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Aficio MP C305SP/305SPF
Service master full training module

Ricoh Academy Europe

Created by: Group L&D Version:1.0.a Classification: Internal
 After completing this training you should be able to: 2

 Install the machine and options in the field.

 Do routine maintenance on the machine.
 Troubleshoot and repair this product in the field.
 Griffin-C1 (Full option when available) 3

 Windows PC

 Printer drivers

 Field service manual

 Operation manual

 This presentation
 Before starting this training you should have already 4

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”.
Module overview
1. Introduction 5

2. Specifications
3. New & improved features
4. Installation
5. Detailed section descriptions
6. Maintenance
7. Replacements & adjustments
8. Options

Ricoh Academy Europe

 Griffin-C1, Aficio MP C305SPF(D117) 7

 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)
 Up to two additional paper tray units can be installed. 8

 There are no finishers.

Colour LCD touch panel

Optional one-bin tray

One paper tray is standard

Machine layout

Laser units

Fusing unit
Toner bottles

Duplex path
ITB cleaning unit

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

Operation panel (1/3)
 4.3” Touch panel. 10

 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.

Home button Touch panel SD/USB Slot

Function keys
Operation panel (2/3)
 Status key: 11

 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.

Energy saver key

Status key Stop key

Operation panel (3/3)
 The operation panel can be tilted. 12
 The FCU and MBU boards are combined to one board. 14

 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.
Controller slots
 Interface slot: 15

 Used for one of the

following: IEEE1284,
IEEE802.11 (a/g & g), File
Format Converter, Gigabit
 USB slot:
USB slot  Used for the Bluetooth unit
or the external USB
 SD card slots (1&2):
SD card 1  See the next slides.

SD card 2

Interface slot
 Caution: Do not remove the
Bluetooth unit while the
machine is switched on.
SD card slot 1&2
 Slot 1 (upper slot) can be used for: 16

 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
SD card slot 3
 SD card slot on the operation panel can be used for: 17

 PDF direct print from SD card

 SMC data export (SP5-992)
Storage location for SD cards
 Store SD cards in locations [A, B] on the inner cover. 18

 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.
Data overwrite security (DOS), HDD encryption
 These features are embedded on the controller board for 19

all models.
 There is no Security SD Card.
 At installation, these features must be enabled with SP
 See field service manual.
 Then the user must enable them in the User Tool.
2. Specifications

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General specifications

Black 30 cpm
Copy speed
Full colour 30 cpm
Black 30 cpm
ARDF speed 1 to 1
Full colour 20 cpm
Warm-up time 30 sec
Recovery time 10 sec
Standard A4
Custom paper size 216x297mm
Max paper size
Standard A4
Custom paper size 216x600mm
Standard 350 sheets
Paper capacity A4, 80 g/m2
Full option 1350 sheets
Standard 100
Paper output capacity
Maximum 200
Standard tray 60-163
By-pass tray 60-220
Paper Weight g/m2
Duplex 60-163
Optional paper tray 60-163
 Colour ratio: 20%. 22

 Average Copy Volume (ACV): 2K.

 Max CV: 5K.
 PM Cycle: 60K.
 Life: 300K or 5 years, which ever comes first.
Target yields
 Maintenance must be done by the field engineer. 23

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

3. New & improved features

GW 2011A

Ricoh Academy Europe

Controller capabilities
<Workflow Improvement> <TCO> 25

• Customizable Home screen: HDD required • Remote FAX (opt): HDD required
• External USB Keyboard support • Improved Gray Reproduction (PCL6)
• Auto Job Promotion: HDD required • Quota management: HDD required
• Enhanced Media Print
• Scheduled Print : HDD required <Environment>
• Banner Page Print • Information Screen (Eco-Friendly Indicator):
• JBIG2 Compression HDD required
• Reduce/Enlarge Scan
• Enhanced Batch Scan: HDD required <Security>
• Split Scan from Book type original • Unauthorized Copy Control (PCL6/PS)

• Import/Export of Preference Settings • Enhanced Print Functions using HDD

• Expanded User Code • Mandatory Security Information Print

• Scheduling of Quota Management • Output Switch Timer for received FAX:HDD

• Home folder over LDAP
• Enhanced Encryption Level (AES256bit, SHA2)
• Greek/Brazilian Portuguese support

• Scan to PDF-A/digitally signed PDF
Operation panel design
 Note that there has been a big design change between 26

the Pre-11A and 11A Operation panels.

