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Technical Bulletin

Solutions Support Division


Bulletin #: 8215
Date: 12/19/11
Subject:

Fusing Unit Noise Troubleshooting Guide

bizhub 552:

016

bizhub 652:

016

bizhub C451:

094

bizhub C452:

101

bizhub C550:

103

bizhub C552:

112

bizhub C552DS:

050

bizhub C650:

087

bizhub C652:

112

bizhub C652DS:

050

Noise that appears to emanate from the fusing unit can be a very elusive issue to resolve. This is a direct
result of many factors, including:

Moving parts, each of which may contribute to a noise

Tight tolerances required for the unit to operate reliably and efficiently

The non-directional nature of sound, especially in an MFP, which make it difficult to identify the source of
the sound

Accuracy and thoroughness of routine maintenance, including proper cleaning and lubrication

SOLUTIONS
The attached guide represents a thorough investigation of the various sources of noise emitted by the fusing
area in these products. Although there are many causes, each has been identified and a solution developed.
Please implement all of the solutions in the attached Troubleshooting Guide to make a significant
reduction in the amount of unwanted sound and improve the users experience.
Audio
In several cases, audio files are available so that you can actually hear the kind of noise that results from
specific areas.
If you are viewing this document on a computer, the audio samples can be accessed by clicking on the
speaker icon.
PARTS INFORMATION
A number of parts are referred to in the Troubleshooting Guide. In most cases, they have been addressed in
previous bulletins.
One new modification appears in the Guide to address noise from the Fusing Drive Unit (see page 10 of the
guide).

Page 2 of 2

Bulletin #: 8215
Model

Kit Installed During Production


Beginning at Serial No.

552
652
C451
C550
C650

A2WV011001737
A2WU011001472
*
*
*

Model

Kit Installed During Production


Beginning at Serial No.

C452
C552
C652
C552DS
C652DS

A0P2011014802
A0P1011009110
A0P0011005305
A1DN011001580
A1DM011001407

* Production of these models ended before the modification was developed.

FOC PARTS ORDERING PROCEDURE (Fuser Kit - Technical Bulletin #8215A)


Description

Fuser Kit
Paper exit shaft 1
Bushing
Bearing 1
Gear 33T
Pin
Bushing

Qty.

Part No.

1
1
1
1
1
1
2

U226-0950
A00J231812
A0P0232500
A00J232111
A00J230711
V231201050
A0P0749500

Notes

Contains all parts listed below


For fusing drive unit
For fusing drive unit
For fusing drive unit
For fusing drive unit
For fusing drive unit
For cleaning roller

Free-of-charge (FOC) Fuser Kit p/n U226-0950 can be ordered via the Online Technical (FOC) & Special
Program order form, located within MyKonicaMinolta.com (Service Warranty, Repair & Special Programs).
Select Technical Bulletin #8215A.
FOC parts for this program will be available for units that are within the affected serial number range as
mentioned above. These FOC parts will be available from December 19, 2011 to March 19, 2012.
Upon our receipt and verification of your online claim information, KMBS Service Operations will process a
Free-of-Charge order. All replacements will be shipped via UPS 2nd-Day service. As mentioned above, KMBS
will ship these parts at no charge; therefore, no invoice will be generated. No defective parts are to be returned
to KMBS for this specific FOC Program. Questions related to your FOC claims may be directed to KMBS
Service Operations at (201) 818-3515.
FOC PARTS ORDERING PROCEDURE (Drysurf - Technical Bulletin #8215B)
In addition to the kit above, it may be necessary to order Drysurf lubricant.
Drysurf can be ordered via the Online Technical (FOC) & Special Program order form, located within
MyKonicaMinolta.com (Service Warranty, Repair & Special Programs). Select Technical Bulletin #8215B.
Description

Drysurf (lubricant)

Part No.

U226-0482FOC

Notes

Each container services


approximately 10 fusing units

Note: Apply Drysurf only to those areas specified. Do not use it as a general lubricant. Applying
Drysurf to areas not specified may cause damage to the machine.

