1. D117/D118 Aficio MP C305SP/305SPF Service master full training module
Griffin-C1
D117/D118
Aficio MP C305SP/305SPF
Service master full training module
See notes for version changes.
Date of change
Version History
Description
draft
Initial version (no changes)
Created by: Group L&D Version:1.0.a Classification: Internal

2. 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.
No additional notes.

3. Requirements Griffin-C1 (Full option when available) Windows PC
Printer drivers
Field service manual
Operation manual
This presentation
No additional notes.

4. “Ricoh Knowledge and Learning system”.
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”.
No additional notes.

5. Module overview Introduction Specifications New & improved features
Installation
Detailed section descriptions
Maintenance
Replacements & adjustments
Options
No additional notes.

6. Introduction
No additional notes.

7. Models Griffin-C1, Aficio MP C305SPF(D117)
ARDF is standard.
Fax is standard.
Griffin-C1, Aficio MP C305SP(D118)
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)
SPF: Scanner, Printer and Fax.
SP: Scanner and Printer.

8. One paper tray is standard
Appearance
Up to two additional paper tray units can be installed.
There are no finishers.
Colour LCD touch panel
No additional notes.
Optional one-bin tray
One paper tray is standard

9. Machine layout Laser units Fusing unit Toner bottles Duplex path PCDU
ITB cleaning unit
No additional notes.
Image transfer belt unit (ITB)
Paper transfer roller (PTR)

10. Operation panel (1/3) 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.
Home button
Touch panel
SD/USB Slot
Function keys:
If the browser unit is installed, a URL can be assigned to a function key.
Function keys

11. Operation panel (2/3) Status key: Energy saver key: Stop 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.
No additional notes.
Energy saver key
Status key
Stop key

12. Operation panel (3/3) The operation panel can be tilted.
No additional notes.

13. Configuration
No additional notes.

14. 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.
No additional notes.

15. Controller slots Interface slot: USB slot: SD card slots (1&2):
Used for one of the following: IEEE1284, IEEE (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.
USB slot
SD card 1
The Bluetooth interface unit and the Wireless LAN interface unit cannot be used simultaneously.
SD card 2
Interface slot

16. 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:
Service procedures like:
Firmware update
SMC data export (SP5-992)
NVRAM backup
There is no App2Me for this model.
SMC data export is a feature that was added for the GW+ controller and is explained later in this presentation.

17. 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)
No additional notes.

18. 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.
No additional notes.

19. 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.
No additional notes.

20. 2. Specifications
No additional notes.

21. General specifications
Standard paper capacity 350 sheets = standard tray (250 sheets) + By-pass tray (100 sheets).
Full option paper capacity 1350 sheets = standard tray (250 sheets) + By-pass tray (100 sheets) + 2X optional tray (500 sheets).
Maximum output capacity is with optional one-bin tray.
More specifications are mentioned in the field service manuals.

22. Reliability Colour ratio: 20%. Average Copy Volume (ACV): 2K.
Max CV: 5K.
PM Cycle: 60K.
Life: 300K or 5 years, which ever comes first.
No additional notes.

23. 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.
No additional notes.

24. 3. New & improved features
GW 2011A
No additional notes.

25. 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
The underlined items are more explained in the next slides.
For some items a HDD is required.
For more information about the other items download the Ricoh’s-Next-Generation-Controller material from WICE. (See additional files to support the training material)

26. Operation panel design
Note that there has been a big design change between the Pre-11A and 11A Operation panels.
4-line display
Pre-11A
Customizable logo
No additional notes.
Home button
Function keys
11A
Menu with programmable icons

27. 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.
Shortcuts to webpages can only be stored when the optional browser unit is installed.

28. 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.
No additional notes.
User1’s icons are shown after he logs in.
Other users can’t see User1’s icons.

29. 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.
Device settings can be imported/exported using a csv file.
As the programmable icons are stored in binary fields in the csv, they are not easy to edit manually.

30. 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.
At installation the function keys are programmed. (Copier, Scanner and Printer)
Function keys

31. 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
With using WIM you can choose the file name. (xxxxxx.jpg)
With using the SD-card you must use the folder structure (./custom_ui/image/) and name the file insert.jpg.

