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Service Bulletin

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

Subject Measures against Bk Toner Smudge Model TASKalfa500ci, TASKalfa400ci, TASKalfa300ci, TASKalfa250ci
Topic
Depending on the operating environment (*), the cohesive materials of the deteriorated toner and the additives detaching from toner might accumulate on the top side of the Bk developer magnet cover, which might interrupt air flow of the developer cooling fan. If the deteriorated toner accumulates and adheres to the magnet/sleeve roller, Bk toner smudge might occur. Therefore, the following changes were made. (*) Bk toner smudge can appear if the temperature inside the machine rises due to long time drive, or the originals/data with low print coverage are continuously printed in monochrome mode. (The conditions above can cause deteriorated toner.)

Note:
In conjunction with the below mentioned parts replacements, we would like to draw your attention to the occurring Service Call C2810 problems (related Service Bulletins attached). We recommend incorporating the C2810 measures, when exchanging the Black Developer Units, to avoid further quality problems. SB-2H7-0081-B022_1.pdf Change Waste Toner Motor (Measure against Service Call C2810) TASKalfa250ci-300ci-400ci-500ci-552ci, FS-C8500DN ICL screw transfer belt (Measure against Service Call C2810) TASKalfa250ci-300ci-400ci-500ci-552ci, FS-C8500DN

SB-2H7-0068-A210_1.pdf

Content of Changes
1) Bk developer units with countermeasures (No.1-4) are now registered and supplied to the field. Bk developer units with the below mentioned countermeasures are not implemented to machines manufactured in the factory. They are provided as service parts only. The following points are changed from the normal Bk developer unit. <Changed Points> (For more details, please refer to page 4 and after.) Item Details Prevention of the deteriorated The shape of the magnet cover was changed to saucer shape to collect the 1 2
toner from accumulating on the magnet cover Restraint of scattering toner in the developer unit additives and the deteriorated toner. The toner scattering from the front/rear side edge of the magnet cover is now restrained. (A magnet was added.) 2) The scattering of deteriorated toner accumulated inside of the new magnet cover is prevented. (A metal plate was added.) 3) The internal pressure at the front/rear side edges of the developer unit was decreased in order to restrain the toner scattering to the magnet cover. The Bk developer unit will be vibrated by reversely rotating Bk developer drive in order to remove the toner adhered on the metal plate which was added due to the change above 2-2). (The developer drive gear was changed.) * every two minutes while continuous printing The following changes were made in order to prevent the toner from scattering to the top of the Bk developer unit and the drum unit. - A sponge was added to the side facing the drum unit of the developer unit. - Sponge (L), sponge (S), a sticker and affixing procedure leaflet are now bundled in the Bk developer unit with countermeasure (No.1-4) to affix to the side facing the developer unit of the drum unit. The color of the upper/lower edges of the barcode label was changed to green. 1)

Support of reverse rotation of the developing drive (* Firmware upgrade is necessary at the same time.) Restraint of the toner scattering from the developer unit (Toner scattering to the top side of the developer unit and the main charger roller) Distinction from the normal Bk developer unit

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Service Bulletin
1
New control and settings of the reverse rotation of the developing drive

Ref. No.

2H7-0080 (B010)
e Pack Ver.11.00

<Date> Sep. 7, 2011 2) The firmware was upgraded as followed. (For more details on the subject Upgrade Pack, please refer to page 8.) Upgrad Item Content
- The new control was added to distinguish the normal Bk developer unit from the new one and to reversely rotate the drive for 0.5 seconds once per passing the fixed Bk developer drive time, only when the new developer unit was installed. (Initial setting: Reverse rotation is executed every 2 min. of Bk developer drive time.) - Interval Time" was added to Maintenance mode U147. (Setting value: 0 to 3, Initial value: 2) "Interval Time" 0: No reverse rotating 1: 1 min. 2: 2 min. 3: 5 min. * Don't set "0" to the machine when the new Bk developer unit is installed. (-->) (If the setting is "0", the phenomenon might be more frequently recognized depending on the usage.)

