Ricoh Academy Europe Griffin-C1 D117/D118 Aficio MP C305SP/305SPF Service master full training module 1 Created by: Group L&D Version:1.0.a Classification:

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Griffin-C1D117/D118

Aficio MP C305SP/305SPF

Service master full training module

Created by: Group L&D Version:1.0.a Classification: Internal

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Objectives

After completing this training you should be able to: Install the machine and options in the field. Do routine maintenance on the machine. Troubleshoot and repair this product in the field.

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Requirements

Griffin-C1 (Full option when available)

Windows PC

Printer drivers

Field service manual

Operation manual

This presentation

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Pre-requisites

Before starting this training you should have already passed the training for:

Printing (Basic)

Colour (Basic)

At the end of this course, you can do the exam on:

“Ricoh Knowledge and Learning system”.

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Module overview

1. Introduction

2. Specifications

3. New & improved features

4. Installation

5. Detailed section descriptions

6. Maintenance

7. Replacements & adjustments

8. Options

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Introduction

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Models

Griffin-C1, Aficio MP C305SPF(D117) ARDF is standard. Fax is standard.

Griffin-C1, Aficio MP C305SP(D118) ARDF is standard. Fax is an option.

For both models: A4, 30cpm (full colour/black&white). Duplex and by-pass is standard. Printer scanner kit is standard. HDD is an option. GW2011A controller. PS3 is standard. (embedded on the controller)

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Appearance

Up to two additional paper tray units can be installed. There are no finishers.

Optional one-bin tray

Colour LCD touch panel

One paper tray is standard

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Machine layout

ITB cleaning unit

Duplex path

Fusing unit

Laser units

Toner bottles

PCDU

Image transfer belt unit (ITB) Paper transfer roller (PTR)

10 4.3” Touch panel. To return to home screen a home button is added. 3 Function keys which can be programmed. An SD/USB slot is standard on the right side of the panel.

Operation panel (1/3)

SD/USB SlotTouch panelHome button

Function keys

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Operation panel (2/3)

Status key: The machine displays a list that shows the status of all jobs.

Energy saver key: There is no operation panel power button, only this energy saver button. Press this

once, and the machine goes to the energy saver mode. To cut the power, turn off the main switch; the machine goes into the safe shutdown process. Energy saver lamp: Blinks slowly when the machine is in energy saver mode. Stays off when

the machine is in normal operation mode (full power).

Stop key: For the GW2011A controller, this button can be used to stop all types of jobs, including

printer, fax, etc. With the old GW controller, this button can only be used to stop copy jobs.

Status key Stop key

Energy saver key

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Operation panel (3/3)

The operation panel can be tilted.

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Configuration

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Fax

The FCU and MBU boards are combined to one board. Because of this the data backup procedure is changed.

The FCU contains the ROM, SRAM and NCU circuits.

Options for the fax: There is NO optional memory. There is NO optional additional G3 interface unit. Fax connection unit is needed for remote fax function.

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Controller slots

Interface slot: Used for one of the

following: IEEE1284, IEEE802.11 (a/g & g), File Format Converter, Gigabit Ethernet.

USB slot: Used for the Bluetooth unit

or the external USB keyboard.

SD card slots (1&2): See the next slides.

Caution: Do not remove the Bluetooth unit while the machine is switched on.

Interface slot

SD card 2

SD card 1

USB slot

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SD card slot 1&2

Slot 1 (upper slot) can be used for: Empty when shipped. Installing the following options:

VM card PictBridge Browser unit SD card for Netware printing

Slot 2 (lower slot) can be used for: Empty when shipped. Service procedures like:

Firmware update SMC data export (SP5-992) NVRAM backup

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SD card slot 3

SD card slot on the operation panel can be used for: PDF direct print from SD card SMC data export (SP5-992)

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Storage location for SD cards

Store SD cards in locations [A, B] on the inner cover. Location [C] is where the SMC sheet is stored when the

machine is shipped. Some disassembly is required to access this cover:

See field service manual.

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Data overwrite security (DOS), HDD encryption

These features are embedded on the controller board for all models. There is no Security SD Card.

At installation, these features must be enabled with SP mode. See field service manual.

Then the user must enable them in the User Tool.

