5 Machine Code: D009/D011/D012/D013/D091/D092 Field Service Manual 10 November, 2009 Safety Notices Important Safety Notices Prevention of Physical Injury 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. The wall outlet should be near the copier and easily accessible. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main power switch is turned off.
If any adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on, keep hands away from electrified or mechanically driven components. If the Start key is pressed before the copier completes the warm-up period (the Start key starts blinking red and green alternatively), keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm-up period is completed. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.
• To prevent a fire or explosion, keep the machine away from flammable liquids, gases, and aerosols. Health Safety Conditions 1. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Immediately wash eyes with plenty of water.
If unsuccessful, get medical attention. This machine, which uses a high voltage power source, can generate ozone gas. High ozone density is harmful to human health. Therefore, the machine must be installed in a well-ventilated room.
Observance of Electrical Safety Standards 1. This machine and its peripherals must be serviced by a customer service representative who has completed the training course on those models. The NVRAM on the system control board has a lithium battery which can explode if replaced incorrectly. Replace the NVRAM only with an identical one.
The manufacturer recommends replacing the entire NVRAM. Do not recharge or burn this battery. Used NVRAM must be handled in accordance with local regulations. 1 Handling Toner • Work carefully when removing paper jams or replacing toner bottles or cartridges to avoid spilling toner on clothing or the hands.
• If toner is inhaled, immediately gargle with large amounts of cold water and move to a well ventilated location. If there are signs of irritation or other problems, seek medical attention. • If toner gets on the skin, wash immediately with soap and cold running water. • If toner gets into the eyes, flush the eyes with cold running water or eye wash.
If there are signs of irritation or other problems, seek medical attention. • If toner is swallowed, drink a large amount of cold water to dilute the ingested toner. If there are signs of any problem, seek medical attention. • If toner spills on clothing, wash the affected area immediately with soap and cold water.
Never use hot water! Hot water can cause toner to set and permanently stain fabric. • Always store toner and developer supplies such as toner and developer packages, cartridges, and bottles (including used toner and empty bottles and cartridges) out of the reach of children. • Always store fresh toner supplies or empty bottles or cartridges in a cool, dry location that is not exposed to direct sunlight. Safety and Ecological Notes for Disposal 1.
Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly when exposed to an open flame. Dispose of used toner, the maintenance unit which includes developer or the organic photoconductor in accordance with local regulations. (These are non-toxic supplies.
Dispose of replaced parts in accordance 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 heat build-up. Laser Safety The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field.
The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.
2 • Use of controls, or adjustment, or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. • Turn off the main switch before attempting any of the procedures in the Laser Optics Housing Unit section. Laser beams can seriously damage your eyes. CAUTION MARKING: 3 Symbols and Abbreviations Symbols and Abbreviations This manual uses several symbols and abbreviations.
The meaning of those symbols and abbreviations are as follows: See or Refer to Clip ring Screw Connector Clamp E-ring SEF Short Edge Feed LEF Long Edge Feed Cautions, Notes, etc. The following headings provide special information: • FAILURE TO OBEY WARNING INFORMATION COULD RESULT IN SERIOUS INJURY OR DEATH. • Obey these guidelines to ensure safe operation and prevent minor injuries. 4 • This information provides tips and advice about how to best service the machine.
5 TABLE OF CONTENTS Safety Notices.1 Important Safety Notices.1 Safety and Ecological Notes for Disposal.2 Symbols and Abbreviations.4 Symbols and Abbreviations.4 Cautions, Notes, etc. Product Information Specifications.16 Guidance for Those Who are Familiar with Predecessor Products. Installation Installation Requirements.27 Minimum Space Requirements.28 Installation Flow Chart.29 Main Machine Installation.32 Moving the Machine.42 Transporting the Machine.42 Paper Feed Unit Installation (D351).51 Auto Reverse Document Feeder (B802).54 Platen Cover Installation (G329).59 1-Bin Tray Unit (D389).81 Key Counter Bracket.85 Key Counter Interface Unit.88 Anti-Condensation Heater (Scanner).106 Copy Data Security Unit.111 Controller Board Slots.118 File Format Converter.121 HDD Encryption Unit.123 DataOverwriteSecurity Unit Type I (D362).128 Browser Unit Type D.132 VM Card Type F (D377).136 Printer and P/S Options (only for D009/D012).137 Check All Connections. Preventive maintenance PM Tables.