3) According to the registration of the part No. for the Bk developer unit with countermeasure in the above 1), the description and check box of [DV-855B], [DV-865B] and [DV-856B] were added to the packaging case which is commonly used with the normal developer unit (DV-855/865/856 for four colors). KMCs Classification Entire Stock Rework In-Field modification at next visit In-Field modification by case No modification necessary Field Measure: Please execute the following steps 1 to 3 when the phenomenon described above occurs. 1. Upgrade the firmware by the Upgrade Pack Ver.11.00 or later. (When the Bk developer unit with countermeasure is installed before upgrading the firmware, the self-diagnosis code C7401 (Developing unit K type mismatch problem) will appear). After the Firmware upgrade, please set the machine by service emulation mode U147 submenu Set operation mode to mode 0, and submenu Interval time to value 2 and submenu BK density to value 1 (only high speed model). Please check U464 submenu High altitude must be mode 1 as well perform ac calibration with value +4 for all colors. 2. Replace the Bk developer unit with the Bk developer unit with countermeasures (No.1-4). 3. Affix two sponges and the sticker bundled in No.1-4 to the drum unit installed in the machine. 4. At the next visit it is advisable to check and if necessary clean the BK developer. The sponges and the sticker mentioned in 1-4 above must be affixed to the new drum unit when replacing the drum unit in the machine on which the Bk developer unit with countermeasure is installed. Please separately order the seal kit (No.5) and make sure to affix the sponge and sticker to the new drum unit when replacing the drum unit. (Please refer to the affixing procedure leaflet bundled in the seal kit for alignment.) Serial Nos. of the Affected Machines: - Registration of the Bk developer unit with countermeasure/Change of the packaging case for the developer unit (Changes 1) and 3)): As these are service parts, no affected serial number is available. - Firmware upgrade (Change 2)): (-->) Please refer to the table below.
TASKalfa500ci TASKalfa400ci TASKalfa300ci From the next production From the next production KMA120V CS QJC1107195QEH1101821KMID KTST Q4C1100009QMN1100147KMA120V CS QJH1109660QEG1101825KMTW Other specs. QGE1100066- From the next production

TASKalfa250ci

KME QJE1107042KMTW QGF1100080KMBR Q9A1100466-

UTAX/TA QER1101996Other specs.

From the next production

KMSG QFF1100036-

UTAX/TA QEQ1112628-

KTST QMP1100789-

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Service Bulletin

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

<Image sample of Bk toner smudge>

Paper feeding direction

Bk toner smudge especially appears at the leading/trailing edge of the sheet.

[Important] Details :
1

Related Change
(Refer to the previous page)

Please explain your user that a sound might be recognized when the coupling of the main unit side and the developer side engage each other at reverse rotation of the developer drive and acquire the user's approval. (*1) This is a little clicking sound and normal in this operation mode.

<Changed point 3> Firmware upgrade

<Bk developer unit with countermeasure> Important: DLP Unit Version A will be replaced by DLP Unit Version B. Version A is no longer supplied to the field.
Old Part No. 302H793178 2H793178 302JZ93199 2JZ93199 -----------New Part No. 302H793710 2H793710 302JZ93410 2JZ93410 302H794830 2H794830 Qty Old New PARTS DLP K UNIT B PARTS DLP K L UNIT B PARTS SEAL FRONT DRUM SET SP 1 1 1 Com patibi lity Old New O* O* O

No. 1 3 (-->) 5

Description

Remarks *1, DV-855B *2, DV-865B Seal kit for replacing the drum unit *3

*1: TASKalfa500ci/400ci (Normal Bk developer unit --- For all specs. except KMKR: 302H79317_/For KMKR: 302H79K17_) *2: TASKalfa300ci/250ci (Normal Bk developer unit --- For all specs. except KMKR: 302JZ9319_/For KMKR: 302JZ9K19_) (-->)*3: Bundled item of No.5 (same as the parts bundled in Nos.1-4 in <Changed point 4> mentioned on the previous page) --Sponge (L), sponge (S), sticker and affixing procedure leaflet * The developer drive gear of the normal developer unit is individually supplied. However, the developer drive gear (The shape was changed from the gear of the normal developer unit in Changed points 3) of the Bk developer with countermeasure (No.14) is not registered as individual supply part

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Service Bulletin

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

<Normal Bk developer unit> (The illustration below shows the cross section of the magnet roller/sleeve roller section viewed from the machine front side.)

Sleeve roller

Metal plate

Magnet roller

Magnet cover

Cohesive materials of the additives and the deteriorated toner

: Air flow direction of the developer cooling fan

Normally, the air from the developer cooling fan removes the additives and the deteriorated toner accumulated on the magnet cover by passing through the cutout of the magnet cover. However, the remaining materials may be condensed depending on the operating condition which increases the amount of deteriorated toner, which may interrupt the air flow of the developer cooling fan over the magnet cover. In this case, the deteriorated toner accumulated on the cohesive materials may adhere to the magnet roller or the sleeve roller, which might cause the Bk toner smudge. <Bk developer unit for preventing the toner smudge>

Sleeve roller
Measured metal plate 1 Additives and the deteriorated toner

Magnet roller

(*)
Magnet Measured metal plate 2 Measured magnet cover (Saucer shape)

(*) Air flow from the developer cooling fan does not pass through inside the developer unit according to change of the shape of the magnet cover.