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2. Specifications

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General specifications

30 cpm30 cpm30 cpm20 cpm30 sec 10 sec

Standard A4Custom paper size 216x297mmStandard A4Custom paper size 216x600mm

Standard 350 sheetsFull option 1350 sheetsStandard 100Maximum 200

Standard tray 60-163By-pass tray 60-220Duplex 60-163Optional paper tray 60-163

BlackFull colour

BlackFull colour

Copy speed

ARDF speed 1 to 1

Paper output capacity

Paper Weight g/m2

Warm-up timeRecovery time

Max paper sizeCassettes

Bypass

Paper capacity A4, 80 g/m2

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Reliability

Colour ratio: 20%. Average Copy Volume (ACV): 2K. Max CV: 5K. PM Cycle: 60K. Life: 300K or 5 years, which ever comes first.

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Target yields

Maintenance must be done by the field engineer.

Consumables: Toner Black:12K (A4, 5% coverage) Toner YMC: 4K prints (A4, 5% coverage) NO starter cartridges.

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3. New & improved featuresGW 2011A

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Controller capabilities

<Workflow Improvement>• Customizable Home screen: HDD required• External USB Keyboard support• Auto Job Promotion: HDD required• Enhanced Media Print• Scheduled Print : HDD required• Banner Page Print• JBIG2 Compression• Reduce/Enlarge Scan• Enhanced Batch Scan: HDD required• Split Scan from Book type original• Import/Export of Preference Settings• Expanded User Code• Scheduling of Quota Management• Home folder over LDAP• Greek/Brazilian Portuguese support

<TCO>• Remote FAX (opt): HDD required• Improved Gray Reproduction (PCL6)• Quota management: HDD required

<Environment>• Information Screen (Eco-Friendly Indicator):

HDD required

<Security>• Unauthorized Copy Control (PCL6/PS)• Enhanced Print Functions using HDD• Mandatory Security Information Print• Output Switch Timer for received FAX:HDD

required• Enhanced Encryption Level (AES256bit,

SHA2)

<Compliance>• Scan to PDF-A/digitally signed PDF

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Operation panel design

Note that there has been a big design change between the Pre-11A and 11A Operation panels.

Pre-11A

11A

Customizable logo

Home button

Function keys

Menu with programmable icons

4-line display

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Programmable icons (1/3)

Shortcuts can be added to frequently often used programs or web pages.

The order of the shortcuts and function icons can be changed.

Program: The functionality is same as what could be done previously

with the “Program” key. Number of each type of item that can be added to the

Program menu: Copy = 25 Scanner = 25 FAX = 100 URL = 100

72 Items that can be added to the home screen.

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Programmable icons (2/3)

User authentication: Only the icons to which a user has permission will be

displayed in that user’s Home Screen. User Own Home Screen Allow:

If enabled in WIM, users can add icons to their home screen using the Program menu.

User1’s icons are shown after he logs in. Other users can’t see User1’s icons.

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Programmable icons (3/3)

Administrators can configure which icons are displayed to users. Web Image Monitor:

Home Device Management Device Home Management Edit Icons.

Operation Panel.

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Function keys

Specific icons on the Home screen can be assigned to any of the five “function keys”. By default, none of the function keys will have anything

assigned to them. Web Image Monitor

Home Device Management Configuration Function Key Allocation/Function Priority.

Function keys

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Customizable logo

A logo can be added to the Home screen. The logo must be exactly 180x40 pixels or it cannot be

loaded to the home screen. Importing a logo:

SD card (inserted into the slot at the front of the device) ./custom_ui/image/insert.jpg.

Web Image Monitor.

Customizable logo

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External USB keyboard

A USB 101-key keyboard can be used with the MFP if the following conditions are met: SP mode 5-075-001 must be set to “1” The use of USB keyboard must be enabled via SP5-075-001

and user mode. The USB keyboard for SDK is not connected.

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Auto job promotion (1/2)

The machine can skip specific defective jobs and start printing the subsequent jobs. HDD must be installed. The function must be enabled in user tools.

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Auto job promotion (2/2)

Specific error jobs can be skipped. When an error occurs during printing a job, the job cannot

be skipped and the machine will stop with an error message.

To reduce the occurrence of such situations, administrators can set the number of pages for pre-detection of errors. The machine predicts an error, so the job will be skipped

and handled as 'Hold Print'.