4-line display


Customizable logo

Home button

Function keys 11A

Menu with programmable icons

Programmable icons (1/3)
 Shortcuts can be added to frequently often used programs 27

or web pages.
 The order of the shortcuts and function icons can be
 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.
Programmable icons (2/3)
 User authentication: 28

 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.
Programmable icons (3/3)
 Administrators can configure which icons are displayed to 29

 Web Image Monitor:
 Home  Device Management  Device Home Management
 Edit Icons.
 Operation Panel.
Function keys
 Specific icons on the Home screen can be assigned to 30

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
Customizable logo
 A logo can be added to the Home screen. 31

 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
External USB keyboard
 A USB 101-key keyboard can be used with the MFP if the 32

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.
Auto job promotion (1/2)
 The machine can skip specific defective jobs and start 33

printing the subsequent jobs.

 HDD must be installed.
 The function must be enabled in user tools.
Auto job promotion (2/2)
 Specific error jobs can be skipped. 34

 When an error occurs during printing a job, the job cannot

be skipped and the machine will stop with an error
 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'.
Scheduled print
 This lets users delay printing to a specified time. 35

 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.

Operation panel
Split scan from book original
 This function scans the left page and right page of a 36

double-page spread original separately.

 Users will receive the left and right pages as separate
Import/export MFP settings (1/2)
 For a customer/engineer it is possible to import and export 37

MFP settings by using an SD-card.

UP/SP Category Method Administrator Service

UP Copy SD P -
Scanner P -
Printer P -
System P -
MFP Browser P -
SP System - P
Printer - P
Scanner - P

Note1: To do the import/export function is possible when the machines have

completely the same configuration.
Import/export MFP settings (2/2)
 Backup/restore MFP settings to/from a SD card. 38


SD slot
Remote fax (1/2)
 With remote fax option, GW2011A machines can send or 39

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.
Up to 6
Sub machines
Same Network Machine: B
w/o Fax option

Machine: C
Fax Receiving
w/o Fax option
Fax Sending

Center Machine: A
with Fax option Machine: D
w/o Fax option
Remote fax (2/2)
 Center Machine 40

 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

Machine: C
w/o Fax option
SD Fax Connection Unit
Center Machine: A
with Fax option
Browser unit
 With the browser unit correctly installed: 41

 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
 Customizable logo. 42

 SD-card
 Function key assignment.
 External USB keyboard.
 Import/Export MFP settings.
 Browser unit.
4. Installation

Ricoh Academy Europe

Seals from drum unit
 Pull all protection seals [A] from the drum units straight out towards the 44

 For tape [B] there is an other procedure
 See the next slide for details.
Don’t forget this tape
 To access this, you must remove the paper tray first and 45

remove the waste toner tank.

 Remove the tape [A] and set the lever [B] to the upper
 This moves the ITB into contact with the K PCDU.
Toner bottles
 Shake each bottle 10 times before you install it in the 46

 The PCDUs already contain developer.
Switching the machine on for the first time
 Close the front door. 47

 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.
Language selection
 The user can set up to 5 languages and switch between 48

Selecting the languages in
the Administrator Tools

User tools
HDD installation
 After installing the hard disk set up HDD encryption and 49

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

Optional paper tray unit
 When installing a second paper feed unit: 50

 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.
1-Bin tray unit
 Points to note: 51

 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].


Fax unit
 Don’t forget to switch the FCU battery jumper switch [A] to 52

the "ON" position.

Adding an icon to the home screen
 After installing an option (for example the fax unit) the icon 53

must be added to the home screen.

Tray heater installation
 For installing the tray heater the left stay [A] must be 54

 Never press the main frame from above when the left stay
is removed.
 The mainframe may be damaged.
 Install the machine with available options according to the 55

service manual.

5. Detailed section descriptions

Ricoh Academy Europe

Chapter overview
6.1 General 57

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
6.1 General

Ricoh Academy Europe

How to enter the SP-mode
 The “Clear/Stop” key is separated into two keys. 59

 “Clear” key.