Replacement and Adjustment General Cautions.151 Special Tools and Lubricants.153 Front Door, Upper and Lower Inner Cover.154 Right Rear Cover.156 Paper Exit Cover.159 Original Length/Width Sensors.163 Sensor Board Unit (SBU).167 Scanner HP Sensor.168 Platen Cover Sensor.170 Front Scanner Wire.170 Rear Scanner Wire.173 Touch Panel Position Adjustment.177 Caution Decal Locations.178 Polygon Mirror Motor.179 Laser Synchronization Detector.183 Pick-off Pawls.187 Charge Roller and Cleaning Roller.187 Drum Cleaning Blade 1.198 Transfer Belt Unit.198 Toner Overflow Sensor.201 Transfer Belt Cleaning Blade .202 Paper Feed Unit.202 Pick-Up, Feed and Separation Rollers.202 Tray Lift Motor.203 Relay, Tray Lift, Paper End and Paper Feed Sensors.207 Web Roller Unit.208 Web Holder Roller and Web Rollers.209 Pressure Roller Cleaning Roller.214 Hot Roller Strippers.216 Hot Roller and Pressure Roller.220 Paper Exit Unit.220 Fusing Exit, Paper Overflow, and Paper Exit Sensors.220 Junction Jam Sensor.221 Paper Exit Motor.223 10 Right Door Cover.225 Duplex Door Sensor.226 Duplex Entrance Sensor.226 Duplex Exit Sensor.227 Duplex/By-pass Motor.229 Duplex Inverter Motor.232 By-pass Paper Size Sensor.232 By-pass Paper End Sensor.233 By-pass Pick-up, Feed and Separation Roller, Torque Limiter.234 By-pass Feed Clutch.236 Paper Feed Clutch.236 Development Paddle Motor.236 Transfer/Development Motor.239 Paper Feed Motor.240 Transfer Belt Contact Motor.241 Toner Supply Motor.249 High Voltage Power Supply Board.250 Fusing Exhaust Fan.257 ADF Image Adjustment.259 Touch Screen Calibration. Service Tables Service Program Mode.263 Service Program Mode Operation.263 Service Program Mode Tables.264 Service Program Mode Tables.265 Using SP Modes.266 Test Pattern Printing.266 SMC Print Out Lists: SP5-990.267 Nip Band Width Adjustment: SP1-109.268 Memory Clear: SP5-801.271 System Settings and Copy Setting Reset.271 Copier Setting Reset.272 Updating the Firmware.273 Before You Begin.273 Handling Firmware Update Errors.276 NVRAM Data Upload/Download.278 Uploading NVRAM Data (SP5-824).278 Downloading NVRAM Data (SP5-825).278 SD Card Appli Move.280 Self-Diagnostic Mode.281 Self-Diagnostic Mode at Power On.281 12 Self-Diagnostic Test Flow.282 Detailed Self-Diagnostic Mode.283 Executing Detailed Self-Diagnosis.283 Using the Debug Log.284 Switching On And Setting Up Save Debug Log.289 I/O Board: DIP SW101. Troubleshooting Service Call Conditions.291 Electrical Component Defects.295 Blown Fuse Conditions. Energy Saving Energy Save.299 Energy Saver Modes.299 Energy Save Effectiveness.303 Effectiveness of Duplex/Combine Function.
