CF1501/CF2001

SERVICE MANUAL

[TROUBLESHOOTING]

INDEX (TROUBLESHOOTING) TROUBLESHOOTING UNIT REPLACEMENT MANUAL

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 technicians attention to what is graphically represented inside the marking (including a warning). Used to prohibit the service technicians from doing what is graphically represented inside the marking. Used to instruct the service technicians to do what is graphically represented inside the marking.

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. 3. 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.

P-1

4. 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. 5. 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. 6. 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.

7. 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. 8. 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. 9. 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. 10. 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.

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CAUTION
1. Precautions for Service Jobs A toothed 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. 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.

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5. Precautions for the Laser Beam (Only for Products Employing a Laser) Removing the cover marked with the following 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.

1167P001AA

ANGR
Invisible laser radiation when open.

AVOID DIRECT TO BEAM

EXPOSURE
0947-7127-01 1144D270AA

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.

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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 hnlichen Typ. Entsorgung gebrauchter batterien nach Angaben des Herstellers. France ATTENTION Ily a danger dexplosion sily a remplacement incorrec de la batterie. Remplacer uniquement avec une batterie du meme type ou dun type quivalent recommande par le constructueur. 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. 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. Sweden VARNING Explosionsfara vid felaktigt batteribyte. Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera anvnt batteri enligt fabrikantens instruktion. Finland VAROlTUS Paristo voi rjht, los se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit Kytetty paristo valmistajan ohjeiden mukaisesti.

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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.

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.

How to Use this Book

1. DIS/REASSEMBLY, ADJUSTMENT To reassemble the product, reverse the order of disassembly unless otherwise specified. 2. 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.

Precautions for Service

Check the area surrounding the service site for any signs of damage, wear or need of repair. 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.

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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. If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice.

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.

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Handling of PWBs
1. 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. 2. 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.

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.

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Handling of the PC Drum

Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: Use the specified carton whenever moving or storing the PC Drum. The storage temperature is in the range between 20C and +40C. In summer, avoid leaving the PC Drum in a car for a long time. 2. Handling: Ensure that the correct PC Drum is used. Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth. The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. 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 apply chemicals to the surface of the PC Drum. Do not attempt to wipe clean the surface of the PC Drum. If, however, the surface is contaminated with fingerprints, clean it using the following procedure. 1. Place the PC Drum into one half of its carton.

1076D001

1076D002

2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. A. Turn the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. B. Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping.

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3. 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

4. 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.

Handling of the Imaging Cartridge

Only for Products Employing an Imaging Cartridge. 1. 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. 2. Handling: Store the Imaging Cartridge in a place that is not exposed to direct sunlight. 3. 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.

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TROUBLESHOOTING

18605

CONTENTS
1. INTRODUCTION ............................................................................................. T-1 1-1. Reading the Text ..................................................................................... T-1 2. I/O CHECK ...................................................................................................... T-1 2-1. Electrical Components Check Procedure ................................................ T-1 2-2. I/O Check List .......................................................................................... T-3 2-3. How to Interpret State Confirm of Tech. Rep. Mode ........................... T-9 (1) Table # ............................................................................................. T-9 (2) Level History 1 ................................................................................. T-10 (3) Level History 2 ................................................................................. T-10 2-4. Paper Misfeed .......................................................................................... T-11 2-5. Misfeed Detecting Sensor Layout ............................................................ T-12 2-6. Types of Misfeed Detection and Detection Timing .................................. T-14 2-7. Misfeed Troubleshooting Procedures ...................................................... T-17 (1) Copier Paper Take-Up Misfeed ....................................................... T-17 (2) Manual Bypass Take-Up Misfeed .................................................... T-19 (3) Copier Vertical Transport Misfeed ................................................... T-22 (4) 2nd Image Transfer Misfeed ............................................................ T-25 (5) Exit Misfeed ..................................................................................... T-27 (6) PF-118 Paper Take-Up Misfeed ...................................................... T-29 (7) PF-117 Paper Take-Up Misfeed ...................................................... T-32 (8) Duplex Paper Take-Up Misfeed ...................................................... T-35 3. MALFUNCTIONS ............................................................................................ T-37 3-1. Detection Timing by Warning Code ......................................................... T-38 3-2. Detection Timing by Malfunction Code .................................................... T-40 3-3. Troubleshooting Procedures by Malfunction Code .................................. T-48 (1) C0000: Main Motors failure to turn C0001: Main Motor turning at abnormal timing ............................... T-48 (2) C0010: Imaging Unit Motor Cs failure to turn C0011: Imaging Unit Motor C turning at abnormal timing C0012: Imaging Unit Motor Ms failure to turn C0013: Imaging Unit Motor M turning at abnormal timing C0014: Imaging Unit Motor Ys failure to turn C0015: Imaging Unit Motor Y turning at abnormal timing C0016: Imaging Unit Motor Bks failure to turn C0017: Imaging Unit Motor Bk turning at abnormal timing .............. T-49 (3) C0040: Fusing Cooling Fan Motor 1s failure to turn C0046: Fusing Cooling Fan Motor 2s failure to turn C004C: Ozone Ventilation Fan Motors failure to turn C004E: Power Supply Cooling Fan Motors failure to turn .............. T-51 (4) C0060: Fusing Drive Motors failure to turn C0061: Fusing Drive Motor turning at abnormal timing ................... T-53 (5) C0094: 2nd Image Transfer Roller pressure/retraction failure ........ T-54 (6) C0096: Image Transfer Belt pressure/retraction failure ................... T-55 (7) C0098: Fusing Roller pressure/retraction failure ............................. T-56 (8) C0200: Cyan PC Drum Charge Corona malfunction C0202: Magenta PC Drum Charge Corona malfunction

(9) (10)

(11) (12)

(13)

(14)

(15)

(16)

(17)

(18) (19)

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C0204: Yellow PC Drum Charge Corona malfunction C0206: Black PC Drum Charge Corona malfunction ...................... T-58 C0400: Exposure Lamps failure to turn ON C0410: Exposure Lamp turning ON at abnormal timing .................. T-60 C0500: Heating Roller warm-up failure C0501: Lower Fusing Roller Heater Lamp warm-up failure C0510: Heating Roller abnormally low temperature C0511: Lower Fusing Roller Heater Lamp abnormally low temperature C0520: Heating Roller abnormally high temperature C0521: Lower Fusing Roller Heater Lamp abnormally high temperature ............................................................................................. T-61 C0650: Scanner Home Sensor malfunction C0660: Scanner overrun failure ....................................................... T-63 C0990: LCC Lift-Up Motor malfunction C0991: LCC Lift 1 ascent motion failure C0995: LCC Transport Motor malfunction C0999: LCC Lift 2 ascent motion failure .......................................... T-65 C0F30: Abnormally low toner density detected by Cyan ATDC Sensor/ C0F31: Abnormally high toner density detected by Cyan ATDC Sensor C0F32: Abnormally low toner density detected by Magenta ATDC Sensor/ C0F33: Abnormally high toner density detected by Magenta ATDC Sensor C0F34: Abnormally low toner density detected by Yellow ATDC Sensor/ C0F35: Abnormally high toner density detected by Yellow ATDC Sensor ............................................................................................. T-67 C0F36: Abnormally low toner density detected by Black ATDC Sensor/ C0F37: Abnormally high toner density detected by Black ATDC Sensor ............................................................................................. T-69 C0F3A: Cyan ATDC Sensor adjustment failure C0F3B: Magenta ATDC Sensor adjustment failure C0F3C: Yellow ATDC Sensor adjustment failure C0F3D: Black ATDC Sensor adjustment failure .............................. T-70 C13C8: New Transfer Belt Unit resetting failure C13CA: New Fusing Unit resetting failure C13CB: New Fusing Web Unit resetting failure C13CC: New Oil Coating Unit resetting failure ................................ T-71 C13D1: Cyan IU EEPROM failure C13D2: Magenta IU EEPROM failure C13D3: Yellow IU EEPROM failure C13D4: Black IU EEPROM failure ................................................... T-72 C3310: CCD clamp/gain adjustment failure .................................... T-73 C3700: IR Cooling Fan Motor 1 turning at abnormal timing C3710: IR Cooling Fan Motor 2 turning at abnormal timing C3720: Original Glass Cooling Fan Motor turning at abnormal timing ............................................................................................. T-74 C3A00: PIC communication error C3A01: PIC Board malfunction C3FFF: ROM contents fault detected upon start ............................. T-75

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3-4. Power Supply-Related Malfunctions ........................................................ T-76 (1) Copier Does not Turned ON. ........................................................... T-76 (2) No Control Panel Indicators Light up. .............................................. T-77 (3) No Power is Supplied to Options. .................................................... T-78 4. IMAGE QUALITY PROBLEMS ........................................................................ T-79 4-1. Troubleshooting Image Quality Problems ................................................ T-79 4-2. Initial Check Items ................................................................................... T-79 4-3. Troubleshooting Procedure by a Particular Image Quality Problem ........ T-82 (1) IR Scanner System: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD .................................. T-82 (2) IR Scanner System: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD ................................. T-83 (3) IR Scanner System: color spots ...................................................... T-84 (4) IR Scanner System: fog ................................................................... T-85 (5) IR Scanner System: blurred image, blotchy image ......................... T-87 (6) IR Scanner System: incorrect color image registration ................... T-88 (7) IR Scanner System: moire ............................................................... T-89 (8) IR Scanner System: skewed image ................................................. T-90 (9) IR Scanner System: distorted image ............................................... T-91 (10) IR Scanner System: low image density, rough image ..................... T-92 (11) IR Scanner System: defective ACS ................................................. T-93 (12) IR Control System: blank copy, black copy ..................................... T-94 (13) IR Control System: abnormal image ................................................ T-95 (14) Printer Monocolor: white lines in FD, white bands in FD, colored lines in FD, colored bands in FD, white lines in CD, white bands in CD, colored lines in CD, colored bands in CD ......... T-96 (15) Printer Monocolor: uneven density in FD ........................................ T-98 (16) Printer Monocolor: uneven density in CD ........................................ T-100 (17) Printer Monocolor: low image density .............................................. T-101 (18) Printer Monocolor: gradation reproduction failure ........................... T-103 (19) Printer Monocolor: foggy background .............................................. T-105 (20) Printer Monocolor: void areas, white spots ...................................... T-107 (21) Printer Monocolor: colored spots ..................................................... T-108 (22) Printer Monocolor: blurred image .................................................... T-109 (23) Printer Monocolor: blank copy, black copy ...................................... T-110 (24) Printer Monocolor: 0.5-mm-pitch uneven image .............................. T-111 (25) Printer Monocolor: 2-mm-pitch uneven image ................................. T-112 (26) Printer Monocolor: 94-mm-pitch uneven image ............................... T-113 (27) Printer 4-Color: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD .................................. T-114 (28) Printer 4-Color: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD ................................. T-116 (29) Printer 4-Color: uneven density in FD ............................................. T-118 (30) Printer 4-Color: uneven density in CD ............................................. T-119 (31) Printer 4-Color: low image density ................................................... T-120 (32) Printer 4-Color: poor color reproduction .......................................... T-122 (33) Printer 4-Color: incorrect color image registration ........................... T-124

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Printer 4-Color: void areas, white spots ........................................... T-126 Printer 4-Color: colored spots .......................................................... T-127 Printer 4-Color: oil lines, oil on copy ................................................ T-129 Printer 4-Color: poor fusing performance, offset ............................. T-130 Printer 4-Color: brush effect, blurred image .................................... T-131 Printer 4-Color: back marking .......................................................... T-132 Printer 4-Color: 75-mm-pitch uneven image, 200-mm-pitch uneven image ........................................................... T-133 (41) Printer 4-Color: 94-mm-pitch uneven image .................................... T-134 4-4. Image Stabilizer Malfunction .................................................................... T-135 (1) P-5: AIDC Sensor Failure (AIDC Sensor 2) P-28: AIDC Sensor Failure (AIDC Sensor 1) ................................... T-135 (2) P-6: Cyan Imaging Unit Failure P-7: Magenta Imaging Unit Failure P-8: Yellow Imaging Unit Failure P-9: Black Imaging Unit Failure ....................................................... T-135 (3) P-21: Color Shift Correction Failure (Test Pattern Failure) .............. T-136 (4) P-22: Color Shift Correction Failure (Correction Amount Failure) ... T-136 (5) P-23: Cyan 1st Image Transfer ATVC Failure P-24: Magenta 1st Image Transfer ATVC Failure P-25: Yellow 1st Image Transfer ATVC Failure P-26: Black 1st Image Transfer ATVC Failure P-27: 2nd Image Transfer ATVC Failure ......................................... T-136 (6) S-1: CCD Gain Adjustment Failure .................................................. T-137 (7) S-2: Intensity Adjustment Failure ..................................................... T-137

(34) (35) (36) (37) (38) (39) (40)

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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. Pattern 1 Step 1 2 Go to step 2 if you answered No. 2 Go to step 2 if it is checked okay. Check Is ..? Result YES Action Do this. Pattern 2 Step 1 Check Is ..? Result YES NO Action Do this. Check that.

2.
2-1.

I/O CHECK
Electrical Components Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular electrical component is fully operational, this copier provides the following provision. Checking the data of the input port of the board IC with the copier in the standby state (including a misfeed, malfunction, and closure failure condition) allows the Tech. Rep. to determine whether signals are properly input to an electrical component. <Procedure> 1. When a misfeed or malfunction occurs, identify on the circuit diagram accompanying the text the electrical component that is probably responsible for the problem. 2. Select State Confirm from the Tech. Rep. Mode menu and then select I/O Check. Then, from among the Sensors 1 to 7 screens, select the screen that contains the electrical component picked out in step 1 above. (See Tech. Rep. Mode contained in SWITCHES ON PWBs.) 3. Check the input data to determine if the signal is correctly input.

T-1

<Electrical Component Check Procedure Through Checking Input Data> Example When a paper misfeed occurs in the paper take-up section of the copier, the 2nd Drawer Paper Take-Up Sensor is considered to be responsible for it. <Procedure> 1. Remove the sheet of paper misfed. 2. From the I/O Check List that follows, it is known that the input signal of the 2nd Drawer Paper Take-Up Sensor may be checked with the data of Take-Up of 2nd Drawer. 3. From the Tech. Rep. Mode menu, select State Confirm and then I/O Check. Then, select the screen that contains Take-Up under 2nd Drawer. 4. Check that the data for Take-Up under 2nd Drawer is 0 (sensor blocked). 5. Move the actuator to unblock the 2nd Drawer Paper Take-Up Sensor. 6. Check that the data for Take-up under 2nd Drawer changes from 0 to 1 on the screen. 1: Sensor is operational. 0: Sensor is faulty.

T-2

2-2.

