Di 152183 Field

Service Manual
Field Service
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1.
SAFETY PRECAUTIONS FOR INSPECTION AND

SERVICE
When performing inspection and service procedures, observe the following precautions
to prevent accidents and ensure utmost safety.
Depending on the model, some of the precautions given in the following do not apply.
Different markings are used to denote specific meanings as detailed below.
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
The following graphic symbols are used to give instructions that need to be observed.
Used to call the service technician attention to what is graphically represented
inside the marking (including a warning).
Used to prohibit the service technician from doing what is graphically represented
inside the marking.
Used to instruct the service technician to do what is graphically represented
inside the marking.
1-1.
Warning
WARNING
1. Always observe precautions.

Parts requiring special attention in this product will include a label containing the
mark shown on the left plus precautionary notes. Be sure to observe the precautions.
Be sure to observe the Safety Information given in the Operators Manual.
2. Before starting the procedures, be sure to unplug the power cord.
This product contains a high-voltage unit and a circuit with a large current
capacity that may cause an electric shock or burn.
The product also contains parts that can jerk suddenly and cause injury.
If this product uses a laser, laser beam leakage may cause eye damage or
blindness.
P-1
3. Do not throw toner or the toner bottle into a fire.

Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner
expelled from the fire may cause burns.
4. Use the specified parts.
For replacement parts, always use the genuine parts specified in the manufacturers parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible
electric shock or fire.
Replace a blown electrical fuse or thermal fuse with its corresponding genuine
part specified in the manufacturers parts manual. Installing a fuse of a different
make or rating could lead to a possible fire. If a thermal fuse blows frequently,
the temperature control system may have a problem and action must be taken
to eliminate the cause of the problem.
5. Handle the power cord with care and never use a multiple outlet.
Do not break, crush or otherwise damage the power cord. Placing a heavy
object on the power cord, or pulling or bending it may damage it, resulting in a
possible fire or electric shock.
Do not use a multiple outlet to which any other appliance or machine is connected.
Be sure the power outlet meets or exceeds the specified capacity.
6. Be careful with the high-voltage parts.
A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord
before servicing this part or the parts near it.
7. Do not work with wet hands.
Do not unplug or plug in the power cord, or perform any kind of service or
inspection with wet hands. Doing so could result in an electric shock.
8. Do not touch a high-temperature part.
A part marked with the symbol shown on the left and other parts such as the
exposure lamp and fusing roller can be very hot while the machine is energized.
Touching them may result in a burn.
Wait until these parts have cooled down before replacing them or any surrounding parts.
9. Maintain a grounded connection at all times. (This item may not apply in the USA.)
Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could
result in an electric shock or fire.
Never connect the ground wire to a gas pipe, water pipe, telephone ground wire,
or a lightning conductor.
10. Do not remodel the product.
Modifying this product in a manner not authorized by the manufacturer may
result in a fire or electric shock. If this product uses a laser, laser beam leakage
may cause eye damage or blindness.
P-2
11. Restore all parts and harnesses to their original positions.

To promote safety and prevent product damage, make sure the harnesses are
returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being
crushed.
To promote safety, make sure that all tubing and other insulating materials are
returned to their original positions. Make sure that floating components mounted
on the circuit boards are at their correct distance and position off the boards.
1-2.
Caution
CAUTION
1. Precautions for Service Jobs.

A star washer and spring washer, if used originally, must be reinstalled. Omitting
them may result in contact failure which could cause an electric shock or fire.
When reassembling parts, make sure that the correct screws (size, type) are
used in the correct places. Using the wrong screw could lead to stripped
threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.
Take great care to avoid personal injury from possible burrs and sharp edges on
the parts, frames and chassis of the product.
When moving the product or removing an option, use care not to injure your
back or allow your hands to be caught in mechanisms.
2. Precautions for Servicing with Covers and Parts Removed.
Wherever feasible, keep all parts and covers mounted when energizing the
product.
If energizing the product with a cover removed is absolutely unavoidable, do not
touch any exposed live parts and use care not to allow your clothing to be
caught in the moving parts. Never leave a product in this condition unattended.
Never place disassembled parts or a container of liquid on the product. Parts
falling into, or the liquid spilling inside the mechanism could result in an electric
shock or fire.
Never use a flammable spray near the product. This could result in a fire.
Make sure the power cord is unplugged before removing or installing circuit
boards or plugging in or unplugging connectors.
Always use the interlock switch actuating jig to actuate an interlock switch when
a cover is opened or removed. The use of folded paper or some other object
may damage the interlock switch mechanism, possibly resulting in an electric
shock, injury or blindness.
P-3
3. Precautions for the Working Environment.

The product must be placed on a flat, level surface that is stable and secure.
Never place this product or its parts on an unsteady or tilting workbench when
servicing.
Provide good ventilation at regular intervals if a service job must be done in a
confined space for a long period of time.
Avoid dusty locations and places exposed to oil or steam.
Avoid working positions that may block the ventilation ports of the product.
4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, etc.)
Replace a rundown battery with the same type as specified in the manufacturers parts manual.
Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.
Dispose of used batteries according to the local regulations. Never dispose of
them at the users premises or attempt to try to discharge one.
5. Precautions for the Laser Beam. (Only for Products Employing a Laser)
Removing the cover marked with the caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug
the power cord before removing this cover.
If removing this cover while the power is ON is unavoidable, be sure to wear
protective laser goggles that meet specifications.
Make sure that no one enters the room when the machine is in this condition.
When handling the laser unit, observe the Precautions for Handling Laser
Equipment.
6. Precautions for storing the toner or imaging cartridge.
Be sure to keep the toner or imaging cartridge out of the reach of children. Licking the imaging cartridge or ingesting its contents is harmful to your health.
1-3.
Other Precautions
When handling circuit boards, observe the HANDLING of PWBs.

The PC Drum is a very delicate component. Observe the precautions given in HANDLING OF THE PC DRUM because mishandling may result in serious image problems.
Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.
P-4
1-4.
Used Batteries Precautions
ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturers instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
ATTENTION
Il y a danger dexplosion sil y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du mme type ou dun type quivalent recommand par le constructeur.
Mettre au rebut les batteries usages conformment aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.
Udskiftning m kun ske med batteri af samme fabrikat og type.
Levr det brugte batteri tilbage til leverandren.
Finland, Sweden
VAROlTUS
Paristo voi rjht, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hvit kytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren.
Kassera anvnt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
P-5
1-5.
Precautions for Service
When performing inspection and service procedures, observe the following precautions
to prevent mishandling of the machine and its parts.
Depending on the model, some of the precautions given in the following do not apply.
1. Precautions Before Service
When the user is using a word processor or personal computer from a wall outlet of the
same line, take necessary steps to prevent the circuit breaker from opening due to overloads.
Never disturb the LAN by breaking or making a network connection, altering termination,
installing or removing networking hardware or software, or shutting down networked
devices without the knowledge and express permission of the network administrator or
the shop supervisor.
2. How to Use this Book
DIS/REASSEMBLY, ADJUSTMENT
To reassemble the product, reverse the order of disassembly unless otherwise specified.
TROUBLESHOOTING
If a component on a PWB or any other functional unit including a motor is defective, the
text only instructs you to replace the whole PWB or functional unit and does not give
troubleshooting procedures applicable within the defective unit.
All troubleshooting procedures contained herein assume that there are no breaks in the
harnesses and cords and all connectors are plugged into the right positions.
The procedures preclude possible malfunctions due to noise and other external causes.
3. Precautions for Service.
Keep all disassembled parts in good order and keep tools under control so that none will
be lost or damaged.
After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged motor or locking mechanism.
If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.
Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit
containing these sensors is to be cleaned, first remove the sensors from the unit.
P-6
4. Precautions for Dis/Reassembly

Be sure to unplug the copier from the outlet before attempting to service the copier.
The basic rule is not to operate the copier anytime during disassembly. If it is absolutely
necessary to run the copier with its covers removed, use care not to allow your clothing
to be caught in revolving parts such as the timing belt and gears.
Before attempting to replace parts and unplug connectors, make sure that the power
cord of the copier has been unplugged from the wall outlet.
Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the
Interlock Switch with the covers left open or removed.
While the product is energized, do not unplug or plug connectors into the circuit boards
or harnesses.
Never use flammable sprays near the copier.
A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the users premises.
When reassembling parts, make sure that the correct screws (size, type) and toothed
washer are used in the correct places.
5. Precautions for Circuit Inspection
Never create a closed circuit across connector pins except those specified in the text and
on the printed circuit.
When creating a closed circuit and measuring a voltage across connector pins specified
in the text, be sure to use the GND wire.
P-7
6. Handling of PWBs
During Transportation/Storage
During transportation or when in storage, new P.W. Boards must not be indiscriminately
removed from their protective conductive bags.
Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature.
When it becomes absolutely necessary to remove a Board from its conductive bag or
case, always place it on its conductive mat in an area as free as possible from static electricity.
Do not touch the pins of the ICs with your bare hands.
Protect the PWBs from any external force so that they are not bent or damaged.
During Inspection/Replacement
Avoid checking the IC directly with a multimeter; use connectors on the Board.
Never create a closed circuit across IC pins with a metal tool.
Before unplugging connectors from the P.W. Boards, make sure that the power cord has
been unplugged from the outlet.
When removing a Board from its conductive bag or conductive case, do not touch the
pins of the ICs or the printed pattern. Place it in position by holding only the edges of the
Board.
When touching the PWB, wear a wrist strap and connect its cord to a securely grounded
place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB.
Note that replacement of a PWB may call for readjustments or resetting of particular
items.
7. Handling of Other Parts
The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
P-8
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3
C. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters.
Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front
edge and off its surface one to two times.
Never move the Pad back and forth.
1076D003
D. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the
entire surface of the PC Drum has been wiped.
Always OVERLAP the areas when wiping. Two
complete turns of the PC Drum would be appropriate for cleaning.
1076D004
NOTES
Even when the PC Drum is only locally dirtied, wipe the entire surface.
Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under
interior illumination.
If dirt remains after cleaning, repeat the entire procedure from the beginning one more
time.
9. Handling of the Imaging Cartridge