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Scheduled print

This lets users delay printing to a specified time. The time can be input with the printer driver, as shown

below left. The time can be changed with WIM or at the operation

panel, as shown.

WIM

Operation panel

Driver

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Split scan from book original

This function scans the left page and right page of a double-page spread original separately. Users will receive the left and right pages as separate

images.

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Import/export MFP settings (1/2)

For a customer/engineer it is possible to import and export MFP settings by using an SD-card.

UP/SP Category Method Administrator Service

UP Copy SD P -

Scanner P -

Printer P -

FAX P -

SDK P -

WIM P -

System P -

MFP Browser P -

SP System - P

FAX - P

Printer - P

Scanner - P

Note1: To do the import/export function is possible when the machines have completely the same configuration.

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Import/export MFP settings (2/2)

Backup/restore MFP settings to/from a SD card.

SD slot

MFP

Settings(UP)

MFP

Settings(SP)

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Remote fax (1/2)

With remote fax option, GW2011A machines can send or receive faxes through a central GW2011A machine with a fax option.

Users can share the fax function with the central machine if it is on the same network. No need to buy multiple fax options and can reduce the

number of fax lines.

Center Machine: A

with Fax option

Machine: B

w/o Fax option

Fax Receiving

Fax Sending

Network

Machine: C

w/o Fax option

Machine: D

w/o Fax option

Same Network

Up to 6

Sub machines

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Remote fax (2/2)

Center Machine Fax Option must be installed. HDD and printer option must be installed. “Fax Connection Unit (SD card option)” must be installed.

Sub Machines HDD and printer option must be installed. “Fax Connection Unit (SD card option)” must be installed.

In order to receive fax document on sub machines, operators must register the addresses of specific senders as default settings.

Center Machine: A with Fax option

Machine: Cw/o Fax option

SD Fax Connection UnitSD

SD

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Browser unit

With the browser unit correctly installed: Users are able to browse external web sites and print the

displayed page from the machine’s operation panel. Web page addresses can be registered as bookmark

icons on the home screen. Example of use: If Ricoh’s support web pages are

bookmarked, users can check the machine’s manuals at the operation panel.

Example of websites

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Demonstration

Customizable logo. SD-card WIM

Function key assignment. External USB keyboard. Import/Export MFP settings. Browser unit.

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4. Installation

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Seals from drum unit

Pull all protection seals [A] from the drum units straight out towards the front.

For tape [B] there is an other procedure See the next slide for details.

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Don’t forget this tape

To access this, you must remove the paper tray first and remove the waste toner tank.

Remove the tape [A] and set the lever [B] to the upper position. This moves the ITB into contact with the K PCDU.

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Toner bottles

Shake each bottle 10 times before you install it in the machine.

The PCDUs already contain developer.

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Switching the machine on for the first time

Close the front door. Connect the power cord to the machine. Turn on the main power.

The machine will start the initial settings automatically. No need to do SPs for machine initialization.

Wait until the initialization is done and “Ready” is shown on the operation panel.

Never turn off the main power before “Ready” is displayed.

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Language selection

The user can set up to 5 languages and switch between them.

User tools

Selecting the languages in the Administrator Tools

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HDD installation

After installing the hard disk set up HDD encryption and data overwrite security when the customer wants to use these features.

For details on how to set up these features: See the installation procedure for the hard disk in the field

service manual.

HDD encryption

DOS

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Optional paper tray unit

When installing a second paper feed unit: Place the copier on the two paper feed units.

After installing the paper tray unit(s), check the side-to-side registration for each tray. For tray 2, use SP1002-003 For tray 3, use SP1002-004 Tray 2 is the upper of the two optional feed units, and tray 3

is the lower.

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1-Bin tray unit

Points to note: The unit comes with a mounting frame [10] and 4 covers. Two of

these covers [6, 7] replace existing covers on the machine, and two [8, 9] are additional covers needed after installing the unit.

The cables [A] and [B] in the diagram must be routed behind the cable [D].

A

D

B

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Fax unit

Don’t forget to switch the FCU battery jumper switch [A] to the "ON" position.

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Adding an icon to the home screen

After installing an option (for example the fax unit) the icon must be added to the home screen.