<Changed point 1> New magnet cover/new metal plate 1: The saucer shape to collect the deteriorated toner and the additives was added to the position not close to the magnet roller so that service personnel can periodically clean it. <Changed points 2-1) and 2-2)> - Magnet: The magnets were added to the both ends of the magnet cover to collect the deteriorated toner as grain ear shape (X in the figure below) over the measured metal plate 2 so that that deteriorated toner will fill the gap between the magnet cover and the magnet roller to prevent the toner scattering from the gap. - New metal plate 2: The metal plate 2 was installed in the front of the magnet roller to prevent scattering of deteriorated toner scatter collected in the new magnet cover for the magnet roller.

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Service Bulletin

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

<Changed point 2-3)> Developer housing: The diameter of the hole at the both sides of the developer housing was widened from 3 mm to 6 mm to reduce scattering of toner from the inside of the developer unit to the magnet cover by decreasing the internal pressure of the edge section of the developer unit. (Due to this change, the amount of the toner scattering from the hole with 6 mm diameter of the developer housing will increase. However, there is the developer filter in the upper part of the 6 mm hole which partly removes the scattered toner.) (Cross section of the normal Bk developer unit viewed from the machine front side) Sleeve roller Magnet roller
: Where the internal pressure of the developer unit is applied. : Direction of scattering toner

Toner scattering is prevented by decreasing the internal pressure at the both ends where the toner is frequently scattered since the toner is scattered from the section where the internal pressure is applied to the side of the sleeve/magnet roller where the pressure is not applied.

(Bk developer unit with countermeasure viewed from the upper side)

Developer housing

Machine rear side

Diameter of the hole: Widened from 3 mm to 6 mm to decrease the internal pressure at the both ends of the developer unit

Machine front side

<Changed point 3> and firmware upgrade Developer drive gear: One side of the coupling part of the gear was changed to slope shape. Firmware upgrade: Firmware was upgraded to enable reverse rotation of the developer drive only when the Bk developer unit with countermeasure is installed. --> The operation that the gear comes off from the coupling on the main unit drive side and engages again can be repeated when reverse rotation is performed due to the change above. The deteriorated toner adhered to the upper side of the new metal plate 2 which was added in <Changed point 2-2)> can be shaken off and removed by applying vibration to the developer unit when it is engaged with the coupling.
(Normal gear) (Gear with countermeasure) (Machine rear side of the Bk developer unit with countermeasure)

Slope shape Y Z

* The gears shown in the photo above are for TA500ci series. (Right gear is a prototype.)

Y: Normal rotation of the developer drive Z: Reverse rotation of the developer drive

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Service Bulletin

Ref. No.

2H7-0080 (B010)

<Date> Sep. 7, 2011 <Changed point 4> The sponges/sticker were affixed to interrupt the air flow between the developer unit and drum unit: The air flow from the developer cooling fan normally enters into the developer unit from the cut-out of the developer magnet cover. However, due to the deleted cut-out of the developer magnet cover, the air flow is led to pass between the developer/drum units, which blows up the scattered toner from the developer unit. In order to interrupt this air flow, the sponges and sticker were affixed to the side facing the drum unit/developer unit. (The photo below shows a prototype. The color of the actual sponge is dark gray.) - Developer unit: The sponge was attached to the side facing the developer unit to prevent toner smudge. - Drum unit: The sponge (L), (S), sticker and affixing procedure leaflet (refer to the attached leaflet) are now bundled in the Bk developer unit with countermeasure. The sponges and sticker shall be affixed to the drum unit when installing the developer unit. Sponge (L)

(Drum unit)

(Bk developer unit with countermeasure)

Stick er Sponge (S)

Sponge

(-->)(*) The sponge and the sticker above are not affixed or bundled in the drum unit. Please separately order the seal kit (No.5) and affix the sponge and the sticker to the new drum unit when replacing the drum unit of the machine on which the Bk developer unit with countermeasure is installed. [Normal air flow of the developer cooling fan] Normal Bk developer unit [Air flow when using the new magnet cover (without sponge)] [Air flow when using the new magnet cover and the sponge]

Bk developer unit with countermeasure

Bk developer unit with countermeasure Sponge Air flow

Scattered toner from the developer unit is blown up and adheres to the top of the main charger roller and the developer unit.