I/O Check List

<I/O Check Screens> These are only typical screens which may be different from what are shown on each individual copier. Previous Screen

Next Screen
4004P047CA 4004P048CA

Next Screen

Previous Screen

4004P049CA

Next Screen

Previous Screen

4004P053CA

4004P050CA

Previous Screen

Next Screen Next Screen

Next Screen

Previous Screen

Previous Screen
4004P052CA 4004P051CA

T-3

<I/O Check List>

Operation Characteristics/Panel Display 1 PC3 PC6 PC4 PC13 SW D PC102 PC103 PC101 PC105 SW D PC2 PC3 PC1 PC5 SW D PC2 PC3 PC1 PC5 PC15 PC15 PC17 PC10 PC19 Paper Passage Paper Passage Manual 4th Drawer 3rd Drawer 2nd Drawer 1st Drawer Set Paper Empty 1st Drawer Set Sensor 1st Drawer Paper Empty Sensor In position Paper not present Blocked Paper present In position Paper not present Blocked Paper present Paper present In position Paper not present Blocked Paper present Paper present In position Paper not present Blocked Paper present Paper present Paper present In position Paper present Paper present OHP present 0 Out of position Paper present Unblocked Paper not present Out of position Paper present Unblocked Paper not present Paper not present Out of position Paper present Unblocked Paper not present Paper not present Out of position Paper present Unblocked Paper not present Paper not present Paper not present Out of position Paper not present Paper not present OHP not present Master Board (PWB-I) Control Board (PWB-A) Control Board (PWB-A) Control Board (PWB-A) Input Board Master Board (PWB-I) IC No. IC6 IC5 IC6 IC6 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC6 IC5 IC1 IC6 IC1 Port No. PG1 PI7 PG0 PI0 PC0 PB5 PB6 PB7 PC3 PC0 PB5 PB6 PB7 PC3 PC0 PB5 PB6 PB7 PC3 PI5 PH4 P77 PI4 AN5 CN/PJ No. PJ17I-9A PJ3I-8A PJ17I-6A PJ5I-8B PJ3A-4B PJ3A-14A PJ3A-11A PJ3A-5A PJ3A-8A PJ3A-4B PJ3A-14A PJ3A-11A PJ3A-5A PJ3A-8A PJ3A-4B PJ3A-14A PJ3A-11A PJ3A-5A PJ3A-8A PJ15I-7B PJ15I10B PJ14I-9B PJ3I-14A PJ14-2B

Symbol

Panel Display

Part/Signal Name

Paper Near 1st Drawer Paper Empty Near-Empty Sensor Double Feed Set Paper Empty 1st Drawer Double Feed Sensor 2nd Drawer Set Switch 2nd Drawer Paper Empty Sensor

Paper Near 2nd Drawer Paper Empty Near-Empty Sensor Take-Up Double Feed Set Paper Empty 2nd Drawer Paper Take-Up Sensor 2nd Drawer Double Feed Sensor Drawer Set Switch Drawer Paper Empty Sensor

Paper Near Drawer Paper NearEmpty Empty Sensor Take-Up Double Feed Set Paper Empty Drawer Paper TakeUp Sensor Drawer Double Feed Sensor Drawer Set Switch Drawer Paper Empty Sensor

Paper Near Drawer Paper NearEmpty Empty Sensor Take-Up Double Feed Take-Up Set Timing Roller Exit Drawer Paper TakeUp Sensor Drawer Double Feed Sensor Manual Feed Paper Take-Up Sensor Manual Feed Paper Take-Up Sensor Synchronizing Roller Sensor Exit Sensor

OHP Detect OHP Detecting Sensor Sensor

T-4

Symbol LS1

Panel Display LCC Lift-Up 1

Part/Signal Name Lift-Up Sensor 1

Operation Characteristics/Panel Display 1 At raised position At raised position Paper present At standby position Paper present Paper present Paper not present Unblocked Unblocked 0 Not at raised position Not at raised position Paper not present Not at standby position Paper not present Paper not present Paper present Blocked Blocked

Input Board LCC Control Board (PWB-A)

IC No. IC4

Port No. P74/ ANI4 P73/ ANI3 P22/ INTP1 P23/ INTP2/ CI P24/ INTP3 P25/ INTP4/ ASCK P72/ ANI2 P75/ ANI5 P76/ ANI6 -

CN/PJ No. CN4A-6

LS2

Lift-Up 2

Lift-Up Sensor 2

IC4

CN4A-9

RSEN S1

Registration Registration Sensor Paper Wait Paper Standby Position Sensor Take-Up 1 Take-Up 2 LCC Paper Take-Up Sensor Paper Empty Sensor 1 Paper Empty Sensor 2

IC4 IC4

CN4A-2 CN3A-5

PPS0 PPS1

IC4 IC4

CN4A-11 CN3A-2

EMP RS1 RS2 PWB-A PI2 PWB-A PI1 PC1 PC1 PC6 PWB-B PWB-B PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D Mail Bin Sorter Horizontal Trans. Unit Duplex

Paper Empty

IC4 IC4 IC4 Duplex Control Board -

CN3A-8 CN6A-12 CN5A-5 PJ1A-3 PJ1A-12

Paper Near Paper Near Empty Empty 1 Sensor 1 Paper Near Paper Near Empty Empty 2 Sensor 2 Set Paper passage 1 Paper passage 2 Horizontal Transport Duplex Unit Door Set Sensor (in PWB-A) Duplex Unit Transport Sensor 1 (in PWB-A) Duplex Unit Transport Sensor 2 Paper Sensor

Paper present Paper present Paper not present Paper present Paper present Paper present Paper present Paper present Paper present Paper present Paper present Paper present Paper present Paper present Paper present

Paper not present Paper not present Paper present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present Paper not present

Control Board (PWB-A) IC1 IC1 IC26 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 P21

P26 P27 PE3 P22 P25 P40 P41 P42 P43 P44 P45 P46 P47 P23 PJ9A4

PJ4A-3 PJ15A-4 PJ12-2 PJ15A-12 PJ13-2 PJ6A-7 PJ6A-5 PJ7A-4A PJ7A-11A PJ7A-4B PJ7A-11B PJ8A-4A PJ8A-11A PJ8A-4B PJ8A-11B PWB-D

Rev. Empty Turnover Empty Detecting Sensor Exit Section 1st bin Empty 2nd bin Empty 3rd bin Empty 4th bin Empty 5th bin Empty 6th bin Empty 7th bin Empty 8th bin Empty 9th bin Empty 10th bin Empty Exit Sensor Board Non-Sort Bin Empty Sensor 2nd Bin Empty Sensor 3rd Bin Empty Sensor 4th Bin Empty Sensor 5th Bin Empty Sensor 6th Bin Empty Sensor 7th Bin Empty Sensor 8th Bin Empty Sensor 9th Bin Empty Sensor 10th Bin Empty Sensor

T-5

Symbol PWB-B PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-D PWB-C PC1 PC3 PC4 PC2 PC6 PC7 PC5 PWB-D PC8 PC9 PC14 PC12 PC13 -

Panel Display Mail Bin Sorter

Part/Signal Name

Operation Characteristics/Panel Display 1 0 Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Paper not present

Input Board Control Board (PWB-A)

IC No. IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1 IC1

Port No. P70 P71 P72 P73 P74 P75 P76 P77 P66 P67 PC4 PD0 PE6 PE7 PC5 PA7 PD1 PA6 PA5 PD2 PD3 PC6 PC7 P71, ANI1 P72, ANI2

CN/PJ No. PJ6A-4 PJ7A-1A PJ7A-8A PJ7A-1B PJ7A-8B PJ8A-1A PJ8A-8A PJ8A-1B PJ8A-8B PJ9A-1 PJ19A-6 PJ20A-3 PJ20A-9 PJ19A-8 PJ19A-3 PJ19A-12 PJ25A-2 PJ21A-2 PJ25A-9 PJ25A-6 PJ22A-3 PJ20A-6 PJ19A-15 PJ23A-2 PJ23A-4

1st bin Full Non-Sort Bin Full Sensor 2nd bin Full 2nd Bin Full Sensor 3rd bin Full 3rd Bin Full Sensor 4th bin Full 4th Bin Full Sensor 5th bin Full 5th Bin Full Sensor 6th bin Full 6th Bin Full Sensor 7th bin Full 7th Bin Full Sensor 8th bin Full 8th Bin Full Sensor 9th bin Full 9th Bin Full Sensor 10th bin Full 10th Bin Full Sensor

Blocked Blocked Blocked Blocked Blocked Blocked Blocked Blocked Blocked Blocked Paper present Paper present Paper present Paper present Blocked Blocked Out of position Paper present Blocked Blocked Blocked Blocked Blocked Blocked Blocked

Finisher

Exit (Non-sort) Exit (Finisher) Transport Upper Transport Lower Full (Non-sort)

1st Tray Exit Sensor Storage Sensor Upper Entrance Sensor Lower Entrance Sensor 1st Tray Full Detecting Sensor

Control IC26 Board (PWB-A) Paper not IC26 present Paper not present Paper not present Unblocked Unblocked In position Paper not present Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked Unblocked IC26 IC26 IC26 IC26 IC26 IC26 IC26 IC26 IC26 IC26 IC26 IC1 IC1

Full Elevator Tray Full (Elev. Tray) Detecting Sensor Empty Finisher Surface (Elev.) Empty (Elev.) Home (CD-Align) Finisher Tray Paper Detecting Sensor Elevator Tray Upper Limit Sensor PQ Elevator Tray Paper Detecting Sensor CD Aligning Home Position Sensor Staple Home Position Sensor

Home Storage Roller Home (Stap. Unit) Position Sensor Hole Exit Rolls Home (store roller) Position Sensor Home (Stapler 1) Stapler Home 1

Empty St. 1 Stapler Empty 1 Needle

T-6

Symbol S2 S3

Panel Display Finisher

Part/Signal Name

Operation Characteristics/Panel Display 1 0 Unblocked Unblocked Unblocked Unblocked OFF

Input Board Control Board (PWB-A)

IC No. IC1 IC1 IC1 IC1 -

Port No. P73, ANI3 P75, ANI5 P76, ANI6 P77, ANI7 -

CN/PJ No. PJ23A-3 PJ24A-2 PJ24A-4 PJ24A-3 PJ4A-4

Self Stapler Self-Priming Priming S1 1 Home (Stapler 2) Stapler Home 2

Blocked Blocked Blocked Blocked ON

Empty St. 2 Staple Empty 2 Needle Self Stapler Self-Priming Priming S2 2 Elevate Tray Raised/ Lowered Home (Shift) Elevate Tray Raised/ Lowered

PC10 S4 PC15 PC11 SW6 SW7 Dev.

Shift Home Position Sensor

Blocked ON Blocked Blocked ON ON

Unblocked OFF Unblocked Unblocked OFF OFF Master Board (PWB-I)

IC26 IC28 IC1 IC1 IC6 IC6

PD4 PE2 P21 INPO P24 INPO PH6 PH5

PJ25A-12 PJ12A-3 PJ13A-8 PJ25A-14 PJ5I-5A PJ5I-3A

Punch Hole Hole Punch Position Change Switch Punch Speed Punch Motor Pulse Sensor

Shift Speed Shift Motor Pulse Sensor Cyan Toner Toner Empty Switch Empty C Magenta Toner Empty Yellow Toner Empty Toner Empty Switch M Toner Empty Switch Y

SW8

ON

OFF

IC6

PH4

PJ5I-1A

SW5 PC28 Transfer Belt

Black Toner Toner Empty Switch Empty Bk Transfer 1st Image Transfer Unit Retraction Position Separation Sensor Set 2nd Transfer Toner Collect -

ON Not Retracted In position Not Retracted Unblocked In position In position Not used Pressed

OFF Retracted

IC6 IC5

PH7 PI1

PJ5I-5B PJ17I-1A

PC23

Out of position Retracted

IC5 IC5

PE7 PI2

PJ4I-8 PJ14I-6B

2nd Image Transfer Transfer Unit Pressure Position Separation Sensor Waste Toner Toner Box Set Waste Toner Full Detecting Sensor Waste Toner Bottle Set Sensor Fusing Unit

PC29 PC18 PC7

Blocked Out of position Out of position Not used State other than pressed Out of home Raised Image Processing Board (PWB-C)

IC8 IC5 IC5 IC5

3Y PI4 PH5 PI6

PJ7I-7B PJ7I-5B PJ6I-7A PJ17I-3B

Fusing Unit

Set

Fusing Web Not used Unit Fuser Roller Fusing Pressure Separation Position Sensor IR Scanner Home Sensor Home Sensor Org. Detect Sensor

PC24 SW10

At home Lowered

PJ6C-2 PJ7D-2

Org. Cover Size Reset Switch

T-7

Symbol PC25 PC30

Panel Display Orig. Detect Sensor 15 Degree Sensor

Part/Signal Name Original Cover Detecting Sensor

Operation Characteristics/Panel Display 1 Less than 15 Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted Original loaded, not mounted 0 15 or more

Input Board

IC No. -

Port No. -

CN/PJ No. PJ2C-2B PJ7C-1

Org. Detect Original Size Sensor 1 Detecting Sensor FD1 Orig. Detect Original Size Sensor 2 Detecting Sensor FD2 Orig. Detect Original Size Sensor 3 Detecting Sensor FD2 Orig. Detect Original Size Sensor 4 Detecting Sensor FD3 Orig. Detect Original Size Sensor 5 Detecting Sensor FD3 Orig. Detect Original Size Sensor 6 Detecting Sensor CD1 Orig. Detect Original Size Sensor 7 Detecting Sensor CD1 Orig. Detect Original Size Sensor 8 Detecting Sensor CD2

Image Processing Original Board not loaded (PWB-C)

PC31

Original not loaded

PJ7C-7

PC31

Original not loaded

PJ7C-9

PC33

Original not loaded

PJ9C-3

PC33

Original not loaded

PJ9C-5

PC32

Original not loaded

PJ7C-12

PC32

Original not loaded

PJ7C-14

PC34

Original not loaded

PJ9C-10

T-8

2-3.

How to Interpret State Confirm of Tech. Rep. Mode

Study the following to interpret data provided by State Confirm of Tech. Rep. Mode. Note, however, that the specific data given hereunder is only for reference.

4004P054CA

(1)

Table # Vb-C/-M/-Y/-Bk Output table value of each developing bias, representing data applicable during making copies. Though the minus sign is not displayed, all are negative values. Standard: Color (C, M, and Y): Around -400 V Black (Bk): Around -800 V If the image is light, the value becomes great. If the image is dark, the value becomes small. Used as a means of correcting image quality problems. Vg-C/-M/-Y/-Bk Output table value of each PC Drum Charge Corona grid mesh, representing data applicable during making copies. Though the minus sign is not displayed, all are negative values. Standard: Color (C, M, and Y): Around -500 V Black (Bk): Around -900 V If the image is light, the value becomes great. If the image is dark, the value becomes small. Used as a means of correcting image quality problems.

4004P055CA

4004P056CA

T-9

(2)

Level History 1 ATDC-C/-M/-Y/-Bk Displays T/C ratios. The value is displayed in units of 0.01 %. Target value: Color (C, M, and Y) T/C: 5 1 % Black (Bk) T/C: 4.5 1 % AIDC1/2 Displays the AIDC Sensor output values. The value is displayed in units of 0.01 V. Normally, the value should be around 4.5 V and the output can range from 0 V to 5 V. Temp Upr./Lwr. Displays the temperatures of the Upper and Lower Fusing Rollers. The value is displayed in units of 5 C.

