Corona-C1

D197/D198/D199/D200/D201/D202
MP 2554/3054/3554/4054/5054/6054
Service Master Full Training

Ricoh Academy Europe

29/01/2020 Version: [###] Classification: Internal Owner: [Insert name] 1
 Objectives
 After completing this training you should be:
 Able to install the MP 2554 series in the field.
 Able to perform routine maintenance.
 Able to troubleshoot and repair the product in the field.
 Familiar with the Cheetah operation panel.

2
 Requirements
 Corona-C1 with Cheetah operation panel.

 Windows PC.

 Field Service Manual.

 This presentation.

3
 Pre-requisites and exam
 Before starting this training you must already have
followed the My-Ricoh training for:
 Printing V2
 MP 2554 series – Introduction

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

www.my-ricoh.com

4
 Module overview
 1. Introduction
 2. Installation
 3. Maintenance
 4. Detailed Section Descriptions

5
1. Introduction

6
 Which Models?

AD model (ARDF) SP model (ARDF) SP model (SPDF) SP Cheetah model (ARDF) SP Cheetah model (SPDF)
Corona-C1c (25cpm) MP 2554SP MP 2554ZSP
Corona-C1d (30cpm) MP 3054 MP 3054SP MP 3054ZSP
Corona-C1e (35cpm) MP 3554SP MP 3554ZSP
Corona-C1f (40cpm) MP 4054SP MP 4054ASP MP 4054AZSP
Corona-C1g (50cpm) MP 5054SP MP 5054ASP MP 5054AZSP
Corona-C1h (60cpm) MP 6054SP MP 6054ZSP

 MP 2554/3054/3554: Low end models.

 MP 4054/5054/6054: High end models.

7
Differences between models

Corona-C1 c/d/e Corona-C1 f/g/h

Low end models High end models
Laser Unit 1 Laser beam 2 Laser beams

Toner Cartridges 24k type only 24k and 37k

Fusing Corona-C1 f/g/h have a stronger fusing lamps

Fusing and exit

Fusing and exit have
Motors mechanism are driven by
separate motors
1 motor

The following items are different between the c/d/e

Other Differences models and the f/g/h models:
Air flow, IPU, PSU.

8
 Yield & Targets
 Toner:
 24k (all models)
 37k (Corona-C1 f/g/h)

Corona-C1 c/d/e Corona-C1 f/g/h

C1c C1d C1e C1f C1g C1h

Average CV per Month 4K 5K 7K 10K 15K 20K

Maximum CV per Month 15K 20K 30K 50K

PM cycle 120K 160K

Life time (5 years) 900K 1,200K 1,800K 3,200K

Scanner life time (5 Years) 1,000K scans

9
2.0 Installation
Mainframe
Installation flow chart
 The flow chart in the field
service manual shows the
correct order.
 SR3140/SR3150/SR3160/
SR3170 can only be
installed when the
PB3210/PB3150/Low
Cabinet 38 is installed.
 RT3030 can only be
installed when the
PB3210/PB3150 is
installed.

11
 Main machine installation
 See the installation procedure in the field service manual
for full details.
 On the following slides some important items are
mentioned.
 The following options are installed at the factory:
 ARDF (DF3090)
 SPDF (DF3080)
 Smart Operation Panel (Cheetah)

12
 Lifting the machine
 When lifting the machine off the pallet, use the grips as
shown in the diagram.
 Lift slowly, using 4 people.
 Do not lift the machine by holding the scanner unit, etc,
because this may cause the machine to deform.
 Note that the grip at the front right is hidden by the
cushioning material [A]. Remove the material to grip it.

13
 Scanner support storage
location
 When the machine is shipped with the scanner support.
 The scanner support can be stored at the indicated
location.
 At this location also the factory data sheet is stored.

Factory Data Sheet

14
 Heater harness
 Pull out the tray and connect the heater harness.

15
 Toner
 Before removing the black cap [A], shake the toner bottle
up and down 5-10 times.
 After shaking remove the black cap and slide the toner
bottle inside the machine.

16
 Security screen
 The screen below is displayed when you switch on the
machine for the first time.
 Ask the customer’s administrator to set the passwords
before you continue the installation.
 Use SP 5-755-002 to temporarily skip this screen.

17
 Initial toner supply
 To do the initial toner supply:
 Open the front cover.
 Switch on the machine.
 Go into the SP-mode.
 Set SSP3-510-031 to “1” and press ‘#’, then press ‘Exit’ to
leave SP mode.
 Close the front cover and the machine automatically starts
the initial toner supply.
 It takes about one to two minutes to finish the initial toner
supply.
 If the toner has not been shaken well, it may take up to
about 10 minutes.

18
 Initial toner supply is Not Done
 If you start printing without doing the initial toner supply at
installation, the following can happen:
 The machine goes to the toner-end condition even if the
machine has plenty of toner in the toner bottle.
 The image becomes gray and no toner-end condition.
 Do the following procedure to perform the toner end
recovery.
 Open the front cover for five seconds or more.
 Make sure that the toner bottle is set properly.
 Close the front cover and the toner end recovery starts.
 To solve the gray image:
 Execute forced toner supply (SP 3-050-001).
 Execute manual ProCon (SP 3-011-001).

19
 Other SP-modes
 During the installation process the following SP-modes
must be executed:
 SP 7-622-250: Initialize PM counters.
 SP 3-011-001: Manual Process control.

20
 Sensor feeler
 If there are NO option's installed, you must swing the
sensor feeler [A] out.

21
 SP 5-985-001 & 002
 Set SP 5-985-001 (on board NIC) to ‘1’, this enables the
NIB function when this is used for printing and @Remote.
 Set SP 5-985-001 to ‘2’, this enables the NIB function
when this is used for @Remote.
 Set SP 5-985-002 (On board USB) to ‘1’, this enables the
USB function.

22
2.1 Installation
Options

23
 Paper tray units
 Lift the copier by holding the grips.
 Do not hold the scanner unit while lifting.
 Secure the copier immediately after you put the copier on
top of the tray.
 At the front of the machine 1 screw.
 At the rear of the machine, at two locations.
 Finally, check the registration.

Front Rear
24
 Side LCT (RT3030)
 This cannot be installed unless you have already installed
the optional two-tray paper feed unit or the tandem LCT.
 Paper size is set to A4 LEF when the unit is shipped from
the factory.
 The paper size can be changed to LT, or B5 (all LEF).
 First, adjust the side fences, then change SP5-181-017
 0: A4, 1: LT, 2: B5

25
 ARDF (DF3090)
 When feeding thin paper, adjust the sliding tray to the
point shown below [A].
 When feeding normal paper, adjust the sliding tray to the
point shown below [B].
 If the sliding plate is not set correctly for feeding thin paper,
you may get the following problems:
 Original jam
 Original curl
 Originals cannot be stacked neatly

26
 One-bin tray
 The one-bin tray can be installed with other finishing
options.
 Install the one-bin tray first.

27
 D686,D687,D688,D689 Finishers
 Install the following before you install one of these
finishers:
 Bridge unit
 Tandem LCT / two-tray paper feed unit or a cabinet.

28
 D687 Finisher (SR3140)
 Only for D687: Two stabilizers [A] are included as
accessories.
 They must be attached to the finisher just after it is taken out
of the shipping box.

29
 Alignment
 Check the side-to-side registration by printing 5x an
A4LEF/A3 sheet to the proof tray.
 Using the markings on the front-most exit roller, check
where the paper edge is located when the paper is exited.
 Center marking – Paper is aligned correctly.
 If the paper edge is lined up with any marking to the right of
center - paper is shifted toward the front.
 If the paper edge is lined up with any marking to the left of
center - paper is shifted toward the rear.

30
 Proof support & auxiliary tray
 When the customer complains about a curl output on the
finisher, you can install the proof support tray and the
auxiliary tray on the finisher.

31
 Jogger adjustment
 When a paper alignment occurs like shown below, you
must do the jogger adjustment.

32
 Internal finisher (SR3130)
 When a punch unit is required, install the punch unit first
before installing the finisher.
 When the one-bin tray is required, install the bottom plate
of the finisher first, then install the one-bin tray, then
complete installing the internal finisher.
 Attach stabilizers to the base of the machine as explained
in the installation procedure, to prevent the machine from
falling over.
 These stabilizers are shipped with the internal finisher as
accessories.

33
 SD card slots
 Upper slot: SD card slot 1 (option slot)
 For the basic models, an SD card with the scanner/printer
option on it is shipped in this slot.
 This card stays in the machine at all times. Other SD card
options can be merged to this card.
 Lower slot: SD card slot 2 (service slot)

Storage location
34
 OCR unit
 When the OCR unit is installed, its function is stored in the HDD, and ID
information from the SD card is stored in the NVRAM.
 So the OCR unit must be installed again if you replace the HDD and/or
NVRAM.
 The exact procedure depends on the circumstances, as follows:
 If you have the original SD card and you replaced the HDD only: Re-install
the unit with the original SD card.
 If you have the original SD card and you replaced the NVRAM only:
 Re-install with the original SD card if you can upload/download the NVRAM data.
 Order a new SD card and re-install with the new SD card if you cannot
upload/download the NVRAM data.
 If you have the original SD card and you replaced both the HDD and
NVRAM at the same time: Re-install the unit with the original SD card.
 If you do not have the original SD card: Order a new SD card and re-install
with the new SD card.
 The re-installation procedure is the same as the installation procedure.