Drum unit

Drum unit

Sponge Air flow from the developer cooling fan Air flow

* The illustrations above are the simplified figures of the developer/drum unit viewed from the upper side.

Drum unit

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Service Bulletin

Ref. No.

2H7-0080 (B010)

<Date> Sep. 7, 2011 <Changed point 5> The barcode label with green lines at the upper/lower edges is now used to the Bk developer unit with countermeasure in order to distinguish it from the normal Bk developer unit.

<Barcode label affixed on the unit>

<Barcode label affixed on the side of the master packaging case>

*K**8800001 **

MADE IN CHINA

302******* 4/pcs 2******* Assembled in China/Designed in Japan

[Change 3: Change of the packaging case for the developer unit (Common use with the normal/new unit in all colors)] <New individual packaging case: Side indicating the unit name >

Name and check box for the new unit added <New master packaging case: Side indicating the unit name>

* The part numbers of the normal developer units remain unchanged. * A separate service bulletin will be issued for DV-856 developer unit for TASKalfa552ci and FS-C8500DN.

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Service Bulletin
<Firmware upgrade for TASKalfa500ci/400ci/300ci/250ci>
2011/7 Type MAIN FRAME MAIN *1 MMI
*1

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

Pack Version Fixed code 2H7_2F00 2H7_7000 2H7_81BR 2H7_F000 2H7_1000 2JZ_1000 2H7_1200 2H7_1400 2H7_1600 2H7_1800
*4 Fax Sys(Q) *4 Fax Sys(Q) *4 Fax Sys(Q) *4 Fax Sys(S)C *4 Fax Sys(S)C

New upgrade V11.00 011.006 011.002 <--<--021.001 021.001 <--<--<--<--<--<--<--<--<--<--<--<--<--<--<--<--<--<--<--V12.00 012.012 012.012 001.029 001.016 023.001 023.001 <--<--<--<--<--<--<--<--<--<--<--V1.13 <--<--<--<--<--<--005.001 Remark

---009.020 009.018 001.021 001.015 ------005.002 003.003 001.014 002.001 001.016 (005.002) 001.016 001.022
(C06.001)

V10.00 010.007 010.007 001.025 <--020.003 020.003 <--<--<--<--<--<--<--<--(C08.002)

LANGUAGE BR(OPTION) BROWSER ENGINE (high) *2*3 ENGINE (low) *2*3 SCANNER MOTOR MAIN H VLT MAIN SLEEP MAIN FAX BOOT FAX APL FAX IPL FAX BOOT FAX APL

3MB_5000 3MB_5100 3MB_5200 5JP_5000 5JP_5100 J00_E000 Fixed code 3LK_9500 3LM_9000 5H8_9000 5JA_9200 3LT_9200 3LT_9600 3LW_9800

FaxSystem (Q)/(S)C MIX *5 SOLUTION (DBA) ENHANCEMENT DP-750/750B, 760/760B PF-720/720B (2 cassette) PF-760/760B (3000) DF-780/780B (1000) DF-760/760B (3000) MAIN DF-760/760B (3000) MIDDLE MT-720/720B (3000)MAIL BOX

SaturnFAX_Pack C06001_005002 C08002_005002

003.002 ---009.003 004.001 003.002 007.005 006.003 007.002 004.002

005.001 V1.12 <--<--<--<--007.001 008.001 <---

For the KM sales companies, it is possible to download the firmware at the download center on the ESDC.net. When upgrading the firmware or replacing a board, please upgrade each kind of the firmware (PACK of MAIN FRAME/ENHANCEMENT) to the latest version at the same time. *1) Please make sure to upgrade the MAIN and MMI firmware at the same time. If the firmware is individually upgraded, the CF000 error message may appear which cannot be cleared at customer site. *2) Please note that the default value of U327 (Setting Cassette Heater Control) will be reset to OFF in case that the firmware was upgrade to the version 004.001 or later from the older version. For more details, please refer to the Service Bulletin SB2H7-0012 -8746). *3) Please perform AC Calibration in the maintenance mode U464 (Set ID Adjustment Mode) after upgrading the firmware of the version 006.009 or later from the older version. *4) Combined firmware of five kinds of FAX firmware (*4). When downloading the combined firmware, the appropriate firmware will be automatically installed by detecting the FAX system (Q) or (S) C.