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Tray heater installation

For installing the tray heater the left stay [A] must be removed.

Never press the main frame from above when the left stay is removed. The mainframe may be damaged.

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Exercise

Install the machine with available options according to the service manual.

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5. Detailed section descriptions

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Chapter overview

6.1 General

6.2 ARDF

6.3 Scanner

6.4 Laser units

6.5 Photoconductor unit

6.6 Toner supply

6.7 Paper feed

6.8 Transfer

6.9 Waste toner collection

6.10 Fusing

6.11 Paper exit

6.12 Duplex feed

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6.1 General

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How to enter the SP-mode

The “Clear/Stop” key is separated into two keys. “Clear” key.

“Stop” key.

1. Press Clear Mode key

2. Enter “1 0 7”

3. Press and hold Clear for at least 3 seconds

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Machine layout

ITB cleaning unit

Duplex path

Fusing unit

Laser units

Toner bottles

PCDU

Image transfer belt unit (ITB) Paper transfer roller (PTR)

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Paper feed path

Duplex path

Standard output tray

Optional 1-bin tray

ARDF

By-pass tray

Optional trays

Standard tray

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Drive

1

8 7 6 5 4 3

2

10

9

12

11

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Ventilation

The airflow inside the machine is from the right side to the left side.

The temperature sensor is a thermistor, above the YM laser unit.

Scanner cooling fan

PSU cooling fan

PCDU cooling fan

Exhaust fan

Ozone filter

Temperature sensor

Humidity sensor

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6.2 ARDF

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Component layout

ARDF relay board

Junction gate solenoid

Upper cover sensor

Original set sensor

Pick-up solenoidARDF motor

Transport sensor

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Drive

The ARDF motor drives all the rollers. The pick-up roller and Junction gate are operated by a

solenoid.

ARDF motor

Pick-up solenoid Junction gate solenoid

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Original detection

The stopper prevents the user from placing originals too far into the feeder.

Stopper Original set sensor

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Pick-up

The pick-up solenoid drops the pick-up roller onto the top original of the stack.

This moves the stopper out of the way, and the original can be fed to the feed roller.

The friction pad ensures that only one sheet of the original enters the feeder at a time.

Feed Roller Stopper Pick-up Roller

Friction Pad

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Feed

For single-sided scanning, the original passes through the ARDF as shown below to the exit tray.

Scanning guide plateTransport sensor

Scanning roller

Pull-out roller

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Duplex mechanism

The junction gate solenoid drops the junction gate, and the original is guided to the inverter roller.

When the trailing edge of the original has passed the exit roller, the junction gate solenoid turns off and the inverter roller changes direction.

The original is fed back into the ARDF and the other side is scanned. After scanning the second side, the machine inverts the original again,

so that it is stacked correctly in the exit tray.

Exit roller

Inverter roller

Junction gate

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Exercise

Go to the machine remove the back cover of the ARDF and have a look to the mechanical parts.

Read the service manual on how to remove the back cover.

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6.3 Scanner

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Overview

All scanner optics are included inside one carriage. When you move the carriage, use the drive belt.

Do not pull the carriage directly otherwise you get image skew.

ARDF/Platen cover open sensor

Exposure glassADF scan glass

Scanner carriage HP sensor

Scanner carriage

Scanner drive belt

Scanner drive motor

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Inside the carriage

The light source is an LED array. Light from the LED board goes to the original via the two

reflectors. To make sure that enough light reaches the left and right

edges of the original, the elements in the LED array are more closer to each other at the ends than at the center.

CCD

2nd Mirror

4th Mirror

LED Board Reflectors

1st Mirror

3rd Mirror

5th Mirror

Optical pathLens

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Drive

The drive belt moves the carriage along the guide rod. The actuator for the HP sensor is on the underside of the

carriage.

Scanner drive motorGuide rod

Scanner drive belt

Carriage HP sensor Scanner carriage

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Moving the carriage by hand

When you must move the carriage by hand, move the belt, as shown below.

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6.4 Laser units

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Overview

There are two laser units. 1 for Black and Cyan. 1 for Magenta and Yellow.

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Laser unit details

Both laser units are physical identical. Don’t exchange them because the colour skew adjustments

for each colour can be different. This is explained later in this presentation.