35
 USB Ports and I/F Board Slot
 USB port [A]
 Bluetooth Interface Unit Type D
 Smart Card Reader Built-in Unit Type M12
 There is no difference between the left and right USB ports.
 I/F slot A [B]
 IEEE 1284 Interface Board Type A
 IEEE 802.11a/g/n Interface Unit Type M2
 File Format Converter Type E
 USB Device Server Option Type M12
 Mini USB port [C]
 USB Device Server Option Type M12

36
 Heaters (1/2)
 There are heaters available as a service part for the
following locations:
 Scanner
 PCU
 Main & Optional paper trays
 In default (SP 5-805-001is set to ‘0’) the machine will
behave as follow:
 When the machine is operating, in standby mode, low power
mode or under an abnormal condition (cover open, SC, jam):
All heaters are off.
 When the machine is in sleep mode or when the main switch
is turned off: All heaters are on.

37
 Heaters (2/2)
 When SP 5-805-001 is set to ‘1’ the machine will behave
as follow:
 When the machine is operating: The heaters are off.
 When the machine is in standby mode, low power mode,
sleep mode, under an abnormal condition (cover open,
SC, jam) or when the main power switch is turned off: The
heaters are on.

! SP 5-805-001 affects all heaters !

 To avoid that the temperature inside the machine gets too

high don’t install or disconnect the PCU and scanner
heaters.

38
 After Installing the Machine and
All Options
 After you have finished installing the machine, back up the
NVRAM to an SD card. Also, do this after every service
visit.

39
3. Maintenance

40
 Important
 1 of the changed items from the predecessor is the total
weight of the machines.
 This is achieved by (where it is possible) replacing metal
frame by plastic frame.
 So the screws which are used are:
 Self tapping
 Metal
 The way to insert these screws is different.
 The self tapping screw always turn them counter clockwise
first until you feel a click.

Self Tapping Metal

41
 Firmware update
 3 firmware types available:
 .fwu – Regular firmware type used in the ‘Romdata’ folder on
the SD-card.
 .rfu – Firmware which is used for remote firmware update via
WIM.
 .pkg – Firmware which can be used for firmware update via
@Remote and via SD-card.

42
 Package Firmware Update
 Normally, firmware modules must be updated one-by-one
(System/Copy, Engine, etc).
 With the combined firmware package (package_ALL), all
modules can be updated with one operation.
 This package can be used in one of two ways:
 Over the network (Smart Firmware Update, SFU)
 With an SD card
 The machine must have a HDD installed.

43
 Package Firmware Update via
Network
 This feature is also known as Smart Firmware Update
(SFU).
 The machine must be connected to @Remote with a
embedded appliance.
 SFU will not work if the machine is connected to @Remote
with an external appliance.

 The machine must also have a hard disk installed.

44
 SFU
 There are two ways to do SFU.
 Immediate Update: Download and update the firmware
during a service visit.
 Update at the next visit: Set a date and time for downloading.
 The firmware will be automatically downloaded beforehand and
you can update it at the following visit.
 “Update at the next visit” is recommended because
firmware download may take some time depending on the
network condition.

45
 SFU: Immediate Update
 To start the procedure, go into SP mode, and touch the
‘Firmware Update’ button that appears at the bottom of
the display. Then touch ‘Update’.
 Update begins immediately after download is finished.
 If download fails, error code E66 appears, and you must
start again from the beginning.

46
 SFU: Immediate Update
 The update is suspended when a print job comes in.
 After the print job has finished, the following display
appears. Press Yes to resume the update.

47
 SFU: Update at the Next Visit
 To start the procedure, go into SP mode, and touch the
‘Firmware Update’ button that appears at the bottom of
the display. Then touch ‘Reserve’.

48
 SFU: Update at the Next Visit
 When ‘Reservation Setting’ is selected the date and time
of the next visit can be entered and when you want the
machine to start to receive the package.

49
 SFU: Update at the Next Visit
 Then, when you visit the machine the next time, to update
the firmware with the downloaded package, touch
‘Download Firmware’ and ‘Reserve’ again.
 Then touch [Reserved and received package information].
 ‘Success’ means that the firmware was downloaded. Now
you have to install it.

50
 SFU: Update at the Next Visit
 If there is a newer version available then the version which
is already downloaded, the display shows the following
choices.
 If you wish to download the latest version, touch [Execute]
beside the message “Download and update the latest
package.” Then update of the package firmware will start.
 If you wish to update using the firmware in the HDD (old
version), touch [Execute] beside the message “Update to the
received package.”

51
 SFU: Error Codes
 When you touch ‘Firmware Update’ to start an SFU, an
error code may appear.
 E49: Firmware update is prohibited by User Tools settings
(see ‘Package Firmware Update’ in the service manual for
the user tool that is used to enable/disable this feature).
 E51: The package firmware is now being downloaded.
 E57: The machine is not @Remote connected.
 E58: The machine is @Remote connected, but not via an
embedded appliance.
 E59: There is no HDD installed on the machine.
 E60: The machine does not support installation of an HDD.
 E68: SFU is not ready (Package firmware does not exist)
 E71: Network error.
 E72: @Remote connection is prohibited.
52
 Update with SD card:
Preparation
 You must create a folder called ‘package’.
 Not ‘romdata’.
 Only one version of the package firmware should be
copied into the folder.
 If you copy multiple versions of package firmware to the SD
card, the machine will select one version of the firmware at
random.
 If the SD card contains both a package and some
individual modules, the machine will detect this and the
screen below will appear.

53
 PM Schedule
 Corona-C1cde
 PCDU components (drum, pick-off pawl, charge roller, charge roller
cleaning roller, drum cleaning blade, developer, development unit
filter/seal): 120k
 Transfer unit: 120k
 Development unit gears, fusing unit (pressure roller, bearing,
sleeve unit): 240k
 Waste toner bottle: 120K
 Corona-C1fgh
 PCDU components (drum, pick-off pawl, charge roller, charge roller
cleaning roller, drum cleaning blade, developer, development unit
filter/seal): 160k
 Transfer unit: 160k
 Development unit gears, fusing unit (pressure roller, bearing,
sleeve unit): 320k
 Toner waste bottle: 160K
54
 PM-part replacing procedure
 Execute the SP for forced detection of a new part.
 See the next slide for a list of SP modes for each part.
 Set the SP to 1.
 Turn the power off.
 Do not turn on again until after replacing the part.
 If you have to turn the power on again before replacing the
part, go back to step 1 to execute the SP before replacing
the part.
 Replace the part.
 Turn the power on.
 The machine automatically resets the counter,
replacement day, remaining number of days, and
executes the necessary automatic adjustments for the
new part.
 Do not use the PM counter clear SP mode.
55
 PM Part Replacement - PCDU
 If the complete PCDU is replaced, no need to reset an SP;
the machine detects a new PCDU automatically and
resets the counters.
 PCU: SP3-701-002
 Cleaning blade: SP3-701-009
 Charge roller: SP3-701-018
 Cleaner for the charge roller: SP3-701-019
 OPC: SP3-701-021
 Separation pawl: SP3-701-022
 Development unit: SP3-701-023
 - Developer: SP3-701-024
 - Development filter: SP3-701-025
 - Bearings for development mixing augers: SP3-701-028

56
 PM Part Replacement - Others
 Paper Transfer Unit: SP3-701-108
 Fusing Unit:
 If the complete fusing unit is replaced, no need to reset an
SP; the machine detects a new fusing unit automatically and
resets the counters.
 Fusing belt unit: SP3-701-116
 Pressure roller: SP3-701-118
 Pressure roller bearings: SP3-701-119
 ADF
 Pick-up roller: SP3-701-206
 Feed belt: SP3-701-207
 Reverse roller: SP3-701-208

57
 Counters
 Estimated remaining days (SP7-956-002 to -208) counters
for each PM part allow you to judge when a part will reach
its target PM replacement time.
 The “No. of Minimum Remaining Days” Counter displays the
estimated minimum number of days left until a given PM part
is expected to reach its target yield in terms of either pages
or rotational distance. This estimate takes into account the
current value of the page or rotational counter, as well as the
daily usage trends (number of pages, rotational distance).
 Checking this value is an easier and more accurate way of
knowing how close a PM part is to its target yield than simply
checking the PM counter.
 The current % of unit usage can be displayed with the
following SPs:
 % of yield based on pages: SP7-954-002 to -208
 % of yield based on rotational distance: SP7-942-002 to -119 58
 Counters
 The page counters and rotation counters are increased
based on the following conditions.
 Page counter (SP7-621-002 to -208)：
 Each page is counted up once.
 A3 is set by default on double count. (SP5-104-01 is ON)
 Rotations counter (SSP)：
 This SP displays the rotational distance of the PM part (number
of revolutions converted into distance), including all rotations
that take place before, during, and after the actual job.