FUSING SECTION NOISE


TROUBLESHOOTING GUIDE
552, 652
C451, C550, C650
C452, C552, C652
C552DS, C652DS
Contents
Click a subject

Noise from Rotation Sensor 1

Noise from Rotation Sensor 2

Noise from the Exit Roller Drive

Noise from the Cleaning Roller Bushings

Noise from the Paper Exit Section

Modifications to the Fusing Unit

Noise from the Fusing Drive Unit

10

Noise from the Separation Claws

17

How to Apply Drysurf

18

To hear noise samples


on the following pages...

Page

...click this icon with


your mouse.

December 19, 2011

Noise from Rotation Sensor 1


C451 / C550 / C650

RETURN TO
CONTENTS

C452 / C552 / C652 / C552DS / C652DS


SYMPTOM
Squeaking or binding noise from the cam gear in the fusing unit.
Refresh page
to play again

CAUSE
This is caused by a backlash of the drive gears and the brake pad gears.

COUNTERMEASURE
The drive was changed from a gear system to a belt system.
Note: Insufficient application of Drysurf can result in a different noise.
Refresh page
to play again

FIELD ACTION
If the fusing unit has a gear drive, replace it with a belt drive unit.
Model

C451, C550, C650

Description

Part No.

Fusing unit (gear drive) A00JR72122


Fusing unit (belt drive)

Notes

Modify to belt drive according to


previous technical bulletin #7677.

A00JR72133

Modify to belt drive according to


C452, C552, C652, Fusing unit (gear drive) A0P0R73311 previous technical bulletin #7676.
C552DS, C652DS
Fusing unit (belt drive) A0P0R73322

Be sure that Drysurf has been applied thoroughly to belt-drive units,


including those modified from gear drive. Apply it with a brush or by soaking.
It the belt is not covered fully with Drysurf, the high-pitch noise can return.

Page 1 of 18

December 19, 2011

Noise from Rotation Sensor 2


552 / 652
C451 / C550 / C650

RETURN TO
CONTENTS

C452 / C552 / C652 / C552DS / C652DS


SYMPTOM 1
Squeaking from the Rotation Detection Sensor.

CAUSE
This is caused by friction between the sensor actuator and its shaft.

FIELD ACTION
Using a small brush, apply Drysurf to the shaft.

SYMPTOM 2
Clicking noise from the Rotation Detection Sensor.

CAUSE
A washer was omitted while reassembling the unit during service.

FIELD ACTION
Be sure that the washer is installed to limit motion of the actuator.

Page 2 of 18

December 19, 2011

Noise from the Exit Roller Drive


RETURN TO
CONTENTS

SYMPTOM
Unusual noise may be generated from the exit roller drive gears.

C451 / C550 / C650


CAUSE
The drive gear bushing is worn.

Drive
gears

FIELD ACTION
Replace the cam and the bushing. Both parts
must be replaced as a set.

Cam

Shaft
Description

Cam
Bushing

Part No.

A0P0897300
A00JP89000

These parts are already installed in models


552, 652, C452, C552, C652, C552DS, and
C652DS.
Cam

Bushing

552 / 652
C451 / C550 / C650
C452 / C552 / C652 / C552DS / C652DS
FIELD ACTION
Apply Drysurf if there is any noise from this area.
Page 3 of 18

December 19, 2011

Noise from the Cleaning Roller Bushings


552 / 652

RETURN TO
CONTENTS

C451 / C550 / C650


C452 / C552 / C652 / C552DS / C652DS
SYMPTOM
A metallic creaking sound may be generated by the cleaning
roller bushings.

Edge of
bushing

CAUSE

Roller
shaft

If a bushing becomes slightly tilted against the shaft, it can bind, creating the
noise. See the exaggerated diagram at the right.

Bushing

FIELD ACTION
Replace the bushings with the new grooved style, and apply high-temperature grease to the bushings. The
grooves help to retain grease to prevent friction that can cause the bushings to tilt. Follow the instructions
below.
Description

Bushing, grooved*
High-temperature grease
(Sankol ECG25)

Qty.

Part No.

2
1

A0P0749500
A00JPP0000

* Contained in Fuser Kit (p/n U226-0950)

Grooves
(top and bottom)
Actual bushing color: black

Bushing Replacement Procedure


1. Remove the fusing unit front cover (3 screws).

WARNING
The fusing unit is very hot. To avoid burning
yourself, allow it to cool before proceeding.