 “Stop” key.

1. Press Clear Mode key

2. Enter “1 0 7”

3. Press and hold Clear for at least

3 seconds
Machine layout

Laser units

Fusing unit
Toner bottles
Duplex path
ITB cleaning unit

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

Paper feed path


Optional 1-bin tray

Standard output tray

Duplex path

Standard tray By-pass tray

Optional trays


11 2


9 8 7 6 5 4 3
 The airflow inside the machine is from the right side to the 63

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

Exhaust fan

Scanner cooling fan Ozone filter

Temperature sensor

PSU cooling fan

Humidity sensor

PCDU cooling fan

6.2 ARDF

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Component layout

ARDF motor Pick-up solenoid

Original set sensor

Transport sensor
Upper cover sensor

Junction gate solenoid

ARDF relay board

 The ARDF motor drives all the rollers. 66

 The pick-up roller and Junction gate are operated by a


Pick-up solenoid Junction gate solenoid

ARDF motor
Original detection
 The stopper prevents the user from placing originals too 67

far into the feeder.

Stopper Original set sensor

 The pick-up solenoid drops the pick-up roller onto the top 68

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
 For single-sided scanning, the original passes through the 69

ARDF as shown below to the exit tray.

Pull-out roller

Scanning roller

Transport sensor Scanning guide plate

Duplex mechanism
 The junction gate solenoid drops the junction gate, and the original is 70

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
 Go to the machine remove the back cover of the ARDF 71

and have a look to the mechanical parts.

 Read the service manual on how to remove the back
6.3 Scanner

Ricoh Academy Europe

 All scanner optics are included inside one carriage. 73

 When you move the carriage, use the drive belt.

 Do not pull the carriage directly otherwise you get image

ADF scan glass Exposure glass

ARDF/Platen cover open sensor

Scanner carriage HP sensor Scanner drive belt

Scanner carriage Scanner drive motor

Inside the carriage
 The light source is an LED array. 74

 Light from the LED board goes to the original via the two
 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.
LED Board Reflectors
4th Mirror
1st Mirror

2nd Mirror
3rd Mirror

5th Mirror

Lens Optical path
 The drive belt moves the carriage along the guide rod. 75

 The actuator for the HP sensor is on the underside of the


Carriage HP sensor Scanner carriage

Scanner drive belt

Guide rod Scanner drive motor

Moving the carriage by hand
 When you must move the carriage by hand, move the belt, 76

as shown below.
6.4 Laser units

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 There are two laser units. 78

 1 for Black and Cyan.

 1 for Magenta and Yellow.
Laser unit details
 Both laser units are physical identical. 79

 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-1 LD unit 1st mirror

Polygon mirror

2nd mirror F-theta lens-2

Toner shield glass

Laser beam path
 The scan line is written on the drum from the front end 80

towards the rear of the machine.

Collimating lens
LD unit
Colour skew adjustment
 The adjusters must be used after installing a new LD unit. There is one 81

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.

F-theta lens-2

After replacing a laser unit
 There are two things to do: 82

 Initialize the D-phase data and shading data.

 See the service manual (Replacement and Adjustment, Laser
 Do the color skew adjustment procedure.
 Explained on the next few slides.
Colour skew adjustment (1/5)
 Execute ‘MUSIC’ (SP2-111-002). 83

 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.
Colour skew adjustment (2/5)
 Open the front cover [A]. 84

 Remove the upper cover [B]. Then close the front cover
 Execute ‘MUSIC’ (SP2-111-002) again.
 This is because removing the upper cover may have caused
the LD units to slip out of alignment.
Colour skew adjustment (3/5)
 Adjust the colours that need correction using the knobs 85

shown below.
 See the procedure in the service manual for details.
 These adjustments move the L2 F-theta lenses-2 inside the
laser units.
Colour skew adjustment (4/5)
 This shows one of the four knobs. 86

 Rotate each knob corresponding to

the value shown in SP2-117-001 to
 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
 If the SP value is -7, turn knob
[A] 7 clicks counterclockwise.
Colour skew adjustment (5/5)
 Reassemble the machine. 87

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

Before adjustment After adjustment

 Do the colour skew adjustment according to the procedure 88

in the field service manual.