59
 How to check the PM Counters
 Step 1: Enter the SP mode (Yellow-806182-Clear for
+/- 5 seconds) and select PM Counter.

60
 New Function: PM Counter
 For some machines this function was already available.

SP Mode initial screen 61

 PM counter
 By pressing the PM Counter button, you go into the PM
Parts menu of the SP Mode.

62
All PM parts list

63
Counter clear for parts
exceeding target yield

64
Parts list for PM yield indicator

65
Clear all PM settings

66
Parts exceeding target yield

67
Counter list print out

68
Estimated Usage Rate/Remain
Days

69
Commissioning Status Report
Print

70
 Page counter and Running
distance

Running Distance

A B C
You should
replace the
part when the
running
distance
reaches 100%

PM Counter 71
 Page Counter and Running
Distance
 PM parts yield is based on the page counter when the
customer prints using the target conditions.
 But, for most PM parts, the yield depends on running
distance
 See the formula below for how this is calculated.
 So, a function was added to display the estimated PM
yield, in which the running distance is included.

Running Distance (m) (SP7-944-001~127)

= Motor rotation time (s) × Paper speed (mm/s)/1000

72
Estimated Value Display

A B C D E

73
 Estimated Usage Rate Display
 Displays the larger of these two values: Page counter (SP7-
954-xxx) and running distance (SP7-942-xxx).
 Note that parts such as rollers are displayed using the page
counter value since running distance is not measured.

Estimated usage rate % by page counter = A/B*100

A: Current page counter value (SP7-621-xxx)
B: Standard page end value (SP7-623-xxx)

Estimated usage rate % by running distance = A/B*100

A: Current distance value (SP7-944-xxx)
B: Standard distance end value (SP7-940-xxx)

74
 Estimated Remaining Days Display
 Displays the smaller of these two values: Page counter (SP7-
951-XXX) and running distance (SP7-952-XXX).
 Again, note that parts such as rollers are displayed using the
page counter value since running distance is not measured.

Remaining days by page counter (SP7-951-XXX) = (A – B) / C

A: Standard end value by pages (SP7-623-xxx)
B: PM page counter (SP7-621-xxx)
C: Average PM page counter per day = PM page counter (SP7621-xxx)/Number
of days since last replacement

Remaining days by running distance (SP7-952-XXX) = (A – B) / C

A: Standard end value by distance (SP7-940-xxx)
B: PM distance counter (SP7-944-xxx)
C: Average distance per day = PM distance counter (SP7-944-xxx) /Number of
days since last replacement
75
 Commissioning Status Report
 You can print the Status Report to check the machine status.

1. SP7-403-001~010 SC History
2. SP7-507-001~010 Printer Engine Jam History
3. SP7-508-001~010 Original Jam History
4. SP7-910-001, 002 ROM No
5. SP7-911-001, 002 Firmware version
6. SP8-581-001 T: Counter
7. SP8-591-001 O: Counter

76
4. Detailed Section Descriptions

77
 Chapter overview
 4.1 Machine overview
 4.2 Scanner
 4.3 Laser Unit
 4.4 PCDU
 4.5 Process control
 4.6 Toner supply
 4.7 Paper feed
 4.8 Image transfer
 4.9 Fusing
 4.10 Paper exit/duplex
 4.11 Waste toner collection

78
4.1 Machine Overview

79
 Main Components
1. Scanner Unit
2. Inverter Unit
3. Paper Exit Unit
4. Fusing Unit
5. OPC Drum
6. Duplex Unit
7. Bypass Tray Unit
8. Vertical Transport
9. Paper Feed Unit
10. Laser Unit
11. Toner Supply Unit

80
 Paper Path: Tandem Tray,
Finisher
1. ADF
2. LCIT
3. Tandem Tray
4. Booklet Finisher
5. Bridge Unit

81
 Paper Path: Internal Finisher
1. ARDF
2. LCIT
3. Paper Feed Unit
4. Internal Finisher

82
 Paper Path: Side Tray, One-bin
Tray
1. Platen Cover
2. Paper Feed Unit
3. Side Tray
4. One-bin Tray

83
Drive Components

84
Parts Layout: Scanner

85
Parts Layout: Paper Feed

86
Parts Layout: Laser Unit, PCU

87
Parts Layout: Fusing Unit

88
Parts Layout: Waste Toner
Bottle

89
Parts Layout: Duplex, Bypass
Tray

90
Parts Layout: Paper Exit,
Inverter

91
Parts Layout: Motors

92
Parts Layout: PCBs

93
Parts Layout: Fans

94
Air Flow

95
 Cooling (1/3)
 Paper is cooled immediately after fusing to reduce:
 Temperature of the stack
 Curling
 Condensation in the paper exit area.
 During output, the operation of fans depends on the
machine’s internal temperature (see the next slide).
 This temperature is measured by a temperature/humidity
sensor above the PCDU.
 After output, the fans stay on until the machine is cooled
down enough.
Temp./Hum.
sensor

96
 Cooling (2/3)
Condition Development Paper exit Fan Fusing Fan Development
exhaust heat fan bearing cooling fan PSU Cooling fan
*2 *2

Warm-up Stops Stops Stops Stops Stops

Rotates at low Rotates at
Standby Stops Stops Stops
speed low speed
Printing Rotates Rotates Rotates Rotates Rotates
Rotates at low Rotates at
After Printing Stops *1 Stops *1 Stops *1
speed *1 low speed *1
Abnormal
Stops Stops Stops Stops Stops
(Jam)

 This table shows the fans operation under specific

conditions.
 *1 When the temperature in the machine reaches 39
degrees, these fans keep revolving until the temperature
falls by 2 degrees.
 *2 D200/D201/D202 only.
97
 Cooling (3/3)
 In addition to fan operation, CPM is reduced if the
temperature remains too high during continuous printing.
 The machine pauses for 25 seconds after each block of 20
pages is printed.
 ‘The printing speed is being limited’ is displayed.
 If the machine temperature returns below a certain level, the
machine returns to normal speed.

98
 Switch off procedure
 Push the power switch [A] on the machine.
 Wait until the shut-off screen disappears.
 Take out the power cord.
 Push the power switch [A] again to remove the residual
charge.
 Note: If some LEDs on any of the boards are blinking or lit,
current is still present.

99
 Starting the machine again
 To start the machine, press the main power switch.
 If you press the main power switch during the shutdown
procedure, the machine will not start.

100
 Forced Shutdown
 In case normal shutdown does not complete, the machine
has a forced shutdown function.
 To make a forced shutdown, press and hold the main
power switch for 6 seconds.
 In general, do not use the forced shutdown.
 Forced shutdown may damage the hard disk and memory,
and can cause damage to the machine.

Use a forced shutdown only if it is unavoidable.

101
 Replacement of parts
 Some of the covers have tabs on them which break easily.
 The procedures in the service manual have diagrams to
show where the tabs are.
 Take care not to break them when handling the covers.

For example:
Upper Left Cover
102
 LCD Panel (1/2)
 LCD panels from two different vendors are used.
 Depending on which type is used in the machine:
 The bracket for attaching the panel has a different shape.
 The exterior cover on the machine has a different shape.
 So, if you replace the LCD panel, make sure that you
install the correct type.

103
 LCD Panel (2/2)
 How to determine the correct type to install?
 There are three labels on the rear of the operation panel.
The center label [A] shows the LCD model number.
 The first letter is either an S or a C, to indicate the
different vendors.
 If your machine has a label starting with S, you can only
replace the LCD with one that has a label starting with S.
 If your machine has a label starting with C, you can only
replace the LCD with one that has a label starting with C.

104
Locations of PCBs - 1

Controller
IPU
HDD

HVPS BCU

105
Power supply unit

PSU

106
 If the Self-encrypting HDD
(SED) is installed
 The machine holds data, linking the controller board and
SED, created automatically during SED installation.
 The data, however, will not be deleted automatically at
controller board replacement.
 Therefore, before replacing a controller board, you must
delete the link data manually so that the machine can
create new link data.
 Do the following steps when replacing a controller board.
1. Execute [Erase All Memory] on the operation panel: [System
Settings] – [Administrator Tools] – [Erase All Memory]
2. Turn OFF the main power switch
3. Replace the controller board
4. Turn ON the main power switch
 Do not turn the main power ON after step 2 until after you replaced the
board.
107
 Replacing NVRAMs on the
Controller Board (1/2)
 Make sure that the NVRAM is installed in the correct
orientation.
 If you install it the wrong way round, the NVRAM and the
controller board may be damaged.