32. External USB keyboard
A USB 101-key keyboard can be used with the MFP if the following conditions are met:
SP mode must be set to “1”
The use of USB keyboard must be enabled via SP and user mode.
The USB keyboard for SDK is not connected.
No additional notes.

33. 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.
When the following errors occur, the job will be skipped and the next job will be printed.
Specified paper size is not available.
Specified paper type is not available.
No paper on the specified paper tray
No staples (*This is not covered by pre-detection of errors.)
Hole punch receptacle is full (*This is not covered by pre-detection of errors.)

34. 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'.
No additional notes.

35. 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
Driver
Use this to print large jobs after office hours, so that others will not be prevented from using the machine.
User authentication must be enabled.
When the main power of the machine is turned off if the specified time has arrived, the Scheduled Print jobs are stored as Hold Print jobs.
Operation panel

36. 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.
No additional notes.

37. 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
Printer
FAX
SDK
WIM
System
MFP Browser SP
To do the import/export, administrator authentication must be enabled.
This import/export function doesn’t apply to the address book. The address book has its own import/export function.
Note1: To do the import/export function is possible when the machines have completely the same configuration.

38. Import/export MFP settings (2/2)
Backup/restore MFP settings to/from a SD card.
No additional notes.
MFP
Settings(UP)
SD slot
MFP
Settings(SP)

39. 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.
Up to 6
Sub machines
No additional notes.
Same Network
Machine: B
w/o Fax option
Machine: C
w/o Fax option
Fax Receiving
Network
Fax Sending
Center Machine: A
with Fax option
Machine: D
w/o Fax option

40. Remote fax (2/2) Center Machine Sub Machines
Fax Option must be installed.
HDD and printer option must be installed.
“Fax Connection Unit (SD card option)” must be installed.
Sub Machines
In order to receive fax document on sub machines, operators must register the addresses of specific senders as default settings.
No additional notes. SD
Machine: C
w/o Fax option SD SD
Fax Connection Unit
Center Machine: A
with Fax option

41. 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.
Paper size for HTML direct printing is fixed to A4/Letter.
The 10 key pad on the operation panel can't be used for entering numbers in the url. Use the displayed character entry screen or the external USB keyboard.
Example of websites

42. Demonstration Customizable logo. Function key assignment.
SD-card
WIM
Function key assignment.
External USB keyboard.
Import/Export MFP settings.
Browser unit.
No additional notes.

43. 4. Installation
No additional notes.

44. 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.
No additional notes.

45. 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.
No additional notes.

46. Toner bottles
Shake each bottle 10 times before you install it in the machine.
The PCDUs already contain developer.
No additional notes.

47. 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.
What happens if the power is turned off during the initialization process?
It depends on when the power is turned off during the process. In the worst case, it may be necessary to replace all PCDUs and the ITB.

48. Selecting the languages in the Administrator Tools
Language selection
The user can set up to 5 languages and switch between them.
Selecting the languages in the Administrator Tools
User tools
No additional notes.

49. 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.
No additional notes.
HDD encryption
DOS

50. 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 SP
For tray 3, use SP
Tray 2 is the upper of the two optional feed units, and tray 3 is the lower.
No additional notes.

51. 1-Bin tray unit A B D 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 B
No additional notes. D

52. Fax unit
Don’t forget to switch the FCU battery jumper switch [A] to the "ON" position.
After this you must do the local settings for the fax unit.

53. 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.
The icon can be added for different options:
Application
Program
Extended feature
URL

54. 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.
No additional notes.

55. Exercise
Install the machine with available options according to the service manual.
No additional notes.

56. 5. Detailed section descriptions
No additional notes.

57. 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

58. 6.1 General

59. How to enter the SP-mode
The “Clear/Stop” key is separated into two keys.
“Clear” key.
“Stop” key.
Press Clear Mode key
Enter “1 0 7”
Press and hold Clear for at least 3 seconds
No additional notes.