Only for Products Employing an Imaging Cartridge.
During Transportation/Storage
The storage temperature is in the range between 20C and +40C.
In summer, avoid leaving the Imaging Cartridge in a car for a long time.
Handling
Store the Imaging Cartridge in a place that is not exposed to direct sunlight.
Precautionary Information on the PC Drum Inside the Imaging Cartridge
Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.
Do not scratch the surface of the PC Drum.
Do not attempt to wipe clean the surface of the PC Drum.
P-10
DIS/REASSEMBLY,
ADJUSTMENT
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No.
Name
Description
Printer Lamp
Lit while data received from personal computer is being

printed
Job Input key
Press to select the Job Input mode. Two different jobs can
be programmed.
Meter Counter key
Press to display the Total Counter or Size Counter value.
Neg. Pos. key
Press to copy an original with the original total arrangements reversed.
Original key
Press to select the Mixed Orig. or Book Separation function.
Copy key
Press to select the 2in1 or 4in1 function.
Erase key
Press to select the erase position.
Finishing key
Press to select the finishing function.
File Margin key
Press to select the File Margin mode.
10 X/Y Zoom key
Press to make a copy with different zoom ratios set for

X (horizontal) and Y (vertical) directions.
11 Job Recall key
Press to recall either one of the two jobs previously stored

in memory.
12 Paper Misfeed indicator Lights up when a paper misfeed occurs in the copier.
Malfunction indicator
Lights up when malfunction occurs in the copier.
13 Maintenance indicator
Blinks or lights up when the time approaches that copier

needs maintenance service.
14 Add Paper indicator
Lights up when paper source currently selected for use

runs out of paper.
15 Add Toner indicator
Lights up when toner will soon run out.
16 Bypass Tray Size

Select key
Press to select the size of the paper loaded in the Bypass

Tray.
17 Zoom () key
Press to change the zoom ratio in the range between

50 % and 200 % in 1 % increments.
What is shown on the Display changes from the number
of copies to be made to the zoom ratio.
18 Display
Shows the number of copies to be made, the zoom ratio,

and other setting data.
19 10-key Pad
Use to type in the number of copies to be made and any

other numeric data.
20 Access key
Press when entering an account number.

Becomes valid only when Copy Track has been set.
21 Energy Saver key
Press to set the copier into the Energy Saver mode.
22 Interrupt key
Press to interrupt a copy job.
23 Panel Reset key
Press to reset all copy functions and settings to their

defaults.
Holding down the key for 3 seconds or more will set the
copies into the Utility mode.
S-2
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2.
UTILITY MODE
Utility Mode is used to make various settings according to the users need.
2-1.
Settings in the Utility Mode

Number
Description
U-1
Users Choice Mode
U-2
Drum Dehumidify Mode
U-3
Toner Replenisher Mode
U-4
Custom Size Input Mode
U-5
Administrator Mode
2-2.
Utility Mode Setting Procedure
Procedure
1. Hold down the Panel Reset key for 3 seconds.
2. Using the 10-Key Pad, enter the code corresponding to the desired subfunction.
No.: 1 to 5
3. Press the Start key.
Exiting the Mode
Press the Panel Reset key.
(1)
Users Choice Mode (Display: U-1)
Users Choice is used to make various settings according to the users need.
1. Settings in the Users Choice Mode
Number
Function
Number
Function
C-1
Mixed Orig.
C18
Density (ADF)
C-2
Paper Priority
C19
Print Density
C-3
Copy Priority
C20
Paper Auto Detection (1st Tray)
C-4
Density Priority
C21
Paper Auto Detection (2nd Tray)
C-5
Density Level (Auto)
C22
Paper Auto Detection (3rd Tray)
C-6
Density Level (Manual)
C23
Paper Auto Detection (4th Tray)
C-7
Output Priority
C24
Paper Auto Detection (5th Tray)
C-8
Crisscross Mode
C25
Paper Size Detection (1st Tray)
C-9
4in1 Copy Order
C26
Paper Type (1st Tray)
C10
Book Binding Position
C27
Paper Type (Bypass Tray)

Special Paper Setting (1st Tray)
C11
Margin Setting
C28
C12
Erase Setting (Left)
C29
Special Paper Setting (2nd Tray)
C13
Erase Setting (Upper)
C30
Special Paper Setting (3rd Tray)
C14
Erase Setting (Frame)
C31
Special Paper Setting (4th Tray)
C15
Auto Panel Reset
C32
Special Paper Setting (5th Tray)
C16
Energy Saver
C33
C17
Auto Shut OFF
Special Paper Setting

(Multiple Bypass Tray)
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3-3.
(1)
Setting in the Tech.Rep.Mode

Control Panel LED Check
The LEDs on the Control Panel are made to blink to check for any LED that has burned
out.
Any LED that is not blinking is considered to be out.
(2)
Function
This function allows the Tech. Rep. to make the various function tests and adjustments.
Procedure
1. Enter the number corresponding to the function to be used from the 10-Key Pad.
2. Press the Start key.
Exiting the Mode
Press the Panel Reset key until the initial screen reappears.
Number
Operation
F-1
Paper Passage Test

Correct paper passage (paper transport path) is checked without
involving any printing action.
This test is used to check for a paper misfeed and transport path.
Procedure
1. Select the paper source.
2. Press the Start key to start the paper passage cycle.
3. Press the Stop key to stop the paper passage cycle.
F-2
HV Output
This test is for factory adjustment only and should NOT be used.
F-8
ATDC Sensor Automatic Adjustment

Adjusts the output level of the ATDC Sensor.
This test is used when the copier is set up, developer is changed, and
the IU is replaced.
For details, see DIS/REASSEMBLY, ADJUSTMENT.
F12
Test Pattern Output

Outputs a test pattern. (Halftone)
This test is used to determine whether the engine is responsible for
an image problem which has occurred or the IR is responsible for it.
Procedure
1. Select the paper source.
2. Press the Start key to start the output sequence.
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Number
Setting
Trouble Counter
Counts the number of malfunctions that have occurred at different
parts of the copier.
If all malfunction counters are 0, ALL and 0 alternate.
--6
Display
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Main Motor malfunction

Fusing Cooling Fan Motor malfunction
Power Supply Cooling Fan Motor malfunction
Toner Replenishing Motor malfunction
Faulty image transfer voltage
Warm-up failure
Abnormally low fusing temperature
Abnormally high fusing temperature
Scanner Home Sensor malfunction
Tray Selecting Motor malfunction
Shift Motor malfunction
ATDC Sensor malfunction
ATDC adjustment failure
ASIC/memory malfunction
Polygon Motor malfunction
HSYNC detection failure
EEPROM malfunction
Exposure Lamp malfunction
Paper Size Counter

Counts the number of sheets of paper used according to the size and
type.
Display
--7
1
2
3
4
5
6
7
8
9
10
11
12
Description
A3 (L)
B4 (L)
A4 (L)
A4 (C)
B5 (L)
B5 (C)
A5 (L)
A5 (C)
FLS (L)
Ledger (L)
1114 (L)
Legal (L)
Display
13
14
15
16
17
18
19
20
21
22
S-20
Description
Letter (L)
Letter (C)
Invoice (L)
Invoice (C)
Other size
Paper enabling Auto Paper/
enabling auto tray switching
Paper disabling Auto Paper/
enabling auto tray switching
Paper disabling Auto Paper/
disabling auto tray switching
OHP
Thick paper
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(11) Memory Clear

This function is used to clear all data except that of the various electronic counters.
Procedure
1. Press the Start key to display CLr on the Display.
2. Press the Start key to blank out the Display.
Then, CLr will reappear.
3. Turn OFF and ON the Power Switch.
(12) Total Clear
This function is used to clear all data of the various electronic counters.
Procedure
1. Press the Start key to display tCL on the Display.
2. Press the Start key to blank out the Display.
Then, tCL will reappear.
3. Turn OFF and ON the Power Switch.
List of Types of Data to be Cleared
Clearing Method
Data Cleared
Door
Open/Close
Memory
Clear
Total
Clear
Jam display
Trouble display
Erratic operation/display
Utility (*1)
Tech. Rep. Mode (*2)
Security
Adjust
Job programs
Electronic counters
: Cleared : Not cleared

*1: Except Copy Track, Input Account, and Total Counter Display by Account.
*2: Except Marketing Area Setting and Serial No. Display.
(13) ADF Document Passage Test

This function is used to check for correct document passage through the ADF when a
document misfeed occurs.
Procedure
1. Load a stack of paper in the Document Feeding Tray.
2. Press the Start key to let the ADF start feeding the paper.
3. Press the Stop key to stop the sequence.
For details, see the relevant option service manual.
S-23
(14) ADF Original Glass Check

The original scanning area of the ADF is scanned to check for possible dirt or scratches
on the glass. The scanned area is produced as a copy.
Procedure
Press the Start key to start the sequence.
For details, see the relevant option service manual.
(15) Scanner Move Check
This function is used to check the Scanner Drive.
It is also used when securing the Scanner in position with the fixing pin (for transportation
of the machine).
Procedure
Press the Start key. This will move the Scanner to the left and stop.
(16) Serial No. Display
This function is used to display the serial number (consisting of 8 digits).
Procedure
Press the Start key to display the serial number.
E.g.: The Display shows Sn 12 345 678 in that order if the serial number is
12345678.
S-24

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1.
1-1.
INTRODUCTION
Reading the Text
1. The paper transport failure troubleshooting procedures are given according to the
symptom. First identify the location where the paper is present and start the procedure
for that particular location. For malfunction troubleshooting, start with step 1 and
onward.
2. Make checks in the numerical order of steps and, if an item is checked okay, go to the
next step.
E.g.: Pattern 1
Step
Check
Result
Action
NO
2
Go to the next step if you answered
YES.
E.g.: Pattern 2
Step
1
Check
Result
Action
YES
NO
2
Go to the next step if it checks
T-1
2.
PAPER TRANSPORT FAILURE
2-1.
(1)
Paper Misfeed Detection