4004P057CA

(3)

Level History 2 AIDC Sensor Adjust Value 1/2 Displays the AIDC intensity adjustment values. The values represent the intensity determined through AIDC intensity control. The value is displayed in units of 1 step. Intensity range: 0 to 255

4004P058CA

T-10

2-4.

Paper Misfeed

When a paper misfeed occurs in the copier, the misfeed message, misfeed location, and paper location are displayed on the Touch Panel.

3 2

4 7 8 9

11 10 12 11 13 11 14 11 15

4004P059CA

Display 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Misfeed/Paper Location ADF take-up ADF transport ADF turnover/exit Horizontal Unit Mailbin/Finishing option transport/ Finishing option exit Mailbins Duplex Unit transport Fusing/Exit 2nd Image Transfer Manual Bypass take-up Vertical Transport/Duplex Unit take-up 1st Drawer take-up 2nd Drawer take-up 3rd Drawer take-up/LCC take-up/ LCC Lift 2 to 1 paper transport 4th Drawer take-up

Ref. Item No.

See relevant Option Service Manual.

(8) (5) (4) (2) (3) (1) (1) (6) (7) (6) (7)

<Misfeed Display Resetting Procedure> Misfeed in copier Misfeed in option Open the relevant door, clear the misfeed and remove paper left, and then close the door. (For the option, clear the misfeed and then install the option back up against the copier.)

T-11

2-5.

Misfeed Detecting Sensor Layout

System Mounted with AD-14 and PF-117 Exit Sensor (PC10) 2/ OHP Detecting Sensor (PC19) Synchronizing Roller Sensor (PC17) Duplex Unit Transport Sensor 1 (PI1) Duplex Unit Transport Sensor 2 (PC1) Manual Feed Paper Take-Up Sensor (PC15) 1st Drawer Double Feed Sensor (PC13) 2nd Drawer Paper Take-Up Sensor (PC101) 2nd Drawer Double Feed Sensor (PC105) LCC Registration Sensor (RSEN) LCC Paper Take-Up Sensor (PPS0)
4011T055AA

T-12

 System Mounted with AD-14 and PF-118 Exit Sensor (PC10) OHP Detecting Sensor (PC19) Synchronizing Roller Sensor (PC17) Duplex Unit Transport Sensor 1 (PI1) Duplex Unit Transport Sensor 2 (PC1) Manual Feed Paper Take-Up Sensor (PC15) 1st Drawer Double Feed Sensor (PC13) 2nd Drawer Paper Take-Up Sensor (PC101) 2nd Drawer Double Feed Sensor (PC105) 3rd Drawer Paper Take-Up Sensor (PC1) 3rd Drawer Double Feed Sensor (PC5) 4th Drawer Paper Take-Up Sensor (PC1) 4th Drawer Double Feed Sensor (PC5)

4011T056AA

T-13

2-6.

Types of Misfeed Detection and Detection Timing

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. <Copier Paper Take-Up Misfeed> Type Detection Start Detection Synchronizing Roller Sensor (L) 2nd Drawer Paper Take-Up Sensor (L)

Paper take-up 1st Drawer Paper Take-Up failure detection Clutch energized 2nd Drawer Paper Take-Up Clutch energized

1st Drawer size Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T) error detection [When the paper size detected is 20 mm or more of the size data fed from the controller] 2nd Drawer size 2nd Drawer Paper Take-Up error detection Sensor (L) 2nd Drawer Paper Take-Up Sensor (T) [When the paper size detected is 20 mm or more of the size data fed from the controller] 2nd Drawer Paper Take-Up Sensor activated

Detection of Power Switch is turned ON, paper left in 2nd door or cover is opened and Drawer closed, misfeed or malfunction is reset <Manual Bypass Take-Up Misfeed> Type Bypass paper take-up failure detection Detection Start Manual Feed Paper Take-Up Sensor (L)

Detection Synchronizing Roller Sensor (L)

Manual bypass Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T) size error detec[When the paper size detected is 20 tion mm or more of the size data fed from the controller] Detection of paper left in Manual Bypass Table Power Switch is turned ON, door or cover is opened and closed, misfeed or malfunction is reset Manual Feed Paper Take-Up Sensor activated

<Copier Vertical Transport Misfeed> Type 2nd Drawer paper take-up failure Detection Start 2nd Drawer Paper Take-Up Sensor (L) Detection Synchronizing Roller Sensor (L)

T-14

<2nd Image Transfer Misfeed> Type 2nd Image Transfer misfeed detection Detection Start Detection Exit Sensor (L) Synchronizing Roller Sensor activated, OHP Detecting Sensor activated

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)

Detection of Power Switch is turned ON, paper left at 2nd door or cover is opened and Image Transfer closed, misfeed or malfunction is reset <Exit Misfeed> Type Exit misfeed Detection Start Exit Sensor activated (L) Exit Sensor deactivated (T) Detection of Power Switch is turned ON, paper left at exit door or cover is opened and closed, misfeed or malfunction is reset <PF-118 Paper Take-Up Misfeed> Type Detection Start

Detection Exit Sensor deactivated (T) Duplex Unit Transport Sensor 1 (L) Exit Sensor activated

Detection 3rd Drawer Paper Take-Up Sensor (T) [When the paper size detected is 20 mm or more of the size data fed from the controller] 4th Drawer Paper Take-Up Sensor (T) [When the paper size detected is 20 mm or more of the size data fed from the controller] 3rd Drawer Paper Take-Up Sensor activated

3rd Drawer size 3rd Drawer Paper Take-Up error detection Sensor (L)

4th Drawer size 4th Drawer Paper Take-Up error detection Sensor (L)

Power Switch is turned ON, Detection of paper left in 3rd door or cover is opened and closed, misfeed or malfunction Drawer is reset Detection of Power Switch is turned ON, paper left in 4th door or cover is opened and Drawer closed, misfeed or malfunction is reset

4th Drawer Paper Take-Up Sensor activated

T-15

<PF-117 Paper Take-Up Misfeed> Type LCC misfeed detection Lift 2 to 1 misfeed detection Detection Start LCC paper take-up request LCC Paper Take-Up Request Detection LCC Exit signal ON LCC Paper Take-Up Sensor activated, LCC Paper Empty Sensor 1 activated, Paper Standby Position Sensor activated 2nd Drawer Paper Take-Up Sensor (L)

LCC vertical transport misfeed detection LCC size error detection

LCC Exit signal ON

2nd Drawer Paper Take-Up Sensor (L)

2nd Drawer Paper Take-Up Sensor (T) [When the paper size detected is 20 mm or more of the size data fed from the controller] LCC Registration Sensor Paper-Left Misfeed signal ON

Detection of paper left in LCC

Power Switch is turned ON, door or cover is opened and closed, misfeed or malfunction is reset

<Duplex Paper Take-Up Misfeed> Type Duplex paper take-up misfeed detection Duplex transport misfeed detection Detection of paper left in Duplex Detection Start Duplex paper take-up start Detection Synchronizing Roller Sensor (L), Manual Feed Paper Take-Up Sensor (L)

Duplex Unit Transport Sensor 1 Duplex Unit Transport Sensor 2 (L) (L) Power Switch is turned ON, door or cover is opened and closed, misfeed or malfunction is reset Duplex Unit Transport Sensor 1 activated, Duplex Unit Transport Sensor 2 activated

T-16

2-7.
(1)

Misfeed Troubleshooting Procedures

Copier Paper Take-Up Misfeed Relevant Electrical Parts

1st Drawer Paper Take-Up Clutch (CL1) 2nd Drawer Paper Take-Up Clutch (CL101) Synchronizing Roller Sensor (PC17) Main Motor (M13)

2nd Drawer Paper Take-Up Motor (M101) Master Board (PWB-I) DC Power Supply 1 (PU1) 2nd Drawer Control Board (PWB-A)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PJ105 M13
1 2 3 4 5 6 7 8

PWB-I
PJ13I-7A(M13 LOCK) PJ13I-8A(M13 REM) PJ13I-9A(M13 CLK) PJ13I-10A(DC5 V) PJ13I-11A(GND) PJ13I-12A(M13 CW/CCW)

CN63 PJ116 PC17

3 2 1 1 12 7 8 9 6 5 4 PJ14I-7A(DC5 V) PJ14I-8A(GND) PJ14I-9A(PC17 ON)

12 1

CN55 CL1
1 2 2 1 PJ15I-10A(DC24 V) PJ15I-11A(CL1 REM)

CN1 CL101
1 2 2 1

PWB-A(2nd Tray)
PJ3A-13B(DC24 V) PJ3A-14B(CL101 REM)

CN61 M101
4 3 2 1 1 2 3 4 PJ5A-4( B) PJ5A-3(B) ) PJ5A-2( A PJ5A-1(A)
4004C16TAD

T-17

Copier Paper Take-Up Misfeed Troubleshooting Procedures Paper is not taken up at all. Step 1 2 Check Item Paper meets product specifications. Paper is curled, wavy, or damp. Result NO YES Action Change paper. Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater. Set as necessary. Clean or change. Clean or change. Clean or change. Clean or change. Clean or change. Reinstall. Correct drive coupling (coupling engagement, position of drive transmitting pin). Check for overload. Change clutch. Change Master Board.

3 4 5 6 7 8 9 10

Edge Guide and Trailing Edge Stop are at correct position to accommodate paper. Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter. Paper Lifting Plate is dirty, deformed, or scratched. Separator Pad is deformed, worn, or dirty with paper dust or other foreign matter. Separator Roll is deformed, worn, or dirty with paper dust or other foreign matter. Paper take-up guide plate is dirty, deformed, or scratched. Paper take-up guide plate is installed properly. Paper Take-Up Roll turns when the Start key is pressed with the 1st Drawer selected. 1st Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 1st Drawer selected: the voltage across PJ15I11A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. Paper Take-Up Roll turns when the Start key is pressed with the 2nd Drawer selected. 2nd Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 2nd Drawer selected: the voltage across PJ3A-14B on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

NO YES YES YES YES YES NO NO

11

YES NO

12

NO

Correct drive coupling (coupling engagement, position of drive transmitting pin). Check for overload. Change clutch. Change Control Board.

13

YES NO

T-18

(2)

Manual Bypass Take-Up Misfeed Relevant Electrical Parts

Synchronizing Roller Sensor (PC17) Manual Feed Paper Take-Up Sensor (PC15) Synchronizing Roller Clutch (CL21) Manual Feed Paper Take-Up Clutch (CL13) Master Board (PWB-I)

CN65 CN30 CL21

1 2 2 1 1 6 7 7 2 1

PWB-I
PJ14I-14A(DC24 V) PJ14I-15A(CL21 REM)

CN63 PJ116 PC17

3 2 1 1 12 7 8 9 6 5 4 PJ14I-7B(DC5 V) PJ14I-8B(GND) PJ14I-9B(PC17 ON)

12 1

CN41 CL3
1 2 2 1

CN33
1 2 3 4 5 1 2 3 4 5 DC24 V PJ15I-9A(CL3 REM) PJ15I-7B(PC15 ON) PJ15I-8B(GND) PJ15I-9B(DC5 V)

PJ40 PC15
1 2 3

8 8

4004C17AD

T-19

Manual Bypass Take-Up Misfeed Troubleshooting Procedures Paper is not detected. Step 1 Check Item I/O check for Manual Feed Paper Take-Up Sensor operation when the Manual Bypass Table is used: the voltage across PJ15I-7B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (paper present). Result YES NO Action Change Master Board. Correct actuator. Check sensor connector connection. Change sensor.

Paper is not taken up at all. Step 1 2 Check Item Paper meets product specifications. Paper is curled, wavy, or damp. Result NO YES Action Change paper. Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater. Clean or change. Clean or change. Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change Master Board.

3 4 5

Guide plate is dirty with paper dust, deformed, or scratched. Manual Bypass Take-Up Roll is dirty with paper dust, deformed, or worn. Manual Bypass Take-Up Roll turns when the Start key is pressed with the Manual Bypass Table used. Manual Feed Paper Take-Up Clutch operation when the Manual Feed Paper Take-Up Sensor is blocked with the Manual Bypass Table used: the voltage across PJ15I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES YES NO

YES NO

T-20

 Paper is at a stop at the vertical transport section. Step 1 2 3 4 5 6 Check Item Paper meets product specifications. Synchronizing Rollers are dirty with paper dust, deformed, or worn. Paper Dust Remover is deformed or worn. Paper Dust Remover is installed properly. An adequate length of loop is formed before the Synchronizing Rollers. I/O check for Synchronizing Roller Sensor operation when the Manual Bypass Table is used: the voltage across PJ14I-9B on Master Board and GND is DC 0 V when the sensor is unblocked (paper present) and DC 5 V when the sensor is blocked. Synchronizing Rollers turn when the Start key is pressed with the Manual Bypass Table used. Synchronizing Roller Clutch operation when the Manual Bypass Table is used: the voltage across PJ15I-9A on Master Board and GND after the Manual Feed Paper Take-Up Clutch has been energized is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. Size error display after the misfeed display has been reset. Result NO YES NO NO NO YES NO Action Change paper. Clean or change. Change Paper Dust Remover Unit. Reinstall Paper Dust Remover Unit. Adjust Paper Loop. (See ADJUSTMENT.) Change Master Board. Correct actuator. Check sensor connector connection. Change sensor.

NO

Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change Master Board.

YES NO

YES

Check paper size.

T-21

(3)

Copier Vertical Transport Misfeed Relevant Electrical Parts

Synchronizing Roller Sensor (PC17) 2nd Drawer Paper Take-Up Sensor (PC101) Synchronizing Roller Clutch (CL21) 1st Drawer Paper Take-Up Clutch (CL1) 2nd Drawer Paper Take-Up Clutch (CL101)

Main Motor (M13) 2nd Drawer Paper Take-Up Motor (M101) Master Board (PWB-I) DC Power Supply 1 (PU1) 2nd Drawer Control Board (PWB-A)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PJ105 M13
1 2 3 4 5 6 7 8

PWB-I
PJ13I-7A(M13 LOCK) PJ13I-8A(M13 REM) PJ13I-9A(M13 CLK) PJ13I-10A(DC5 V) PJ13I-11A(GND) PJ13I-12A(M13 CW/CCW)

CN65 CN30 CL21

1 2 2 1 1 6 7 7 2 1 PJ14I-14A(DC24 V) PJ14I-15A(CL21 REM)

CN63 PJ116 PC17

3 2 1 1 12 7 8 9 6 5 4 PJ14I-7A(DC5 V) PJ14I-8A(GND) PJ14I-9A(PC17 ON)

12 1

CN55 CL1
1 2 2 1 PJ15I-10A(DC24 V) PJ15I-11A(CL1 REM)

PJ12 PC101
3 2 1

PWB-A(2nd Tray)
PJ3A-3A(DC5 V) PJ3A-4A(GND) PJ3A-5A(PC101 ON)

CN1 CL101
1 2 2 1 PJ3A-13B(DC24 V) PJ3A-14B(CL101 REM)

CN61 M101
4 3 2 1 1 2 3 4 PJ5A-4( B) PJ5A-3(B) ) PJ5A-2( A PJ5A-1(A)
4004C18TAD

T-22

Copier Vertical Transport Misfeed Troubleshooting Procedures Paper is at a stop at the vertical transport section. Step 1 2 Check Item Synchronizing Rollers are deformed or worn. Paper dust deposits on Synchronizing Rollers. Paper Dust Remover is deformed or worn. Paper Dust Remover is installed properly. An adequate length of loop is formed before the Synchronizing Rollers. Vertical transport guide plate is dirty, deformed, or scratched. I/O check for Synchronizing Roller Sensor operation: the voltage across PJ14I-9B on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked. Synchronizing Rollers turn when the Start key is pressed with the 1st Drawer selected. Synchronizing Roller Clutch operation when the 1st Drawer is used: the voltage across PJ14I-14A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. 2nd Drawer Vertical Transport Roller 1 is dirty with paper dust, deformed, or scratched. 2nd Drawer vertical transport guide plate is dirty, deformed, or scratched. Synchronizing Rollers turn when the Start key is pressed with the 2nd Drawer selected. Synchronizing Roller Clutch operation when the 2nd Drawer is used: the voltage across PJ14I-14A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. Result YES YES Action Check type of paper being used. Clean Synchronizing Rollers. Check Paper Dust Remover for proper function. Change Paper Dust Remover Unit. Reinstall Paper Dust Remover Unit. Adjust Paper Loop. (See ADJUSTMENT.) Clean or change. Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor. Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change Master Board.