F-theta lens-2

1st mirrorLD unitF-theta lens-1

2nd mirror

Toner shield glass

Polygon mirror

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Laser beam path

The scan line is written on the drum from the front end towards the rear of the machine.

Collimating lens

LD unit

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Colour skew adjustment

The adjusters must be used after installing a new LD unit. There is one for each color.

They move the front of the F-theta lens-2 from left to right, seen from the front of the machine.

This moves the position of the scan line on the drum, to correct for colour skew.

Adjusters

F-theta lens-2

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After replacing a laser unit

There are two things to do: Initialize the D-phase data and shading data.

See the service manual (Replacement and Adjustment, Laser Optics).

Do the color skew adjustment procedure. Explained on the next few slides.

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Colour skew adjustment (1/5)

Execute ‘MUSIC’ (SP2-111-002). After you execute MUSIC, check the adjustment with the following SPs.

2-117-004 (Black) 2-117-002 (Cyan) 2-117-001 (Magenta) 2-117-003 (Yellow)

No skew adjustment is required when all SP values are within ±5. When one or more of the SP values is not within ±5, then you must

adjust colour skew for any color that has an SP value that is not 0.

For example: If 2-117-001 is -4, and the others are +1, no adjustment is necessary. If 2-117-001 is -6, and the others are +1, the adjustment must be done for

all four colours. If 2-117-001 is -6, and the others are 0, the adjustment must be done only

for magenta.

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Colour skew adjustment (2/5)

Open the front cover [A]. Remove the upper cover [B]. Then close the front cover

again. Execute ‘MUSIC’ (SP2-111-002) again.

This is because removing the upper cover may have caused the LD units to slip out of alignment.

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Colour skew adjustment (3/5)

Adjust the colours that need correction using the knobs shown below.

See the procedure in the service manual for details. These adjustments move the L2 F-theta lenses-2 inside the

laser units.

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Colour skew adjustment (4/5)

This shows one of the four knobs. Rotate each knob corresponding to

the value shown in SP2-117-001 to 004. Clockwise: 90 degrees

corresponds to changing the SP value by “+1”

Counterclockwise: 90 degrees corresponds to changing the SP value by “-1“

A click is felt every 90 degree rotation of the knob.

Examples: If the SP value is +6, turn knob

[A] in the diagram 6 clicks clockwise.

If the SP value is -7, turn knob [A] 7 clicks counterclockwise.

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Colour skew adjustment (5/5)

Reassemble the machine. Execute ‘MUSIC’ (SP2-111-002) Check the SPs (SP2-117-001 to 004). If one or more of

them is over ±5 (either positive or negative), repeat the adjustment.

The adjustment is finished when all SP values are ±5.

Before adjustment After adjustment

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Exercise

Do the colour skew adjustment according to the procedure in the field service manual.

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6.5 Photoconductor unitPCDU

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Overview

1. Drum2. Waste toner transport coil3. Lubricant brush roller4. Lubricant bar5. Cleaning blade6. Charge roller7. Charge roller cleaning roller8. Doctor blade9. Toner mixing coil (upper)10.Depressurization outlet, with

filter11. Development roller12.Toner mixing coil (lower)13.Toner density sensor

6

5

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2

7

1

8

9

11

10

12

13

The photoconductor unit contains the drum and the development unit.

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Drum unit

Lubricant is applied by the lubricant brush and spread out by the cleaning blade.

At the end of a job, the drum reverses for a short while to remove toner and dust that has adhered to the edge of the blade.

Toner removed from the drum is transported to the front of the machine by the toner collection coil.

Toner collection coil

Lubricant brush

Cleaning blade

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Development unit

Toner density sensor

Lower agitator

Development roller

Upper agitator

Doctor blade

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Drive

For CMY, there are two motors (drum drive, and development unit drive).

For K, there is one motor. A clutch connects this motor to the development unit at the

correct time.

Never remove gears 3,5 or 7. The phase between these gears are adjusted at the factory.

6

12

2

11

1

10

543

9

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Replacement procedures

Do not disassemble the PCDUs. There are no service parts for the individual components of

the PCDUs. If you are working around the drive area (see the previous

slide), mark the positions of the drum phase gears. If these gears come off, it is very difficult to get them back in

the correct place, and the machine may have to be replaced. The drive unit is available as a spare part, but it is very

difficult to replace.