Outline
A paper misfeed is detected by detecting different states of signals (H, L) of several sensors located near the paper take-up section and the Exit Paper Sensor.
The timings of the rising and falling edges of the paper take-up-related sensors and the
Exit Paper Sensor are monitored to detect a misfeed of paper being fed through the
copier.
The states (H, L) of the paper take-up-related sensors and the Exit Paper Sensor are
monitored to detect a sheet of paper left in the copier.
All drives are brought to an immediate stop when a paper misfeed or paper left in the
copier is detected.
2-2.
Paper Misfeed
When a paper misfeed occurs, the control panel shows the misfeed location and paper
location.
Display
Misfeed Location
Indicator LED
4022T501AA
4022T503AA
4022T502AA
LED No.
Code
J01
Misfeed at the 1st Tray
Misfeed/Paper Location
T-7
J02
Misfeed at the 2nd Tray
T-11
J03
Misfeed at the 3rd Tray
T-11
J04
Misfeed at the 4th Tray
T-11
J05
Misfeed at the 5th Tray
T-11
J06
Misfeed at the Bypass Tray
T-7
T-2
Action Ref. Page
LED No.
Code
2/3
J1
Misfeed/Paper Location
Action Ref. Page
Misfeed on paper transport path between PC1

and PC12 (3rd Tray)
T-11
3/4

(3rd Tray) and PC12 (4th Tray)
T-11
4/5

(4th Tray) and PC12 (5th Tray)
T-11
T-13
J2
Misfeed at the PC Drum
J3
Misfeed at the Fusing Unit
J80
Original misfeed: ADF Separator
J81
Original misfeed: ADF registration
1/7
T-16
See option
service manual.
J83
Original misfeed: ADF exit
Paper left: PC1
T-7
Paper left: PC3
T-16
7
2
Paper left: 2nd Tray Paper Take-Up Sensor
T-11
Paper left: 3rd Tray Paper Take-Up Sensor
T-11
Paper left: 4th Tray Paper Take-Up Sensor
T-11
Paper left: 5th Tray Paper Take-Up Sensor
T-11
Paper left: ADF
byp
See option
service manual.
Paper left: Manual Bypass Tray
T-3
T-7
2-3.
Misfeed Detection Sensor Layout

PC4*
PC3*
PC5*
PC3
PC1
PC2
PC12*
PC12*
PC12*
PC12*
Paper Path
Copier
Symbol
Name
PC1
Synchronizing Roller Sensor
PC2
Manual Feed Paper Sensor
PC3
Exit Paper Sensor
Paper Feed Cabinet (option)

Symbol
Name
PC12*
2nd Tray Paper Take-Up Sensor
PC12*
3rd Tray Paper Take-Up Sensor
PC12*
4th Tray Paper Take-Up Sensor
PC12*
5th Tray Paper Take-Up Sensor
ADF (option)
Symbol
Name
PC3*
Registration Sensor
PC4*
Separator Sensor
PC5*
Paper Exit Sensor
T-4
4022T504AA
Resetting the Misfeed Display

Misfeed Location
Resetting Procedure
Misfeed in Misfeed at 1st Tray J01,

the copier misfeed at Multiple Bypass Tray J06,
misfeed at Manual Bypass Tray J06,
misfeed at PC Drum J2,
misfeed at Fusing Unit J3,
paper left J - Paper wedged at Manual Bypass Tray
Misfeed in the option:

J02, J03, J04, J05, J1, J80, J81, and J83
Open the Right Door or slide out

the 1st Tray, remove all sheets of
paper left inside, and close the
Right Door.
Pull the paper wedged out of the

tray. (Removing the paper will
reset the misfeed display.)
Remove all sheets of paper left
inside and then raise and lower or
disconnect and reconnect the
option.
T-5
2-4.
Types of Misfeed Detection and Detection Timings
The following lists the types of misfeed detection and detection timings for different misfeed locations.
The symbol L (for the leading edge) and T (for the trailing edge) given in ( ) indicate
the particular edge of the paper detected by the sensor.
NOTE
For the types of misfeed detection and detection timings of options, see the relevant
option service manual.
Misfeed at the Paper Take-Up Section

Type
Detection Start
Paper Detection
Misfeed at 1st Tray

J01
Paper Take-Up Solenoid (SL1)

energized

(PC1) (L)
Misfeed at Manual
Bypass Tray J06
Manual Bypass Solenoid (SL2)

energized

(PC1) (L)
Misfeed at Multiple
Bypass Tray J06
Multiple Bypass Solenoid (SL21)

energized

(PC1) (L)
Misfeed at the PC Drum

Type
Detection Start
Paper Detection
Misfeed at PC Drum Synchronizing Roller Sensor (PC1) Exit Paper Sensor (PC3) (L)
J2
(L)
Synchronizing Roller Sensor (PC1) Synchronizing Roller Sensor
(L)
(PC1) (T)
Misfeed at the Fusing Unit
Type
Misfeed at Fusing
Unit J3
Detection Start
Paper Detection
Synchronizing Roller Sensor (PC1) Exit Paper Sensor (PC3) (T)

(T)
T-6
3.
MISFEED TROUBLESHOOTING PROCEDURES
3-1.
Misfeed at Copier Paper Take-Up J01 and Misfeed at Bypass

Tray J06
Relevant Electrical Parts
Manual Bypass Solenoid (SL2)
Multiple Bypass Solenoid (SL21)
Master Board (PWB-A)
Synchronizing Roller Sensor (PC1)

Manual Feed Paper Sensor (PC2)
PWB-A
Master Board
MANUAL BYPASS SECTION

Manual Feed
Paper Sensor
Multiple Bypass
Multiple
Bypass Solenoid
CN26
Manual Feed
Bypass Solenoid
DRAWER SECTION
Paper Take-Up
Solenoid
TRANSPORT SECTION
Synchronizing
Roller Sensor
PC1 ANODE
4022T522AA
Misfeed at 1st Tray J01 Troubleshooting Procedures

Step
Check
Result
Action
Paper meets product specifications.
NO
Paper is curled, wavy, or damp.
YES Change paper.

Instruct user to load paper that
meets product specifications.
Edge Guide and Trailing Edge Stop

are at correct position to accommodate paper.
NO
T-7
Change paper.
Adjust as necessary.
Step
Check
Result
Action
Paper Take-Up Roller (1st Tray) is

dirty, scratched, deformed, or worn.
YES Clean or change.
Paper Separator Roller (1st Tray) is

Paper Take-Up Roll drive shaft turns

when the Start key is pressed.
NO
Reinstall the Paper Take-Up Roll

drive shaft.
Reinstall the Paper Take-Up Roll
drive gear and spring.
Paper Take-Up Solenoid (SL1) is

operational when the Start key is
pressed.
Check Procedure
Check voltage across a Master
Board (copier: PWB-A) pin and GND.
Voltage across PJ5A-2 and GND
In standby: DC24 V
When pressed: DC0 V
NO
Change Paper Take-Up Solenoid

(SL1).
Synchronizing Roller Sensor (PC1) is

operational.
Check Procedure
Board (copier: PWB-A) pin and GND
when the sensor is blocked.
When blocked: DC5 V
When unblocked: DC0 V
NO
Change Synchronizing Roller Sensor (PC1).
YES Change Master Board (copier:

PWB-A).
Misfeed at Manual Bypass Tray J06 Troubleshooting Procedures

Step
Check
Result
Action
NO
YES Change paper.

Paper Guides are at correct position

to accommodate paper.
NO
Transport Roller (Manual Bypass

Tray) is dirty, scratched, deformed, or
worn.
T-8
Change paper.
Step
Check
Result
Manual Bypass Solenoid (SL2) is

pressed.
Check Procedure
In standby: DC24 V
When pressed: DC0 V
NO
Change Manual Bypass Solenoid

(SL2).
Action
Manual Feed Paper Sensor (PC2) is

operational.
Check Procedure
When blocked: DC0 V
NO
Change Manual Feed Paper Sensor (PC2).

operational.
Check Procedure
When blocked: DC5 V
NO

PWB-A).
Misfeed at Multiple Bypass Tray J06 Troubleshooting Procedures

Step
Check
Result
Action
NO
YES Change paper.

Paper Guides are at correct position

to accommodate paper.
NO
Paper Take-Up Roller drive shaft

(Multiple Bypass Tray) turns when
the Start key is pressed.
NO
Reinstall.
T-9
Change paper.
Step
Check
Result
Multiple Bypass Solenoid (SL21) is

pressed.
Check Procedure
In standby: DC24 V
When pressed: DC0 V
NO
Action
Paper Take-Up Roller (Multiple

Bypass Tray) is dirty, scratched,
deformed, or worn.
Separator Roller (Multiple Bypass

Tray) is dirty, scratched, deformed, or
worn.

operational.
Check Procedure
When blocked: DC0 V
NO
Change Multiple Bypass Solenoid

(SL21).

PWB-A).
T-10
3-2.
Misfeed at Paper Feed Cabinet Paper Take-Up and Transport

Section J02, J03, J04, J05, J1 (PF-120)
Control Board (PWB-A): PF-120

Paper Take-Up Sensor (PC12)
PJ6
PJ6A-1(PC1 ANODE)
PJ6A-2(GND)
PJ6A-3(PC1 ON)
PC1
Synchronizing
Roller Sensor
PJ18A
PWB-A
Master Board
13
CN25
CN53
2nd Tray
PJ3A-1A(SL11 ON)
PJ3A-2A(GND)
SL11
PJ1A
PJ53
PJ3A-3B(DC5 V)
PJ3A-2B( PC12ON)
PJ3A-1B(GND)
PC12
Paper
Take-Up
Sensor
PC12
Paper
Take-Up
Sensor
PC12
Paper
Take-Up
Sensor
PC12
Paper
Take-Up
Sensor
PWB-A
(PF-120)
PJ2APJ1A
13
CN53
3rd Tray
PJ3A-1A(SL11 ON)
PJ3A-2A(GND)
SL11
PJ1A
PJ53
PJ3A-3B(DC5 V)
PJ3A-2B( PC12ON)
PJ3A-1B(GND)
PWB-A
(PF-120)
PJ2APJ1A
13
CN53
4th Tray
PJ3A-1A(SL11 ON)
PJ3A-2A(GND)
SL11
PJ1A
PJ53
PJ3A-3B(DC5 V)
PJ3A-2B( PC12ON)
PJ3A-1B(GND)
PWB-A
(PF-120)
PJ2APJ1A
13
CN53
SL11
5th Tray
PJ3A-1A(SL11 ON)
PJ3A-2A(GND)
PJ1A
PJ3A-3B(DC5 V)
PJ3A-2B( PC12ON)
PJ3A-1B(GND)
PJ53
PWB-A
(PF-120)
4022T543AA
T-11
Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05,
J1 (PF-120) Troubleshooting Procedures
Paper is not taken up at all.
Step
Check
Result
Action
NO
Change paper.
YES Change paper.