Product Information Specifications 1 See "Appendices" for the following information: • General Specifications • Optional Equipment 15 1. Product Information Machine Configuration 1 Copier Key: Symbol: U: Unique option, C: Option also used with other products 16 Machine Configuration Item Callout Key Machine Code D009/D011 D009/D011 D012/D013 D091/D092 [1] - D012/D013 D091/D092 1 ARDF (See Note 1) [3] C B802 Platen Cover (See Note 1) [2] C G329 Two-Tray Paper Feed Unit [6] C D351 2000-sheet LCT [5] C D352 1200-sheet LCT [4] C D353 1-Bin Tray [10] U D389 Bridge Unit [9] U D386 1000-sheet Finisher (See Note 2.) [7] C B408 2000/3000-Sheet (Booklet) Finisher (See Copier [8] C B804/B805 Note 2) B702-17 (2/3-hole) -Punch Unit (See Note 3.) - C US B702-27 (2/4-hole) -Punch Unit (See Note 3.) - C Metric B702-28 (4-hole) -Punch Unit (See Note 3.) - C Scandinavia Key Counter Bracket - C A674 HDD (for D009/D012 only) - U D362 DataOverwriteSecurity - U D362 Copy Data Security Unit - C B829 HDD Encryption Unit - C D377 Scanner Accessibility Option - C B838 17 1. Product Information Item Callout Key Machine Code Fax Option D346 1 for D009/D011/D012/D013 - U Fax Option for D091/D092 D509 Fax G3 Interface Unit - U D346 SAF Memory - C G578 Handset (USA model only) - C B433 Printer/Scanner Unit - U D381 Printer Unit - U D381 RPCS Printer Unit - U D381 Printer Upgrade Unit - U D381 Scanner Upgrade Unit - U D381 PostScript3 Unit - U D381 Printer/ IPDS Unit - U D381 Scanner Gigabit Ethernet - C G874 IEEE 1284 - C B679 IEEE 802.11a/g, g Wireless LAN - C D377 Bluetooth - C B826 Memory Unit 256 MB - U D362 File Format Converter - C D377 NOTE: 1. The ARDF and platen cover cannot be installed together.
The finisher requires the bridge unit and two-tray paper feed unit or 2000-sheet LCT. The 1000-sheet finisher and 2000/3000-sheet (Booklet) finisher cannot be installed together. The punch unit requires the 2000/3000-sheet (Booklet) finisher. 18 Guidance for Those Who are Familiar with Predecessor Products Guidance for Those Who are Familiar with Predecessor Products The D091/D092 series are successor models to the D009/D011/D012/D013 series.
If you have 1 experience with the predecessor products, the following information will be of help when you read this manual. Different Points from Predecessor Products D091/D092 D009/D011/D012/D013 Scanner Color only Color and B/W VM Card Standard Option 19 1. Product Information Overview 1 Component Layout 1 Exposure Glass 22 By-pass Feed Roller 2 2nd Mirror 23 By-pass Separation Roller 3 1st Mirror 24 Duplex/by-pass transport roller 4 Exposure Lamp 25 Upper Relay Roller 20 Overview 5 Original Width Sensors 26 Feed Roller 6 Original Length Sensors 27 Separation Roller 7 Scanner Motor 28 Pick-up Roller 1 8 Lens 29 Bottom Plate 9 SBU 30 Development Unit 10 Junction Gate 2 31 Charge Roller 11 Duplex Inverter Gate 32 Fθ Mirror 12 Duplex Entrance Sensor 33 Barrel Toroidal Lens (BTL) 13 Duplex Inverter Roller 34 Polygonal Mirror Motor 14 Hot Roller 35 Laser Unit 15 Pressure Roller 36 Toner Bottle Holder 16 Transfer Belt Cleaning Blade 37 Junction Gate 1 17 Duplex Transport Roller 38 Exit Roller 18 Transfer Belt 39 Paper Exit Sensor 19 OPC Drum 40 3rd Mirror 20 Registration Roller 41 Scanner HP Sensor 21 By-pass Pick-up Roller 21 1. Product Information Paper Path 1 1 ARDF 2 Interchange Unit 3 Duplex Unit 4 By-pass Tray 5 Large Capacity Tray (LCT: 1200-sheet) 6 Paper Tray Unit 7 Two-Tray Finisher 8 Bridge Unit 9 1-Bin Tray 22 Overview Drive Layout 1 1 Scanner Motor 10 Paper Feed Clutch 1 2 Fusing Motor 11 Feed Motor 3 Web Motor 12 By-pass Paper Feed Clutch 4 Transfer/Development Motor 13 Registration Motor 5 Drum Motor 14 Duplex/By-pass Motor 6 Development Paddle Motor 15 Transfer Belt Contact Motor 7 Tray Lift Motor 1 16 Duplex Inverter Motor 23 1.