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PCDU replacement procedure

You must release the lock lever and check that the ITB has no tension.

Lock lever released

Tension releasedTension applied

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Exercise

Remove the PCDUs and have a look at the differences between the units.

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6.6 Toner supply

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Overview

Toner supply coilAgitatorToner end sensorShutter

ID chip BRB (Bottle Read Board) Toner bottle Toner supply motor

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Toner supply path

Toner is moved into the hopper when the bottle is rotated.

The agitator in the hopper pushes the toner towards the toner supply coil and transported into the development unit.

Only the colour units have toner end sensors.

In the K unit, the ID chip monitors toner end. The machine calculates near

end from how much toner is supplied during the life of the bottle.

Toner supply coilAgitatorToner end sensor

Toner supply motor

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Toner bottle detection

When the BRB board detects an ID chip, the machine detects that the toner bottle is installed.

ID chipBRB

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After replacing the toner supply

Set the following SPs (New unit flag) to “1” depending upon the replaced unit. SP3-701-027 (Black) SP3-701-028 (Cyan) SP3-701-029 (Magenta) SP3-701-030 (Yellow)

Set the following SPs (Toner supply flag) to “1” depending upon the replaced unit. SP3-510-031 (Black) SP3-510-032 (Cyan) SP3-510-033 (Magenta) SP3-510-034 (Yellow)

Exit from the SP mode. Turn the main power off and on.

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6.7 Paper feed

103

Overview

1. End fence.

2. Paper tray.

3. Side fence.

4. Paper end sensor.

5. Paper feed roller.

6. Paper dust collector.

7. Registration roller.

8. Registration sensor.

9. Paper feed sensor.

10. Bypass feed roller.

11. Bypass paper size sensor.

12. Bypass paper end sensor.

13. Friction pad.

1

11

765432 8 9 10

1213

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Drive

The paper transport motor drives the paper feed, registration, and bypass mechanisms through gears and clutches.

It also drives the duplex and bypass bottom plate lift mechanisms.

Bypass feed clutch

Paper feed clutch

Registration clutch

Paper transport motor

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Bottom plate lift

A rack and pinion mechanism lifts the bottom plate. The motor turns the pinion. The rack pulls the lift arm through a spring.

The HP sensor detects when the bottom plate is lifted. The lift motor contains a sensor.

The machine uses this sensor and the HP sensor to monitor the amount of lift.

Rack and pinion Lift motor

106

Bypass bottom plate

The bypass bottom-plate is operated by a clutch. When the clutch is energized, drive from the paper

transport motor turns the bottom plate cam shaft, through gears.

The front cam and the rear cam, lift and lower the bottom plate.

The HP sensor monitors the position of the bottom plate.

HP sensor

Bottom plate cam

Bottom plate clutch

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Bypass tray sensors

The paper size sensor detects the size for B5 paper or wider.

The paper end sensor detects whether there is paper in the tray.

Paper end sensorPaper size sensor

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6.8 TransferImage transfer and paper transfer

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Overview

1

15 8 7

6

5432

914 13 12 11 1016

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Image transfer process

A typical image transfer belt and paper transfer system is used.

K C M Y

111

Image transfer power supply

Image transfer bias (to transfer toner from the drum to the ITB) is applied at the four image transfer rollers.

Paper transfer bias (to transfer toner from the ITB to the paper) is applied at the ITB drive roller.

The paper transfer roller and discharge plate are both grounded.

K C M Y

P.P

112

ITB contact mechanism

This mechanism only exists for CMY. K is always in contact except when the lock lever is released.

The ITB contact motor drives this mechanism through a worm gear and a cam.

When the cam moves the slider, the image transfer rollers for CMY move up into contact with the OPC drums, or down away from them.

If the mechanism is defective, make sure the transfer belt is not in contact with the drum units. This is explained earlier in this presentation.

K C M Y

Slider

ITB contact sensor ITB contact motor

ITB contact cam

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ITB cleaning

The ITB cleaning blade removes remaining toner from the ITB.

The waste toner transport coil moves the toner towards the front of the machine into the waste toner bottle.

The lubricant brush roller applies lubricant to the ITB.