3 4 5 6 7

YES NO NO YES YES NO

NO

YES NO

10

YES

Clean or change.

11 12

YES NO

Clean or change. Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change Master Board.

13

YES NO

T-23

Step 14

Check Item 2nd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 2nd Drawer selected.

Result NO

Action Correct drive coupling (coupling engagement, position of drive transmitting pin). Change motor. Change 2nd Drawer Control Board. Check paper size. Check positioning of the Edge Guide and Trailing Edge Stop.

15

Size error display after the misfeed display has been reset.

YES

T-24

(4)

2nd Image Transfer Misfeed Relevant Electrical Parts

Exit Sensor (PC10) Synchronizing Roller Sensor (PC17) Main Motor (M13)

Fusing Drive Motor (M14) Master Board (PWB-I) DC Power Supply 1 (PU1)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PJ106 M14
1 2 3 4 5 6 7 8

PWB-I
PJ13I-1A(M14 LOCK) PJ13I-2A(M14 REM) PJ13I-3A(M14 CLK) PJ13I-4A(DC5 V) PJ13I-5A(GND) PJ13I-6A(M14 CCM/CM) PJ13I-7A(M13 LOCK) PJ13I-8A(M13 REM) PJ13I-9A(M13 CLK) PJ13I-10A(DC5 V) PJ13I-11A(GND) PJ13I-12A(M13 CCM/CM)

PJ105 M13
1 2 3 4 5 6 7 8

PJ133 PC10
3 2 1

CN17
1 2 3 3 2 1 PJ3I-12A(DC5 V) PJ3I-13A(GND) PJ3I-14A(PC10 ON)

CN63 PJ116 PC17

3 2 1 1 12 7 8 9 6 5 4 PJ14I-7B(DC5 V) PJ14I-8B(GND) PJ14I-9B(PC17 ON)
4004C20TAB

12 1

T-25

2nd Image Transfer Misfeed Troubleshooting Procedures Paper is at a stop at the 2nd Image Transfer section. Step 1 2 3 Check Item Vertical transport guide plate is dirty, deformed, or scratched. Image Transfer Roller Unit is not installed properly. Pre-Image Transfer Guide Plate is dirty, deformed, or scratched. Seal is separated. Transfer Belt is driven when the Start key is pressed. Result YES YES YES Action Clean or change. Reinstall. Clean or change Image Transfer Roller Unit. Correct drive coupling (drive transmitting gear engagement). Reinstall Transfer Belt Unit. Change Transfer Belt Unit. Correct drive coupling (drive transmitting gear engagement). Reinstall Transfer Roller Unit. Clean or change Image Transfer Roller Unit. Correct drive coupling (drive transmitting gear engagement). Correct the installed position of Fusing Unit. Readjust Paper Separator Fingers. Readjust Top Margin. Change Transfer Roller Unit. Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor.

NO

5 6

Transfer Belt is deformed or damaged. Transfer Roller turns when the Start key is pressed.

YES NO

7 8

Transfer Roller is dirty with paper dust or other foreign matter, deformed, or worn. Fusing Rollers turn when the Start key is pressed.

YES NO

Paper winds around Transfer Belt.

YES

10 11

Paper winds around Transfer Roller. I/O check for Exit Sensor operation: the voltage across PJ3I-14A on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked.

YES YES NO

T-26

(5)

Exit Misfeed Relevant Electrical Parts

Exit Sensor (PC10) Fusing Drive Motor (M14)

Master Board (PWB-I) DC Power Supply 1 (PU1)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PJ106 M14
1 2 3 4 5 6 7 8

PWB-I
PJ13I-1A(M14 LOCK) PJ13I-2A(M14 REM) PJ13I-3A(M14 CLK) PJ13I-4A(DC5 V) PJ13I-5A(GND) PJ13I-6A(M14 CCM/CM) PJ3I-12A(DC5 V) PJ3I-13A(GND) PJ3I-14A(PC10 ON)
4004C21TAA

PJ133 PC10
3 2 1

CN17
1 2 3 3 2 1

T-27

Exit Misfeed Troubleshooting Procedures Paper is at a stop at the 2nd Image Transfer section. Step 1 2 3 4 5 Check Item Fusing guide plate is dirty, deformed, or damaged. Fusing Rollers are dirty, deformed, or scratched. Fusing Paper Separator Fingers are dirty, deformed, or worn. Fusing Exit Roller is dirty, deformed, or scratched. Fusing Rollers turn when the Start key is pressed. Result YES YES YES YES NO Action Clean or change. Clean or change Fusing Unit. Clean, correct, or change. Clean or change. Correct drive coupling (drive transmitting gear engagement). Correct installed position of Fusing Unit. Change Fusing Unit. Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor. Clean or change. Correct drive coupling (roller position).

I/O check for Exit Sensor operation: the voltage across PJ3I-14A on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked. Exit Turnover Roller is dirty, deformed, or scratched. Exit Turnover Roller turns when the Start key is pressed.

YES NO

7 8

YES NO

T-28

(6)

PF-118 Paper Take-Up Misfeed Relevant Electrical Parts

3rd Drawer Paper Take-Up Sensor (PC1) 4th Drawer Paper Take-Up Sensor (PC1) 3rd Drawer Paper Take-Up Clutch (CL1) 4th Drawer Paper Take-Up Clutch (CL1)

3rd Drawer Paper Take-Up Motor (M1) 4th Drawer Paper Take-Up Motor (M1) 3rd Drawer Control Board (PWB-A) 4th Drawer Control Board (PWB-A)

PJ12 PC1
3 2 1

PWB-A(3rd Tray)
PJ3A-3A(DC5 V) PJ3A-4A(GND) PJ3A-5A(PC1 ON)

CN73 CL1
1 2 2 1 PJ3A-13B(DC24 V) PJ3A-14B(CL1 REM)

CN61 M1
4 3 2 1 1 2 3 4 PJ5A-4( B) PJ5A-3(B) PJ5A-2( A) PJ5A-1(A)

PJ12 PC1
3 2 1

PWB-A(4th Tray)
PJ3A-3A(DC5 V) PJ3A-4A(GND) PJ3A-5A(PC1 ON)

CN73 CL1
1 2 2 1 PJ3A-13B(DC24 V) PJ3A-14B(CL1 REM)

CN61 M1
4 3 2 1 1 2 3 4 PJ5A-4( B) PJ5A-3(B) PJ5A-2( A) PJ5A-1(A)
4004C22TAB

T-29

PF-118 Paper Take-Up Misfeed Troubleshooting Procedures Paper is not taken up at all. Step 1 2 Check Item Paper meets product specifications. Paper is curled, wavy, or damp. Result NO YES Action Change paper. Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater. Set as necessary. Clean or change. Clean or change. Clean or change. Clean or change. Reinstall. Correct drive coupling (coupling engagement, position of drive transmitting pin). Check for overload. Change clutch. Change 3rd Drawer Control Board.

3 4 5 6 7 8 9

Edge Guide and Trailing Edge Stop are at correct position to accommodate paper. Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter. Paper Lifting Plate is dirty, deformed, or scratched. Separator Roll is deformed, worn, or dirty with paper dust or other foreign matter. Paper take-up guide plate is dirty, deformed, or scratched. Paper take-up guide plate is installed properly. Paper Take-Up Roll turns when the Start key is pressed with the 3rd Drawer selected. 3rd Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 3rd Drawer selected: the voltage across PJ3A-14B on Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. 3rd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 3rd Drawer selected.

NO YES YES YES YES NO NO

10

YES NO

11

NO

Correct drive coupling (drive transmitting gear engagement). Change motor. Change 3rd Drawer Control Board. Correct drive coupling (coupling engagement, position of drive transmitting pin). Check for overload. Change clutch. Change 4th Drawer Control Board.

12

Paper Take-Up Roll turns when the Start key is pressed with the 4th Drawer selected. 4th Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 4th Drawer selected: the voltage across PJ3A-14B on Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

NO

13

YES NO

T-30

Step 14

Check Item 4th Drawer Paper Take-Up Motor turns when the Start key is pressed with the 4th Drawer selected.

Result NO

Action Correct drive coupling (drive transmitting gear engagement). Change motor. Change 4th Drawer Control Board.

Paper is at a stop at the Vertical Transport Rollers. Step 1 2 3 Check Item Paper take-up guide plate or vertical transport guide plate is dirty or deformed. Vertical Transport Rollers are dirty with paper dust, deformed, or worn. I/O check for 3rd Drawer Paper Take-Up Sensor operation when the 3rd Drawer is used: the voltage across PJ3A-5A on Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked. Vertical Transport Roller 3 turns when the Start key is pressed with 3rd Drawer selected. I/O check for 4th Drawer Paper Take-Up Sensor operation when the 4th Drawer is used: the voltage across PJ3A-5A on Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked. Vertical Transport Roller 4 turns when the Start key is pressed with 4th Drawer selected. Size error display after the misfeed display has been reset. Result YES YES YES NO Action Clean, correct, or change. Clean or change. Change 3rd Drawer Control Board. Correct actuator. Check sensor connector for connection. Change sensor. Correct drive coupling (drive transmitting gear engagement, clutch spring operation). Change 4th Drawer Control Board. Correct actuator. Check sensor connector for connection. Change sensor. Correct drive coupling (drive transmitting gear engagement, clutch spring operation). Check paper size.

NO

YES NO

NO

YES

T-31

(7)

PF-117 Paper Take-Up Misfeed Relevant Electrical Parts

LCC Paper Take-Up Sensor (PPS0) Paper Standby Position Sensor (S1) LCC Registration Sensor (RSEN) LCC Paper Take-Up Clutch 1 (P1CL) LCC Paper Take-Up Clutch 2 (P2CL)

LCC Separator Clutch (BCL) LCC Registration Clutch (RCL) LCC Transport Motor (HMOT) LCC Control Board (PWB-A)

PJ10 S1
1 2 3

PWB-A(LCC Tray)
CN3A-6(S1 LED) CN3A-5(S1 ON) CN3A-4(DC5 V)

PJ7 RSEN
1 2 3 CN4A-3(RSEN LED) CN4A-2(RSEN ON) CN4A-1(DC5 V)

PJ4 PPSO
1 2 3 CN4A-12(PPSO LED) CN4A-11(PPSO ON) CN4A-10(DC5 V)

PJ4 HMOT
1 2 3 4 5 6 CN6A-6(HMOT CLK) CN6A-5(DC5 V) CN6A-4(HMOT SIG) CN6A-3(CTND) CN6A-1(DC24 V)

CN14 BCL
2 1 1 2 CN7A-2(BCL ON) CN7A-1(DC24 V)

CN13 RCL
2 1 1 2 CN7A-4(RCL ON) CN7A-3(DC24 V)

CN12 P2CL
2 1 1 2 CN7A-6(P2CL ON) CN7A-5(DC24 V)

CN11 P1CL
2 1 1 2 CN7A-8(P1CL ON) CN7A-7(DC24 V)
4004C23TAB

T-32

PF-117 Paper Take-Up Misfeed Troubleshooting Procedures Paper is not taken up at all. (Lift 1) Step 1 2 Check Item Paper meets product specifications. Paper is curled, wavy, or damp. Result NO YES Action Change paper. Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater. Clean or change. Clean or change. Correct drive coupling (drive transmitting gear engagement, spring operation, belt tension). Check for overload. Change clutch. Change LCC Control Board.

3 4 5

Lift is dirty, deformed, or damaged. Paper Take-Up Roll 1 is dirty, deformed, or scratched. Paper Take-Up Roll 1 turns when the Start key is pressed with Lift 1 used.

YES YES NO

LCC Paper Take-Up Clutch 1 operation when the Start key is pressed with Lift 1 used: the voltage across CN7A-8 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES NO

Paper is not taken up at all. (Lift 2) Step 1 2 Check Item Paper meets product specifications. Paper is curled, wavy, or damp. Result NO YES Action Change paper. Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater. Clean or change. Clean or change. Correct drive coupling (drive transmitting gear engagement, spring operation, belt tension). Check for overload. Change clutch. Change LCC Control Board.

3 4 5

Lift is dirty, deformed, or damaged. Paper Take-Up Roll 2 is dirty, deformed, or scratched. Paper Take-Up Roll 2 turns when the Start key is pressed with Lift 2 used.

YES YES NO

LCC Paper Take-Up Clutch 2 operation when the Start key is pressed with Lift 2 used: the voltage across PJ7A-6 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES NO

T-33

 Paper is stationary at the Vertical Transport Roller. Step 1 2 3 4 5 6 Check Item Feed Roll is deformed, worn, or dirty with paper dust or other foreign matter. Separator Roll is deformed, worn, or dirty with paper dust or other foreign matter. Paper take-up guide plate is dirty, deformed, or damaged. Vertical Transport Roller is dirty with paper dust, deformed, or worn. Vertical transport guide plate is dirty or deformed. I/O check for Paper Standby Position Sensor operation when the LCC Drawer is used: the voltage across PJ3A-5 on LCC Control Board and GND is DC 5 V when there is reflected light and DC 0 V when there is no reflected light. Feed Roll turns when the Start key is pressed with the LCC Drawer selected. Separator Roll turns when the Start key is pressed with the LCC Drawer selected. LCC Separator Clutch operation when the Start key is pressed with the LCC Drawer selected: the voltage across CN7A-2 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. I/O check for LCC Registration Sensor operation when the LCC Drawer is used: the voltage across CN4A-2 on LCC Control Board and GND is DC 5 V when there is reflected light and DC 0 V when there is no reflected light. Vertical Transport Rollers turn when the Start key is pressed with the LCC Drawer selected. LCC Registration Clutch operation when the Start key is pressed with the LCC Drawer selected: the voltage across CN7A4 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. Result YES YES YES YES YES YES NO Action Clean or change. Clean or change. Clean or change. Clean or change. Clean, correct, or change. Change LCC Control Board. Check sensor connector for connection. Change sensor.