Edge Guides and Trailing Edge Stop

are at correct position to accommodate paper.
NO
Paper Take-Up Roller is dirty,

scratched, deformed, or worn.
Adjust position as necessary.
Mylar is dirty, scratched, or deformed. YES Clean or change.
Separator Fingers are dirty or

deformed.
Paper guide plate is dirty or

deformed.
YES Change Paper Take-Up Solenoid

(SL11).
operation check:
The voltage across PJ3A-1A on Con- NO Change Control Board (PF-120:
trol Board (PF-120: PWB-A) and
PWB-A).
GND changes from DC0 V to DC24 V
Paper Take-Up Sensor (PC12) oper- YES Change Control Board (PF-120:
PWB-A) and/or Master Board
ation check:
(copier: PWB-A).
The voltage across PJ3A-2 on Control Board (PF-120: PWB-A) and
NO Correct actuator and/or change
GND is DC 5 V when the sensor is
Paper Take-Up Sensor (PC12).
unblocked and DC 0 V when the sensor is blocked.
Paper is stopped near the vertical transport section or Synchronizing Roller.

Step
Check
Result
Action
Vertical Transport Roller/Rollers are

dirty, deformed, or worn.
YES Change paper.


operation check:
The voltage across PJ6A-3 on Master Board (copier: PWB-A) and GND
is DC5 V when the sensor is blocked
and DC0 V when the sensor is
unblocked.

PWB-A).
NO
T-12
Correct actuator and/or change

(PC1).
3-3.
Misfeed at PC Drum J2

Fusing Cooling Fan Motor (M3)
Synchronizing Roller Clutch (CL1)

PWB-A
Master Board
TRANSPORT SECTION
Synchronizing
Roller Clutch
Synchronizing
Roller Sensor
PC1 ANODE
FUSING SECTION
Fusing Cooling
Fan Motor
4022T523AA
Misfeed at PC Drum J2 Troubleshooting Procedures

Paper is stopped at the Synchronizing Roller.
Step
Check
Result
Action
Synchronizing Rollers are dirty,

YES Clean or change the Synchronizing

Rollers.
Clean or change the Paper Dust
Remover.
Loop length is set to an appropriate

value.
NO
T-13
Adjust loop length using Tech. Rep.

Choice.
For details, see DIS/REASSEMBLY, ADJUSTMENT.
Step
Check
Result
Action

operational.
Check Procedure
When blocked: DC5 V
NO
The following voltage is supplied to

the Synchronizing Roller Clutch
(CL1).
Check Procedure
In standby: DC24 V
When pressed: DC0 V
YES Change Synchronizing Roller

Clutch (CL1).
NO
Change Master Board (copier:

PWB-A).
Paper is stopped at the PC Drum.

Step
Check
Result
Action
Image Transfer Roller is dirty.
PC Drum Paper Separator Fingers

are dirty, scratched, deformed, worn,
or damaged.
Charge Neutralizing Plate is dirty,

scratched, broken, or bent.
YES Clean, correct, or change.
T-14
Paper is stopped at the transport section.

Step
Check
Result
Action
Transport guide plate is dirty,

scratched, deformed, worn, or damaged.
YES Change Fusing Cooling Fan Motor

(M3).
the Fusing Cooling Fan Motor (M3).
Check Procedure
NO Change Master Board (copier:
PWB-A).
During decelerated rotation: DC8 V
During full speed rotation: DC24 V
T-15
3-4.
Misfeed at Fusing Unit J3

Exit Paper Sensor (PC3)

FUSING SECTION
Fusing Cooling
Fan Motor
PC3 ANODE
PWB-A
Master Board
PAPER EXIT SECTION

Exit Paper
Sensor
4022T511AA
Misfeed at Fusing Unit J3 Troubleshooting Procedures

Paper is stopped at the Fusing Unit.
Step
Check
Fusing guide plate is dirty, scratched,

deformed, worn, or damaged.
Result
Action
Fusing Paper Separator Fingers are

YES Clean or change the Fusing Paper

Separator Fingers, or change
spring.
Fusing Rollers are dirty, scratched,

deformed, or worn.
Paper is stopped at the paper exit section.

Step
Check
Result
Action
Exit guide plate is dirty, scratched,

Transport Roller is dirty, scratched,

deformed, or worn.
Exit Roller/Rollers are dirty,

T-16
Step
Check
Result
Exit Paper Sensor (PC3) is operational.

Check Procedure
When blocked: DC5 V
NO
Action
Change Exit Paper Sensor (PC3).

PWB-A).
T-17
4.
MALFUNCTION
The copiers CPU is equipped with a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code on the Display.
4-1.
Code
Detection Timing by Malfunction Code

Description
Detection Timing
C0000
The Main Motor (M1) Lock signal remains HIGH for a

continuous 1-sec. period at any time 1 sec. after the
Main Motor has started turning.
C0045
Fusing Cooling Fan

Motor malfunction
The Fusing Cooling Fan Motor (M3) Lock signal

remains HIGH for a continuous 1-sec. period while
the Fusing Cooling Fan Motor is turning at full speed
or decelerated speed.
C004E Power Supply Cooling The Power Supply Cooling Fan Motor (M4) Lock signal remains HIGH for a continuous 1-sec. period while
Fan Motor malfuncthe Power Supply Cooling Fan Motor Remote signal
tion
remains ON (for full-speed rotation) or OFF (for decelerated-speed rotation).
C0070
Toner Replenishing
Motor malfunction
The Toner Bottle Home Position Sensor (PC7) outputs a HIGH signal for a continuous 3.5-sec. period
while the Toner Bottle is turning.
The Toner Bottle Home Position Sensor (PC7) outputs a LOW signal for a continuous 2-sec. period
while the Toner Bottle is turning.
C0210
Abnormal image
transfer voltage
The image transfer voltage remains more than 100 V

for a continuous given period of time while the PC
Drum remains stationary.
C03FF Improperly set Adjust An incorrect setting is made of Adjust 11.

Mode 11
C0500
Warm-up failure
It takes the surface temperature of the Left Fusing

Roller more than 35 sec. to reach 100 C since the
start of a warm-up cycle.
It takes the surface temperature of the Left Fusing
Roller more than 25 sec. to reach 140 C after it has
reached 100 C.
It takes more than 20 sec. for the warm-up cycle to be
completed after the surface temperature of the Left
Fusing Roller has reached 140 C.
C0510
The surface temperature of the Left Fusing Roller

remains lower than 120 C for a given period of time
while the copier is in a standby state.
remains lower than 120 C for a given period of time
during a print cycle.
C0520

remains higher than 240 C for a given period of time.
T-18
Code
C0650
Description
Detection Timing
Faulty Scanner Home The Scanner Home Position Sensor (PC6) does not
Position Sensor
go from HIGH to LOW when the Scanner Motor (M5)
is energized for a given number of steps after the
sequence to bring the Scanner back to its home position has been started at the end of a scan motion and
during re-shading.
The Scanner Home Position Sensor (PC6) does not
go from LOW to HIGH when the Scanner Motor (M5)
is energized for a given number of steps after a scan
motion has been started at the end of a Scanner
Home Position Sensor home check scan motion and
during re-shading.
C0B60 Bin Switching Motor

malfunction
If the Upper Home Position Sensor is LOW during an

initial operation:
The Lower Home Position Sensor (PC33) is LOW
when the Bin Switching Motor (M1) starts turning forward.
If the Lower Home Position Sensor (PC33) does not
go LOW at a time 2.5 sec. after the Bin Switching
Motor (M1) has started turning forward, the Bin
Switching Motor is kept deenergized for a given
period of time and then energized again to turn backward. The Upper Home Position Sensor (PC32) does
not go LOW after the motor has started turning backward.
The Upper Home Position Sensor (PC32) does not go
HIGH at a time 1 sec. after the Bin Switching Motor
(M1) has started turning forward.
When the Lower Home Position Sensor (PC33) goes
LOW, the Bin Switching Motor (M1) starts turning
backward. The Upper Home Position Sensor (PC32)
does not go LOW at a time 2.5 sec. after the motor
has started turning backward.
backward. The Lower Home Position Sensor (PC33)
does not go HIGH at a time 1 sec. after the motor has
started turning backward.
If the Lower Home Position Sensor is LOW during an
initial operation:
The Upper Home Position Sensor (PC32) does not go
LOW at a time 2.5 sec. after the Bin Switching Motor
(M1) has started turning backward.
The Lower Home Position Sensor (PC33) does not go
HIGH at a time 1 sec. after the Bin Switching Motor
(M1) has started turning backward.
T-19
Code
Description
Detection Timing
C0B60 Bin Switching Motor

malfunction
If both the Upper Home Position Sensor and the Lower

Home Position Sensor are HIGH during an initial operation:
If the Lower Home Position Sensor (PC33) does not
go LOW at a time 2.5 sec. after the Bin Switching
Motor (M1) has started turning forward, the Bin
Switching Motor is kept deenergized for a given
period of time and then energized again to turn backward. The Upper Home Position Sensor (PC32) does
not go LOW after the motor has started turning backward.
backward. The Upper Home Position Sensor (PC32)
does not go LOW at a time 2.5 sec. after the motor
has started turning backward.
backward. The Lower Home Position Sensor (PC33)
does not go HIGH at a time 1 sec. after the motor has
C0B80 Shift Motor malfunction
The Home Sensor (S31) is LOW at a timing immediately before the Shift Motor (M1) starts turning backward.
The Home Sensor (S31) is LOW after the lapse of a
given period of time after the Shift Motor (M1) has
C0F32
Faulty ATDC Sensor
The measurement taken by the ATDC Sensor (UN1)

at a time 2.5 sec. after the Main Motor (M1) has
started turning is less than 3 % (greater than 4.98 V).
The measurement taken by the ATDC Sensor (UN1)
at a time 2.5 sec. after the Main Motor (M1) has
started turning is 19 % or more (1.41 V or less).
C0F33
Improperly adjusted
ATDC Sensor
The adjustment of the ATDC control voltage is not

completed within 1 sec. after sampling has started of
the ATDC Sensor (UN1) as part of an operation of
ATDC Sensor Automatic Adjustment.
The ATDC Sensor control voltage falls outside the
range of 5.39 V to 8.15 V during an operation of ATDC
Sensor Automatic Adjustment.
C1038
Engine connection
failure
Master Board (PWB-A) to Control Board (PWB-C) connection failure