<NOTE>
Please note that the cleaning roller reverse rotation control after finishing a job was disabled by this firmware upgrade (since the drum pinhole might occur at the user whose printing pages per job are a few).

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Service Bulletin
Service Information
Affected models: Saturn series Firmware: Ver.12

Ref. No.

2H7-0080 (B010)
<Date> Sep. 7, 2011

Depending on the complaint from user, it is recommended to change the parameter below in the maintenance mode. Default setting (If there is no problem with low density or productivity, please recommend to use this default setting.) U147 U325 Mode0 Mode1 Mode1 If print job with high density (10% or higher) is often performed, set to Mode3. If print job with low density (less than10%) is often performed, set to Mode2. U464 >TargetValue >ThickCalib >Bk U486 Bad Effects Mode2 Mode1 Higher toner consumption (with the 3sheets intermittent printing pattern) The amount of toner consumption will be increased by approx. 20%. 0 +100 To optimize the black density Please recommend this setting if user complained on unstable density and low productivity.

Procedures of cleaning the developer unit for preventing the Bk toner smudge
January, 2011 1. Turn off the power and detach the developer unit from the main machine. Remove four toner containers, waste toner tray, image formation holder. Remove the fuser unit and draw out the transfer belt unit slightly. Close the toner replenishment lid. Disconnect the connector and remove the developer unit from the main machine. 2. Clean the toner on the developer magnet cover. (Refer to photo 1/figure) Remove the toner that resides on the developer magnet cover by slanting the developer unit so that the sleeve roller side faces down. If unable to cleanly remove the toner, pat the developer housing with a screwdriver while slanting the developer unit. 3. Remove the toner adhered on the sleeve roller. (Refer to photo 2) Rotate the sleeve roller once by rotating the gear at the developer rear side and remove the toner that is adhered on the sleeve roller when cleaning in the above 2. 4. Clean the side of the developer unit and others. (Refer to photo 3) Clean the sponge that is affixed on the side of the developer unit, and the part around the toner replenishment lid at the front side and around the sleeve roller and others. 5. Clean the topside of the developer unit. (Refer to photo 3) Cleanly wipe off the toner accumulated on the topside of the developer unit. (Use of the vacuum cleaner is effective.) 6. Remove and clean the filter. (Refer to figure 4) Remove the duct by removing the hook at the front/rear side of the topside of the developer unit and remove three filters from the duct and then clean them. (Use of the vacuum cleaner is effective.)

2. Cleaning the developer unit

2. Cross section figure around the developer magnet cover

Sleeve roller
Magnet roller
Accumulated toner Magnet cover

3. Gear

5. Topside of DV unit

6. Filter (2 filters in other place

6. Duct

4. Sleeve roller 4. Sponge

4. Toner replenishment lid 6. Hook *Another hook at the opposite side.

7. Refit the filters. (Refer to photo 5) Refit three filters and the duct. * Note the filter is not pinched when fitting it. 8. Remove the drum unit. 9. Clean the topside of the drum unit. (Refer to photo 6) Remove the toner that resides on the topside of the drum unit. 10. Clean the side of the drum unit and others. (Refer to photo 6) Clean the sponge that is affixed on the side and the surrounding smudge. 11. Clean the main charger roller in the drum unit. Pull out the main charger roller from the drum unit and clean it with a dry cloth. * Don't clean with water or alcohol to avoid uneven image that may occur due to uneven cleaning. . * Remove the adhesion if any by using adhesive of Post-it. 12. Clean smudges in the machine. Clean the toner smudges in the machine. (Paper path, neighborhood of the image formation holder, etc.)

7. Note the filter is not pinched as in the above photo.

9. Topside of drum unit

11. Main charger roller

10. Sponge

13. Hook of the developer rear cover * Another hook at the opposite side.

7
13. Refit the drum unit, developer unit and other parts to the machine. Connect the connector after installing the drum unit and developer unit. Refit the transfer belt unit and the fuser unit, open the toner replenishment lid. Install the image formation holder, waste toner tray and four toner containers in order. * Check if three hooks of the developer rear cover are hung in place before installing the developer unit. (Refer to photo 7) * Surely connect the connector between the 13. Hook of the developer rear cover developer unit and the drum unit. * Surely connect the connector of the image formation holder. 14. Turn on the power and execute Gray Adjustment. After the machine normally starts up by turning on the power, enter Adjustment/Maintenance from System Menu and execute Gray Adjustment. * Color adjustment (Calibration) is unnecessary because color adjustment is automatically executed too if executing Gray Adjustment. 15. Check the image. Copy the color original or print out the color file, and check the output image.