NO

Correct drive coupling (drive transmitting gear engagement, belt tension). Correct drive coupling (spring operation). Check for overload. Change clutch. Change LCC Control Board.

8 9

NO YES NO

10

YES NO

Change LCC Control Board. Check sensor connector for connection. Change sensor.

11

NO

Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change LCC Control Board.

12

YES NO

T-34

(8)

Duplex Paper Take-Up Misfeed Relevant Electrical Parts

Duplex Unit Transport Sensor 1 (PI1) Duplex Unit Transport Sensor 2 (PC1) Manual Feed Paper Take-Up Sensor (PC15) Manual Feed Paper Take-Up Clutch (CL3)

Duplex Unit Transport Motor (M2) Switchback Motor (M1) Duplex Control Board (PWB-A) Master Board (PWB-I)

DC24 V

CN41 CL3
1 2 2 1

CN33
1 2 3 4 5 1 2 3 4 5

PWB-I
PJ15A-9A(CL3 REM) PJ15A-7B(PC15 ON) PJ15A-8B(GND) PJ15A-9B(DC5 V)

PJ40 PC15
1 2 3

8 8

PWB-A
M1
PJ3A-1( B) PJ3A-2(B) PJ3A-3( A) PJ3A-4(A) PJ2A-1( B) PJ2A-2(B) PJ2A-3( A) PJ2A-4(A)

M2 PJ10 PC1
3 2 1

PJ4A-1(DC5 V) PJ4A-2(GND) PJ4A-3(PC1 ON)

PI1
4004C24TAD 4004C24TAD

T-35

Duplex Paper Take-Up Misfeed Troubleshooting Procedures Paper is at a stop in the Duplex Unit transport section. Step 1 2 3 4 5 Check Item Transport Roller is dirty, deformed, or worn. Transport Roll is dirty, deformed, or worn. Transport guide is dirty, deformed, or damaged. Torn piece of paper left at the transport section. Duplex Unit Transport Roller 1 turns when the Start key is pressed with the Duplex Unit used. Switchback Motor turns when the Start key is pressed with the Duplex Unit used. Duplex Unit Transport Roller 2 turns when the Start key is pressed with the Duplex Unit used. Duplex Unit Transport Roller 3 turns when the Start key is pressed with the Duplex Unit used. Duplex Unit Transport Motor turns when the Start key is pressed with the Duplex Unit used. Result YES YES YES YES NO Action Clean or change. Clean or change. Clean, correct, or change. Clean. Correct drive coupling (drive transmitting gear engagement). Correct drive coupling. Change motor. Change Duplex Control Board. Correct drive coupling (drive transmitting gear engagement). Correct drive coupling (drive transmitting gear engagement). Correct drive coupling. Change motor. Change Duplex Control Board.

NO

NO

NO

NO

Paper is at a stop at the Manual Bypass take-up section. Step 1 Check Item I/O check for Manual Feed Paper Take-Up Sensor operation when the Manual Bypass Table is used: the voltage across PJ15I-7B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked. Manual Bypass Paper Take-Up Roll is dirty with paper dust, deformed, or worn. Manual Bypass Paper Take-Up Roll turns when the Start key is pressed with the Manual Bypass Table used. Manual Feed Paper Take-Up Clutch operation when Manual Feed Paper Take-Up Sensor is unblocked with the Manual Bypass Table used: the voltage across PJ15I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. Result YES NO Action Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor.

2 3

YES NO

Clean or change. Correct drive coupling (drive transmitting gear engagement). Check for overload. Change clutch. Change Master Board.

YES NO

T-36

3.

MALFUNCTIONS

The copiers CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel. Resetting a Malfunction Press the Trouble Reset Switch on the Tech. Rep. Setting Switches Board to reset the following malfunctions: IR-related malfunctions (except the following, i.e., C3310: CCD clamp gain adjustment failure; C3700: IR Cooling Fan Motor 1 turning at abnormal timing; C3710: IR Cooling Fan Motor 2 turning at abnormal timing; C3720: Original Glass Cooling Fan Motor turning at abnormal timing) and fusing-related malfunctions. For any other malfunctions, open and close the Front Door or turn OFF and ON the Power Switch. <Warning>

4004P060CA

If the maintenance call mark appears, touch it to view a screen (State Confirm) that shows data in greater details.
4004P045BA

4004P061CA

T-37

3-1.

Detection Timing by Warning Code

If an image stabilization or IR-related fault occurs, the corresponding warning code appears. Refer to the following table and take necessary action to remedy the faulty spot. Code P-5 Fault Detection Timing

AIDC Sensor failure (AIDC All readings of the detection points are 4.8 V or Sensor 1) more or the selected reading is 1.0 V or less during AIDC Sensor intensity correction. The results of converting the adjustment pattern reading to reflection density on paper fall short of Magenta Imaging Unit failthe specified value during max. density adjustment ure (Vg/Vb adjustment). Yellow Imaging Unit failure The ATDC Sensor output when 0 gradation meaBlack Imaging Unit failure surement is taken is 253 (4.96 V) or more during correction. The result of converting the adjustment pattern reading to reflection density on paper is 0.4 V or less. Color Shift Correction fail- The calculated value of the CD color shift correcure (test pattern failure) tion amount is more or less than the specified value. The calculated value of the FD color shift correction amount is more or less than the specified value. Color Shift Correction fail- The CD registration distance is greater than the ure (correction amount failspecified range during registration correction. ure) The FD registration distance is greater than the specified range during registration correction. Skew correction amount is more than the specified value. Cyan 1st Image Transfer ATVC Failure The average value of voltage readings taken by the ATVC adjustment circuit is less than 0.5 V during ATVC adjustment. Magenta 1st Image Trans The average value of voltage readings taken by fer ATVC Failure the ATVC adjustment circuit is 0.5 V or more and Yellow 1st Image Transfer less than 0.6 V during ATVC adjustment. Or there ATVC Failure are five consecutive adjustment sequences, each Black 1st Image Transfer exceeding 4.6 V. (ATVC adjustment is made when ATVC Failure power is turned OFF and ON. A warning is issued through a minimum of five sequences of turning 2nd Image Transfer ATVC power OFF and ON.) Failure AIDC Sensor failure (AIDC All readings of the detection points are 4.8 V or Sensor 2) more or the selected reading is 1.0 V or less during AIDC Sensor intensity correction. Cyan Imaging Unit failure

P-6 P-7 P-8 P-9

P-21

P-22

P-23 P-24 P-25 P-26 P-27 P-28

T-38

Code S-1

Fault Gain adjustment failure

Detection Timing Each gain adjustment value for R, G, or B is 240 or more when a gain adjustment is made after the Power Switch has been turned ON. Lamp adjustment value is 255 and, at the same time, the target value cannot be achieved through gain adjustment.

S-2

Intensity adjustment failure Lamp voltage adjustment value Dx = 255 when a lamp voltage adjustment is made after the Power Switch has been turned ON and, at the same time, the target value cannot be achieved through the adjustment.

T-39

3-2.
Code

Detection Timing by Malfunction Code

Description Detection Timing

C0000 Main Motors failure to turn The Main Motor Lock signal remains faulty for a predetermined continuous period of time while the Main Motor is turning. C0001 Main Motor turning at abnormal timing C0010 Imaging Unit Motor Cs failure to turn The Main Motor Lock signal remains faulty for a predetermined continuous period of time while the Main Motor remains stationary. The Lock signal remains faulty for a continuous 1sec. period after the motor rotation has stabilized and before the motor starts decelerating.

C0011 Imaging Unit Motor C turn- The Lock signal remains faulty for a continuous 1ing at abnormal timing sec. period after the motor has completely stopped and before the motor starts accelerating. C0012 Imaging Unit Motor Ms failure to turn The Lock signal remains faulty for a continuous 1sec. period after the motor rotation has stabilized and before the motor starts decelerating.

C0013 Imaging Unit Motor M turn- The Lock signal remains faulty for a continuous 1ing at abnormal timing sec. period after the motor has completely stopped and before the motor starts accelerating. C0014 Imaging Unit Motor Ys fail- The Lock signal remains faulty for a continuous 1ure to turn sec. period after the motor rotation has stabilized and before the motor starts decelerating. C0015 Imaging Unit Motor Y turn- The Lock signal remains faulty for a continuous 1ing at abnormal timing sec. period after the motor has completely stopped and before the motor starts accelerating. C0016 Imaging Unit Motor Bks failure to turn The Lock signal remains faulty for a continuous 1sec. period after the motor rotation has stabilized and before the motor starts decelerating.

C0017 Imaging Unit Motor Bk The Lock signal remains faulty for a continuous 1turning at abnormal timing sec. period after the motor has completely stopped and before the motor starts accelerating. C0040 Fusing Cooling Fan Motor A Fusing Cooling Fan Lock signal is detected for a 2s failure to turn continuous 3-sec. period while Fusing Cooling Fan Motor 2 is turning. C0046 Fusing Cooling Fan Motor A Fusing Cooling Fan Lock signal is detected for a 1s failure to turn continuous 3-sec. period while the Fusing Cooling Fan Motor is turning. C004C Ozone Ventilation Fan Motors failure to turn An Ozone Fan Lock signal is detected for a continuous 3-sec. period while the Ozone Ventilation Fan Motor is turning.

C004E Power Supply Cooling Fan A Power Supply Cooling Fan Lock signal is detected Motors failure to turn for a continuous 3-sec. period while the Power Supply Cooling Fan Motor is turning.

T-40

Code

Description

Detection Timing A Fusing Drive Motor Lock signal remains faulty for a predetermined continuous period of time while the Fusing Drive Motor is turning. The Fusing Drive Motor Lock signal remains faulty for a predetermined continuous period of time while the Fusing Drive Motor remains stationary.

C0060 Fusing Drive Motors failure to turn C0061 Fusing Drive Motor turning at abnormal timing

C0094 2nd Image Transfer Roller The 2nd Image Transfer Pressure Position Sensor pressure/retraction failure is not activated (retracted position) within 1 sec. after the 2nd Image Transfer Roller has started its retracting motion. The 2nd Image Transfer Pressure Position Sensor is not deactivated (not the retracted position) within 1 sec. after the 2nd Image Transfer Roller has started its pressing motion. C0096 1st Image Transfer Roller pressure/retraction failure The 1st Image Transfer Retraction Position Sensor is not activated (retracted position) within 3 sec. after the 1st Image Transfer Pressure/Retraction Motor has started turning. The 1st Image Transfer Retraction Position Sensor is not deactivated (pressed position) within 1.5 sec. after the 1st Image Transfer Pressure/Retraction Motor has started turning. No change is observed in the encoder pulse even after the lapse of 0.5 sec. after the Fusing Pressure/Retraction Motor has started turning for retraction direction during retraction control. No change is observed in the encoder pulse even after the lapse of 0.5 sec. after the Fusing Pressure/Retraction Motor has started turning for pressure direction during pressure control. The Fusing Pressure Position Sensor is not activated (pressed position) even when 31 motor encoder pulses have been counted after the Fusing Pressure/Retraction Motor has started turning for pressure direction during pressure control. The SCD signal remains inactive for a continuous 1sec. period while charge corona is being output (i.e., the Remote signal is being turned ON).

C0098 Fusing Roller pressure/ retraction failure

C0200 Cyan PC Drum Charge Corona malfunction

C0202 Magenta PC Drum Charge The SCD signal remains inactive for a continuous 1Corona malfunction sec. period while charge corona is being output (i.e., the Remote signal is being turned ON). C0204 Yellow PC Drum Charge Corona malfunction C0206 Black PC Drum Charge Corona malfunction The SCD signal remains inactive for a continuous 1sec. period while charge corona is being output (i.e., the Remote signal is being turned ON). The SCD signal remains inactive for a continuous 1sec. period while charge corona is being output (i.e., the Remote signal is being turned ON).

T-41

Code

Description

Detection Timing

C0400 Exposure Lamps failure to A Lamp-Out Detection signal is ON after the lapse of turn ON 5 sec. after the Exposure Lamp has been turned ON. C0410 Exposure Lamp turning ON at abnormal timing C0500 Heating Roller warm-up failure (Fusing Thermistor 1) CCD Sensor outputs are written in line RAM at the end of a scan job and the average of these readings exceeds a predetermined value. Fusing Thermistor 1 does not detect a predetermined temperature and the warm-up cycle is not completed within the period of 9 min. 10 sec. after the warm-up cycle has been started. The temperature of Fusing Thermistor 1 does not rise to a level more than the predetermined output value within 30 sec. after the warm-up cycle has started.

C0501 Lower Fusing Roller The temperature of Fusing Thermistor 2 does not Heater Lamp warm-up failreach 100 C within 180 sec. after the warm-up ure cycle has started. (Fusing Thermistor 2) The temperature of Fusing Thermistor 1 does not rise to a level more than the predetermined output value within 130 sec. after the warm-up cycle has started. C0510 Heating Roller abnormally The temperature of Fusing Thermistor 1 remains low temperature below 120 C for 1 sec. or more in the standby (Fusing Thermistor 1) state. The temperature of Fusing Thermistor 1 remains below 130 C for 1 sec. or more during a print cycle. The temperature of Fusing Thermistor 1 remains below 90 C for 1 sec. or more in the Energy Saver mode. C0511 Lower Fusing Roller Heater Lamp abnormally low temperature (Fusing Thermistor 2) The temperature of Fusing Thermistor 2 remains below 100 C for 1 sec. or more in the standby state. The temperature of Fusing Thermistor 2 remains below 100 C for 1 sec. or more during a print cycle. The temperature of Fusing Thermistor 2 remains below 100 C for 1 sec. or more in the Energy Saver mode.

C0520 Heating Roller abnormally The temperature of Fusing Thermistor 1 remains high temperature above 220 C for 1 sec. or more at all times. (Fusing Thermistor 1) C0521 Lower Fusing Roller Heater Lamp abnormally high temperature (Fusing Thermistor 2) The temperature of Fusing Thermistor 2 remains above 190 C for 1 sec. or more at all times.

T-42

Code

Description

Detection Timing The Scanner Home Sensor fails to detect the Scanner at its home position though the Scanner is so located. The Scanner Home Sensor fails to detect the Scanner though the motor has been energized to move the Scanner over the maximum distance. The Scanner Home Sensor detects the Scanner at its home position though the Scanner has moved 5 mm away from the home position. The Scanner Home Sensor detects the Scanner at its home position during a period from when the prescan command and scan preparation command have been executed to when home return command is executed.

C0650 Scanner Home Sensor malfunction

C0660 Scanner overrun failure

C0990 LCC Lift-Up Motor malfunction C0991 LCC Lift 1 ascent motion failure C0995 LCC Transport Motor malfunction C0999 LCC Lift 2 ascent motion failure C0B00 Finishing option transport drive malfunction C0B20 Stapling Unit CD drive malfunction C0B30 Finishing option Paper Aligning Bar moving mechanism malfunction C0B48 Finishing option Exit Roll pressure/retraction failure C0B4A Finishing option Storage Roller pressure/retraction failure

See the relevant Option Service Manual.

