 Ground Plate 1
5 Leveling Shoe 4
6 SD Slot Cover 1
7 Manual Pocket 1
8 Relay Guide Plate for Finisher SR5000 (B830) 1
9 Entrance Guide Plate (A) 1
10 Entrance Guide Plate (B) 1
11 Entrance Guide Plate (C) 1
12 Mylar for Finisher SR5000 (B830) 1
D095+/M077+ 2-16 SM
Page 71
Mainframe
Installation
No. Figure-4 Description Q'ty
1 Screw: M3x8 3
2 Screw: M4x6 4
3 Attention Light 1
4 Developer Bottle for Each Co lor 4
5 Function Name Plate for NA and AA only 1
6 Keytop for Controller 2
7 Operation Panel Unit 1
8 Operation Panel Rear Upper Cov er 1
9 Operation Panel Rear Lower Cover 1
- T6000 (70W) A4/LT (100 sheets) 1
SM 2-17 D095+/M077+
Page 72
Mainframe
2.3.2 INSTALLATION
Rating Voltage for Peripherals
1. Make sure to plug the cables into the correct soc kets.
Right Side
[A]: LCT "Rating Voltage of Output Connector for Accessory : M ax. DC 24 V"
[B]: LCT Tray Heaters "Rating Voltage of Output Connector for Acce ssory : Max. AC 240 V ±10%"
Left Side
[C]: Finishers "Rating Voltage of Output Connector for Accessory: Max. DC 24 V"
D095+/M077+ 2-18 SM
Page 73
Installation
External Tape and Packing Material
Mainframe
§ Always turn the machine of f and d isc onnect the mac hin e power cord be fore y ou do t hese
procedures. (
§ Remove all tapes and packing mater ia l from the mainframe.
§ To set the leveling shoes at the rear side, open the r ear c ont r ol ler box (
§ Set the leveling shoes [ 1] under t he feet [2], then level the machi ne.
page 2-8 "Correct Procedure to Turn Off the Power ")
page 4-28)
SM 2-19 D095+/M077+
Page 74
Mainframe
§ Maximum lift height bet ween a floor and one of caster s is 5 mm. Do not lift the machi ne
over the maximum lift height (5 mm).
Leveling the Mainframe
The level between front side and r ear side of the mainframe mu st be within ± 2.5 mm/1,000 mm.
Adjust the machine's lev el by adjusting the four feet under the ma c hi ne.
1. Open the front doors.
2. Open the waste toner bottle door [1].
3. Take out the waste toner bot t le [ 2] .
4. Place the leveling device [3] in 20 mm [4] from the bottom edge of the waste toner bott le
housing as shown above.
5. Check the level and adjust the four feet to keep t he machine level.
§ Front to rear: Less than 2.5 mm (0. 1") / 1,000 mm away from level
If the front side is lower t han the rear side:
Lift the front side of the m ac hi ne by adjusting both feet at the front side only. Do not adjust
both sides' feet (front and r ear ) at t he sam e time.
If the front side is hi gher than the rea r side:
D095+/M077+ 2-20 SM
Page 75
Mainframe
Installation
Lift the rear side of the machine by adjustin g both feet at the rear side only. Do not adjust both
sides' feet (front and rear) at the same time.
6. Install the waste toner bottle [5] in it s housing.
7. Close the waste toner bottle door.
8. Close the left and right front doors.
9. Close the rear controller box (
10. Reattach the rear top cover (
x 4: upper x 2, lower x 2).
x 3).
Internal Tape and Packing Material
1. Open the front left and right doors.
2. Open tray 1.
3. Remove the bracket [1] with the red tag (
4. Remove all strips of tape and retainers.
5. Close tray 1.
SM 2-21 D095+/M077+
x 1).
Page 76
Mainframe
6. Open tray 2.
7. Remove all strips of tape.
8. Remove the bracket [2] with the red tag (
x 1).
9. Close tray 2.
10. Press down the lock lever of the fusing drawer unit, and then pull out the fusing unit.
11. Remove all tape and retai ner s from the fusing drawer unit.
12. Push in the fusing drawer unit.
13. Press down the lock lever of the registr at ion drawer unit, and then pu ll out t he registration
drawer unit.