There is no acknowledge signal transmitted from the
Master Board (PWB-A) to Control Board (PWB-C) for
1.5 sec. or more.
An error command signal is transmitted from the Control Board (PWB-C) to Master Board (PWB-A).
An error status signal is transmitted from the Master
Board (PWB-A) to Control Board (PWB-C).
T-20
Code
Description
Detection Timing
C1200
Faulty ASIC/memory
ASIC/memory (for image and control) fault

A write or read error occurs with SRAM on the Control
Board (PWB-C).
C1300
Startup failure
A LOW Polygon Motor (M2) Lock signal is not
detected within a given period of time that begins 1
sec. after the Polygon Motor has started turning.
Lock signal fault: Unstable after the first Lock signal has
been detected
For a period of 1 sec. after the first LOW Polygon
Motor (M2) Lock signal (first Lock) has been detected,
the next LOW Polygon Motor Lock signal is not
detected.
Lock signal fault: Lock signal out-of-timing
A LOW Polygon Motor (M2) Lock signal is not
detected for a continuous given period of time while
the rotation of the Polygon Motor remains stabilized.
Faulty Lock signal
A LOW Polygon Motor (M2) Lock signal is detected
for a given period of time or more when the Polygon
Motor remains deenergized.
C13F0
Faulty HSYNC
Laser scanning system malfunction

The SOS Sensor does not detect a rising edge of
SOS within a given period of time after the Polygon
Motor (M2) has started turning and a laser output has
been started.
The SOS Sensor detects no rising edges of SOS
while VIA (image area control) is ON.
C1468
Faulty EEPROM
EEPROM fault
Data cannot be written in EEPROM.
Data stored in EEPROM is wrong.
C14A3 IR fluorescent lamp

fault
The Exposure Lamp (LA2) of the Scanner fails to turn

ON.
The intensity of the Exposure Lamp is a predetermined value or less during shading and re-shading.
T-21
4-2.
Resetting Procedure by Malfunction Code
Code
Description
Resetting Procedure
C0000
C0045
Fusing Cooling Fan Motor malfunction
Turn OFF and ON the Power Switch.
C004E Power Supply Cooling Fan Motor

malfunction
C0070
Toner Replenishing Motor malfunction
C0210
Abnormal image transfer voltage
C03FF Improperly set Adjust Mode 11
Set Adjust Mode 11 correctly and then

turn OFF and ON the Power Switch.
For details, see SWITCHES ON PWBs/
TECH. REP. SETTINGS.
C0500
Warm-up failure
C0510
Turn ON the Power Switch with the Stop

key held down.
C0520
C0650
Faulty Scanner Home Position

Sensor
C0B60 Bin Switching Motor malfunction

C0F32
Faulty ATDC Sensor
C0F33
Improperly adjusted ATDC Sensor
C1038
Engine connection failure
C1200
Faulty ASIC/memory
C1300
C13F0
Faulty HSYNC
C1468
Faulty EEPROM
C14A3 IR fluorescent lamp fault
T-22
4-3.
(1)
Troubleshooting Procedures by Malfunction Code

C0000: Main Motor malfunction
Main Motor (M1)
Master Board (copier: PWB-A)
PWB-A
Master Board
PJ7A
Main Motor
PJ4
1
2
3
4
5
6
7
4022T525AA
Step
Check
Result
Main Motor (M1) turns when the Start

key is pressed.
NO
Check for overload.
Action

the Main Motor (M1) when the Start
key is pressed.
DC5 V when Main Motor (M1) is in
standby state
DC0 V when Main Motor (M1) is
energized
DC5 V when Main Motor (M1) is in
standby state
DC0 V when Main Motor (M1) is
energized
NO
Change Main Motor (M1).

PWB-A).
T-23
(2)
C0045: Fusing Cooling Fan Motor malfunction

PWB-A
Master Board
FUSING SECTION
Fusing Cooling
Fan Motor
4022T526AA
Step
Check
Result
Fusing Cooling Fan Motor (M3) turns

when the Power Switch is turned ON.
NO
YES Change Fusing Cooling Fan Motor

(M3).
Check Procedure
DC8 V during rotation at decelerated speed
DC24 V during rotation at full
speed
NO Change Fusing Cooling Fan Motor

(M3).
Check Procedure
PWB-A).
DC0 V when energized
T-24
Action
Check for overload.
(3)
C004E: Power Supply Cooling Fan Motor malfunction

Power Supply Cooling Fan Motor (M4)
PWB-A
Master Board
POWER SUPPLY SECTION
Power Supply
Cooling Fan Motor
4022T527AA
Step
Check
Result
Power Supply Cooling Fan Motor

(M4) turns when the Power Switch is
turned ON.
NO
YES Change Power Supply Cooling Fan

Motor (M4).
the Power Supply Cooling Fan Motor
(M4).
Check Procedure
DC8 V during rotation at decelerated speed
DC24 V during rotation at full
speed
NO Change Power Supply Cooling Fan

Motor (M4).
the Power Supply Cooling Fan Motor
(M4).
Check Procedure
PWB-A).
T-25
Action
Check for overload.
(4)
C0070: Toner Replenishing Motor malfunction

Toner Replenishing Motor (M6)

Toner Bottle Home Position Sensor (PC7)
PWB-A
Master Board
DEVELOPING SECTION
Toner Replenishing
Motor
Toner Bottle Home
Position Sensor
PC7 ANODE
4022T528AA
Step
Check
Result
The coupling of the Toner Hopper

turns as the Toner Replenishing
Motor (M6) turns.
Check Procedure
Disengage the Toner Bottle
Release Lever.
Turn the Toner Bottle a half turn by
hand.
Turn ON the Power Switch.
NO
Check for overload.
The Toner Bottle Home Position Sensor (PC7) is operational.

Check Procedure
when the Toner Replenishing Motor
(M6) turns.
Voltage across PJ19A-10 and
GND
DC0 V when unblocked
DC5 V when blocked
NO
Change Toner Bottle Home Position Sensor (PC7).

the Toner Replenishing Motor (M6).
Check Procedure
when the Toner Replenishing Motor
(M6) turns.
DC0 V when deenergized
YES Change Toner Replenishing Motor

(M6).
NO
T-26
Action

PWB-A).
(5)
C0210: Abnormal image transfer voltage

High Voltage Unit (HV1)
DEVELOPING SECTION
HV1
High Voltage Unit
PWB-A
Master Board
Developing Bias
P.C/I.T._REM
I.T.Control
Image Transfer
Not Use
I.T.Voltage Monitor
P.C/I.T._REM
I.T.Control
VG Voltage
I.T.Voltage Monitor
Charge Neutralizing Cloth

Photo Conductor
4022T529AA
Step
Check
C0210 reappears when the Power

Switch is turned OFF and ON.
Result
Action
YES Change High Voltage Unit (HV1).

Change Master Board (PWB-A).
T-27
(6)
C0500: Warm-up failure

C0510: Abnormally low fusing temperature
C0520: Abnormally high fusing temperature
Fusing Heater Lamp (H1)

Thermistor (TH1)
Thermoswitch 1 (TS1)
Fusing Unit Interlock Switch (S2)

DC Power Supply (PU1)
PWB-A
Master Board
Not Use
Thermistor
FUSING SECTION
Fusing Heater
Lamp
Thermoswitch 1
POWER SUPPLY SECTION

Fusing Unit
Interlock Switch
R
R
PU1
DC Power Supply
CN2PU1
HEATER_N
Not Use
HEATER_L
4022T530AA
C0500: Warm-up failure; C0510: Abnormally low fusing temperature

Step
Check
Result
Action
Fusing Heater Lamp (H1) turns

ON.
YES Go to step 3.
Fusing Heater Lamp (H1) is open-cir- YES Change Fusing Heater Lamp (H1).
cuited.
Check Procedure
Check the resistance across both
ends of the Fusing Heater Lamp
(H1).
The Fusing Heater Lamp is open-circuited if the resistance is infinity.
Thermoswitch 1 (TS1) is operational.

Check Procedure
Check the resistance across both
ends of the Thermoswitch 1 (TS1).
The Thermoswitch 1 is open-circuited
if the resistance is infinity.
NO
NO
T-28
Go to step 2.
Change Thermoswitch 1 (TS1).
Step
4
Check
Result
Fusing Unit Interlock Switch (S2) is

operational.
Check Procedure
Check continuity across terminals
when the Fusing Unit Interlock
Switch (S2) is turned ON.
Across S2-1A and S2-1B
Across S2-2A and S2-2B
NO
Action
Change Fusing Unit Interlock
Switch (S2).
YES Change DC Power Supply (PU1).
Thermistor (TH1) is open-circuited.