T-43

Code

Description

Detection Timing

C0B50 Finishing option stapling mechanism 1 C0B54 Finishing option stapling mechanism 2 C0B73 Finishing option punch cam motor mechanism malfunction C0B78 Finishing option punch selector motor mechanism malfunction C0B80 Finishing option Shift Motor mechanism malfunction C0BA0 Finishing option Elevator Tray drive failure C0F30 Abnormally low toner den- Toner density that is 2 % or more lower than the tarsity detected by Cyan get level is detected ten consecutive times during a ATDC Sensor print cycle, ATVC, or image stabilization sequence. C0F31 Abnormally high toner density detected by Cyan ATDC Sensor Toner density that is 4 % or more higher than the target level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence. See the relevant Option Service Manual.

C0F32 Abnormally low toner den- Toner density that is 2 % or more lower than the tarsity detected by Magenta get level is detected ten consecutive times during a ATDC Sensor print cycle, ATVC, or image stabilization sequence. C0F33 Abnormally high toner density detected by Magenta ATDC Sensor Toner density that is 4 % or more higher than the target level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence.

C0F34 Abnormally low toner den- Toner density that is 2 % or more lower than the target level is detected ten consecutive times during a sity detected by Yellow print cycle, ATVC, or image stabilization sequence. ATDC Sensor Toner density that is 4 % or more higher than the tarC0F35 Abnormally high toner density detected by Yellow get level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence. ATDC Sensor C0F36 Abnormally low toner den- Toner density that is 2 % or more lower than the target level is detected ten consecutive times during a sity detected by Black print cycle, ATVC, or image stabilization sequence. ATDC Sensor C0F37 Abnormally high toner density detected by Black ATDC Sensor C0F3A Cyan ATDC Sensor adjustment failure C0F3B Magenta ATDC Sensor adjustment failure C0F3C Yellow ATDC Sensor adjustment failure Toner density that is 4 % or more higher than the target level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence. Cyan ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value. Magenta ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value. Yellow ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

T-44

Code

Description

Detection Timing Black ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value. The output from the new unit detecting terminal remains HIGH and the copier does not recognize that a new unit has been installed. 1. After an image stabilization sequence is completed, the fuse blowout signal of the new unit is set to a blowout state. 2. After the lapse of 2 sec. after step 1, the fuse blowout signal is brought to a state where no new units are installed. 3. After the lapse of 0.1 sec. after step 2, a new unit check sequence is carried out. A total of three cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a third time, a malfunction condition results.

C0F3D Black ATDC Sensor adjustment failure C13C8 New Transfer Belt Unit resetting failure

C13CA New Fusing Unit resetting The output from the new unit detecting terminal failure remains HIGH and the copier does not recognize that a new unit has been installed. 1. The fuse blowout signal of the new unit is set to a blowout state. 2. After the lapse of 0.5 sec. after step 1, the fuse blowout signal is brought to a state where no new units are installed. 3. After the lapse of 0.1 sec. after step 2, a new unit check sequence is carried out. A total of two cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a second time, a malfunction condition results. C13CB New Fusing Web Unit resetting failure The output from the new unit detecting terminal remains HIGH and the copier does not recognize that a new unit has been installed. 1. The fuse blowout signal of the new unit is set to a blowout state. 2. After the lapse of 0.5 sec. after step 1, the fuse blowout signal is brought to a state where no new units are installed. 3. After the lapse of 0.1 sec. after step 2, a new unit check sequence is carried out. A total of two cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a second time, a malfunction condition results.

T-45

Code

Description

Detection Timing The output from the new unit detecting terminal remains HIGH and the copier does not recognize that a new unit has been installed. 1. The fuse blowout signal of the new unit is set to a blowout state. 2. After the lapse of 0.5 sec. after step 1, the fuse blowout signal is brought to a state where no new units are installed. 3. After the lapse of 0.1 sec. after step 2, a new unit check sequence is carried out. A total of two cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a second time, a malfunction condition results.

C13CC New Oil Coating Unit resetting failure

C13D1 Cyan IU EEPROM failure

EEPROM access error: When EEPROM access control is executed, setting 1 Start Flag of GA register does not become ready even after the lapse of a predetermined period of time.

C13D2 Magenta IU EEPROM fail- EEPROM access error: ure When EEPROM access control is executed, setting 1 Start Flag of GA register does not become ready even after the lapse of a predetermined period of time. C13D3 Yellow IU EEPROM failure EEPROM access error: When EEPROM access control is executed, setting 1 Start Flag of GA register does not become ready even after the lapse of a predetermined period of time. C13D4 Black IU EEPROM failure EEPROM access error: When EEPROM access control is executed, setting 1 Start Flag of GA register does not become ready even after the lapse of a predetermined period of time. When clamp adjustment is made: (AVE1 - AVE2) =< 4 When gain adjustment is made: The average of CCD Sensor output values is 1 or less. Dgain = 0 Dgain = 255

C3310 CCD clamp/gain adjustment failure

C3700 IR Cooling Fan Motor 1 A Lock signal is detected ten consecutive times turning at abnormal timing when it is monitored at 0.01-sec. intervals while a Fan Motor ON signal is being output and, at the same time, after the lapse of 2 sec. or more after the output of the Fan Motor ON signal has been started.

T-46

Code

Description

Detection Timing

C3710 IR Cooling Fan Motor 2 A Lock signal is detected ten consecutive times turning at abnormal timing when it is monitored at 0.01-sec. intervals while a Fan Motor ON signal is being output and, at the same time, after the lapse of 2 sec. or more after the output of the Fan Motor ON signal has been started. C3720 Original Glass Cooling Fan A Lock signal is detected ten consecutive times Motor turning at abnormal when it is monitored at 0.01-sec. intervals while a timing Fan Motor ON signal is being output and, at the same time, after the lapse of 2 sec. or more after the output of the Fan Motor ON signal has been started. C3A00 PIC communication error A sampling lock is not received after the lapse of a predetermined period of time after IREQ has been received during AIDC sampling of image stabilization sequence or registration adjustment. There is an open-circuit in the communication harness between the PIC Board and Master Board. Either the PIC Board or Master Board is faulty. The PIC Board is faulty. The system fails to rewrite flash memory during updating.

C3A01 PIC Board malfunction C3FFF ROM contents fault detected upon start

T-47

3-3.
(1)

Troubleshooting Procedures by Malfunction Code

C0000: Main Motors failure to turn C0001: Main Motor turning at abnormal timing Relevant Electrical Parts

Main Motor (M13)

Master Board (PWB-I) DC Power Supply 1 (PU1)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PWB-I
PJ105 M13
1 2 3 4 5 6 7 8 PJ13I-7A(M13 LOCK) PJ13I-8A(M13 REM) PJ13I-9A(M13 CLK) PJ13I-10A(DC5 V) PJ13I-11A(GND) PJ13I-12A(M13 CW/CCW)

4004C01TAA

C0000: Main Motors failure to turn Step 1 Check Item Main Motor turns when the Start key is pressed. Result NO Action Check connector for connection. Correct drive coupling (drive transmitting gear engagement). Change motor. Change Master Board.

Main Motor rotation when the Start key is pressed: the voltage across PJ13I-7A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Main Motor rotation when the Start key is pressed: the voltage across PJ7PU1-4 on DC Power Supply 1 and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized.

YES NO

NO

Change DC Power Supply 1.

C0001: Main Motor turning at abnormal timing Step 1 Check Item Main Motor rotation while it is being energized: the voltage across PJ13I-7A on Master Board and GND remains DC 0 V. Result YES NO Action Change Master Board. Change motor.

T-48

(2)

C0010: Imaging Unit Motor Cs failure to turn C0011: Imaging Unit Motor C turning at abnormal timing C0012: Imaging Unit Motor Ms failure to turn C0013: Imaging Unit Motor M turning at abnormal timing C0014: Imaging Unit Motor Ys failure to turn C0015: Imaging Unit Motor Y turning at abnormal timing C0016: Imaging Unit Motor Bks failure to turn C0017: Imaging Unit Motor Bk turning at abnormal timing Relevant Electrical Parts

Imaging Unit Motor C (M17) Imaging Unit Motor M (M16) Imaging Unit Motor Y (M15)

Imaging Unit Motor Bk (M18) Master Board (PWB-I) DC Power Supply 1 (PU1)

M15

PU1
PJ1Y-1(DC5V) PJ1Y-2(GMD) PJ1Y-3(DC24 V) PJ1Y-4(GND) PJ8PU1-4(DC5V) PJ8PU1-3(GND) PJ7PU1-2(DC24 V) PJ7PU1-6(GND)

CL11

M15

PWB-I
PJ2Y-1(M15 REM) PJ2Y-2(M15 LOCK) PJ2Y-3(Speed CHG) PJ2Y-4(CL11 REM) PJ12I-4A(M15 REM) PJ12I-3A(M15 LOCK) PJ12I-2A(Speed CHG) PJ12I-1A(CL11 REM)

M16
CL12

PJ1M-1(DC5V) PJ1M-2(GMD) PJ1M-3(DC24 V) PJ1M-4(GND)

PJ8PU1-4(DC5V) PJ8PU1-3(GND) PJ7PU1-2(DC24 V) PJ7PU1-7(GND)

PU1

M16
PJ2M-1(M16 REM) PJ2M-2(M16 LOCK) PJ2M-3(Speed CHG) PJ2M-4(CL12 REM) PJ12I-8A(M16 REM) PJ12I-7A(M16 LOCK) PJ12I-6A(Speed CHG) PJ12I-5A(CL12 REM)

PWB-I

M17
CL13

PJ1C-1(DC5V) PJ1C-2(GND) PJ1C-3(DC24 V) PJ1C-4(GND)

PJ8PU1-4(DC5V) PJ8PU1-3(GND) PJ7PU1-3(DC24 V) PJ7PU1-8(GND)

PU1

M17
PJ2C-1(M17 REM) PJ2C-2(M17 LOCK) PJ2C-3(Speed CHG) PJ2C-4(CL13 REM) PJ12I-4B(M17 REM) PJ12I-3B(M17 LOCK) PJ12I-2B(Speed CHG) PJ12I-1B(CL13 REM)

PWB-I

M18

PJ1K-1(DC5V) PJ1K-2(GND) PJ1K-3(DC24 V) PJ1K-4(GND)

PJ8PU1-4(DC5V) PJ8PU1-3(GND) PJ7PU1-3(DC24 V) PJ7PU1-9(GND)

PU1

CL14

M18
PJ2K-1(M18 REM) PJ2K-2(M18 LOCK) PJ2K-3(Speed CHG) PJ2K-4(CL14 REM) PJ12I-8B(M18 REM) PJ12I-7B(M18 LOCK) PJ12I-6B(Speed CHG) PJ12I-5B(CL14 REM)

PWB-I

4004C02TAD

T-49

C0010, C0012, C0014, C0016 Step 1 Check Item Imaging Unit Motor turns when the Start key is pressed. Result NO Action Correct drive coupling (drive transmitting gear engagement, coupling engagement). Check that the LED Assy is locked in position. Change motor. Change Master Board.

Imaging Unit Motor rotation when the Start key is pressed: Cyan: the voltage across PJ12I-3B on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Magenta: the voltage across PJ12I-7A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Yellow: the voltage across PJ12I-3A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Black: the voltage across PJ12I-7B on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES NO

C0011, C0013, C0015, C0017 Step 1 Check Item Imaging Unit Motor rotation while it is being energized: Cyan: the voltage across PJ12I-3B on Master Board and GND remains DC 0 V. Magenta: the voltage across PJ12I-7A on Master Board and GND remains DC 0 V. Yellow: the voltage across PJ12I-3A on Master Board and GND remains DC 0 V. Black: the voltage across PJ12I-7B on Master Board and GND remains DC 0 V. Result YES NO Action Change Master Board. Change motor.

T-50

(3)

C0040: Fusing Cooling Fan Motor 1s failure to turn C0046: Fusing Cooling Fan Motor 2s failure to turn C004C: Ozone Ventilation Fan Motors failure to turn C004E: Power Supply Cooling Fan Motors failure to turn Relevant Electrical Parts

Fusing Cooling Fan Motor 1 (M23) Fusing Cooling Fan Motor 2 (M24) Ozone Ventilation Fan Motor (M22)

Power Supply Cooling Fan Motor (M21) High Voltage Unit 3 (HV3) Master Board (PWB-I) DC Power Supply 1 (PU1)

CN77 M21
1 2 3 3 2 1

PJ13PU1-1(DC24 V) PJ13PU1-2(GND) PJ13PU1-3(M21 LOCK) PJ6PU1-1(DC24 V) PJ6PU1-2(DC24 V) PJ6PU1-8(GND) PJ6PU1-9(GND)

PU1

PWB-I
PJ1I-2 PJ1I-3 PJ1I-4 PJ1I-5

HV3
M22
CN2HV3-1(M22 ON) CN1HV3-1(M22 LOCK) CN1HV3-2(M22 ON) CN2HV3-2(GND) CN2HV3-3(M22 LOCK) PJ10I-15(M22 LOCK) PJ10I-14(M22 ON)

CN65 CN31 M23

1 2 3 3 2 1 1 2 3 4 5 6 7 7 6 5 4 3 2 1 PJ14I-11A(M23 ON) PJ14I-12A(GND) PJ14I-13A(M23 LOCK)

CN80 M24
1 2 3 3 2 1

PJ14I-1A(M24 ON) PJ14I-2A(GND) PJ14I-3A(M24 LOCK)

4004C03TAC

4004C03TAC

C0040 Step 1 2 Check Item Fusing Cooling Fan Motor 1 turns when the Start key is pressed. Fusing Cooling Fan Motor 1 rotation when the Start key is pressed: the voltage across PJ14I-13A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Result NO YES NO Action Check connector for connection. Check fan for overload. Change Master Board. Change motor.

T-51

C0046 Step 1 2 Check Item Fusing Cooling Fan Motor 2 turns when the Start key is pressed. Fusing Cooling Fan Motor 2 rotation when the Start key is pressed: the voltage across PJ14I-3A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Result NO YES NO Action Check connector for connection. Check fan for overload. Change motor. Change Master Board.

C004C Step 1 2 Check Item Ozone Ventilation Fan Motor turns when the Start key is pressed. Ozone Ventilation Fan Motor rotation when the Start key is pressed: the voltage across PJ10I-15 on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Ozone Ventilation Fan Motor rotation when the Start key is pressed: the voltage across CN2HV3-3 on High Voltage Unit 3 and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Result NO NO Action Check connector for connection. Check fan for overload. Change Master Board.

YES NO

Change motor. Change High Voltage Unit 3.

C004E Step 1 2 Check Item Power Supply Cooling Fan Motor turns when the Start key is pressed. Power Supply Cooling Fan Motor rotation when the Start key is pressed: the voltage across PJ13PU1-3 on DC Power Supply 1 and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Result NO YES NO Action Check connector for connection. Check fan for overload. Change motor. Change DC Power Supply 1.