D095+/M077+ 2-22 SM
Page 77
Installation
14. Remove all strips of tape, tags, and retainers from the registration unit.
Install the Toner Bottles
§ The toner bottles contain pre-mixed developer.
Mainframe
§ Open the toner hopper door .
§ Install the toner bottles in the toner bottle tank.
1. Shake each toner bottle several times bef or e installing in the toner bot tle tank.
§ Close the toner hopper door .
SM 2-23 D095+/M077+
Page 78
Mainframe
Installing the Operation Panel Unit
§ Take the operation panel unit [1] from the accessory box.
§ Set the operation p anel unit on the operation panel bracket [2].
§ Attach the operat i on panel lower cover [ 3] to the operation panel bracket (
§ Hang the operation panel [4] on the operation p anel bracket [5].
§ Secure the operation panel and connect two connectors to the relay conne ct or s from the
mainframe (
1. The three-pin harness in these harnesses of the operation panel is not used.
x 4, x 1, x 2)
x 2).
D095+/M077+ 2-24 SM
Page 79
Mainframe
Installation
§ Attach the operat i on panel upper cover [5] (
x 2 each: M4x6).
Keytop Adjustment
Only for Pro C901, the keytop adjustment is required depending on the model's destination. See
the keytpo configuration f or each model below.
For NA and AA models:
Fiery Controller
Other
1. Remove the blank keys, and then install the function name plate [1] and c ont r oller function
key top [2].
For EU models:
Fiery Controller
SM 2-25 D095+/M077+
Page 80
Mainframe
Other
1. Remove the blank key, and then install the controller funct ion key top [1].
Attaching the Ground Plate
§ Attach the ground plate [1] to the left bottom of the mainframe (
§ If the Perfect Binder RB5000 ( D391) is to be attached t o t he ma in frame directly, do not
attach the ground plate [1].
x 2).
Installing the Attention Light
§ Connect the cable [1] from the controller box of the ma in frame to the connector [2] of the
attention light.
D095+/M077+ 2-26 SM
Page 81
Mainframe
Installation
§ Stand the attention light [ 3] on the top of the controller box, and t hen fasten the attention lig ht
x 3; M3x8).
(
Connecting the Upper and Lower Tray Heaters
The machine comes fro m the fa ctory w ith the tray heaters alr eady inst alled but disconn ected. T ray
heater connection is optional. The heaters sh ould be connected if the locat ion has high
temperature and high humidity.
Consult with the customer before connecting the tray heaters.
Doing this procedure conn ects the following tray heaters inside the mainframe at t he fol lowing
locations:
§ One unit below the tandem tray
§ One unit below tray 2
§ One unit below the lower t r ay of the optional LCT
There are two ways to connect t he t r ay heaters. If coated paper i s m ai nly used, connect the tray
heaters connector to "CN606" .
Engine ON Engine OFF
Connecting to CN602 Tray heaters: O FF Tray heaters: O N
Connecting to CN606 Tray heaters: O N Tray heaters: ON
§ "Engine ON" is "Low Pow er M ode" , " Stand-by Mode" and "Engine Operating".
§ "Engine OFF" is "Main Pow er O FF", "Operation Switch OFF" an d " Sl eep Mode".
§ Switch off the ma in power switch and disconnect the power cord from the po w er sour ce.
(Refer to page 2-8 "Correct Procedure to Turn Of f the Pow er " in "Installation Req uirements"
for how to turn off the machine without causing damage to the component s. )
§ Open the rear controller box (
SM 2-27 D095+/M077+
page 4-28).
Page 82
Mainframe
To set the connector
§ Release the heater harness [1] ( x 1)
§ Connect the white conn ector [1] to CN602 [2].
To connect the tray heater s connector to CN606
§ First, connect the tray heaters connector to CN602 ( see t he pr ocedure above).
§ Disconnect the 7-pin c onnector [1] from the relay connector (9 pins) [2].
§ Connect the 7-pin connector [1] to CN606 [3].
D095+/M077+ 2-28 SM
Page 83
Mainframe
Installation
Connecting the LCT-MF (D095+ only)
1. Turn off the machine and unplug it from the power source before you start t he installation
procedure. (
2. When removing the LCT-MF from the mainframe, ma ke sur e t hat all cables and
harnesses of the LCT-MF to the mainframe are disconnected.