Toner transport coil

Cleaning blade

Lubricant brush roller

114

ID sensors

3 ID sensors are used for Image density detection and MUSIC.

If you install a new ID Sensor board, input the values [A] from the barcode sheet into the indicated SPs.

ID sensor board

115

Exercise

Go to the machine and do the ITB unit and ID sensor removal procedure according to the service manual.

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6.9 Waste toner collection

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Overview

The waste toner drops at the front of the bottle. A coil moves the waste toner from the ITB unit, the Y

PCDU and M PCDU towards the left-side of the bottle. The agitator makes the surface of the toner level.

There is another agitator for toner that arrives from the ITB (see the next slide).

Waste toner from the C and K drums drops straight into the bottle.

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Mechanism

When the coil rotates, the agitators move the toner towards the rear of the bottle.

The bottle full sensor detects when the bottle is almost full, and the machine displays a warning on the screen.

After near-full is detected, the machine calculates when the bottle becomes full, and stops operating.

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Replacing the waste toner bottle

Move the 5 caps [A] from their storage location on the waste toner bottle to the inlets, so no toner will spill out when you transport the bottle.

Dispose of used bottles in accordance with local regulations.

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6.10 Fusing

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Principle

This machine uses a Quick Start Up Direct Heating (QSU-DH) fusing system which saves energy and improves print quality.

The new fusing unit uses a thin fusing belt which turns freely around the lamp. No heating roller or hot roller.

The fusing belt is much thinner than a hot roller, so less electricity is used to reach the fusing temperature.

By using a flat fusing pad, fusing is done on a flat surface without uneven pressure from the pressure roller. This means that there is less damage/wrinkling to the paper.

This is especially helpful for envelope printing.

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Overview

1. Thermopile.

2. Thermistor.

3. Thermostat.

4. Separation plate.

5. Exit guide plate.

6. Pressure arm.

7. Pressure roller.

8. Pressure roller thermistor. (2X)

9. Entrance guide plate.

10. Fusing sleeve belt.

11. Fusing lamp.

12. Fuse for new unit detection.

9

12

8

7

6

543

2

1

11 10

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Free-belt fusing system

Stay

Reflector plate

Fusing lamp

Mirror

Sleeve beltFusing pad

Pressure roller

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Temperature control components

Sleeve belt thermistor

Sleeve belt thermopile

Fusing lamp

Pressure roller

thermistors

Thermostat

Fuse for new unit detection

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Fusing drive

The fusing/exit motor drives the pressure roller. The fusing sleeve turns when the pressure roller rotates.

Fusing paper jam is detected by sensors at the entrance and exit of the fusing unit.

Fusing motorFusing entrance sensorPressure roller

Fusing sleeve

Fusing exit sensor

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Fusing unit replacement

After the fusing unit is replaced you must do the following: Set SP3-701-014 to “1”. Exit the SP-mode. Switch the machine off and on. Check SP7-803-016 whether the fusing is reset correctly.

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Fusing sleeve belt replacement

The fusing pad must face the pressure roller. The fusing sleeve belt is replaced as an assembly.

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SC 554

If SC 554-00 occurs, there could be temperature damage to the fusing unit.

The fusing unit should be replaced, but if it is not damaged, you can continue to use it.

In the field service manual there is a separate procedure for SC 554-00.

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SP 5-810

From the flow chart on the previous slide, you can see that a new SP (SP5-810-002) is added.

If you do this SP, the machine checks for the fuse for new unit detection, and blows the fuse if it is found. If the fuse is not found and blown, the SP execution fails.

SP 5-810-002 is normally only done as part of the countermeasure for SC 554.

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Fuse for new unit detection

The fuse is shown below [A]. It is not included in machines shipped from the factory. The fuse is present in fusing units that are installed as service

parts, but it is blown immediately after the fusing unit is installed. So, in each case, if you will re-use a fusing unit that has

encountered SC554 but is not damaged, you need to get a new fuse and install it like shown below. (part number: M026 4371)

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Exercise

Do the pressure roller and sleeve belt assembly removal procedure according to the service manual.

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6.11 Paper exit

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Overview

The position of the inverter junction gate determines whether paper from the fusing unit is: Fed out of the machine. Fed towards the duplex feed path.

Inverter junction gateExit/inverter roller

Paper exit sensor

Fusing exit sensor

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Components

The exit/inverter roller is driven by the paper transport motor.