60. Machine layout Laser units Fusing unit Toner bottles Duplex path PCDU
ITB cleaning unit
No additional notes.
Image transfer belt unit (ITB)
Paper transfer roller (PTR)

61. Paper feed path ARDF Optional 1-bin tray Standard output tray
Duplex path
No additional notes.
Standard tray
By-pass tray
Optional trays

62. Drive 1 12 11 2 10 9 8 7 6 5 4 3 Scanner drive motor.
Development clutch (K).
Drum drive motor (K & ITB unit).
Drum drive motor (YMC).
Development motor (YMC).
Paper feed clutch.
By-pass bottom plate clutch.
Paper transport motor.
By-pass feed clutch.
Duplex transport clutch.
Registration clutch.
Fusing drive motor.
Paper feed motor drives the paper feed, duplex and exit. 12 11 2 10 9 8 7 6 5 4 3

63. 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.
Exhaust fan
Scanner cooling fan
Ozone filter
No additional notes.
Temperature sensor
PSU cooling fan
Humidity sensor
PCDU cooling fan

64. 6.2 ARDF
No additional notes.

65. Junction gate solenoid
Component layout
ARDF motor
Pick-up solenoid
Original set sensor
Transport sensor
Upper cover sensor
Junction gate solenoid
No additional notes.
ARDF relay board

66. Junction gate solenoid
Drive
The ARDF motor drives all the rollers.
The pick-up roller and Junction gate are operated by a solenoid.
Pick-up solenoid
Junction gate solenoid
No additional notes.
ARDF motor

67. Original detection
The stopper prevents the user from placing originals too far into the feeder.
Stopper
Original set sensor
No additional notes.

68. 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
No additional notes.
Friction Pad

69. Feed
For single-sided scanning, the original passes through the ARDF as shown below to the exit tray.
Pull-out roller
No additional notes.
Scanning roller
Transport sensor
Scanning guide plate

70. 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.
No additional notes.
Exit roller
Inverter roller
Junction gate

71. 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.
No additional notes.

72. 6.3 Scanner
No additional notes.

73. 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.
ADF scan glass
Exposure glass
ARDF/Platen cover open sensor
No additional notes.
Scanner carriage HP sensor
Scanner drive belt
Scanner carriage
Scanner drive motor

74. 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.
LED Board
Reflectors
4th Mirror
1st Mirror
No additional notes.
2nd Mirror
3rd Mirror
5th Mirror
CCD
Lens
Optical path

75. Drive The drive belt moves the carriage along the guide rod.
The actuator for the HP sensor is on the underside of the carriage.
Carriage HP sensor
Scanner carriage
No additional notes.
Scanner drive belt
Guide rod
Scanner drive motor

76. Moving the carriage by hand
When you must move the carriage by hand, move the belt, as shown below.
No additional notes.

77. 6.4 Laser units
No additional notes.

78. Overview There are two laser units. 1 for Black and Cyan.
1 for Magenta and Yellow.
No additional notes.

79. 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-1
LD unit
1st mirror
Polygon mirror
No additional notes.
2nd mirror
F-theta lens-2
Toner shield glass

80. 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
No additional notes.

81. 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.
F-theta lens-2
Turning the adjuster clockwise moves the front of the scan line to the left, which corrects skew where the left side of the image is lower than the right side.
Adjusters

82. 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.
No additional notes.

83. Colour skew adjustment (1/5)
Execute ‘MUSIC’ (SP ).
After you execute MUSIC, check the adjustment with the following SPs.
(Black)
(Cyan)
(Magenta)
(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 is -4, and the others are +1, no adjustment is necessary.
If is -6, and the others are +1, the adjustment must be done for all four colours.
If is -6, and the others are 0, the adjustment must be done only for magenta.
No additional notes.

84. Colour skew adjustment (2/5)
Open the front cover [A].
Remove the upper cover [B]. Then close the front cover again.
Execute ‘MUSIC’ (SP ) again.
This is because removing the upper cover may have caused the LD units to slip out of alignment.
No additional notes.

85. 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.
No additional notes.

86. Colour skew adjustment (4/5)
This shows one of the four knobs.
Rotate each knob corresponding to the value shown in SP 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.
No additional notes.