Preparing for LCT-MF Installation
Outside of the ADF
page 2-8 "Correct Procedure to Turn Off the Power ")
§ Remove all tapes on the ADF.
SM 2-29 D095+/M077+
Page 84
Mainframe
IF Cable and Feed Unit
§ Remove the ret ainer in the ADF and the tape on t he I/F cable.
Under the ADF
§ Open the ADF, and then remove all tapes and retainers under the ADF and the tapes on the
exposure glass.
D095+/M077+ 2-30 SM
Page 85
Installation
LCT-MF
Mainframe
1. Remove all tapes and retainers on the LCT-MF.
In the Tray of the LCT-MF
2. Remove all tapes in the upper and lower t r ays of the LCT-MF.
SM 2-31 D095+/M077+
Page 86
Mainframe
Inside the Front Left Cov er of the LCT-MF
3. Remove all tapes inside the front left cover of the LCT-MF.
Connecting LCT-MF
4. Remove the covers from the right side of the ma inframe.
§ Cover [A]: (
D095+/M077+ 2-32 SM
x 1), others: (hooks)
Page 87
Installation
5. Install the upper pins [1] with the grooved rings on the right upper cov er.
6. Install the lower pins [2] on the right low er cover .
Mainframe
7. Remove the lower rear left cover [3] of the LCT-MF (
x 5)
8. Open the front door of the LCT-MF and remove scr ew [4].
SM 2-33 D095+/M077+
Page 88
Mainframe
9. Remove the ground plate [5] (
x 2).
10. Turn over the ground plate and use the screws to fasten it to the same holes (
x 2).
11. Release the ground cable [6] (tape x 1,
x 2).
12. If the tray heater will not be used, keep the LCT-MF tray heat er r elay harness [7] clamped.
13. Move the LCT-MF to the right side of the main frame.
14. Fasten the ground cable [8] with t he washer [9] to the mainframe (
x 1).
15. If the tray heater of the LCT-MF will be used, attach the LCT-MF heater relay harness [10] to
the mainframe.
§ If the customer will use co ated paper in high temperature and high humidity
conditions, the tray heat er of the LCT-M F is greatly needed. Conn ect the LCT-MF
relay harness at this moment .
D095+/M077+ 2-34 SM
Page 89
Mainframe
Installation
16. Attach the cushion [11] to the top right side of the mainframe.
17. Align the LCT-MF on the joint pins and then mov e the LCT -MF much closer .
18. Dock the LCT-M F w ith the right side of the main frame, after confirming t hat the ground cable
and LCT-MF tray heater relay har ness are not pinched between t he LCT-MF and the
mainframe.
19. Fasten screw [12] to lock the LCT-MF to the side of the mainframe.
20. Close the front door of the LCT-MF.
21. Reattach the lower rear left cover to the LCT-MF (
x 5).
SM 2-35 D095+/M077+
Page 90
Mainframe
22. Attach I/F connectors [13] of the LCT-MF to the mainframe.
1. When removing the LCT -MF from the mainframe, ma k e sur e t hat all cables and
harnesses of the LCT-MF to the mainframe are disconnected.
23. Attach the IF connector cover [14] (
x 2: M4x16).
24. Insert the leveling shoes [15] (x 4) under the leveling feet and lev el t he LCT-MF.
25. Adjust the LCT-MF level within ±5 mm by rotating each nut on the lev eli ng shoes.
26. Attach the stud screws [16] t o t he r ight side o f t he LCT-MF.
27. Attach the top right cover [17] (
x 2: M4x20).
§ Do not install the stud screws [16] and top right cover [17] if the optional LCT (D532)
is to be installed in add ition to the LCT -MF.
D095+/M077+ 2-36 SM
Page 91
Mainframe
Installation
28. Attach the original output t r ay [18] (
x 2: M4x8)
29. Connect the I/F cable [19] of the ADF to the LCT-MF.
30. Attach the "Tray 3" decal above the line [20] on the LCT -MF and the "Tray 4" decal above the
line [21].
§ When attach ing these decals, align the botto m ed ge of each decal with the line on
the each tray cover.