6.5 Photoconductor unit


Ricoh Academy Europe


 The photoconductor unit contains the drum and the

development unit.

1. Drum
2. Waste toner transport coil
7 3. Lubricant brush roller
4. Lubricant bar
6 5. Cleaning blade
6. Charge roller
5 10 7. Charge roller cleaning roller
4 11 8. Doctor blade
9. Toner mixing coil (upper)
3 12
10. Depressurization outlet, with
2 filter
11. Development roller
12. Toner mixing coil (lower)
13. Toner density sensor
Drum unit
 Lubricant is applied by the lubricant brush and spread out by the 91

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.

Cleaning blade

Lubricant brush

Toner collection coil

Development unit

Doctor blade

Upper agitator

Development roller

Lower agitator

Toner density sensor

 For CMY, there are two motors (drum drive, and 93

development unit drive).

 For K, there is one motor.
 A clutch connects this motor to the development unit at the
correct time.
1 2 3 4 5 6 7 8

12 11 10 9
 Never remove gears 3,5 or 7.
 The phase between these gears are adjusted at the factory.
Replacement procedures
 Do not disassemble the PCDUs. 94

 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.
PCDU replacement procedure
 You must release the lock lever and check that the ITB 95

has no tension.

Tension applied Tension released

Lock lever released
 Remove the PCDUs and have a look at the differences 96

between the units.

6.6 Toner supply

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

Shutter Toner end sensor Agitator Toner supply coil

Toner supply path
 Toner is moved into the hopper 99

Toner supply motor 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

Toner end sensor Agitator Toner supply coil

Toner bottle detection
 When the BRB board detects an ID chip, the machine 100

detects that the toner bottle is installed.

BRB ID chip
After replacing the toner supply
 Set the following SPs (New unit flag) to “1” depending 101

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.
6.7 Paper feed

Ricoh Academy Europe

1. End fence. 8. Registration sensor. 103

2. Paper tray. 9. Paper feed sensor.

3. Side fence. 10. Bypass feed roller.
4. Paper end sensor. 11. Bypass paper size sensor.
5. Paper feed roller. 12. Bypass paper end sensor.
6. Paper dust collector. 13. Friction pad.
7. Registration roller.

1 2 3 4 5 6 7 8 9 10

13 12 11
 The paper transport motor drives the paper feed, 104

registration, and bypass mechanisms through gears and

 It also drives the duplex and bypass bottom plate lift
Paper transport motor

Registration clutch

Paper feed clutch

Bypass feed clutch

Bottom plate lift
 A rack and pinion mechanism lifts the bottom plate. 105

 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

Bypass bottom plate
 The bypass bottom-plate is operated by a clutch. 106

 When the clutch is energized, drive from the paper

transport motor turns the bottom plate cam shaft, through
 The front cam and the rear cam, lift and lower the bottom
 The HP sensor monitors the position of the bottom plate.

Bottom plate clutch

Bottom plate cam

HP sensor
Bypass tray sensors
 The paper size sensor detects the size for B5 paper or 107

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

Paper size sensor Paper end sensor


6.8 Transfer
Image transfer and paper transfer

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1 2 4 5

16 15 14 13 12 11 10 9 8
Image transfer process
 A typical image transfer belt and paper transfer system is 110


Image transfer power supply
 Image transfer bias (to transfer toner from the drum to the 111

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


ITB contact mechanism
 This mechanism only exists for CMY. 112

 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.


ITB contact cam


ITB contact sensor ITB contact motor

ITB cleaning
 The ITB cleaning blade removes remaining toner from the 113

 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.

Cleaning blade

Lubricant brush roller

Toner transport coil

ID sensors
 3 ID sensors are used for Image density detection and 114

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

ID sensor board
 Go to the machine and do the ITB unit and ID sensor 115

removal procedure according to the service manual.


6.9 Waste toner collection

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 The waste toner drops at the front of the bottle. 117

 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.