The paper exit sensor controls the timing for the inverter mechanism.

Inverter junction gateExit/inverter roller

Paper exit sensor

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Inverter mechanism

When the exit sensor detects the leading edge of the paper, both solenoids turn on. The exit roller rotates in the other direction. The junction gate guides the paper to the upper exit.

When the exit sensor detects the trailing edge of the paper, both solenoids turn off. The exit roller rotates in the other direction. The junction gate guides the paper to the duplex feed path.

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Exit/inverter gear train

Drive from the

paper transport motor

Drive to the exit roller

Movement by the solenoid

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Exit unit replacement

Make sure that you do NOT release the exit roller drive belt [B] when removing the paper exit unit.

If the belt is released and dropped down to the lower part of the machine, you will have difficulty in reattaching it.

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Exercise

Remove the exit unit. Follow the instructions in the service manual.

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6.12 Duplex feed

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Overview

After the inverter mechanism feeds the paper back into the machine, the paper goes to the duplex feed path.

Duplex feed is not possible when the bypass tray is in use.

Entrance sensor

Duplex rollers

Exit sensor

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Duplex drive

The paper transport motor drives the duplex mechanism through gears and the duplex clutch.

Two sensors detect paper jams and control paper feed timing.

Duplex clutch

Paper transport

motor

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Interleaving

The order of printing is as follows: Sheet 1, reverse side > Sheet 2, reverse side > Sheet 1,

front side > Sheet 3, reverse side > Sheet 2, front side > sheet 3, front side.

1

2

2

1

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6. Maintenance

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SMC data to SD card

All settings (both SP mode settings and UP mode settings) can obviously be printed using SP5-990 (SMC).

However, as of 11A, you can also save the SMC onto an SD card (csv format). SP5-992

SD slot or Service slot

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PM parts

PCDU: 60K (Black) A4, 5% coverage, 2 pages/job

Waste toner bottle: 90K

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Yield parts

PCDU (CMY) Replacement at 24k colour prints

Replacement at 120k: ITB cleaning unit PTR unit Fusing belt, fusing pressure roller, fusing entrance guide

plate, fusing exit guide roller Bypass feed roller Optional paper tray: Separation pad, pick-up roller

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Before performing maintenance

Print the SMC logging data with SP5-990-004. To reset the PM counter for each item, you must set SP3-

701-001~20 to “1” before you switch off the machine. After switching on the machine, the PM counters are reset

automatically. The developer is initialized automatically.

After installing the new items: Make sure that the PM counters for the replaced units are

"0" with SP7-803. If the PM counter for a unit was not reset, then reset that

counter with SP 7-804. Check the other counters as specified in the ‘After installing

the new PM parts’ procedure.

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Cleaning the ID sensor

Clean the ID sensor [B] with a damp cloth.

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7. Replacements & Adjustments

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Fax unit

The MBU and FCU are combined into one board. After you replace the FCU, you must transfer the SRAM

data from the old FCU to the new board. This is done by connecting the old FCU to the new board

with a flat cable. A flat cable is provided with the new FCU service part.

The following data will be transferred: TTI RTI CSI bit switch settings RAM address settings NCU parameter settings

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8. Options

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Optional paper trayPB1050

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Components

9

13

8

7654321

12 11

10

16 15 14

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Drive

The paper feed motor drives the rollers in the paper tray through two clutches.

After the paper has been fed into the machine, the clutches turn off.

Paper feed clutch

Paper transport clutchPaper feed motor

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Paper feed

This tray uses a feed roller and friction pad system. The paper-end and remaining-paper sensors use the same

actuator.

Paper end sensor

Remaining paper sensor

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Tray lift mechanism

The upward pressure from the bottom plate is adjusted depending on how much paper remains.

The bottom plate lift sensor detects the encoder plate. In response to the output from the sensor, the bottom

plate lift motor lifts the bottom plate.

Bottom plate HP sensor

Encoder plate

Bottom plate lift sensor

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One-bin trayBN1010

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Components

Exit tray Paper sensor LED Exit

rollerExit sensor

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Mechanism

The LED will light when there is an output on the tray. The output is detected by the paper sensor.

The exit sensor detects jams.

Exit sensor

LED

Paper sensor

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Griffin-C1End