31. Change the tray size with User Tools (T r ay Paper Settings).
SM 2-37 D095+/M077+
Page 92
Mainframe
Testing the Breaker Switch and Attaching the Caution Decal
This machine has two breaker switches at the left si de of the controller box. Two switches are
used as follows:
§ For Main: This int err upts the DC power to the mainframe.
§ For Heater: This interrupts the pow er t o the fusing unit. (SC547)
1. Plug the power cord into its power source.
§ Do not turn on the copier. The copier should be off.
2. Use the tip of a small screwdriver to push the brea k er test button.
The breaker switch shoul d flip to the "O" position. This indicates that the breaker switch is
operating normally.
If the breaker switch does not fl ip to t he " O " position, the switch must be rep laced.
3. Raise the switch to the "|" position for normal operation.
§ The copier will not turn on if the br eaker switch is not retur ned t o t he " |" posit i on.
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Installation
Connecting to the Controller
1. Place the controller on a flat floor.
§ For details about t he installation requir ements for the control ler, refer to the service
manual for each controller.
Mainframe
2. Connect the power cable [1] to the power cord socket on the rear side of the control ler.
§ Only use the power cord t hat is provided with the controll er or an appropriate
replacement power cord a vailable from an authorize d provider.
3. Connect the LAN cable [2] to the Gigabit Ethernet slot [3] at the right-rear.
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Mainframe
4. Connect the LAN cable [4] from the mainframe to the lower network cable slot [ 5] of t he
controller.
5. Connect the cable from the client networ k to t he upper network cable slot [6] of t he controller.
Turn on the Machine Power
§ Turn on t he main power switch of the machine.
§ To access this switch, you must open the front left door .
§ Enter SP2253-006 wit h t he front left door open.
§ Press "Execute" to t r ansport toner to each sub-hopper.
§ It may take several minut es (approximately 5 to 10 m in.) t o fill the sub-hoppers.
§ Exit the SP mode af t er "Completed" is displayed.
§ Close the front left door . M achine warm-up starts automatically, followed by process control.
1. Do not turn off the machine dur ing t he w ar m-up. It t a kes a bout 6 min utes to c omp lete
this process.
§ "Ready" appears on t he LCD after the warm-up is complete.
Controller Selection
§ Select a controller to be used with SP5-193-001.
1. For Fiery controller, select "6" with SP5-193-001.
2. For Creo controller, select "5" with SP5-193-001
§ Never select "0" with SP5-193-001. If you do so, the machine cannot do any operations
without the special recov ery procedur e. For details about the spe cial rec ov ery procedur e,
see Operation Error after Controller Selection
Fiery Language Selection
If a customer wants to use a language other than En glish to operate the Fiery control ler, the
language selection must be done first. To select a different lang uage, the Fiery system must be
re-installed. For det ails, see "page 5-36 "Fiery Controller System Updat e"" in the section "Service
Tables" (Fiery System Installation < Firmware Update < Service Tables).
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Mainframe
Installation
Fiery Controller Settings
After turning on the power for the first time, it is required to set the settings for the "Fiery
Controller".
§ Check that t he Activity light on the LCD of the Fiery Contro ller is flashing gre en and t hen go to
the machine's operation panel.
§ "Please wait" may be shown on the operation panel.
§ Press the "Fiery" tab on the LCD after the F iery operating menu has app ear ed.
§ Press the "Setup" butt on on t he operation panel.
§ The "Login" screen app ears.
§ Press the "Password" but t on, and t he s oft key pad screen appears.
§ Input "Fiery. 1" with the soft key pad, and then pres s the "OK" button.
§ When the passw or d is input, capital letters an d small letters must be correctly input.
Use the "Shift" button to input a capital letter.
§ The setup screen appear s after you input the p assword correctly.
§ Press the "WINS" butt on.
§ Press "Use WINS" to d isa ble t hi s function, and then "Save".
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Mainframe
§ Press the "DNS" butt on.
§ Press "Get DNS address automatically" to disab le this function, and then pre ss "Save".
1. If "Get DNS address automatically" is corr ectly disabled, the button color is changed
from yellow to gray-out.
§ Press "IP Address" to enter the IP address.
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Installation
§ Press "IPv4 Address".
Mainframe
§ Press the "Manual Configuration" button.
§ Press the "IP Address" bar [A] to enter the IPv4 address, and t hen enter the IPv4 address.