87. Colour skew adjustment (5/5)
Reassemble the machine.
Execute ‘MUSIC’ (SP )
Check the SPs (SP 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.
No additional notes.
Before adjustment
After adjustment

88. Exercise
Do the colour skew adjustment according to the procedure in the field service manual.
No additional notes.

89. 6.5 Photoconductor unit PCDU
PCDU= Photoconductor and Development unit.

90. Overview
The photoconductor unit contains the drum and the development unit.
Drum
Waste toner transport coil
Lubricant brush roller
Lubricant bar
Cleaning blade
Charge roller
Charge roller cleaning roller
Doctor blade
Toner mixing coil (upper)
Depressurization outlet, with filter
Development roller
Toner mixing coil (lower)
Toner density sensor 8 7 6 9 5 10
No additional notes. 11 4 3 12 2 13 1

91. 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.
Cleaning blade
The charge roller cleaning roller rotates whenever the charge roller rotates.
The drum cleaning blade is a counter blade.
There is no quenching lamp. The OPC discharges itself after cleaning.
Drum units are not exchangeable.
Lubricant brush
Toner collection coil

92. Development unit Doctor blade Upper agitator Development roller
Two agitators are used to mix the toner and developer.
Toner is added by the toner supply unit when the toner density sensor detects low density.
The ID sensor detects the density of a standard patch that is transferred to the ITB.
This sensor is also used for toner supply control
Lower agitator
Toner density sensor

93. 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. 1 2 3 4 5 6 7 8
Drum drive gear. (K)
Development drive gear. (K)
3. & 4. Gears for Cyan.
5. & 6. Gears for Magenta.
7. & 8. Gears for Yellow.
9. Development motor. (CMY)
10. Drum motor. (CMY)
11. Drum motor. (K)
12. Development clutch. (K)
Gears 3,5 and 7 are the drum phase gears. Do not remove in the field. They are adjusted in the factory to the optimum position to reduce banding on outputs. 12 11 10 9

94. 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.
No additional notes.

95. PCDU replacement procedure
You must release the lock lever and check that the ITB has no tension.
Lock lever:
To remove the K PCDU [A], you must release the lock lever.
For the CMY PCDUs, it is not necessary to release the lock lever.
After replacing the K PCDU, do not forget to lock the lock lever again.
ITB tension:
Check that the ITB has no tension before PCDU (CMY) replacement.
Otherwise, the ITB may be damaged.
The tension of the ITB can be released as follows.
Turn the pressure release screw [A] to the left, until the flat part of the half moon on the screw points to the right.
Tension applied
Tension released
Lock lever released

96. Exercise
Remove the PCDUs and have a look at the differences between the units.
No additional notes.

97. 6.6 Toner supply
No additional notes.

98. BRB (Bottle Read Board)
Overview
ID chip
BRB (Bottle Read Board)
Toner bottle
Toner supply motor
There is no toner end sensor for K.
Shutter
Toner end sensor
Agitator
Toner supply coil

99. 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 motor
No additional notes.
Toner end sensor
Agitator
Toner supply coil

100. Toner bottle detection
When the BRB board detects an ID chip, the machine detects that the toner bottle is installed.
No additional notes.
BRB
ID chip

101. After replacing the toner supply
Set the following SPs (New unit flag) to “1” depending upon the replaced unit.
SP (Black)
SP (Cyan)
SP (Magenta)
SP (Yellow)
Set the following SPs (Toner supply flag) to “1” depending upon the replaced unit.
SP (Black)
SP (Cyan)
SP (Magenta)
SP (Yellow)
Exit from the SP mode.
Turn the main power off and on.
SP3-701 will reset the counters for the replaced unit.
SP3-510 will execute toner replenishment for the selected sub-hopper.
Both SP’s are executed after the machine is switched off and on.

102. 6.7 Paper feed
No additional notes.