108
 Replacing NVRAMs on the
Controller Board (2/2)
 When a new NV-RAM is installed in a machine that has a
smart operation panel, some SPs will be reset to the initial
values and a SC will occur.
 In that case, follow the instructions in the service manual
and reset the SC.
 See the procedure ‘NVRAM on the controller board’.
 The procedure is long and complicated, so follow it carefully.
 Note that you must have a backup of the address book
before you start to replace the NVRAM.
 It is best to use the customer’s own backup, because if you
take a backup just before replacing a defective NVRAM, the
data may be corrupted.

109
 Replacing the EEPROM on the
BCU Board
 Install a new NVRAM [C] so that the indentation [A]
on the NVRAM corresponds with the mark [B] on the
BCU.
 Incorrect installation of the NVRAM will damage both
the BCU and NVRAM.

110
 Replacing the Hard disk
 Before replacing the HDD, copy the address book data to
an SD card with SP5846-051 if possible.
 If the customer is using the Data Overwrite Security, the
Data Encryption feature or OCR Scanned PDF, these
applications must be installed again.

111
4.2 Scanner

112
 Overview

1. Sheet-through exposure glass 7. Original length sensor

2. 2nd mirror 8. Anti-condensation heater (Scanner
3. Scanner lamp unit (LED) heater)
4. Exposure glass 9. 1st mirror
5. Scanner motor 10. 3rd mirror
6. Sensor board unit (SBU), with 11. Scanner home position sensor
color CCD
113
 Scanner drive

1. Scanner wire: front  In book mode the scanner

2. 2nd carriage scans the document from left to
3. Scanner home position sensor right.
4. Scanner wire: rear  When the ADF is used, the
5. 1st carriage
scanner stays in the home
6. Scanner motor
7. Drive axis position at the left side and the
document is fed through and
read (sheet-through method). 114
 Original size detection

 Original length is detected by the sensors L1 & L2.

 Original width is detected by the CCD by monitoring three
locations (S1, S2, S3 in the diagram).

115
 DF exposure glass
 Originals may cause streaks on the exposure glass.
 To prevent these streaks non-contact scan is done.
 The ADF exposure glass has a mylar, which guides the
original over the glass.

Mylar

No contact Contact

116
 Dust Detection – Overview
 This function checks the ADF exposure glass for dust that
can cause black lines in copies.
 The dust check is done before the first original is scanned.
 This is done only once at the beginning of a job.
 The check is not done for originals added during a long
scanning job.
 If dust is detected, a message is displayed on the
operation panel, but the machine does not stop.

117
 Dust Detection (SP 4-020)
 SP 4-020-001: Enable/disable (default – disabled)
 SP 4-020-002: Sensitivity adjustment
 SP 4-020-003: Do not adjust in the field
 SP 7-852: Counts how many times the machine detected dust
on the ADF.

118
 Dust Detection - Action Taken
 When dust detection determines that dust exists, the scan
point shifts in order to avoid the dust.
 There are three scanning points.
 a: Home position.
 b: The first time that dust is detected, the scanner moves here.
 c: The next time that dust is detected, the scanner moves here.
 If dust is detected again, the scanner moves back to a. Then with
consecutive dust detections, the scanning position cycles a > b
> c > a > b > c , etc.

119
 ADF Exposure Glass
 The red dot [A] must be on the left at the rear.

120
4.3 Laser Unit

121
Overview
1. Polygon Mirror
2. F-theta Lens
3. Synchronization
Detector Lens
4. Synchronization
Detector Mirror
5. Toner Shield Glass
6. LD Board
7. Cylindrical Lens
8. Shield Glass

122
Parallelogram Image
Adjustment
 The correction is made
by attaching sheets at
three locations on the
laser unit (see the blue
circles in the photo).
 If lines slant down to the
left [A], paste a sheet on
the front side.
 If lines slant down to the
right [B], paste a sheet
at each position on the
rear side.
 Adjustment: 0.5mm –
0.6mm/sheet
 A set of 4 sheets is
available as a service
part.
123
4.4 PCDU

124
Overview
1. Cleaning Blade
2. Toner Collection Coil
3. PCL (Not part of the PCDU)
4. Pick-off Pawl
5. OPC Drum
6. Transfer Roller (not part of the
PCDU)
7. ID Sensor (not part of the
PCDU)
8. Development Roller
9. Charge Roller
10. Brush Roller (Charge Roller
Cleaning)
11. Quenching Lamp (not part of
the PCDU) 125
 Drum Drive
 The drum/waste toner motor [B] drives the drum [A]
through gears and the drum drive shaft [C].

126
 Drum Charge
 A charge roller [B] charges the drum.
 The charge roller is always in contact with the surface of the drum,
because a spring pushes the charge roller against the drum.
 The brush roller [A] is always in contact with the charge roller, to
remove dust.

127
 Drum Cleaning
 A cleaning blade [B] removes toner from the drum [D].
 The cleaning blade is always in contact with the drum.
 Toner removed by the blade is transported by the toner
collection coil [A] from the front to the rear and sent to the
recycling mechanism.
 Depending on Job conditions the used toner is discarded. This is
explained later in the Waste Toner section.
 Paper dust that adheres to the edge of the cleaning blade is
removed by rotating the drum in the reverse direction after job
end.

128
 Pre-cleaning lamp (PCL)
 The PCL [A] improves the cleaning ability of the cleaning
blade by decreasing the electrostatic adhesion between the
drum and toner.

129
 ID sensor pattern
 The ID sensor pattern is made at the following times:
 When the machine has been idle longer than the time set by
SP3-530-001 and the printed sheet count has exceeded the
value set by SP3-530-005.
 When the temperature and/or humidity has changed more than
the limits in SP3-530-002, -003 and/or -004, and the machine
restarts the engine (i.e. the main power is turned on, warming-up
after energy save mode, or the front cover is closed.)
 During a job, if the number of sheets in the job has reached the
value set by SP3-533-001.
 At the end of a job, if the number of sheets was more than the
value set by SP3-533-002.

130
Development Unit Overview
1. Doctor blade
2. Drum
3. Development roller
4. Mixing auger 2
5. TD sensor
6. Mixing auger 1

 The TD sensor and ID

sensor control toner
density.

131
 Development Unit Drive
 The development motor [C] drives the mixing auger 1 [A],
mixing auger 2 [E] and the development sleeve [B] through
gears [D].

132
Developer Mixing
 Two mixing augers, [C] and [D],
keep the developer evenly
mixed.
 Mixing auger 2 [C] transports
excess developer, scraped off
the development roller by the
doctor blade [B], towards the
rear of the machine.
 Mixing auger 1 [D] returns the
excess developer, along with
‘fresh’ toner, to the front of the
mixing assembly. Here the
developer is reapplied to the
development roller.
 The TD sensor [A] measures
the toner density.

133
 Development Bias
 Development bias from the power pack is applied to
development sleeve [A] via the development sleeve drive
shaft and bias terminal [B].

134
 PCDU Life
 The machine will generate a message in the display when the
PCDU life has finished.
 Corona-C1c/d/e: 120K
 Corona-C1f/g/h: 160K
 The user can continue to make copies.

135
 Important for PCDU
replacement
 To prevent damage from toner spillage during the PCDU
removal, be sure to place a ground cloth on the floor.
 To prevent damage from excess light, wrap the OPC drum
with protective paper and store the OPC drum in a cool dark
place.
 Do not touch the OPC drum, cleaning blade, or any seals or
tapes.
 Do not use any alcohols or solvents to clean the OPC drum;
Be sure to wipe with a dry cloth.
 If excess dirt exists, first wipe with a damp cloth, and next wipe
off completely with a dry cloth.
 Do not rotate the OPC drum clockwise after PCDU is set.

136
 Taking out the PCDU
 To prevent toner spilling, carefully pull out the PCDU without
tilting.
 If you replace the PCDU, you do not need to do SP 3-701,
because the machine detects a new unit automatically when
you cycle the main power off/on, and performs the initial
adjustment automatically.
 However, if you replace individual components, you may have
to set an SP before you turn the machine off to replace the
part.
 See each individual replacement procedure in the service
manual for details.
 Also see Maintenance > PM Parts Setting

137
 Separating the PCDU
 The PCDU can be divided into the PCU [A] and
development unit [B].

138
 Reassembling the PCDU
 When installing the face plates, check the following points.
 [A]: The bearing of the face plate must fit on the OPC drum
 [B]: The bearing of the face plate must fit on the bearing of the
development roller

Rear
Front

139
 Installing a New PCDU
 Remove the cap from the new development unit and attach it
to the old development unit.
 Don’t forget to pull out the seal.

Seal

Cap

140
 Counter Reset Before
Replacement
 If you replace a complete PCDU, there is no need to do SP 3-
701, because the machine detects a new unit automatically
when you cycle the main power off/on, and performs the initial
adjustment automatically.

