SB-2H7-0080-B010_8

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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

SB-2H7-0068-A210_1.pdf ICL screw transfer belt (Measure against Service Call C2810) TASKalfa250ci-300ci-400ci-500ci-552ci, FS-C8500DN

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

1 Prevention of the deteriorated

toner from accumulating on the

magnet cover

The shape of the magnet cover was changed to saucer shape to collect the

additives and the deteriorated toner.

2 Restraint of scattering toner in

the developer unit

1) 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.

3 Support of reverse rotation of

the developing drive

(* Firmware upgrade is

necessary at the same time.)

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

4 Restraint of the toner scattering

from the developer unit

(Toner scattering to the top side

of the developer unit and the

main charger roller)

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.

5 Distinction from the normal Bk

developer unit

The color of the upper/lower edges of the barcode label was changed to

green.

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2) The firmware was upgraded as followed. (For more details on the subject Upgrade Pack, please refer to page 8.)

Item Content Upgrade Pack

1 New control and settings of

the reverse rotation of the

developing drive

- 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.)

Ver.11.00

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).

KMC’s 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 From the next production

TASKalfa400ci From the next production

TASKalfa300ci KMA120V CS KME UTAX/TA KMSG

QJC1107195- QEH1101821- QJE1107042- QER1101996- QFF1100036-

KMID KTST KMTW Other specs.

Q4C1100009- QMN1100147- QGF1100080- From the next production

TASKalfa250ci KMA120V CS KMBR UTAX/TA KTST

QJH1109660- QEG1101825- Q9A1100466- QEQ1112628- QMP1100789-

KMTW Other specs.

QGE1100066- From the next production

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<Image sample of Bk toner smudge>

[Important]

Details :

Related Change

(Refer to the previous page)

1 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.

No. Old Part

No. New Part

No. Description

Q’ty Com

bi pati- lity Remarks

Old New Old New

1 302H793178

2H793178 302H793710

2H793710 PARTS DLP K UNIT B - 1 - O*

*1, DV-855B

3 302JZ93199 2JZ93199

302JZ93410 2JZ93410

PARTS DLP K L UNIT B - 1 - O* *2, DV-865B

(-->) 5

------------ 302H794830

2H794830 PARTS SEAL FRONT DRUM SET SP

- 1 - O 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.1-

4) is not registered as individual supply part

Paper feeding

direction

Bk toner smudge especially

appears at the

leading/trailing edge of the

sheet.

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<Normal Bk developer unit> (The illustration below shows the cross section of the magnet roller/sleeve roller

section viewed from the machine front side.)

<Bk developer unit for preventing the toner smudge>

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.

Magnet roller

Sleeve roller

Magnet cover

Metal plate

: Air flow direction of the

developer cooling fan Cohesive materials of the additives and the deteriorated toner

Measured magnet cover (Saucer shape)

Measured metal

plate 1

Measured metal plate 2

Magnet

Additives and the

deteriorated toner

X

(*) 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.

(*)

Sleeve roller

Magnet roller

<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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(Cross section of the normal Bk developer unit viewed from the machine front side)

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

(Normal gear) (Gear with countermeasure) (Machine rear side of the Bk developer unit with countermeasure)

* The gears shown in the photo above are for TA500ci

series. (Right gear is a prototype.)

<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.

Slope shape

Y Z

Y: Normal rotation of the developer drive

Z: Reverse rotation of the developer drive

<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.)

Sleeve roller

Magnet roller

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

Developer housing

: 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.

Machine front side

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(Drum unit) (Bk developer unit with countermeasure)

(-->)(*) 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 [Air flow when using the new [Air flow when using the new

developer cooling fan] magnet cover (without sponge)] magnet cover and the sponge]

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

<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.

Sticker

Sponge (S)

Sponge (L)

Sponge

Air flow from the

developer cooling fan

Dru

m u

nit

Norm

al B

k d

evelo

per

un

it

Dru

m u

nit

Air flow

Dru

m u

nit

Sponge

Scattered toner from the

developer unit is blown

up and adheres to the

top of the main charger

roller and the developer

unit.