103. Overview 1 2 3 4 5 6 7 8 9 10 13 12 11 End fence. Paper tray.
Side fence.
Paper end sensor.
Paper feed roller.
Paper dust collector.
Registration roller.
Registration sensor.
Paper feed sensor.
Bypass feed roller.
Bypass paper size sensor.
Bypass paper end sensor.
Friction pad.
No additional notes. 1 2 3 4 5 6 7 8 9 10 13 12 11

104. 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.
Paper transport motor
Registration clutch
No additional notes.
Paper feed clutch
Bypass feed clutch

105. 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.
No additional notes.
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.
Bottom plate clutch
No additional notes.
Bottom plate cam
HP sensor

107. 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.
No additional notes.
Paper size sensor
Paper end sensor

108. Image transfer and paper transfer
No additional notes.

109. Overview 4 1 2 3 5 6 7 16 15 14 13 12 11 10 9 8 Belt tension roller.
Lubricant brush roller.
Lubricant bar.
ITB cleaning blade.
ITB waste toner transport coil.
Discharge plate.
Paper transfer roller.
ITB drive roller.
ID sensor.
ID sensor shutter.
Shutter solenoid.
ITB contact arm (CMY).
ITB contact slider (CMY).
ITB.
ITB lock lever.
Image transfer roller (K). 7 16 15 14 13 12 11 10 9 8

110. Image transfer process
A typical image transfer belt and paper transfer system is used.
No additional notes.

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.
No additional notes.

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.
No additional notes.
ITB contact cam
Slider
ITB contact sensor
ITB contact motor

113. Lubricant brush roller
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.
Cleaning blade
Lubricant brush roller
The ITB cleaning blade is a counter blade.
Toner transport coil

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.
No additional notes.
ID sensor board

115. Exercise
Go to the machine and do the ITB unit and ID sensor removal procedure according to the service manual.
No additional notes.

116. 6.9 Waste toner collection
No additional notes.

117. 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.
No additional notes.

118. 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.
No additional notes.

119. 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.
These caps are included with every waste toner bottle.

120. 6.10 Fusing
No additional notes.

121. 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.
No additional notes.

122. Overview 3 4 5 6 2 7 1 8 9 12 11 10 Thermopile. Thermistor.
Thermostat.
Separation plate.
Exit guide plate.
Pressure arm.
Pressure roller.
Pressure roller thermistor. (2X)
Entrance guide plate.
Fusing sleeve belt.
Fusing lamp.
Fuse for new unit detection. 3 4 5 6
No additional notes. 2 7 1 8 9 12 11 10

123. Free-belt fusing system
Sleeve belt
Fusing pad
Mirror
Fusing lamp
Pressure roller
The sleeve belt rotates freely.
It is driven by the pressure roller.
The fusing pad has a low friction surface, this allows the sleeve belt to turn easily.
The pressure roller presses against the pad to form the nip zone.
The stay holds the pad in place.
The stay has a mirrored surface facing the fusing lamp.
This to concentrate the energy from the lamps to the left side of the inner surface of the sleeve belt.
The temperature at the ends of the lamp is lower than at the center.
The reflector plate prevents heat from the fusing lamp from damaging other machine components.
There is no lamp in the pressure roller.
Diana-C1.5 series: There is a steel pipe inside the belt.
Griffin-C1: No steel pipe. More energy is conserved.
Reflector plate
Stay

124. Temperature control components
Sleeve belt thermistor
Sleeve belt thermopile
Thermostat
Fusing lamp
The fusing temperature is monitored by thermistors and thermostats.
The thermostat is also a safety switch to prevent overheating.
The thermopile is attached to the main body of the machine.
It is not part of the fusing unit.
The fuse for new fusing unit detection only exists in service parts.
It does not exist in the fusing unit that is built into the machine at the factory.
The fuse is only used to reset SC554.(see later this presentation)
It does NOT reset any counters.
Why are there two pressure roller thermistors?
One of them is just outside the paper width of A4/LT, and the other is just inside. They monitor the roller temperature within the paper feed area and outside this area (where the temperature will be higher).
Pressure roller
thermistors
Fuse for new unit detection

125. Fusing entrance sensor
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 exit sensor
Fusing sleeve
No additional notes.
Pressure roller
Fusing entrance sensor
Fusing motor

126. Fusing unit replacement
After the fusing unit is replaced you must do the following:
Set SP to “1”.
Exit the SP-mode.
Switch the machine off and on.
Check SP whether the fusing is reset correctly.
The fuse for new unit detection does NOT reset SP

127. Fusing sleeve belt replacement
The fusing pad must face the pressure roller.
The fusing sleeve belt is replaced as an assembly.
No additional notes.