 But:
 Before replacing the PCU, set SP3-701-002 to “1” and turn off
the main power switch. Do not turn the main power on until after
you replace the PCU.
 Before replacing the development unit, set SP3-701-023 to “1”
and turn off the main power switch. Do not turn the main power
on again until after you replace the development unit.

141
 Developer Replacement
 Before replacing the developer, set SP3-701-024 to “1” and
turn the main power switch OFF.
 During the procedure, you must replace the development side
seals and development case entrance seals.
 The new ones are included in the ‘development seal set’, which
must also be ordered when the developer is replaced.
 Be careful to install these the correct way.
 See the procedure in the service manual for details.
 After new developer is installed, initialization begins
automatically. No SP is needed.
 If you must replace the development filter during the same
visit as you replace the developer, replace the developer
before you replace the filter.

142
 Mixing Augers
 The two augers have different shapes. Make sure that they
are put back in the correct places.

143
 Mixing Auger Bearings
 Make sure that you install them correctly, in the orientation as
shown below.

144
4.5 Process Control

145
 Process control
 Process control is a system that adjusts the image
creation process to maintain a constant image density.
 Process control consists of two items:
 Potential control
 Toner density control

146
 Timing (1/2)
 Power on, Return from Energy Saver, Closing the front
cover.
 When a certain time (360 minutes) has passed after the
previous job end and when 100 sheets is printed after the
last process control at the previous power-on, return from
Energy Saver mode or closing the front cover.
 When a new PCDU is detected.
 When the TD sensor detects toner end before turning the
power on.

147
 Timing (2/2)
 Job end.
 When 100 sheets is printed after the last job end.
 In the middle of a job.
 When 100 sheets is printed since the start of the job.
 Non-use (Idle).
 When the machine has been idle for more than 360 minutes.
 When there have been significant environmental changes
since the last job end.
 Done only when the energy saver mode is off.
 Manual process control.
 When SP 3-011 is executed.

148
 Potential control
 Adjusts the charge voltage, development bias, LD power
 Uses the ID sensor and TD sensor
 The machine creates an ID sensor pattern
 This pattern has a lower density than usual printing, because
it is made using a lower charge voltage and development
bias than for printing.
 The machine measures the following:
 Vsp (the ID sensor output from the ID sensor pattern)
 Vsg (the ID sensor output from bare surface of the OPC
drum)
 The results are used to adjust the development bias so
that image density is consistent during printing.

149
 Toner density control
 The ID sensor output from the ID sensor pattern (Vsp) is
used to calculate the reference value (Vtref) for the TD
sensor.
 Vtref is the target toner density in the developer required
to maintain good image quality

150
 Process Control Steps
 ID sensor calibration
 The machine adjusts the strength of the ID sensor’s LED so
that Vsg (the charge which is detected from the bare surface
of the drum) is 4.0V ±0.5V.
 When Vsg is detected as not within the target range three
times, SC370 (ID sensor error) appears.
 Developer agitation
 The machine agitates the developer for up to 5 seconds,
then reads the TD sensor output.
 Bias adjustment
 The machine corrects the development bias based on the
readings of Vsp and Vsg.
 The machine corrects the charge voltage and laser power
based on the selected development bias.
151
 TD Sensor Initialization
 When a new PCDU is installed, the following occurs:
 The developer is agitated for 30 seconds.
 The machine monitors the TD sensor during this agitation
period and measures Vt (initial TD sensor value).
 SC360-01 occurs if the sensor cannot be calibrated within the
acceptable range.
 Process control is done automatically.

152
 Components Used: ID Sensor
 The ID sensor is a reflective photosensor (LED and
photosensor assembly) located in the right cover of the
mainframe.
 It detects the density of the Vsp pattern at the center of
the drum.
 To do this, the LED in the sensor shines light on the drum,
and the photosensor measures the amount of light
reflected from the drum.

153
Components Used: TD Sensor
 The TD sensor is just below
the development unit.
 The sensor measures the
toner concentration of the
developer from outside the
case without contacting the
developer and converts the
measured value to the toner
density.
 This type of sensor, known
as a µ sensor, does not
directly measure Vt. The
machine must calculate Vt
from the sensor output.

154
4.6 Toner supply

155
Inserting the Toner Bottle
 When the toner bottle [A] is
set, the nozzle [B] on the
rear of the main machine
is inserted into the bottle.
 When the machine detects
that toner must be added
to the development unit
(see Toner Density Control
after the next slide), the
bottle drive motor turns a
transport coil via a drive
gear [E] and toner in the
bottle is transported
horizontally.

156
Toner to the Development Unit
 Toner transported by the coil
[A] falls directly into the
development unit via the
transport pipe [B].
 The coil in the transport pipe
prevents toner from remaining
in the pipe.
 When the PCDU is installed in
the machine it opens the
shutter [D] on the bottle
assembly and the toner is able
to go to the development unit.
[F]

157
 Toner Density Control
 To control toner supply, the TD sensor output (Vt) is
compared with a reference value (Vref).
 SP3-230 is the default TD sensor reference voltage.
 This is modified by ID sensor readings to provide Vref.
 In this way, the amount of toner added varies depending on
the measured conditions in the development unit (TD
sensor) and on the drum (ID sensor).

158
 Toner End Detection
 The TD sensor checks for toner near end and toner end.
 Toner near end detection:
 If the difference between the output and the target is larger
than a certain amount, the machine determines that a
‘possible near-end condition’ exists and starts to calculate an
integrated value for ‘true near-end detection’.
 If this value is larger than a certain amount, the machine
signals toner near-end.
 Toner end detection:
 If the difference between the output and the target is larger
than a certain amount, the machine determines that a
‘possible end condition’ exists, and starts to calculate an
integrated value for ‘true end detection’.
 If this value is larger than a certain amount, the machine
signals toner end.
159
 Toner End Recovery
 When the machine is in a toner-end situation and the front
cover is opened for more than 5 seconds, the machine
attempts to recover by adding toner when the front cover
is closed.
 Toner-end recovery will not work when the machine is
switch off when inserting a new toner bottle.

160
4.7 Paper Feed

161
 Overview

1. Pick-up roller (1st paper tray)

2. Feed roller (1st paper tray)
3. Separation roller (1st paper tray)
4. Feed roller (2nd paper tray)
5. Separation roller (2nd paper tray)
6. Pick-up roller (2nd paper tray)
162
Paper feed drive

163
Registration

164
Bottom plate lift

5 6

165
Paper feed mechanism

166
Paper Size Detection

167
 Remaining Paper Detection

Paper Height Sensors

Tray Lift Motor

Bottom plate

168
Paper End Detection

169
Paper Dust Removal

170
By-pass Tray: Components

171
 By-pass Tray: Size Detection

Paper Width Sensor

Paper Length Sensor 172

4.8 Image Transfer

173
Overview

174
Drive

175
 Transfer Roller Charge
 The toner is attracted from the drum to the paper by a
positive current which is supplied from the HVPS.
 The current depends on the paper size, paper type, and
paper feed tray.
 The curvature of the drum, discharge plate and the pick-
off pawls help the paper to separate from the drum.
 The discharge plate is supplied with a negative DC voltage
from the HVPS.

Discharge plate

176
Transfer Roller Contact and
Release

177
 Replacement: ID Sensor
 Before you replace the ID sensor, you must input the
value 1 on the decal for the new sensor into SP 3-331-061.
 If this is not done, process control is not performed correctly
(it will use the values for the old sensor).

178
 Replacement: Transfer Roller
Unit
 Before replacing the transfer roller unit, set SP3-701-108
to “1” and turn the main power switch OFF.

179
4.9 Fusing

180
Overview

181
Temperature Control
Components

182
QSU-DH Fusing

183
 Different fusing unit
 One of the differences between the Corona-C1 models is
the fusing unit.
 The difference is in the power of the fusing lamps.
 MP 2554/ 3054/ 3554:
 Center lamp: 720W
 Edge lamp: 514W
 MP 4054/ 5054/ 6054:
 Center lamp: 874W
 Edge lamp: 838W
 The correct fusing unit is recognised by the looped wire in
the harness of the pressure roller temperature sensors.

MP 2554/3054/3554 MP 4054/5054/6054
184
 Heat absorption
 To prevent damage to the heating sleeve belt caused by
high temperatures at the paper edge the heat must be
absorbed.
 At two places the heat is absorbed depending on the
paper size.
 For paper size A4 SEF or smaller at the nip pad.
 For A4 LEF and A3 at the edges by the shield plate.

Nip pad

Shield plate
185
 Heat absorption (nip pad)
 When feeding A4 SEF or smaller paper sizes the fusing is
heated up by the center lamp.
 The nip pad is made of two different metals inside.
 The heat absorbing plates are made of a material that is very
conductive to heat.

A4 SEF print area

Heat absorption plates

186
 Heat absorption A4 LEF/A3
 When feeding A4 LEF or A3 there is no paper at the ends
(area D) so the heat rises up at this point.
 The shields [C] protect the edges of the sleeve belt.