Check Procedure
Check the resistance across CN15-2
and CN15-3 on the Fusing Unit side
with CN15 disconnected.
The Thermistor is open-circuited if
the resistance is infinity.
YES Change Thermistor (TH1).
The following voltages are supplied

from the Master Board (copier: PWBA).
Check Procedure
DC24 V when Fusing Heater Lamp
(H1) is OFF
(H1) is ON
GND
(H1) is OFF
(H1) is ON
NO

PWB-A).
C0520: Abnormally high fusing temperature

Step
Check
Result
Action
Thermistor (TH1) is dirty.
YES Clean Thermistor (TH1).
Thermistor (TH1) is open-circuited.

Check Procedure
Check the resistance across CN15-2
and CN15-3 on the Fusing Unit side
with CN15 disconnected.
The Thermistor is open-circuited if
the resistance is infinity.
YES Change Thermistor (TH1).

NO
T-29

PWB-A).
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PWB-C
Contorol BoardJP11C
IR SECTION
30
Scanner
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PWB-A
Master
Board
Scanner Home
Position Sensor
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(8)
C0B60: Bin Switching Motor malfunction

Main Board (JS-202: PWB-A)
Bin Switching Motor (JS-202: M1)

Upper Home Position Sensor (JS-202: PC32)
Lower Home Position Sensor (JS-202: PC33)
JS-202
PWB-A
Main Board
JS-202
PWB-A
Master
Board
Bin Switching
Motor
Upper Home
Position Sensor
PC32 ANODE
Lower Home
Position Sensor
PC33 ANODE
Not Used
4022T532AA
Step
Check
Result
Action
Bin Switching Motor (JS-202: M1)

turns when the Power Switch is
turned ON.
NO
Change Bin Switching Motor (JS202: M1).
Tray is moved as the Bin Switching

Motor (JS-202: M1) operates.
NO
Reinstall motor unit.
Upper Home Position Sensor (JS202: PC32) is operational.

Check Procedure
Check voltage across a Main Board
(JS-202: PWB-A) pin and GND when
the sensor is blocked.
DC5 V when blocked
NO
Change Upper Home Position Sensor (PC32).
T-31
Step
Check
Result
Action
Lower Home Position Sensor (JS202: PC33) is operational.

Check Procedure
(JS-202: PWB-A) pin and GND when
DC5 V when blocked
NO
Change Lower Home Position Sensor (PC33).

PWB-A).
T-32
(9)
C0B80 Shift Motor malfunction

Shift Motor (OT-103: M1)

Home Sensor (OT-103: S31)
Main Board (OT-103: PWB-A)

OT-103
PWB-A
Main Board
OT-103
PWB-A
Master
Board
CN55
Shift Motor
PJ3A
PJ58
S31 ANODE
Home Sensor
S31
S31 ON
Not Used
4022T536AA
Step
Check
Result
Action
Shift Motor (OT-103: M1) turns when

the Power Switch is turned ON.
NO
Change Shift Motor (OT-103: M1).
Exit Roller operates as the Shift

Motor (OT-103: M1) is energized.
NO
Reinstall motor unit.
Home Sensor (OT-103: S31) is operational.

Check Procedure
(OT-103: PWB-A) pin and GND when
DC5 V when blocked
NO
Change Home Sensor (OT-103:

S31).

PWB-A).
T-33
(10) C0F32: Faulty ATDC Sensor

C0F33: Improperly adjusted ATDC Sensor
ATDC Sensor (UN1)
PWB-A
Master Board
DEVELOPING SECTION
ATDC Sensor
4022T533AA
Step
Check
Result
Action
Developer is not even in the Developer Mixing Chamber.
YES Gently swing the IU in the horizontal direction to even out developer
in the Developer Mixing Chamber.
ATDC Sensor (UN1) is dirty with foreign matter (such as paper dust)
other than developer.
YES Clean ATDC Sensor (UN1).
Foreign matter (such as paper dust)

is trapped in the Developer Mixing
Chamber.
YES Remove foreign matter from the

Developer Mixing Chamber.
The following voltages are supplied

from the Master Board (copier: PWBA).
Check Procedure
Board pin and GND when the Power
Switch is turned ON.
DC5.39 V to 8.15 V across PJ7A-8
and GND
DC1.41 V to 4.98 V across PJ7A10 and GND
YES Change ATDC Sensor (UN1) and

developer.
NO
T-34

PWB-A).
(11) C1038: Engine connection failure

Control Board (copier: PWB-C)
Step
Check
C1038 reappears when the copier is

turned OFF and ON again.
Check Procedure
Turn OFF and ON the Power Switch
to check to see if C1038 reappears.
Result
YES Go to step 2.
The connection between Master

Board (copier: PWB-A) and Control
Board (copier: PWB-C) is loose.
YES Make good connection between

Master Board (copier: PWB-A) and
Control Board (copier: PWB-C).
NO
Action
Change Control Board (copier:

PWB-C).
PWB-A).
(12) C1200: Faulty ASIC/memory

Step
Check
Result

Check Procedure
YES Go to step 2.
Memory (U8) on Control Board

(copier: PWB-C) is loose.
YES Reinstall memory (U8).

NO
T-35
Action

PWB-C).
(13) C1300: Polygon Motor malfunction (startup failure, Lock signal failure, faulty
Lock signal)
C13F0: Faulty HSYNC
Polygon Motor (M2)
PWB-A
Master Board
IR/PH SECTION
Polygon Motor
4022T534AA
Step
Check
Result
Action
YES Go to step 2.
C1300/C13F0 reappears when the
copier is turned OFF and ON again.
Check Procedure
to check to see if C1300/C13F0 reappears.
Polygon Motor (M2) connector

PJ13A is loose.
YES Reconnect connector PJ13A.

the Polygon Motor (M2).
Check Procedure
Board (copier: PWB-A) and GND
DC5 V while Polygon Motor (M2) is
in standby state
DC0 V when Polygon Motor (M2) is
energized
YES Change PH Unit.

NO
T-36

PWB-A).
(14) C1468: Faulty EEPROM

Step
Check

Check Procedure
Result
YES Go to step 2.
Memory (U29) on Control Board

(copier: PWB-C) is loose.
YES Reinstall memory (U29).

NO
T-37
Action

PWB-C).
(15) C14A3: IR fluorescent lamp fault

Exposure Lamp (LA2)
Inverter Board (copier: PU2)
IR SECTION
PWB-C
Control Board
PWB-J
CCD Board
Not Used
Not Used
PU2
Inverter Board
Exposure Lamp
LA2
H/V TERMINAL 1
Not Used
Not Used
H/V TERMINAL 2
CN1PU2
JP16C
4022T535AA
T-38
Step
Check
Result
Action
Exposure Lamp turns ON when the

Power Switch is turned ON.
NO
Go to step 3.
Exposure Lamp is abnormally lit

(flickers or abnormally dark) when
NO
Go to step 4.
Inverter Board (copier: PU2) connector is loose.
YES Reconnect.
CCD Board (copier: PWB-J) connector is loose.
YES Reconnect.
YES Change Inverter Board (PU2).

The following voltage is supplied
from the Control Board (copier: PWB- NO Change Control Board (copier:
C).
PWB-C).
Check Procedure
Check voltage across a Control
Board (copier: PWB-C) pin and GND
Voltage across JP16C-4 and GND
DC24 V when Exposure Lamp
(LA2) is OFF
DC0 V when Exposure Lamp (LA2)
is ON
NO
T-39
Change Exposure Lamp (LA2).
(16) The copier does not turn ON.

Power Switch (S1)

DC Power Supply (PU1)
Control Panel (UN2)
PWB-C
Control Board
JP2UN2
JP4C
UN2
Control
Panel
Main Switch
Not Used
Not Used
PJ11C
Not Used
Fusing
Heater Lamp Thermoswitch 1
HEATER_L
Not Used
HEATER_N
Fusing Unit
Interlock Switch
PU1
DC Power Supply
29
30
29
30
PJ1A
Front Door
InterLock Switch
Right Door
InterLock Switch
PWB-A
Master Boad
4022T545AA
Step
Check
Result
Action
A malfunction code appears when

YES Go to step 2.
The malfunction is temporarily reset

when the Power Switch is turned
OFF and ON with the Stop key held
down.
YES Perform the troubleshooting procedure according to the malfunction

code.
NO
T-40
Go to step 3.
Step
Check
Result
Action
Power supply voltage check

Check Procedure
Check voltage across pins of DC Power Supply (PU1) when the Power Switch is turned
ON.
Voltage across CN1PU1-1 and CN1PU1-3
AC0 V when the Power Switch is OFF
Rated AC voltage when the Power Switch is
turned ON
NO
Check wall outlet for voltage.

Check power cord for
continuity.
Check Power Switch.
Check of output of DC24 V to Control Board

(copier: PWB-C)
Check Procedure
Check voltage across a Control Board (copier:
PWB-C) pin and GND when the Power Switch
is turned ON.
DC0 V when the Power Switch is OFF
DC24 V when the Power Switch is turned
ON
NO
Check Front Door Interlock Switch (S3).

Check Right Door Interlock Switch (S4).
Change DC power Supply
(PU1).
Check of output of DC24 V to Master Board

(copier: PWB-A)
Check Procedure
Check voltage across a Master Board (copier:
PWB-A) pin and GND when the Power Switch
is turned ON.
ON
NO
Check Front Door Interlock Switch (S3).

Check Right Door Interlock Switch (S4).
(PU1).
Check of output of DC 5 V to Master Board

(copier: PWB-A)
Check Procedure
Check voltage across a Master Board (copier:
PWB-A) pin and GND when the Power Switch
is turned ON.
ON
NO

(PU1).
Check of output of DC5 V to control panel

(UN2)
Check Procedure
Check voltage across a Control Board (copier:
PWB-C) pin and GND when the Power Switch
is turned ON.
DC5 V when the Power Switch is turned ON
NO
Check Control Board

(copier: PWB-C).
Change Master Board
(copier: PWB-A).
(PU1).
T-41
YES Change Control Panel

(UN2).
5.
IMAGE FAILURE
5-1.
Image Failure Troubleshooting
In this chapter, troubleshooting is divided into initial checks and troubleshooting procedures classified by image failures.
If any image failure has occurred, first make the initial checks, then proceed to the corresponding image failure troubleshooting procedure.
5-2.
Initial Checks
Determine if the failure is attributable to a basic cause or causes.