Air flow

Sponge

Bk d

eve

lop

er

un

it w

ith

cou

nte

rme

asu

re

Bk d

eve

lop

er

un

it w

ith

cou

nte

rme

asu

re

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

[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 >

<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.

<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.

*K**8800001 ** MADE IN CHINA 302*******

2******* 4/pcs

Assembled in China/Designed in Japan

Name and check box for the new unit added

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<Firmware upgrade for TASKalfa500ci/400ci/300ci/250ci>

2011/7 Type Pack Version New

upgrade

MAIN FRAME Fixed code - - - - V10.00 V11.00 V12.00 Remark

MAIN *1 2H7_2F00 009.020 010.007 011.006 012.012

MMI *1 2H7_7000 009.018 010.007 011.002 012.012

LANGUAGE BR(OPTION) 2H7_81BR 001.021 001.025 <--- 001.029

BROWSER 2H7_F000 001.015 <--- <--- 001.016

ENGINE (high) *2*3 2H7_1000 - - - - 020.003 021.001 023.001

ENGINE (low) *2*3 2JZ_1000 - - - - 020.003 021.001 023.001

SCANNER 2H7_1200 005.002 <--- <--- <---

MOTOR MAIN 2H7_1400 003.003 <--- <--- <---

H VLT MAIN 2H7_1600 001.014 <--- <--- <---

SLEEP MAIN 2H7_1800 002.001 <--- <--- <---

FAX BOOT *4 Fax Sys(Q) 3MB_5000 001.016 <--- <--- <---

FAX APL *4 Fax Sys(Q) 3MB_5100 (005.002) <--- <--- <---

FAX IPL *4 Fax Sys(Q) 3MB_5200 001.016 <--- <--- <---

FAX BOOT *4 Fax Sys(S)C 5JP_5000 001.022 <--- <--- <---

FAX APL *4 Fax Sys(S)C 5JP_5100 (C06.001) (C08.002) <--- <---

FaxSystem (Q)/(S)C MIX *5 SaturnFAX_Pack C06001_005002 C08002_005002 <--- <---

SOLUTION (DBA) J00_E000 003.002 005.001 <--- <---

ENHANCEMENT Fixed code - - - - V1.12 <--- V1.13

DP-750/750B, 760/760B 3LK_9500 009.003 <--- <--- <---

PF-720/720B (2 cassette) 3LM_9000 004.001 <--- <--- <---

PF-760/760B (3000) 5H8_9000 003.002 <--- <--- <---

DF-780/780B (1000) 5JA_9200 007.005 <--- <--- <---

DF-760/760B (3000) MAIN 3LT_9200 006.003 007.001 <--- <---

DF-760/760B (3000) MIDDLE 3LT_9600 007.002 008.001 <--- <---

MT-720/720B (3000)MAIL BOX 3LW_9800 004.002 <--- <--- 005.001

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 SB-

2H7-0012 -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 Information Affected models: Saturn series Firmware: Ver.12 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.)

Please recommend this setting if user

complained on unstable density and low

productivity.

U147 Mode0 Mode1

U325 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

0 +100

To optimize the black density

U486 Mode2 Mode1

Bad Effects - Higher toner consumption (with the 3-

sheets intermittent printing pattern)

The amount of toner consumption will be

increased by approx. 20%.

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.)

6. Hook *Another hook at the opposite side.

6. Filter (2 filters in other place）

6. Duct

4

5. Topside of DV unit

4. Sleeve roller

4. Sponge

4. Toner replenishment lid

3

2. Cleaning the developer unit 1

2

3. Gear

スリーブスリーブスリーブスリーブローラローラローラローラ

マグマグマグマグローラローラローラローラ

マグカバー

堆積トナー

Sleeve

roller

Magnet

roller

Accumulated toner

Magnet cover

2. Cross section figure around the developer

magnet cover

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.)

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

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.

13. Hook of the developer rear cover

* Another hook at the opposite side.

13. Hook of the developer rear cover

7

7. Note the filter is not pinched as in

the above photo.

5

9. Topside of drum unit

10. Sponge 11. Main charger roller

6

SB-2H7-0080-B010_8

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