187
 Fusing drive
 The fusing motor [A] (or fusing/exit motor for the
D197/D198/D199) drives the pressure roller [B].
 The fusing sleeve [C] rotates around the fusing lamps as it
is dragged by the pressure roller.

188
 Pressure release mechanism
 For easier paper jam removal, the pressure between the
pressure roller and heating sleeve is released when the
right cover [A] is opened.

189
 Fusing SC’s
 For the SCs 544-02 & 554-02 a new fusing unit or heating
sleeve unit must be installed before you can reset the machine.

Sensors Cor-C1
Thermopile (Center) SC544-01
Thermopile (Edge) SC554-01
Thermistor (Center) SC564-01
Thermistor (Edge) SC574-01
NC sensor (Center) SC544-02
NC sensor (Edge) SC554-02

190
 Resetting fusing SC’s
 To cancel SC544-02/554-02, you must replace the fusing unit assembly
or the heating sleeve belt unit.
 If you cancel the SC by replacing the fusing unit, do the following.
 Install the new fusing unit (Do not install a previously installed unit because
the machine will check it is a new part or not with the new unit detection
fuse).
 Execute SP5-810-002 (SC Reset: Hard High Temp. Detection) and turn the
machine off/on.
 If you cancel the SC by installing a sleeve belt unit with new detection
fuse, do the following.
 Before replacing, set SP3-701-116 to 1.
 Install the new sleeve belt unit with the fuse. (see ‘To clear SC544-
02/SC554-02' at the end of the Heating Sleeve Belt Unit replacement
procedure)
 Execute SP5-810-002 [SC Reset: Hard High Temp. Detection] and turn the
machine off/on.
 If you are replacing the heating sleeve belt unit for PM or any reason
other than canceling these SCs, discard the fuse that is packed with the
new heating sleeve unit. 191
 CPM Down Control
 In low-temperature environments:
 In a low temperature environment, the fusing lamp may not
be able to keep the fusing unit hot enough.
 The center thermopile is checked at intervals. If the
temperature is too low, CPM is reduced in three stages:
100% > 80% > 65% > 50%
 To prevent belt overheating:
 Areas of the fusing sleeve outside the paper width can get
too hot, and this can cause the sleeve to break.
 If the temperature sensor detects high temperature, CPM is
reduced in three stages: 100% > 80% > 50% > 30%
 The sensor that is used depends on the paper size.
 For some paper sizes, it may not be possible to determine
the areas of the belt that may get too hot.
 For these cases, CPM is reduced one level if paper is fed
continuously for more than a certain time. 192
 Service notes
 When the fusing unit is used past its PM cycle, it may
break, causing a service call.
 Therefore, the machine displays a warning on the operation
panel at (c/d/e: 240k or f/g/h: 320k) pages and stops at
(c/d/e: 260k or f/g/h: 350k) pages.
 If you replace a complete fusing unit, you do not need to
perform SP 3-701, because the machine detects a new
unit automatically.
 If you replace only a part of the fusing unit, however, such
as the pressure roller, you must set SP3-701 for that part.

193
 Fusing wiring
 When reassembling the fusing unit, Make sure the
harnesses are routed the correct way.

Side view Bottom view

194
4.10 Paper Exit/Duplex

195
Duplex components
1. Reverse sensor
2. Reverse roller
3. Junction gate
4. Duplex entrance roller 1
5. Duplex entrance sensor
6. Duplex entrance roller 2
7. Duplex transport roller 1
8. Duplex transport roller 2
9. Duplex exit roller
10. Duplex exit sensor

196
Duplex entrance

197
Paper exit
1. Paper exit full sensor
2. Reverse sensor
3. Reverse roller
4. Junction gate
5. Duplex entrance roller
6. Duplex entrance sensor
7. Paper exit sensor
8. Paper exit roller
9. Paper exit full feeler

198
Exit to the Exit Tray/Bridge Unit

199
To the Duplex Path or One-bin
Tray

200
4.11 Waste toner collection

201
 Overview
 Printing with low toner coverage leaves uncharged toner
in the development unit.
 This degrades developer more quickly.
 To keep toner in the development unit fresh, the machine
makes a pattern on the drum when low toner-coverage
pages are printed.
 This supplies a certain amount of fresh toner to the
development unit.

202
 Mechanism: Overview

1. Solenoid (controls the position of the recycling shutter)

2. Recycling Shutter (does not work; stays fixed in the
‘discard toner’ position)
3. Waste Toner Transfer Coil
4. Development Unit
5. Waste Toner Bottle 203
Mechanism: Discarding Waste
Toner
 Used toner falls into
the waste toner bottle.
 The recycling shutter
[B] closes the hole to
the development unit
underneath the waste
toner transport coil
[C].
 The solenoid [A]
keeps the shutter
closed

204
 Drive
 The waste toner in the waste toner bottle is moved to the
front by the waste toner transport coil [C].
 The drum/waste toner motor drives the waste toner
transfer coil [B] and the waste toner bottle coil [C].

205
 Bottle near-full detection
 When the feeler [B] is lifted, this interrupts the toner collection full
sensor. (about 90% full)
 At this time, the pixel counter starts calculating the remaining days for
the waste toner bottle replacement.
 Remaining day counter = 15 days: The machine informs the status via
@Remote (If connected).
 Remaining day counter = 5 days: The machine displays a message that
indicates near full.
 Remaining day counter = 0 days: The machine displays a warning on the
operation panel and the machine stops.

206
 Bottle full detection
 Bottle full is detected when one of the following occurs:
 The pixel counter calculates the remaining days before
waste toner bottle replacement.
 The remaining day counter = 15 days: the machine informs the
status via @Remote (If connected).
 The remaining day counter = 5 days: the machine displays a
message that indicates the near full condition on the operation
panel.
 The remaining day counter = 0 days: the machine displays a
warning on the operation panel and the machine stops.
 When the machine has printed 7500 sheets since near full is
detected, bottle full is detected.
 The 7500-sheet limit can be adjusted with SP 3-810-011.

207
 Waste bottle set switch
 There is no set switch.
 If you remove the waste toner bottle, don’t forget to put it
back or install a new one.

208
5.0 Appendix

209
OPTIONAL PERIPHERALS
Finishers
(D686/D687)
 What are the D686 and D687
Finishers?
 1000-sheet Booklet Finisher D686
 This finisher has three trays: a proof tray on top of the
finisher, an upper (shift) tray, and a lower tray for booklets.
 This is a replacement for the B793 finisher.
 The mechanisms are very similar to the B793 finisher.
 1000-sheet Finisher D687
 This finisher has two trays: a proof tray on top of the finisher
and the upper (shift) tray.
 This finisher does corner stapling only. It does not have a
lower tray for stapled and folded booklets.
 General Layout
Proof Tray  Three trays.
Punch Unit  Proof tray
 Shift tray
 Booklet tray
 The shift tray can be used for
shift-sorting and stapling. The
Stapler proof tray cannot be used for
Shift Tray Unit these two functions.
 The shift tray does not move
Booklet Tray
from side to side. A roller in
the machine (the shift roller)
moves from side to side, to do
the shift sorting.
 There is only one stapler.
Booklet Folder  It does corner stapling and
booklet (saddle-stitch)
stapling
 Optional: punch unit.
 Compare with the B793
Finisher - 1
B793 D686

Shift Tray

Stapler Unit

Booklet
Folder
 Compare with the B793
Finisher - 2
 Better for thick paper
 D686/D687 has a less severe bend going back to the stapler
tray from the shift tray. So, heavier paper can be stapled
than in the B793.
 Better for thin paper
 In the B793, the stapler tray is almost vertical, so thin paper
bends while in the staple tray. In D686/D687, the stapler tray
is at a smaller angle, so thin paper can be stapled better.
 Proof Tray
 No shift-sorting or up/down mechanism.
 Proof tray junction gate solenoid: Drops the junction gate
 Proof tray full sensor: Detects when the tray is full
 Proof tray exit sensor: Detects jams

Proof Tray
Exit Sensor

Proof Tray
Full Sensor

Proof Tray
Junction Gate
 Shift Tray

 Has shift-sorting and up/down mechanism.

 Proof tray junction gate solenoid: Does not turn on
 This is the default mode.
 Shift Tray – Up/Down
Mechanism
 Shift tray motor: Moves the tray up/down until the top of the stack is at
the correct position
 Shift tray position sensor: Detects the top of the stack when it is at the
correct position
 Upper limit switch: Stops the shift tray motor when the tray moves up
too far
 Lower limit sensors 1 and 2: Detect when the tray cannot go down
more Shift Tray
 Sensor 1: Used for A3 Shift Tray Motor
Position Sensor
 Sensor 2: Used for A4

Upper Limit Switch

Lower Limit Sensor 1

Lower Limit Sensor 2

 Shift Tray – Side-to-side
Mechanism
 Shift motor: Moves the shift roller from side to side, after
the paper eject sensor detects the trailing edge of the
paper
 After the sheet is fed out, the shift roller moves back to
home position
 Detected by the shift HP sensor

Shift
Motor
Paper Eject
Shift HP Sensor
Sensor

Shift Roller
 Booklet Tray - Overview
 This tray does not have a lift mechanism.
 Two sensors detect when the tray is full.
 The actuators for these sensors are attached to the
sensor arm.
 This tray is for booklets only.