 When the coil rotates, the agitators move the toner 118

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.
Replacing the waste toner bottle
 Move the 5 caps [A] from their storage location on the waste 119

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.
6.10 Fusing

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 This machine uses a Quick Start Up Direct Heating (QSU- 121

DH) fusing system which saves energy and improves print

 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.
1. Thermopile. 7. Pressure roller. 122

2. Thermistor. 8. Pressure roller thermistor. (2X)

3. Thermostat. 9. Entrance guide plate.
4. Separation plate. 10. Fusing sleeve belt.
5. Exit guide plate. 11. Fusing lamp.
6. Pressure arm. 12. Fuse for new unit detection.

3 4 5
2 6

1 7

12 11 10
Free-belt fusing system

Sleeve belt
Fusing pad


Fusing lamp Pressure roller

Reflector plate

Temperature control components

Sleeve belt thermistor

Sleeve belt thermopile


Fusing lamp

Pressure roller

Fuse for new unit detection

Fusing drive
 The fusing/exit motor drives the pressure roller. 125

 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 exit sensor

Fusing sleeve

Pressure roller Fusing entrance sensor Fusing motor

Fusing unit replacement
 After the fusing unit is replaced you must do the following: 126

 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.
Fusing sleeve belt replacement
 The fusing pad must face the pressure roller. 127

 The fusing sleeve belt is replaced as an assembly.

SC 554
 If SC 554-00 occurs, 128

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.
SP 5-810
 From the flow chart on the previous slide, you can see 129

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.
Fuse for new unit detection
 The fuse is shown below [A]. 130

 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)
 Do the pressure roller and sleeve belt assembly removal 131

procedure according to the service manual.

6.11 Paper exit

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 The position of the inverter junction gate determines whether 133

paper from the fusing unit is:

 Fed out of the machine.
 Fed towards the duplex feed path.

Exit/inverter roller Inverter junction gate

Paper exit sensor

Fusing exit sensor

 The exit/inverter roller is driven by the paper transport 134

 The paper exit sensor controls the timing for the inverter

Exit/inverter roller Inverter junction gate

Paper exit sensor

Inverter mechanism
 When the exit sensor detects the leading edge of the 135

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.
Exit/inverter gear train

Movement by the solenoid

Drive from the

paper transport motor

Drive to the exit roller

Exit unit replacement
 Make sure that you do NOT release the exit roller drive 137

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.
 Remove the exit unit. 138

 Follow the instructions in the service manual.

6.12 Duplex feed

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Entrance sensor  After the inverter 140

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.
Duplex rollers

Exit sensor
Duplex drive
 The paper transport 141

Paper transport motor drives the duplex

motor mechanism through
gears and the duplex
 Two sensors detect
paper jams and control
paper feed timing.

Duplex clutch
 The order of printing is as follows: 142

 Sheet 1, reverse side > Sheet 2, reverse side > Sheet 1,

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

6. Maintenance

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SMC data to SD card
 All settings (both SP mode settings and UP mode 144

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

PM parts
 PCDU: 60K (Black) 145

 A4, 5% coverage, 2 pages/job

 Waste toner bottle: 90K
Yield parts
 PCDU (CMY) 146

 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
Before performing maintenance
 Print the SMC logging data with SP5-990-004. 147

 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
 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.
Cleaning the ID sensor
 Clean the ID sensor [B] with a damp cloth. 148

7. Replacements & Adjustments

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Fax unit
 The MBU and FCU are combined into one board. 150

 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:
 bit switch settings
 RAM address settings
 NCU parameter settings
8. Options

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Optional paper tray


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1 2 3 4 5 6 9 10

16 15 14 13 12 11
 The paper feed motor drives the rollers in the paper tray 154

through two clutches.

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

Paper feed motor Paper transport clutch

Paper feed clutch

Paper feed
 This tray uses a feed roller and friction pad system. 155

 The paper-end and remaining-paper sensors use the same


Remaining paper sensor

Paper end sensor

Tray lift mechanism
 The upward pressure from the bottom plate is adjusted 156

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 lift sensor

Encoder plate

Bottom plate HP sensor


One-bin tray

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Exit tray Paper sensor LED Exit Exit sensor

 The LED will light when there is an output on the tray. 159

 The output is detected by the paper sensor.

 The exit sensor detects jams.


Exit sensor

Paper sensor

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