Section
Step
Check
Result
Installation
site
The installation site complies

with the requirements specified in PRECAUTIONS FOR
INSTALLATION contained in
GENERAL.
NO
Change the installation site.
Paper
NO
Change paper for one that

meets specifications.
Instruct user to use paper
that meets specifications and
is recommended.
Paper is damp.
YES Change paper for one that is

dry.
Then, instruct user to use
paper that meets specifications and in how to store
paper.
Original is placed correctly.
NO
Original is written in light pencil.
YES Change original.

Instruct user to use original
with appropriate image density.
Original is transparent (OHP

transparencies, etc.).
YES Change original.

Instruct user to use originals
that meet specifications.
Original Glass is dirty.
YES Clean Original Glass.
Original Glass is scratched.
YES Change Original Glass.
The PM parts relating to

image formation have
reached the end of cleaning/
replacement cycles.
YES Clean PM parts.

Change PM parts.
Original
PM parts
T-42
Action
Reposition original.
Instruct user in how to place
original correctly.
Determine if the failure is attributable to an input system (IR) or output system (engine).
Check
Copy made at a reduced
ratio.
Result
Full-size copy
Action
Reduced copy
Input system
Original
1177T04YA
Full-size copy
Reduced copy
1177T03YA
Output system
1177T05YA
T-43
5-3.
Image Failure Samples
1. Blank copy
2. Black copy
3. Low image density
4. Foggy background or rough

image
5. Black streaks or bands
6. Black spots
7. Blank streaks or bands
8. Void areas
9. Smear on back
10. Uneven image density
11. Gradation reproduction failure
12. Periodically
uneven image
4022T542
T-44
5-4.
(1)
Troubleshooting Procedures by Image Failure

Blank copy
Section
Step
Check
Result
Output system
Imaging Unit is installed correctly.
NO
Connector between the Imaging

Unit and copier is dirty.
YES Clean.
PH Shutter (located along the

laser path between the PH Unit
and PC Drum) is not in correct
position or malfunctions.
YES Correct or reinstall.
PH Unit connectors PJ12A and

PJ13A are loose.
YES Reconnect.
Image Transfer Roller Assy is

installed correctly.
NO
Image transfer current contact is

dirty, broken, or bent.
YES Clean, correct, or

change.
Developing bias contact is dirty,

broken, or bent.

change.
High Voltage Unit (HV1) connectors CN1HV1 and CN2HV1 are

loose.
YES Reconnect.
The following voltage is supplied

from the Master Board (copier:
PWB-A).
Check Procedure
Board pin and GND when the
Start key is pressed.
GND
DC14 V in standby state
DC0 V when Start key is
pressed
YES Change IU.

Change PH Unit.
Change High Voltage Unit (HV1).
CCD Board (PWB-J) connector

JP7C is loose.
YES Reconnect.

connector PJ1A is loose.
YES Reconnect.
Input system
T-45
NO
NO
Action
Reinstall.
Reinstall.
Change Master
Board (copier:
PWB-A).
Change Control
Board (copier:
PWB-C).
Change Master
Board (copier:
PWB-A).
(2)
Black copy
Section
Step
Check
Output
system
PC Drum Charge Corona grid mesh and

Comb Electrode are loose.
YES Reinstall.
PC Drum Charge Corona contact is dirty,

scratched, folded, bent, or damaged.
YES Correct or change.
Grid bias contact is dirty, folded, or bent.

change.
PC Drum ground contact is dirty,

scratched, bent, or damaged.

change.
High Voltage Unit (HV1) connectors

CN1HV1 and CN2HV1 are loose.
YES Reconnect.
PH Unit connectors PJ12A and PJ13A

are loose.
YES Reconnect.
The following voltage is supplied from

the Master Board (copier: PWB-A).
Check Procedure
Check voltage across a Master Board
pin and GND when the Start key is
pressed.
DC0 V when Start key is pressed
YES Change IU.

Change PH Unit.
Change High Voltage Unit (HV1).
NO
Change Master
Board (copier:
PWB-A).
Exposure Lamp turns ON when the

NO
Go to step 3.
Exposure Lamp is abnormally lit (flickers

or abnormally dark) when the Power
NO
Go to step 4.
Inverter Board (copier: PU2) connector

is loose.
YES Reconnect.
CCD Board (copier: PWB-J) connector is

loose.
YES Reconnect.
Control Board (copier: PWB-C) connector PJ1A is loose.
YES Reconnect.

the Control Board (copier: PWB-C).
Check Procedure
Check voltage across a Control Board
(copier: PWB-C) pin and GND when the
DC24 V when Exposure Lamp (LA2) is
OFF
DC0 V when Exposure Lamp (LA2) is
ON
YES Change Inverter

Board (PU2).
Change CCD Unit.
Input
system
T-46
Result
NO
NO
Action
Change Exposure
Lamp.
Change Control
Board (copier:
PWB-C).
(3)
Low image density
Section Step
Output
system
Check
Result
Action
Image density changes after Toner

Replenisher has been run.
Toner Replenisher of Utility
YES Replenish the supply of

toner using Toner
Replenisher.
Image density changes after ID Adjustment and VG Adjustment have been

made.
YES Readjust.
For more details, see
SWITCHES ON PWBs/
Image transfer current contact is dirty,

folded, or bent.

change.
Developing bias contact is dirty, folded,

or bent.

change.
High Voltage Unit (HV1) connectors

CN1HV1 and CN2HV1 are loose.
YES Reconnect.
ATDC Sensor (UN1) is dirty with foreign

matter (such as paper dust) other than
developer.
YES Clean.
The following voltages develop from the

ATDC Sensor (UN1).
Check Procedure
pin and GND when the Power Switch is
turned ON.
and GND
and GND
NO

Check Procedure
pressed.
YES Change IU.

Change High Voltage
Unit (HV1).
T-47
NO
Change ATDC Sensor

(UN1) and then change
developer.
Change Master Board

(copier: PWB-A).
Section Step
Input
system
Check
Result
Action
Shading sheet reading portion (the portion on the backside of the Original
Glass to which Original Width Scale is
affixed) is dirty.
YES Clean.
CCD Board (copier: PWB-J) connector

is loose.
YES Reconnect.
YES Reconnect.
T-48
NO
Change Control Board

(copier: PWB-C).
Change Master Board
(copier: PWB-A).
(4)
Foggy background or rough image
Section Step
Output
system
Check
Result
Image condition changes after ID

Adjustment and VG Adjustment have
been made.
YES Readjust.
For more details, see
SWITCHES ON PWBs/
PC Drum surface and the areas in contact with Ds Collars are dirty with foreign
matter, or deformed or worn.
Main Erase (LA1) is dirty.
YES Clean.
Grid bias contact is dirty, scratched,


change.
ATDC Sensor (UN1) is dirty with foreign

matter (such as paper dust) other than
developer.
YES Clean.

ATDC Sensor (UN1).
Check Procedure
pin and GND when the Power Switch is
turned ON.
and GND
and GND
NO

Check Procedure
pressed.
YES Adjust Db.

For details, see DIS/
REASSEMBLY,
ADJUSTMENT.
Change Main Erase
(LA1).
Change PC Drum.
Change IU.
Change High Voltage
Unit (HV1).
NO
Input
system
Action
Change ATDC Sensor

(UN1) and then change
developer.
Change Master Board

(copier: PWB-A).
Original Glass is dirty.
Scanner mirrors are dirty.
YES Clean.
YES Clean.
Exposure Lamp (LA2) is dirty.
YES Clean.
CCD Unit lens and CCD surface are

dirty.
Check Procedure
Remove lens cover to check for possible
contamination.
YES Clean.
T-49
Section Step
Input
system
Check
Result

or abnormally dark) when the Start key
is pressed.
NO

CN1PU2 is loose.
YES Reconnect.

PJ7C is loose.
YES Reconnect.
T-50
NO
NO
Action
Go to step 7.
Change Exposure
Lamp (LA2).
Change Inverter Board
(PU2).
(copier: PWB-C).
(5)
Black streaks or bands
Section Step
Output
system
Input
system
Check
Result
Action
PC Drum is dirty or scratched.
Foreign matter (such as paper dust)

sticks to the Cleaning Blade of IU or the
blade curves upward.
YES Remove foreign matter,

correct, or change.
DB of IU is plugged with foreign matter

(such as paper dust).
YES Remove foreign matter.

Comb Electrode are dirty, scratched,
deformed, damaged, or out of position.
Left Fusing Roller is dirty or scratched.
PH window of the PH Unit is dirty or

scratched.
Original Glass is dirty, scratched, worn,

or damaged.
affixed) is dirty.
YES Clean.
Scanner mirrors are dirty, scratched, or

damaged.

dirty or scratched.
Check Procedure
contamination.

is loose.
YES Reconnect.
YES Reconnect.
T-51
NO
NO
Change IU.
Change CCD Unit.

(copier: PWB-C).
(6)
Black spots
Section Step
Output
system
Input
system
Check
Result
Action
Toner is present along the paper path.
YES Clean.
PC Drum is dirty or scratched.
Tip of the PC Drum Paper Separator

Finger is dirty, scratched, deformed,
worn, or damaged.
Left Fusing Roller is dirty or scratched.
Tip of the Fusing Paper Separator Finger is dirty, scratched, deformed, worn,
or damaged.
YES Clean or change Fusing Paper Separator

Fingers and finger
springs.
Image condition changes after VG

Adjustment has been made.
YES Readjust.
For details, see
SWITCHES ON PWBs/
Original Glass is dirty or scratched.
YES Clean.

is loose.
YES Reconnect.
YES Reconnect.
T-52
NO
Change CCD Unit.

(copier: PWB-C).
(7)
Blank streaks or bands
Section Step
Output
system
Input
system
Check
Result
Action
PC Drum ground terminal is dirty,

scratched, deformed, or damaged.

change.


deformed, or damaged.

change.
Post-fusing guide plate is dirty,

PH window of the PH Unit is dirty,

scratched, or damaged.

or damaged.
affixed) is dirty.
YES Clean.

damaged.

dirty or scratched.
Check Procedure
contamination.

is loose.
YES Reconnect.
YES Reconnect.
T-53
NO
NO
Change IU.
Change CCD Unit.