Tray Full
Sensors

Sensor
Arm

Depressor
 Booklet Tray – Stacking
 The sensor arm rests on the top of the booklets.
 The depressor pushes the open ends of the booklets
down.
 This lets the machine stack more booklets on the tray.
 Booklet Tray – Tray Full
Sensors
 The sensors detect four conditions.
 Ready, Full 1, Full 2, Full 3
 The three ‘Full’ conditions are not ‘half-full’, ‘almost full’, and
‘completely full’. The machine checks for one of these
conditions to detect that the tray is full. The condition that the
machine checks depends on the size of the paper and the
number of sheets in one stapled and folded booklet.
 If the tray is removed, the machine detects the Full 3
condition. Full 3

Rear Tray Full Front Tray Full

Sensor Sensor

Ready Full 1 Full 2

No tray
 Stoppers for Stapling
Upper Stopper - 1
 Used for the following:
 Corner stapling: All paper sizes
 Booklet stapling: B5, A4, LT
 Stoppers for Stapling
Upper Stopper - 2
 At the start of the set, the upper retraction motor starts. This
motor does two things.
 The stopper moves down to catch the paper.
 The upper clamp roller contacts the stack. It does not rotate
until stacking is finished.

Upper Retraction
Motor

2
Upper Clamp Roller

Upper 1
Stopper
 Stoppers for Stapling
Upper Stopper - 3
 At the end of the set, the stopper moves away.
 The upper clamp roller feeds the stack to the correct
position for stapling.
 Driven by the upper clamp roller motor
 Stoppers for Stapling
Lower Stopper - 1
 Used for the following:
 Booklet stapling: LG, B4, A3, DLT, 12"x17.7"
 Stoppers for Stapling
Lower Stopper - 2
 At the start of the set, the stapler moves to the center.
 A bracket on the stapler pushes the stopper, and the pawl moves into
the correct position to catch the leading edge of the paper.
 The upper clamp roller holds the stack (see the previous slide).
 When the stack is complete, the stapler moves to the rear-side position,
and the stopper moves away. The upper clamp roller feeds the stack to
the correct position for stapling.

Lower Stopper

Pawl Bracket
 Stacking in the Stapler Tray
 To send the paper to the stapler, the paper must be fed
back into the machine.
 The lower transport motor drives the reverse roller, which
feeds the paper into the stapler.
 It also drives the positioning rollers, which feed the edge of
the paper against the stopper.
 The other motor in this diagram moves the reverse roller
up/down. Lower
 A sensor detects the position of the roller. Transport
Motor

Reverse Roller

Positioning Rollers
 Jogger Unit
 Jogger motor: Moves the jogger fences every job

Jogger HP Sensor

Jogger Motor
Jogger
Fences
 Stapler Unit Movement
 Stapler unit motor: Moves the stapler from side to side
 Stapler HP sensor: After the job, the stapler moves back
to this position

Motor

Sensor
 Corner Stapling
One Staple
 The home position is at the front of the machine.
 The stapler moves to the stapling position, which is at the
rear of the machine, and inserts the staple.
 The stapler stays at the rear until all copies are stapled,
then comes back to home position.
 Corner Stapling
Two Staples
 On the first set, the stapler inserts the first staple at the
rear of the machine, and the second at the front of the
machine. Then the first copy is fed out.
 For the second set, the first staple is inserted at the front.
Then the stapler moves to the rear and inserts the second
staple. Then the second copy is fed out.
 The stapler returns to home position after all sets are
stapled.
 Booklet Stapling
B5, A4, LT
 The stapler moves from the home position to the rear of
the machine, then to the center.
 The stapler then moves to the first stapling position,
towards the rear from the center, and inserts the staple.
 The stapler then moves to the second stapling position,
towards the front from the center, and inserts the staple.
 The booklet is then fed to the booklet folder, while the
stapler waits at the rear of the machine for the next copy.
 Booklet Stapling
LG, B4, A3, DLT, 12"x17.7"
 The stapler first moves to the center position. At this position,
the bracket on the stapler releases the lower stopper, which is
necessary to catch the bottom edge of long paper.
 The stapler then moves to the first stapling position, towards the
rear from the center, and inserts the staple.
 The stapler then moves to the second stapling position, towards
the front from the center, and inserts the staple.
 The booklet is then fed to the booklet folder, then the stapler
moves to the center position for the next copy.
 Exit Guide Plate Open/Close
 For no stapling, no shift tray side-to-side motion:
 The exit guide plate stays down
 Shift tray side-to-side motion
 When the shift motor starts, the exit guide plate motor lifts the exit guide
plate. When shift has finished, the exit guide plate drops again.
 Stapling: The motor the exit guide plate up at the start of the job and drops
it at the end of the job.
 Necessary to make sufficient space between the exit rollers for long paper (for
example, A3/DLT)
 The exit guide plate HP sensor detects the correct time to stop moving down.

Motor

HP
Sensor
 Stack Feed-out
 Stack feed-out motor: Feeds the stapled stack out of the
jogger tray
 Stack feed out belt HP sensor: Detects when the belt is at
home position
 The pawl is next to the HP sensor at HP. This keeps it away
from the stapler when it moves.

Pawl

HP
Sensor

Motor
 Booklet Feed
Through the Stapler - 1
 These rollers feed the stack into the stapler and out to the
booklet folder, and apply pressure to the stack during this
process.
Upper Clamp
Roller Motor

Upper
Clamp
Rollers

Lower Clamp
Roller Motor
Lower
Clamp
Rollers
 Booklet Feed
Through the Stapler - 2
 This shows a side view of the mechanism that we have
just described.

Upper Clamp
Rollers

Lower Clamp
Rollers
 Booklet Feed
Into the Folder - 1

Lower Clamp
 The lower clamp rollers feed
Rollers the stack of paper down
towards the folder.
 The bottom fence is lifts the
Bottom Fence stack to the folding position,
HP Sensor
based on the paper size
used for the booklet.
 The clamp rollers open to let
the booklet fall onto the
bottom fence of the folder
unit.
 The lower retraction motor
opens and closes the gap
Bottom Fence between the clamp rollers
Bottom Fence Lift Motor
(see the next slide).
 Booklet Feed
Into the Folder - 2

Fold Roller
Motor

Clamp
Rollers

Bottom Fence Lift

Motor Lower Retraction
Motor

Bottom Fence
 Fold Plate Drive Mechanism
 A motor and cam drive the fold plate.
 The fold plate and cam both have home position sensors,
to control the folding operation.
Fold Plate
HP Sensor

Cam HP
Sensor

Fold Plate

Fold Plate
Motor
 Fold Roller Drive Mechanism
 The fold roller motor drives these rollers.
 Springs apply pressure between the rollers.

Fold Roller
Motor

Fold Rollers
 Punch Unit - Overview
 This punch unit has two new mechanisms to make the
positions of punch holes more accurate
 Skew correction
 The punch unit corrects skew in the paper before the holes are
punched.
 Side-to-side movement of the punch unit
 The paper must be in the middle of the paper feed path, or the
punch holes will be too high or too low along the edge of the
paper.
 The punch unit detects the distance that the paper is away from
the ideal position.
 Then it moves the punch unit across to put the holes in the
correct position at the edge of the paper.
 Punch Unit Operation
Skew Correction
 Finisher entrance sensor: Detects the leading edge of the
sheet
 Finisher entrance roller: Stops for a short time, to correct
skew
 These SPs control the skew correction mechanism
 SP 6146: Enable/disable
 SP 6145: Amount of time that the roller stops. Finisher
Entrance Roller

Finisher Entrance
Sensor
 Hole Position Correction - 1
 The paper position
Paper Position sensor is moved until
Sensor
it detects the edge of
the paper.
 This measures the
distance of the
paper from the ideal
central position in
the feed path.
 The machine uses
this to calculate the
distance that the
punch unit must be
moved across the
page.
 Hole Position Correction - 2
 The paper position sensor moves back to home position.
 The rollers feed the paper to the punch position.
 The punch unit moves across the page, to put the holes in
the correct position.
 Hole Position Correction - 3
 The paper is fed out of the punch unit.
 Punch hole position adjustments
 SP 6142: Moves the position parallel to the feed direction
 SP 6144: Moves the punch position perpendicular to the
feed direction

SP6142

SP6144
 Paper Position Detection
 The motor moves the sensor across the paper feed path
until the sensor detect the edge of the paper.

Paper Position
Sensor
Paper Position
HP Sensor

Paper Position
Sensor Slide Motor
 Punch Unit Movement

 Punch movement motor: Moves the punch unit across

until it is in the correct position.
 Punch drive motor (see the next slide): Puts the punch
holes in the paper.