Page 4 of 18

December 19, 2011

Noise from the Cleaning Roller Bushings (continued)


2. Remove the rear cover (2 screws).

3. Disconnect the connector and unhook the wires


from the clamp.

4. Remove the side cover (1 screw, 2 hooks).


Be careful not to break the hooks.
Pull the wiring harness out of the cover before completely removing the cover.

Harness
Hook

Page 5 of 18

Hook

December 19, 2011

Noise from the Cleaning Roller Bushings (continued)


5. Swing the cleaning brush roller bracket upward. Hold it in
position with a piece of folded paper.

6. Replace the bushings. It is necessary to remove 1 e-clip with each bearing, and the gear and e-clip shown.
Clean the shaft before installing the new bushings.
Apply high-temperature grease (Sankol ECG25) to ends of the roller shaft when installing the new
bushings.
Be careful not to let grease get on the roller surface.

7. Reassemble all removed parts.


Be sure to place the high voltage wire into the guide on
the cover.

Page 6 of 18

December 19, 2011

Noise from the Cleaning Roller Bushings (continued)


Bushing Lubrication Procedure
Although the high-temperaure grease has been applied since the beginning of production for models 552, 652,
C452, C552, C652, C552DS, and C652DS, additional application may be needed.
Use this procedure to add lubrication when the bearings do not need to be changed.
1. Remove the front, rear, and side covers as described in the Bushing Replacement Procedure (steps 1-4)
beginning on page 4.
2. Remove the e-clips at the bushings. Slide the shaft back and forth to apply the high-temperature grease.
Be careful not to let grease get onto the roller surface.

Apply grease between the


bushings and the roller shaft

3. Reassemble all removed parts.


Be sure to place the high voltage wire into the guide on the cover (see step 7 on page 6).

Page 7 of 18

December 19, 2011

Noise from the Paper Exit Section


552 / 652

RETURN TO
CONTENTS

C451 / C550 / C650


C452 / C552 / C652 / C552DS / C652DS
SYMPTOM
Noise may be generated at the exit rollers and the shaft.

CAUSE
Paper dust, toner particles, and other debris have accumulated on and around the exit rollers and the shaft.

FIELD ACTION
Clean the rollers, shafts, and plates shown below.
Then apply Drysurf.
Apply Drysurf to the ends of the lower exit roller
shaft.

Shaft
Upper exit
roller assy.

Rollers/plates

Apply Drysurf to the entire upper exit roller shaft.


Lower exit roller assy. (roller not visible)

Note: There are two obvious differences in the exit rollers for these two model groups. The changes were
made for compatibility with future models.
The color of the rollers was changed from white to black
for models 552, 652, C452, C552, C652, C552DS, and
C652DS. There was no material change other than color.

C451 / C550 / C650

For the same models, the number of rollers was reduced


from 8 to 4.
These changes have no impact on the potential for noise.

Page 8 of 18

552 / 652
C452 / C552 / C652 / C552DS / C652DS

December 19, 2011

Modifications to the Fusing Unit


RETURN TO
CONTENTS
A number of changes were made the fusing unit for these models to improve reliability and address noise
issues.
Feature

Original Style

Rotation Detection
Gear drive
Brush roller coupling gear Black
Pressure roller drive gear Brown

OLD
STYLE

Do NOT use any grease

New Style

Belt drive
White
Black

Reason for Change

Noise reduction
Wear prevention
Wear prevention

NEW
STYLE

Old pressure roller gear

Old brush roller gear

New pressure roller gear

New brush roller gear

C451 / C550 / C650

552 / 652
C452 / C552 / C652 / C552DS / C652DS

Style

Part No.

Style

Part No.

Fusing unit, OLD style


Fusing unit, NEW style

A00JR72122
A00JR72133

Fusing unit, OLD style


Fusing unit, NEW style

A0P0R73311
A0P0R73322

CAUTION
Applying grease to the old style gears will
accelerate gear wear. The fiberglass dust from
the gears is held onto the gears by the grease,
effectively causing the gears to file themselves.
Page 9 of 18

December 19, 2011

Noise from the Fusing Drive Unit


552 / 652

RETURN TO
CONTENTS

C451 / C550 / C650


C452 / C552 / C652 / C552DS / C652DS
SYMPTOM
A squeaking noise may be generated by the fusing drive gear shaft
and bushing.