(copier: PWB-C).
(8)
Void areas
Section Step
Output
system
Check
Result
Action
Foreign matter is present along the

paper path.
Paper dust plugs up the Paper Dust

Remover.
PC Drum Charge Corona, grid mesh,

and Comb Electrode are loose.
YES Reinstall.
PC Drum Charge Corona contact is

dirty, scratched, deformed, worn, or
damaged.

change.
Developing Roller is dirty, scratched,

Toner is even on Sleeve/Magnet Roller.
NO
Developer is not even in the Developer

Mixing Chamber of IU.
YES Even out developer in

the Developer Mixing
Chamber.

Image Transfer Roller is dirty, scratched,


change.
10
Image Transfer Roller Assy is installed

correctly.
NO
11
Charge Neutralizing Plate is dirty,

scratched, folded, or bent.

change.
12
Left Fusing Roller is dirty, scratched,

deformed, or worn.
T-54
NO
Adjust DB.
REASSEMBLY,
ADJUSTMENT.
Reinstall.
Change IU.
(9)
Smear on back
Section Step
Output
system
Check
Result
Action
Toner is spilled over area inside copier.
YES Clean interior.
Toner is present along the paper path.
YES Clean.
Right Fusing Roller is dirty, scratched, or

damaged.
Image Transfer Roller is dirty.
Grid bias contact is dirty, scratched,


change.
NO
T-55
Change High Voltage

Unit (HV1).
Change Master Board
(copier: PWB-A).
(10) Uneven image density

Section Step
Output
system
Check
Result
PC Drum ground plate is dirty,


change.

deformed, worn, damaged, or loose.

change.

Sleeve/Magnet Roller is dirty, scratched,

Toner is even on Sleeve/Magnet Roller.
NO
Developer is not even in the Developer

Mixing Chamber of IU.
YES Even out developer in

the Developer Mixing
Chamber.
NO
Input
system
Action
Adjust DB.
REASSEMBLY,
ADJUSTMENT.
Change IU.
Change Master Board
(copier: PWB-A).

or damaged.
affixed) is dirty.
YES Clean.

damaged.

dirty or scratched.
Check Procedure
contamination.

or abnormally dark) when the Power
NO

CN1PU2 is loose.
YES Reconnect.

is loose.
YES Reconnect.
T-56
NO
Go to step 8.
Change Exposure
Lamp (LA2).
Section Step
Input
system
Check
Result
T-57
Action
YES Reconnect.
NO
Change CCD Unit.

(copier: PWB-C).
(11) Gradation reproduction failure

Section Step
Output
system
Check
Result
Action
PC Drum is dirty.
YES Clean.

PH Unit connectors PJ12A and PJ13A are

loose.
YES Reconnect.
PH window of PH Unit is dirty.
YES Clean.
ATDC Sensor (UN1) is dirty with foreign matter (such as paper dust) other than developer.
YES Clean.

ATDC Sensor (UN1).
Check Procedure
Check voltage across a Master Board pin
and GND when the Power Switch is turned
ON.
DC5.39 V to 8.15 V across PJ7A-8 and
GND
DC1.41 V to 4.98 V across PJ7A-10 and
GND
NO
T-58
Change ATDC
Sensor (UN1) and
developer.
YES Change Master

Board (copier:
PWB-A).
Input
system
Original Glass is dirty, scratched, worn, or

damaged.
Shading sheet reading portion (the portion on

the backside of the Original Glass to which
Original Width Scale is affixed) is dirty.
YES Clean.
Scanner mirrors are dirty, scratched, or damaged.

CCD Unit lens and CCD surface are dirty or
scratched.
Check Procedure
Remove lens cover to check for possible contamination.
Exposure Lamp is abnormally lit (flickers or

abnormally dark) when the Start key is
pressed.
NO

CN1PU2 is loose.
YES Reconnect.

loose.
YES Reconnect.
Control Board (copier: PWB-C) connector

PJ1A is loose.
YES Reconnect.
NO
NO
Go to step 8.
Change Exposure
Lamp (LA2).
Change CCD Unit.

Change Control
Board (copier:
PWB-C).
(12) Periodically uneven image

Section Step
Output
system
Check
Result
Action
IU is securely fastened using the dedicated fixing screws.
NO
Secure in position.
PH Unit is securely fastened using the

dedicated fixing screws.
NO
Secure in position.
IU drive mechanism is dirty or damaged.
PC Drum surfaces in contact with Ds Col- YES Clean or change.

lars and drive mechanism are dirty,
Synchronizing Roller drive mechanism is

Fusing Unit drive mechanism is dirty,

T-59
NO
Change Master Board

(copier: PWB-A).
Input
system
Scanner Motor (M5) is securely fastened

using the dedicated fixing screws.
NO
Scanner Motor (M5) drive mechanism is

dirty or damaged.
Timing belt of the scanner drive mechanism is dirty with foreign matter or out of
correct position.
YES Remove foreign matter or reinstall belt.
Scanner drive mechanism pulley is dirty

with foreign matter, scratched, deformed,
worn, or damaged.
YES Remove foreign matter or change.
Scanner Drive Cables are wound incorrectly.
YES Re-wind Scanner

Drive Cables.
Scanner rails and bushings are dirty with

foreign matter, scratched, deformed,
worn, or damaged.
Scanner moves smoothly.

Check Procedure
Gently move the Scanner by hand to
check for smooth operation.
NO

loose.
YES Reconnect.
Control Board (copier: PWB-C) connector

PJ1A is loose.
YES Reconnect.
T-60
NO
Secure in position.
Lubricate the Scanner rails.

Reinstall Scanner.
Change CCD Unit.

Change Control
Board (copier: PWBC).
6.
OTHER ERROR CODES
When an error that does not fall into the category of paper transport failure or malfunction, a corresponding error code is displayed in the Display.
4022T503AA
4022T505AA
Code
Description
Resetting Procedure
tnr
Toner empty stop
Change Toner Bottle.
nP
Paper size is physically changed of

the paper source currently selected
for use while a copy cycle is being
run.
Load paper of the size originally

loaded in the paper source being
used.
Load the paper source with paper of

Copier does not find paper of the
the appropriate size.
appropriate size when a copy cycle is
run using the ADF and in the Mixed
Original and Auto Paper mode.
oL
Front Door, Right Door, or Side Door

is open.
oU
ADF is raised.
oA
ADF document take-up door is open.
Close the open door or lower the

ADF.
H11
Scan image memory overrun
H2
The length of the paper set does not Load paper of the correct size again
according to the set paper size.
match that of the paper actually taken
up and fed in.
For copier tray: Slide out and in the
paper tray in which the size error has
occurred.
For Manual Bypass Tray: Place paper
in the Manual Bypass Tray.
For Multiple Bypass Tray: Unload
paper from the Multiple Bypass Tray,
then reload it back again.
H3
JS-202 exit capacity exceeded
J9
JS-202 Bin Switching Motor error (Job Remove paper from the tray.
Tray is unable to return to its home
position because paper left in the tray)
T-61
Remove paper that has been fed out.
Code
PLG
Description
Resetting Procedure
Plug-In Counter not plugged in
Plug in the Plug-In Counter.

Change setting in Security mode.
For details, see SWITCHES ON
PWBs/TECH. REP. SETTINGS.
A numeral outside the specified setting range is entered.
Automatically reset 1 sec. after the

error display is given.
Mechanical total counter not connected
Connect the mechanical total counter

and then turn OFF and ON the Power
Switch.
Change setting in Security mode.
nc1
Maintenance Counter count value

reached (the set count of the Maintenance Counter is reached)
Enter a count value again.

nc2
IU life stop mode (the life value of the Initialize the counter value.
Maintenance Counter is reached)
Err
Blank
T-62
Copyright
2001 MINOLTA CO., LTD.
Use of this manual should be strictly supervised to

avoid disclosure of confidential information.
MINOLTA Co.,Ltd.
7662-4021-11 01100500

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Service Manual

SAFETY PRECAUTIONS FOR INSPECTION AND

Indicates a potentially hazardous situation which, if not avoided,

1. Always observe precautions.

3. Do not throw toner or the toner bottle into a fire.

11. Restore all parts and harnesses to their original positions.

1. Precautions for Service Jobs.

3. Precautions for the Working Environment.

When handling circuit boards, observe the HANDLING of PWBs.

Used Batteries Precautions

Precautions for Service

4. Precautions for Dis/Reassembly

9. Handling of the Imaging Cartridge

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Lit while data received from personal computer is being

Job Input key

Meter Counter key

Press to display the Total Counter or Size Counter value.

Neg. Pos. key

Press to copy an original with the original total arrangements reversed.

Press to select the Mixed Orig. or Book Separation function.

Press to select the 2in1 or 4in1 function.

Press to select the erase position.

Press to select the finishing function.

File Margin key

Press to select the File Margin mode.

10 X/Y Zoom key

Press to make a copy with different zoom ratios set for

11 Job Recall key

Press to recall either one of the two jobs previously stored

Lights up when malfunction occurs in the copier.

Blinks or lights up when the time approaches that copier

14 Add Paper indicator

Lights up when paper source currently selected for use

15 Add Toner indicator

Lights up when toner will soon run out.

16 Bypass Tray Size

Press to select the size of the paper loaded in the Bypass

Press to change the zoom ratio in the range between

Shows the number of copies to be made, the zoom ratio,

Use to type in the number of copies to be made and any

Press when entering an account number.

21 Energy Saver key

Press to set the copier into the Energy Saver mode.

Press to interrupt a copy job.

23 Panel Reset key

Press to reset all copy functions and settings to their

Settings in the Utility Mode

Users Choice Mode

Drum Dehumidify Mode

Toner Replenisher Mode

Custom Size Input Mode

Utility Mode Setting Procedure

Users Choice Mode (Display: U-1)

Paper Auto Detection (1st Tray)

Paper Auto Detection (2nd Tray)

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