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(4)

C0060: Fusing Drive Motors failure to turn C0061: Fusing Drive Motor turning at abnormal timing Relevant Electrical Parts

Fusing Drive Motor (M14)

Master Board (PWB-I) DC Power Supply 1 (PU1)

PU1
PJ7PU1-4(DC24 V) PJ7PU1-5(GND)

PJ106 M14
1 2 3 4 5 6 7 8 9

PWB-I
PJ13I-1A(M14 LOCK) PJ13I-2A(M14 REM) PJ13I-3A(M14 CLK) PJ13I-4A(DC5 V) PJ13I-5A(GND) PJ13I-6A(M14 CCW/CW)
4004C04TAA

4004C04T
C0060 Step 1 2 Check Item Fusing unit driver over-loaded. Fusing Drive Motor turns when the Start key is pressed. Result YES NO Action Correct cause of over-load. Check connector for connection. Correct drive coupling (drive transmitting gear engagement). Change motor. Change Master Board.

Fusing Drive Motor rotation when the Start key is pressed: the voltage across PJ13I-1A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized. Fusing Drive Motor rotation when the Start key is pressed: the voltage across PJ7PU14 on DC Power Supply 1 and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized.

YES NO

NO

Change DC Power Supply 1.

C0061 Step 1 Check Item Fusing Drive Motor rotation while it is being energized: the voltage across PJ13I-1A on Master Board and GND remains DC 0 V. Result YES NO Action Change Master Board. Change motor.

T-53

(5)

C0094: 2nd Image Transfer Roller pressure/retraction failure Relevant Electrical Parts

2nd Image Transfer Pressure Position Sen- Master Board (PWB-I) sor (PC23) 2nd Image Transfer Pressure/Retraction Clutch (CL15)

PJ122 CN14 CL15

4 3 2 1 1 2 2 1

CN65
1 2 7 7 6 1

PWB-I
PJ14I-9A(DC24 V) PJ14I-10A(CL15 REM)

CN63 PJ108
1 12 4 5 6 9 8 7 3 2 1

PC23

PJ14I-4B(DC5 V) PJ14I-5B(GND) PJ14I-6B(PC23 ON)

12 1
4004C05TAB

C0094 Step 1 Check Item While the 2nd Image Transfer Pressure/ Retraction Clutch is supposed to be deenergized during timing of pressure/retraction operation: the voltage across PJ14I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized. I/O check for 2nd Image Transfer Pressure Position Sensor operation during pressure/ retraction operation: the voltage across PJ14I-6B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (pressed position). Result YES Action Check connector for connection. Check for overload. Change clutch. Change Master Board.

NO

YES NO

Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor.

T-54

(6)

C0096: Image Transfer Belt pressure/retraction failure Relevant Electrical Parts

1st Image Transfer Retraction Position Sen- Master Board (PWB-I) sor (PC28) 1st Image Transfer Pressure/Retraction Motor (M11)

CN46
1 2 3 4 5 6 6 5 4 3 2 1

PWB-I
PJ16I-2B(DC24 V) PJ16I-3B(DC24 V) PJ16I-4B(M11 A1) PJ16I-5B(M11 B1) PJ16I-6B(M11 A3) PJ16I-7B(M11 B3)

M11

PJ109 PC28
3 2 1 PJ17I-1A(PC28 ON) PJ17I-2A(DC5 V) PJ17I-3A(GND)

4004C06TAA

C0096 Step 1 Check Item 1st Image Transfer Pressure/Retraction Motor turns during pressure/retraction operation. Result NO Action Check connector for connection. Correct drive coupling (drive transmitting gear engagement). Change motor. Change Master Board. Change Master Board. Correct actuator. Check sensor connector for connection. Change sensor.

I/O check for 1st Image Transfer Retraction Position Sensor operation during pressure/ retraction operation: the voltage across PJ17I-1A on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (retracted position).

YES NO

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(7)

C0098: Fusing Roller pressure/retraction failure Relevant Electrical Parts

Fusing Pressure Position Sensor (PC7) Fusing Retraction Position Sensor (PC8)

Fusing Pressure/Retraction Motor (M8) Master Board (PWB-I)

CN4 PJ136 PC7

3 2 1 1 2 3 4 5 1 2 3 4 5

PWB-I
PJ6I-9B(DC5 V) PJ6I-10B(GND) PJ6I-11B(PC7 ON)

24 24

PJ120 M8
2 1 PJ14I-4A(M8 -) PJ14I-5A(M8 +)

PJ134 PC8
3 2 1 PJ17I-1B(DC5 V) PJ17I-2B(GND) PJ17I-3B(PC8 ON)

40
4004C07TAC

T-56

C0098 Step 1 Check Item Fusing Pressure/Retraction Motor rotation when the Fusing Roller is retracted: the voltage across PJ14I-4A on Master Board and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized. I/O check for Fusing Pressure Position Sensor when the Fusing Roller is retracted: the voltage across PJ6I-11B on Master Board and GND is DC 0 V when the sensor is unblocked (retracted position) and DC 5 V when the sensor is blocked. Fusing Pressure/Retraction Motor rotation when the Fusing Roller is pressed: the voltage across PJ14I-5A on Master Board and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized. I/O check for Fusing Pressure Position Sensor when the Fusing Roller is pressed: the voltage across PJ6I-11B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (pressed position). I/O check for Fusing Retraction Position Sensor operation while the Fusing Pressure/Retraction Motor is turning: the voltage across PJ17I-3B on Master Board and GND remains DC 0 V when the sensor is unblocked or remains DC 5 V when the sensor is blocked while the motor remains stationary, and alternates between DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked while the motor is turning. Result YES NO Action Check motor connector for connection. Change motor. Change Master Board.

YES NO

Change Master Board. Check sensor installation. Correct detecting plate. Check sensor connector for connection. Change sensor. Change Master Board.

NO

YES NO

Change Master Board. Check sensor installation. Correct detecting plate. Check sensor connector for connection. Change sensor. Change Master Board. Check sensor installation. Correct detecting plate. Check sensor connector for connection. Change sensor.

YES NO

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C0200: Cyan PC Drum Charge Corona malfunction C0202: Magenta PC Drum Charge Corona malfunction C0204: Yellow PC Drum Charge Corona malfunction C0206: Black PC Drum Charge Corona malfunction Relevant Electrical Parts

Imaging Unit C Imaging Unit M Imaging Unit Y Imaging Unit Bk

High Voltage Unit 1 (HV1) Master Board (PWB-I) DC Power Supply 1 (PU1)

HV1
PJ16-1(DC 24V) PJ16-2(GND)

PU1
PJ6PU1-4(DC24 V) PJ6PU1-5(GND)

PWB-I
PJ17-12 PJ17-11 PJ17-10 PJ17-9 PJ17-8 PJ17-7 PJ17-6 PJ17-5 PJ17-4 PJ17-3 PJ17-2 PJ17-1 PJ9I-1(G CNT-K) PJ9I-2(G CNT-C) PJ9I-3(G CNT-M) PJ9I-4(G CNT-Y) PJ9I-5(D.C SCD-Y) PJ9I-6(D.C REM-Y) PJ9I-7(D.C SCD-M) PJ9I-8(D.C REM-M) PJ9I-9(D.C SCD-C) PJ9I-10(D.C REM-C) PJ9I-11(D.C SCD-K) PJ9I-12(D.C REM-K)
4004C08TAB

T-58

C0200, C0202, C0204, C0206 Step 1 2 3 Check Item Imaging Unit contact failure High Voltage Unit 1 contact failure After corona output has been turned ON: Cyan (C0200): The voltage across PJ9I-10 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON. Magenta (C0202): The voltage across PJ9I-8 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON. Yellow (C0204): The voltage across PJ9I-6 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON. Bk (C0206): The voltage across PJ9I-12 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON. Result YES YES YES NO Action Correct or clean Imaging Unit contact. Correct or clean High Voltage Unit 1 contact. Change High Voltage Unit 1. Change Master Board.

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(9)

C0400: Exposure Lamps failure to turn ON C0410: Exposure Lamp turning ON at abnormal timing Relevant Electrical Parts

Exposure Lamp (LA1) Flat Cable (PWB-Z)

Temperature Fuse (F4) DC Power Supply 2 (PU2) Image Processing Board (PWB-C)

PJ8 2

PWB-Z
PJ2Z-5 PJ2Z-3

PWB-Z
PJ1Z-1 PJ1Z-3

PU2
PJ2PU2-1(DC0 V) PJ2PU2-3(DC70 V) PJ3PU2-1(DC24 V) PJ3PU2-2(GND) PJ3PU2-3(Lamp REM) PJ3PU2-4(Lamp Down) PJ3PU2-5(Lamp CNT)

F4 LA1

1 PJ7

PWB-C
PJ2C-11B PJ2C-10B PJ2C-9B PJ2C-8B PJ2C-7B

4004C09TAB

C0400/C0410 Step 1 2 3 4 5 Check Item Exposure Lamp conduction Temperature Fuse conduction Flat Cable conduction The problem has been eliminated through the checks of steps up to 3. Exposure Lamp turns ON and OFF correctly after DC Power Supply 2 has been replaced. Result NO NO NO NO NO Action Change Exposure Lamp. Change Temperature Fuse. Check for correct installation or change. Change DC Power Supply 2. Change Image Processing Board.

T-60

(10) C0500: Heating Roller warm-up failure C0501: Lower Fusing Roller Heater Lamp warm-up failure C0510: Heating Roller abnormally low temperature C0511: Lower Fusing Roller Heater Lamp abnormally low temperature C0520: Heating Roller abnormally high temperature C0521: Lower Fusing Roller Heater Lamp abnormally high temperature Relevant Electrical Parts Fusing Unit DC Power Supply 1 (PU1) Master Board (PWB-I)

FUSING UNIT
CN4
1 1 12 13 14 15 16 17 18 12 13 14 15 16 17 18

PU1
PJ12PU1-2(H1 ON) PJ12PU1-3(H2 ON) PJ12PU1-4(H3 ON) PJ4PU1-1(L) PJ4PU1-2(N H1) PJ4PU1-3(N H2) PJ4PU1-4(N H3)

24 24

PWB-I
PJ6I-1B(TH1 ON) PJ6I-2B(GND) PJ6I-3B(TH2 ON) PJ6I-4B(GND) PJ2I-8(H3 ON) PJ2I-9(H2 ON) PJ2I-10(H1 ON)
4004C27TAC

T-61

C0500, C0510 Step 1 Check Item Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is infinity with CN4 (2P) disconnected. Heating Roller Heater Lamps turn ON. Result YES NO YES NO C0520 Step 1 Check Item Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 (or close to 0) with CN4 (2P) disconnected. Result YES NO Action Change Fusing Unit. Change Master Board. Action Change Fusing Unit. Change Master Board. Change DC Power Supply 1. Change Master Board. Change Fusing Unit.

C0501, C0511 Step 1 Check Item Fusing Unit condition: the resistance across CN4-17 and 18 on the Fusing Unit end is infinity with CN4 (2P) disconnected. Lower Fusing Roller Heater Lamp turns ON. Result YES NO YES NO C0521 Step 1 Check Item Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 (or close to 0) with CN4 (2P) disconnected. Result YES NO Action Change Fusing Unit. Change Master Board. Action Change Fusing Unit. Change Master Board. Change DC Power Supply 1. Change Master Board. Change Fusing Unit.

T-62

(11) C0650: Scanner Home Sensor malfunction C0660: Scanner overrun failure Relevant Electrical Parts Scanner Home Sensor (PC24) Scanner Motor (M1) Scanner Motor Drive Board (PWB-IC) DC Power Supply 2 (PU2) Image Processing Board (PWB-C)

PWB-IC
PJ1IC-1 PJ1IC-2 PJ1IC-3 PJ1IC-4

PU2
PJ6PU2-2(DC5 V) PJ6PU2-4(GND) PJ6PU2-7(DC24 V) PJ6PU2-6(GND)

PWB-C
PJ2IC-1 PJ2IC-2 PJ2IC-3 PJ2IC-4 PJ2IC-5 PJ2IC-6 PJ2IC-7 PJ2IC-8 PJ3IC-1(U) PJ3IC-2(V) PJ3IC-3(W) PJ2C-9A(GND) PJ2C-8A(RESET) PJ2C-7A(ENABLE) PJ2C-6A(M1 CRNT SW2) PJ2C-5A(M1 CRNT SW1) PJ2C-4A(HOLD) PJ2C-2A(CW/CCW) PJ2C-1A(CLK)

PJ38 M1
1 2 3

PJ26 PC24
3 2 1 PJ6C-1(GND) PJ6C-2(DC24V) PJ6C-3(DC 5V)

4004C11TAA

4004C11TAA

T-63

C0650, C0660 Step 1 2 3 4 Wire comes off. Screw of scanner motor loose. Tension in scanner belt. Connectors are connected properly on Scanner Motor Drive Board: PWB-IC PJ1IC, PJ2IC, and PJ3IC. Scanner Motor turns when the Start key is pressed. I/O check for Scanner Home Sensor: the voltage across PJ6C-2 on Image Processing Board and GND is DC 0 V (home position) when the sensor is blocked and DC 5 V when the sensor is unblocked. IR Area check: Malfunction when Power Switch is turned ON after Top Image has been set to 0 and FD-Mag. to 1.000. Check Item Result YES YES NO NO Wind wire. Correct. Adjust belt tension. Check connectors for connection. Check connectors for connection. Change motor. Change Scanner Motor Drive Board. Change Image Processing Board. Check sensor for installation. Correct detecting plate. Check sensor connector for connection. Change sensor. Adjust IR Area data. Action

NO

YES NO

NO

T-64

(12) C0990: LCC Lift-Up Motor malfunction C0991: LCC Lift 1 ascent motion failure C0995: LCC Transport Motor malfunction C0999: LCC Lift 2 ascent motion failure Relevant Electrical Parts LCC Set Sensor (FRONT) Lift-Up Sensor 1 (LS1) Lift-Up Sensor 2 (LS2) LCC Transport Motor (HMOT) LCC Lift-Up Motor (EMOT) LCC Control Board (PWB-A)

PJ6 LS1
1 2 3

PWB-A
CN4A-6(LS1 ON) CN4A-5(GND) CN4A-4(DC5 V)

PJ5 LS2
1 2 3 CN4A-9(LS2 ON) CN4A-8(GND) CN4A-7(DC5 V)

CN17 E MOT PJ3 H MOT

1 2 3 4 5 6 CN6A-6(H MOT CLK) CN6A-5(DC5 V) CN6A-4(H MOT SIG) CN6A-3(GND) CN6A-1(DC24 V) 1 2 2 1 CN5A-2(E MOT/CCW) CN5A-1(E MOT/CW)

PJ1 FRONT
1 2 3 CN6A-9(FRONT ON) CN6A-8(GND) CN6A-7(DC5 V)

4004C12TAA

T-65

C0990 Step 1 Check Item LCC Lift-Up Motor turns after the LCC Drawer has been slid into position while the LCC Drawer is being used. Result NO Action Change motor. Change LCC Control Board.