§ The soft key pad scr een appears after pressing the "IP Address" button. Input the IP
address with the soft key pad, and then press t he " O K" but ton.
§ Press the "Subnet Mas k" bar [B] to ent er the subnet mask IP, and then enter the subnet mas k
IP.
1. The soft key pad screen appears af t er pr essing the "Subnet Mask" button. Input the IP
address with the soft key pad, and then press the " O K" but t on.
§ Press the "Defau lt gatew ay " bar [C] t o enter t he de fault gat eway IP, and then e nter the de fault
gateway IP.
§ The soft key pad s cr een a ppears a ft er press in g the " De fault gat eway " but ton. I nput t he IP
address with the soft key pad, and then press t he " O K" but ton.
§ Press the "Save" button after IP addr ess s et t ing has been completed.
§ Press the "Go Back" but t on, then the "Exit Setup" button.
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Mainframe
§ Press the "Reboot Now " but t on.
§ The Fiery server and cop ier system automatical ly turn off to reboot.
Paper Library Data
Install the Paper Librar y data using the follow ing procedure.
Paper Library Updating Procedure
1. Make a folder in the directory of an SD card, and then name the folder "mqp".
2. Copy the paper data base file in the " m qp" folder, and then rename the copied file
"library.mqp".
3. Make sure that the mainframe is turned off.
4. Insert the SD card which has the "library.mqp" file in the upper SD card slot on the controller.
5. Turn on the mainframe.
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 not, prepare the latest data vers ion o f the Paper Library on an SD
card.
§ The version of the data o n the SD card can be checked with S P5711-202
§ The version of the data in t he flash ROM on the controller can be checked with
SP5711-201.
7. Enter SP5-711-001, and then press "Ex ecut e" [ A] on the LCD.
8. Press "Execute" [B] again on the LCD.
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Mainframe
Installation
9. Press "OK" [A] on the LCD after the "Completed." pop-up is displayed, and then exit the SP
mode.
10. Turn off the ma in frame after updating, and t hen remove the SD card from the upper SD card
slot of the controller.
11. Turn on the mainframe, and then check the Paper L ibrar y data version with S P5-711-201
(Flash Rom).
TCRU Setting
§ If the installed ma chine is to be operated by TCRU, change the following SP settings.
1. SP5-062-001: Change the setting from "1" (Not displayed) to "0" (Displayed).
2. SP7-956-001: Change the setting from "0" (No operation) t o " 1" ( O per at ion).
§ If these settings are not correctly set, the PM par ts alarm never appears on the LCD.
§ If the fusing unit is set for the target unit of TCRU operation, chang e t he fo llowing SP setting.
§ SP7-957-001: Change the setting from "1" (Not target) t o "0" ( Target).
Load the Paper Trays
For each paper tray :
1. Move the side fence and bottom fence to the corr ect positions for the paper.
2. Add paper to the trays.
3. Attach the paper size decals to the front of the paper cassett e t r ays and the tandem tray.
§ It is not necessary to input the paper size s etting for tray 2. This is detected aut omatic ally.
Print an SMC Report
1. Go into the SP mode.
2. Do SP5990-1 to print a full SMC report. Ke ep it in a safe location, with the fact or y setting
sheet.
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Mainframe
Checking the Print Quality
It is necessary to check the print quality after inst allation, and before the customer starts to use
the machine. Check the following points and adjust the machine if there is a problem.
§ "T6000 (70W)", "mondi 9 0gsm"
recommended for chec king the output quality. If T6000 (70W), "mondi 90gsm"
"Hammermill Color COPY 105gsm" paper is not available, use an equivalent quality of
these paper.
§ Select the proper pap er t ype in t he paper type select ion when checking the print quality.
For details, see the "T6000 (70W) Paper Selection Pr ocedure" described below.
T6000 (70W) Paper Selection Procedure
1. Press the "Tray Paper Settings" button on the opera tion panel.
or "Hammermill Color COPY 105gsm" pap er is
or
2. Press "Recall Paper Library" [1] on the LCD.
3. Select "0044 TYPE6000<70W> 80 Ricoh" [2] with the "Next " [ 3] at t he bottom-right of the
LCD.
4. Press "0044 TYPE6000<70W> 80 Ricoh" [2].
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