128. SC 554
If SC 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
No additional notes.

129. SP 5-810
From the flow chart on the previous slide, you can see that a new SP (SP ) 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 is normally only done as part of the countermeasure for SC 554.
SP does not look for or try to blow the fuse.

130. 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: M )
No additional notes.

131. Exercise
Do the pressure roller and sleeve belt assembly removal procedure according to the service manual.
No additional notes.

132. 6.11 Paper exit
No additional notes.

133. Inverter junction gate
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.
Exit/inverter roller
Inverter junction gate
Paper exit sensor
No additional notes.
Fusing exit sensor

134. Inverter junction gate
Components
The exit/inverter roller is driven by the paper transport motor.
The paper exit sensor controls the timing for the inverter mechanism.
Exit/inverter roller
Inverter junction gate
Paper exit sensor
No additional notes.

135. 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 junction gate guides the paper to the duplex feed path.
No additional notes.

136. Exit/inverter gear train
Movement by the solenoid
The solenoid which is connected to the black lever engages the drive from the left side or from the right side which changes the rotation direction of the drive exit roller.
Drive from the
paper transport motor
Drive to the exit roller

137. 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.
No additional notes.

138. Exercise Remove the exit unit.
Follow the instructions in the service manual.
No additional notes.

139. 6.12 Duplex feed
No additional notes.

140. 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
No additional notes.
Exit sensor

141. 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.
Paper transport
motor
The drive goes to the lower feed roller and via a timing belt to the upper roller.
Duplex clutch

142. 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.
No additional notes.

143. 6. Maintenance
No additional notes.

144. 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
No additional notes
SD slot or Service slot

145. PM parts PCDU: 60K (Black) Waste toner bottle: 90K
A4, 5% coverage, 2 pages/job
Waste toner bottle: 90K
The PCDU contains developer.
PCDUs are not customer installable.

146. Yield parts PCDU (CMY) Replacement at 120k:
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
A colour ratio of 20% is assumed.
The average machine life is 120k. (ACV= 2 x60)
With a colour ratio of 20%, the life of PCDU for CMY (24k) will run out after 120k. So the PCDU for CMY is a yield part, not a PM part.

147. Before performing maintenance
Print the SMC logging data with SP
To reset the PM counter for each item, you must set SP ~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
Check the other counters as specified in the ‘After installing the new PM parts’ procedure.
No additional notes.

148. Cleaning the ID sensor Clean the ID sensor [B] with a damp cloth.
No additional notes.

149. 7. Replacements & Adjustments
No additional notes.

150. 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
No additional notes.

151. 8. Options
No additional notes.

152. Optional paper tray
PB1050
No additional notes.

153. Components 8 1 2 3 4 5 6 9 10 7
Side fence.
End fence.
Bottom plate lift sensor.
Bottom plate HP sensor.
Paper end sensor.
Remaining paper sensor.
Paper feed sensor.
Paper transport roller.
Paper transport sensor.
Paper transport cover switch.
Friction pad.
Tray set switch.
Bottom plate lift arm.
Bottom plate.
Anti condensation heater (option).
Paper tray. 16 15 14 13 12 11

154. Paper transport clutch
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 motor
Paper transport clutch
The timing of each clutch is as follows.
1. The paper feed clutch is turned on until the paper transport roller begins to operate.
2. The paper transport clutch is turned on until the paper reaches the mainframe.
Paper feed clutch

155. Remaining paper sensor
Paper feed
This tray uses a feed roller and friction pad system.
The paper-end and remaining-paper sensors use the same actuator.
Remaining paper sensor
No additional notes.
Paper end sensor

156. Bottom plate lift sensor
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 lift sensor
Encoder plate
Just after the power is turned on, the tray goes down to home position. After that, the motor lifts it to the correct position.
Bottom plate HP sensor

157. One-bin tray
BN1010
No additional notes.

158. Components Exit tray Paper sensor LED Exit roller Exit sensor
No additional notes.

159. 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.
LED
Exit sensor
No additional notes.
Paper sensor

160. Griffin-C1
End
No additional notes.