CAUSE
The drive gear shaft is mostly D-shaped. As the shaft turns, it can scrape
the inside of the round bushing that supports it, increasing the play between
the shaft and the bushing and causing noise.
The shape of the shaft has been changed and the bushing material was
changed. At the same time, several other parts were changed.
Bushing

D-shaped shaft

Old Style Part No.

A00JR75800
A0P0R73800
A00J231801
1200312109
A00J232100
A00J230700

Pin

Gear

D-shaped shaft

Description

Fusing drive unit (C451, C550,


C650)
Fusing drive unit (552, 652, C452,
C552, C652, C552DS, C652DS)
Paper exit shaft 1
Bushing
Bearing 1
Gear 33T
Pin
Fuser kit*

New Style Part No.

Notes

A00JR75811
A0P0R73811
A00J231812
A0P0232500
A00J232111
A00J230711
V231201050
U226-0950

Old = long D; NEW = short D


Old = white; NEW=black
Old = white; NEW=black
NEW has groove for pin
Includes all parts shaded red

* All 5 parts in the kit must be installed as a set. They can modify either style fusing drive unit.
Page 10 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


FIELD ACTION
Use these procedures to remove the fusing drive unit and install the fuser kit parts.

Fusing Drive Unit Removal Procedure


1. Remove the back covers and the white
corner covers.

2. Disconnect the cables and remove them from the clamps on the control board box.

3. Remove 5 screws that secure the


control board box; then, swing it open.

Page 11 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


4. Remove the side covers and the filter.

5. Remove the air duct (1 screw); then, remove it.

6. Disconnect 3 connectors and remove 4 screws that secure the suction fan unit; then, remove it.

View from right side of machine


Page 12 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


7. Disconnect 1 connector and
remove 4 screws that secure
the motor unit; then, remove it.

8. Unplug 2 connectors
and remove 3 screws
that secure the wire
guide.

9. Unplug the connectors


and remove 4 screws
securing the motor unit.

Page 13 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


10. To make the next steps easier, secure the motor unit on the frame
with a screw as shown.

11. Remove 4 screws fixing the drive unit, then remove the e-ring and the gear.

View from right side of machine

12. Remove the drive unit.

Page 14 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


Modification Procedure
1. Remove 3 e-rings and release the claws of the Bushing/1 of the drive unit.
Note: The actual color of Bushing/1 is BLACK, not white.

2. Slide the both bushings toward Gear 33T.

3. While tilting Shaft/1, remove its assembly from the


drive unit.

Page 15 of 18

December 19, 2011

Noise from the Fusing Drive Unit (continued)


4. Remove the parts as shown; then, install the modified parts.

5. Reassemble the shaft with the parts in the drive unit.

Page 16 of 18

December 19, 2011

Noise from the Separation Claws


552 / 652

RETURN TO
CONTENTS

C451 / C550 / C650


C452 / C552 / C652 / C552DS / C652DS
SYMPTOM
A vibrating noise may be generated involving the separation claws.

CAUSE
The tips of the separations claw interfere with the surface of the fusing roller. As a permanent correction, the
shape of the claw shaft hole has been changed.

FIELD ACTION
Using the worm screw, adjust the gap between the
separation claws and the fusing roller until the noise
disappears.

Worm screw
Holder

Check to be sure that the adjustment does not permit


paper jamming.

Claw

Page 17 of 18

December 19, 2011

How to Apply Drysurf


552 / 652

RETURN TO
CONTENTS

C451 / C550 / C650


C452 / C552 / C652 / C552DS / C652DS
FIELD ACTION

Drysurf must be applied properly in order to effective. It will have little effect if it is simply applied like a viscous
lubricant such as oil or grease.

Shake well before use so that the liquid suspension is well


mixed.

Drysurf may be applied with a small brush. Be sure to


apply it evenly.

Dipping the timing belt is the easiest way to coat the entire
surface with Drysurf. The belt can be dipped in the Drysurf
bottle a little at a time, or the entire belt can be coated by
placing it and the Drysurf in a zipper-top bag.

Be sure to let parts dry completely before reassembling


them.

Page 18 of 18

December 19, 2011