Punch
Movement Motor
 Punching - 1
 First, the punch drive motor turns the encoder wheel until
it is at the correct home position.
 The home position for 2-hole punching is different from the
home position for 3-hole punching.
 Then the punch drive motor punches the holes in the
paper and returns to the home position.
Encoder
Wheel

Punch Drive
Motor

Punch Waste
Hopper Full Sensor
 Punching - 2
 Two-hole punching (top diagram): The motor drives
clockwise then reverse.
 Three-hole punching (bottom diagram): First the punch
gear is turned 180 degrees, then the motor drives
clockwise then reverse
Punch Drive
Motor

Punch Gear
Sensor
 Adjustments
 SP modes
 6140: Stapling position
 6141: Booklet stapling position
 6143: Position of jogger fences
 6147: Folder position adjustment
 Dip switches
 SW100: Stapling position
 SW101: Jogger fence position
 If you adjust a dip switch setting, open and close the finisher
cover to enable the new setting. It is not necessary to switch
the power off/on.
 Replacement and Adjustment
 Stapler Unit
 After you remove this, a special tool is needed when you
reassemble the machine.
 The stapler unit has two parts. The special tool holds the two
parts in the correct positions.
 The special tool is packed with each staple unit that is
ordered as a service part.
OPTIONAL PERIPHERALS
Internal Finisher SR3180
(D766)
 Basic Specifications
 No. of sheets:
 A4, 8 1/2 ×11 or smaller: 250
 B4, 8 1/2 ×14 or larger: 125
 Paper thickness: 52 g/m2 – 300 g/m2
 Up/down tray shift: No
 Left/right tray shift: Yes
 Stapling: Yes
 Punching: No
 Power consumption: Less than 30W
 Stapler Specifications
 Type of stapling: Without metal staples, application of
pressure
 No. of sheets which can be stitched together: 2 to 5
sheets
 Sizes which can be stitched: A3 SEF - B5 SEF, DLT SEF
- LT SEF
 Thickness: 54 g/m2 – 80 g/m2
 Stitching position: 1 position (Top corner, Slanted)
 Components - 1

1. Paper output tray 8. Shift roller

2. Paper output roller/paper output belt 9. Side-to-side registration sensor
3. Paper output sensor
10. Reverse roller
4. Paper output pressure motor
11. Entrance sensor
5. Junction gate
6. Stapler home position sensor 12. Rear edge presser
7. Stapler 13. Stapler drive motor
 Components - 2

1. Open/close door switch

2. Junction solenoid motor HP sensor
 Components - 3

1. Paper output full sensor 2 (stapling)

2. Junction Solenoid Motor
3. Paper output pressure HP sensor
4. Paper output full sensor 1
5. Transport motor
6. Shift HP sensor
7. Shift motor
 Paper Feed Mechanism
 The leading edge of the paper is detected by the entrance
sensor [G].
 If shift mode is used, the shift rollers [A] and [B] move the
paper until the side-to-side registration sensor [E] can
detect the rear edge of the paper.
 Straight-through Feed
 Paper from the mainframe goes to the paper output rollers
[C] and [D], and on to the shift rollers [A] and [B].
 The transport motor drives the rollers in the paper feed
path.
 When shift mode is used, the shift motor moves the shift
rollers from side to side.
 The paper is caught between the shift rollers, but the paper
output rollers separate so that the paper can be moved from
side to side.
 Shift Mechanism
 The shift mechanism starts when the distance between the
trailing edge of paper and the paper output roller on the main
frame is 10mm (timing is based on motor pulses and leading
edge detection by the entrance sensor).
 The shift motor [A] rotates to shift the paper to the front or back.
 The shift amount is 20mm for the front side, 10mm for the back side.
 The home position is at the back of the movement range, and is
detected by the shift roller home position sensor [B].
 Paper Output Rollers/Belt
Pressure Release Mechanism
 Paper output pressure motor [A] rotates, and moves the
paper output roller (driven) [D] to change the pressure
between the output rollers [C] and [D].
 There are three pressure positions:
 Strong pressure (home position)
 Weak pressure
 Pressure released
 Paper output pressure HP sensor [B] detects the home
position.
 Paper Output Rollers/Belt
Three Pressure Positions
 Strong: For paper feed, stapling, and paper exit (including feeding out the
stapled paper stack)
 Pressure released: During shift operation
 Weak: For feeding and stacking paper when stapling is used.
 When the mechanism moves to the ‘weak’ position, the upper output roller
[C] contacts the output belt, and not the lower output roller [D]
 When stacking, weak pressure is applied, to prevent damage due to rubbing
the sheets too strongly.

Strong Released Weak

 Stapling
Stacking in the Stapler Tray - 1
 There is no jogger mechanism.
 The shift mechanism described previously is used to align the left and
right edges of the sheet before feed to the stacking tray.
 The shift rollers [A] and [B] move the paper until the side-to-side
registration sensor [E] can detect the rear edge of the paper.
 The paper output roller and paper output belt move to the pressure
release position during the shift operation.
 Stapling
Stacking in the Stapler Tray - 2
 After the first sheet is fed and shift operation is completed, the paper output rollers move to
the strong pressure position.
 After the trailing edge passes the paper output roller, that roller reverses to send the paper
to the stacking area.
 At this time, the junction gate [J] moves up (shown as the blue arrow and circle) to send the
paper to the stacking area.
 Paper is fed to the stacking area by the reverse roller [H].
 When paper is fed to the reverse roller, the paper output rollers move to the pressure
release position (shown as the red arrow), so that the shift operation can be performed for
the next sheet.
 Stapling
Stacking in the Stapler Tray - 3
 The paper hits the fence [K], to align the edge of the stack in the
paper feed direction.
 After paper is stacked, the trailing edge presser [I] moves to the
pressing position (the reverse roller moves to the pressure
release position) and holds the stacked paper.
 Stapling
Feeding the Second Sheet
 After the first sheet is stacked, the second sheet is fed and
shifted in the same way as the first sheet.
 The trailing edge presser continues to hold the first sheet.
 Stapling
Stacking the Second Sheet
 After shift operation is completed, the paper output rollers move to the
weak pressure position and feed the paper to the stacking area. The
reverse roller then receives the paper.
 This procedure also applies to the third and later sheets.
 The trailing edge presser holds the stacked paper and the shift roller
feeds the second and later sheets into the stacking area where they are
held by the trailing edge presser.
 Stapling
Stapling and Feed-out
 After all sheets are stacked, the paper stack is stapled and fed
out by the paper output rollers.
 The stapled stack is also called the ‘paper bundle’.
 Junction Gate and Trailing
Edge Presser-Mechanism
 Junction solenoid motor [D] rotates clockwise to drive the junction gate
[A], the trailing edge presser [B] and the reverse roller [C].
 Junction solenoid motor HP sensor [E] detects the home position of the
mechanism.
 Junction Gate and Trailing
Edge Presser-Timing
 Junction gate
 Switches over to feed paper down to the stapler when the
trailing edge of the paper is 10mm ahead of the front edge of
the junction gate.
 Switches back to the standard position when the trailing
edge of the paper reaches the fence and the trailing edge
presser has moved to the pressure position.
 Trailing edge presser
 Moves to the pressure release position when the trailing
edge of paper reaches the reverse roller.
 Moves to the pressure position when the trailing edge of the
paper reaches the fence.
 Junction Gate and Trailing
Edge Presser-Procedure
 The junction gate, reverse roller up/down movement, and
trailing edge presser cycle through the four states shown
in these 4 diagrams

Home Position Position A

Position B Position C
 Stapler Mechanism
 Stapling is done by crimping the paper between two teeth. There are no staples.
 The stapler applies pressure (220kg) to the paper between the upper tooth [A] and the lower
tooth [B].
 The machine applies pressure through the pressure cam [C] by stretching the pressure link
[D].
 Moving and stapling is done by the stapler drive motor.
 The home position is detected by stapler home position sensor.
 After stapling, the trailing edge pressure releases the stack and the output rollers feed the
stack out of the machine.
 Stapler Stapling Procedure
 The machine can do single stapling or double stapling. Some paper
types require double stapling because of the arrangement of fibres in
the paper make it necessary for stronger bonding between sheets.
 Single stapling: Moves to the first staple position > Staples the
paper > Moves to the second staple position > Staples the paper >
Moves back to the home position
 Double stapling: First, the same operation as for single stapling >
Transport motor feeds the paper 4 mm > The single stapling
operation is repeated
 Stapler Movement
 The staple motor [B] moves the stapler through a cam [A].
 There is also a home position sensor [C].
 Output Tray Full Detection
 There are two sensors: one for stapling [B], and one for without
stapling [A].
 Paper feed stops when tray full is detected, and the user must
remove the stack from the tray. Then output restarts
automatically.
29/01/2020 Version: [###] Classification: Internal Owner: [Insert name] 277