C0991 Step 1 Check Item Lift 1 ascends after the LCC Lift-Up Motor has been energized. Result NO Action Correct drive coupling (oneway gear engagement, coupling engagement, spring operation, and belt tension). Change LCC Control Board. Check sensor for installation. Check sensor connector for connection. Change sensor.

I/O check for Lift-Up Sensor 1 operation: the voltage across CN4A-6 on LCC Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (during lifting motion detection).

YES NO

C0995 Step 1 Check Item LCC Lift-Up Motor turns when the Start key is pressed while the LCC Drawer is being used. Result NO Action Change motor. Change LCC Control Board.

C0999 Step 1 Check Item Lift 2 ascends after the LCC Lift-Up Motor has been energized. Result NO Action Correct drive coupling (oneway gear engagement, coupling engagement, spring operation, and belt tension). Change LCC Control Board. Check sensor for installation. Check sensor connector for connection. Change sensor.

I/O check for Lift-Up Sensor 2 operation: the voltage across CN4A-9 on LCC Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (during lifting motion detection).

YES NO

T-66

(13) C0F30: Abnormally low toner density detected by Cyan ATDC Sensor/ C0F31: Abnormally high toner density detected by Cyan ATDC Sensor C0F32: Abnormally low toner density detected by Magenta ATDC Sensor/ C0F33: Abnormally high toner density detected by Magenta ATDC Sensor C0F34: Abnormally low toner density detected by Yellow ATDC Sensor/ C0F35: Abnormally high toner density detected by Yellow ATDC Sensor Relevant Electrical Parts ATDC Sensor C (PWB-N3) ATDC Sensor M (PWB-N2) ATDC Sensor Y (PWB-N1) Toner Replenishing Motor C/Bk (M9) Toner Replenishing Motor Y/M (M10) Master Board (PWB-I)

CN72 CN35 M10

1 2 3 4 4 3 2 1 1 10 7 8 9 10 4 3 2 1

PWB-I
PJ5I-7A(A-A1) PJ5I-8A(A-A3) PJ5I-9A(B-B1) PJ5I-10A(B-B3)

CN36 M9
1 2 3 4 4 3 2 1 PJ5I-1B(A-A1) PJ5I-2B(A-A3) PJ5I-3B(B-B1) PJ5I-4B(B-B3)

PWB-N1
PJ88N1-4(TH1 OUT) PJ88N1-3(GND) PJ88N1-2(DC5 V) PJ88N1-1(UN33 REM)

CN50
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 PJ7I-1A(TH1 OUT) PJ7I-2A(GND) PJ7I-3A(DC5 V) PJ7I-4A(UN33 REM) PJ7I-5A(TH2 OUT) PJ7I-6A(GND) PJ7I-7A(DC5 V) PJ7I-8A(UN34 REM) PJ7I-9A(TH3 OUT) PJ7I-10A(GND) PJ7I-11A(DC5 V) PJ7I-12A(UN35 REM)

PWB-N2
PJ89N2-4(TH2OUT) PJ89N2-3(GND) PJ89N2-2(DC5 V) PJ89N2-1(UN34 REM)

PWB-N3
PJ90N3-4(TH3 OUT) PJ90N3-3(GND) PJ90N3-2(DC5 V) PJ90N3-1(UN35 REM)

4004C13TAA 4004C13TAA

T-67

C0F30, C0F32, C0F34 Step 1 2 3 4 5 Check Item Image density is low. ATDC Sensor spring moving part operates properly. ATDC Sensor LED is dirty. ATDC Sensor LED emits light properly. The problem has been eliminated through the checks of steps up to 4. Result YES NO YES NO NO T-101 Correct. Clean. Check connector for connection. Check harness. Change Master Board. Replace ATDC sensor and IU. Action

C0F31, C0F33, C0F35 Step 1 2 3 Check Item ATDC Sensor window is dirty. Bias voltage is properly applied to the ATDC Sensor window. The problem has been eliminated through the checks of steps up to 2. Result YES NO NO Clean. Check wiring. Check contact section. Change Master Board. Action

T-68

(14) C0F36: Abnormally low toner density detected by Black ATDC Sensor/ C0F37: Abnormally high toner density detected by Black ATDC Sensor Relevant Electrical Parts Imaging Unit Bk Toner Replenishing Motor C/Bk (M9) Master Board (PWB-I)

CN36 M9
1 2 3 4 4 3 2 1

PWB-I
PJ5I-1B(A-A1) PJ5I-2B(A-A3) PJ5I-3B(B-B1) PJ5I-4B(B-B3)

Imaging Unit (Bk)

PJ13I-4B PJ13I-3B PJ13I-5B PJ13I-6B

4004C26TAB

C0F36 Step 1 2 3 Check Item Image density is low. The problem has been eliminated through the check of step 1. The problem has been eliminated through the check of step 2. Result YES NO NO T-101 Check and correct Hopper. Change Master Board. Action

C0F37 Step 1 2 3 Check Item Imaging Unit Bk is installed correctly. Each of Imaging Unit Bk contacts makes good contact. ATDC Sensor harness is open-circuited. Result NO NO YES Action Check and correct ATDC drawer CN of imaging unit Bk. Clean or correct. Change Imaging Unit Bk.

T-69

(15) C0F3A: Cyan ATDC Sensor adjustment failure C0F3B: Magenta ATDC Sensor adjustment failure C0F3C: Yellow ATDC Sensor adjustment failure C0F3D: Black ATDC Sensor adjustment failure Relevant Electrical Parts ATDC Sensor C (PWB-N3) ATDC Sensor M (PWB-N2) ATDC Sensor Y (PWB-N1) Imaging Unit Bk
CN72 CN35 M10
1 2 3 4 4 3 2 1 1 10 7 8 9 10 4 3 2 1

Toner Replenishing Motor C/Bk (M9) Toner Replenishing Motor Y/M (M10) Master Board (PWB-I)

PWB-I
PJ5I-1B(A-A1) PJ5I-2B(A-A3) PJ5I-3B(B-B1) PJ5I-4B(B-B3)

CN36 M9
1 2 3 4 4 3 2 1 PJ5I-7A(A-A1) PJ5I-8A(A-A3) PJ5I-9A(B-B1) PJ5I-10A(B-B3)

PWB-N1
PJ88N1-4(TH1 OUT) PJ88N1-3(GND) PJ88N1-2(DC5 V) PJ88N1-1(UN33 REM)

CN50
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1 PJ7I-1A(TH1 OUT) PJ7I-2A(GND) PJ7I-3A(DC5 V) PJ7I-4A(UN33 REM) PJ7I-5A(TH2 OUT) PJ7I-6A(GND) PJ7I-7A(DC5 V) PJ7I-8A(UN34 REM) PJ7I-9A(TH3 OUT) PJ7I-10A(GND) PJ7I-11A(DC5 V) PJ7I-12A(UN35 REM)

PWB-N2
PJ89N2-4(TH2OUT) PJ89N2-3(GND) PJ89N2-2(DC5 V) PJ89N2-1(UN34 REM)

PWB-N3
PJ90N3-4(TH3 OUT) PJ90N3-3(GND) PJ90N3-2(DC5 V) PJ90N3-1(UN35 REM)

Imaging Unit (Bk)

PJ13I-4B PJ13I-3B PJ13I-5B PJ13I-6B

4004C25TAC

T-70

C0F3A, C0F3B, C0F3C Step 1 2 3 4 5 6 Check Item ATDC Sensor window is dirty. Imaging Unit window for ATDC Sensor is dirty. LED retracting lever is locked in position. The problem has been eliminated through the checks of steps up to 3. The problem is eliminated after the ATDC Sensor has been replaced. The problem is eliminated after the Imaging Unit has been replaced. Result YES YES NO NO NO NO Clean. Clean. Slide out the Imaging Unit and then reinstall. Check ATDC Sensor connector. Change ATDC Sensor. Change Imaging Unit. Change Master Board. Action

COF3D Step 1 2 3 Check Item Imaging unit Bk is installed correctly. Trouble in COF3D is indicated again. The problem is eliminated after the Imaging Unit has been replaced. Result NO YES NO Action Check and correct ATDC drawer CN of imaging unit Bk. Change Imaging Unit. Check harness. Check connector for connection. Change Master Board.

(16) C13C8: New Transfer Belt Unit resetting failure C13CA: New Fusing Unit resetting failure C13CB: New Fusing Web Unit resetting failure C13CC: New Oil Coating Unit resetting failure C13C8, C13CA, C13CB, C13CC Step 1 Check Item Each unit is installed properly in the copier (good contact connection). Result YES NO Reinstall. Action Change Master Board.

T-71

(17) C13D1: Cyan IU EEPROM failure C13D2: Magenta IU EEPROM failure C13D3: Yellow IU EEPROM failure C13D4: Black IU EEPROM failure C13D1, C13D2, C13D3, C13D4 Step 1 2 3 4 Check Item Imaging Unit is installed properly. Connector between the Imaging Unit and copier is dirty. The problem has been eliminated through the checks of steps up to 2. The problem is eliminated after the Imaging Unit has been replaced. Result NO YES NO NO Reinstall. Clean. Change Imaging Unit. Change Master Board. Action

T-72

(18) C3310: CCD clamp/gain adjustment failure Relevant Electrical Parts Exposure Lamp (LA1) Flat Cable (PWB-Z) Clamp/Gain Adjustment Values RO Clamp Gain Lamp Adjustment Value 130 RO 160 RE 130 RE 160 GO 130 GO 170 135 GE 130 GE 170 BO 130 BO 160 BE 130 BE 160 CCD Sensor Board (PWB-A) Image Processing Board (PWB-C)

Clamp: Allowable up to 100 of the above values. Gain: Allowable up to 90 of the above values for R and B; allowable up to 50 of the above values for G. Exposure Lamp adjustment value: Allowable in the range between 64 and 192. A difference of up to 30 is allowed between RO and RE, between GO and GE, and between BO and BE. C3310 Step 1 2 Check Item There is a wide difference between the clamp and gain adjustment values, the value being close to 0 or 255. Clamp adjustment value exceeds the allowable range. The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great. The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small. Result YES Action Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board. Reinstall covers, as extraneous light is the cause of the problem. Clean lens, mirrors, CCD surface, shading sheet, and related parts. Reinstall covers, as extraneous light is the cause of the problem. Change Scanner, as the reflectors are deformed.

Check that each of the values displayed on the screen falls within the above range.

YES

YES

YES

T-73

(19) C3700: IR Cooling Fan Motor 1 turning at abnormal timing C3710: IR Cooling Fan Motor 2 turning at abnormal timing C3720: Original Glass Cooling Fan Motor turning at abnormal timing Relevant Electrical Parts IR Cooling Fan Motor 1 (M3) IR Cooling Fan Motor 2 (M4) Original Glass Cooling Fan Motor (M2) Image Processing Board (PWB-C) DC Power Supply 2 (PU2)

CN3 M2
1 2 3 3 2 1

PWB-C
PJ2C-4B(M2 REM) PJ2C-5B(GND) PJ2C-6B(M2 LOCK)

CN2 M3
1 2 3 3 2 1 PJ6C-4(M3 REM) PJ6C-5(GND) PJ6C-6(M3 LOCK)

CN22 M4
1 2 3 3 2 1 PJ6C-7(M4 REM) PJ6C-8(GND) PJ6C-9(M4 LOCK) PJ1C-2 PJ1C-1

PU2
PJ4PU2-1(DC24 V) PJ4PU2-4(GND)
4004C19TAB

C3700 Step 1 Check Item IR Cooling Fan Motor 1 rotation: the voltage across PJ6C-6 on Image Processing Board and GND remains DC 0 V while the motor is turning. Result YES NO Action Change Image Processing Board. Change motor.

C3710 Step 1 Check Item IR Cooling Fan Motor 2 rotation: the voltage across PJ6C-9 on Image Processing Board and GND remains DC 0 V while the motor is turning. Result YES NO Action Change Image Processing Board. Change motor.

C3720 Step 1 Check Item Original Glass Cooling Fan Motor rotation: the voltage across PJ2C-6B on Image Processing Board and GND remains DC 0 V while the motor is turning. Result YES NO Action Change Image Processing Board. Change motor.

T-74

(20) C3A00: PIC communication error C3A01: PIC Board malfunction C3FFF: ROM contents fault detected upon start C3A00 Step 1 Check Item Harnesses and connectors connecting PIC Board to Master Board are in good condition. The problem has been eliminated through the check of step 1. The problem is eliminated after the PIC Board has been replaced. Result NO Action Change harnesses. Reconnect connectors. Change PIC Board. Change Master Board.

2 3

NO NO

C3A01 Step 1 Check Item The same malfunction recurs even after the malfunction has been reset, Power Switch turned OFF and ON, and the power cord plugged out and back in. Result YES Action Change PIC Board.

C3FFF Step 1 Check Item This malfunction occurs when an attempt is made to update firmware (rewriting of flash ROM). The problem has been eliminated through the check of step 1. Result YES Action Try downloading again.

NO

Change Master Board.

T-75

3-4.
(1)

Malfunctions related to power supply

Power is not turned ON. Relevant Electrical Parts

DC power supply 2 (PU2)

Step 1 2 3

Check Item Power cooling fan rotates when main switch is turned ON. Power voltage is applied to IR power plug when main switch is turned ON. Scanner operates and exposure lamp lights when main switch is turned ON.

Result NO NO NO YES T-77 T-78-1

Action

Replace power supply 2. T-78-2

T-76

(2)

Engine and IR are not turned ON. Relevant Electrical Parts

Master Board (PWB-1)

DC power supply 1 (PU1)

PWB-I PJ1I-7
PJ1I-6

PJ11PU1-12 (DC5 V) PJ11PU1-2 (DC5 V)

PU1

CN88
N

CN12
Bk W 1 1 2 2 PJ3PU1-1 PJ3PU1-2

PG1

4004C31TAB

Step 1 2 3 4 5

Check Item Power voltage is supplied to power outlet. Power voltage is supplied to PJ3PU1 and 2 on DC power supply 1. Fuse (F1) on DC power supply 1 is conducting. DC 5 V is output from PJ11PU1-2/12 on DC power supply 1. DC 5 V is input to PJ1I-6/7 on master board.

Result NO NO NO NO NO

Action Secure power supply. Check wiring between power outlet and PJ3PU1. Replace DC power supply 1.

Replace DC power supply 1. Check wiring between PJ11PU1 on DC power supply and PJ1I on master board. Replace master board.

YES

T-77

(3)

No Power is Supplied to Options. Relevant Electrical Parts

DC Power Supply 1 (PU1)

DC Power Supply 2 (PU2)

PU1
PJ5PU1-2(DC24 V) PJ5PU1-3(GND)

Sorter
CN60-11 CN60-5

L N
PJ5PU1-4(GND) PJ5PU1-5(DC24 V)

Duplex
CN62-2 CN62-1

Tray
PJ5PU1-6(DC24 V) PJ7PU1-5(GND) CN82-1 CN83-1 CN82-2 CN83-2

PU2
PJ5PU2-1(DC24 V) PJ5PU2-2(GND)

ADF
CN5-11 CN5-5
4004C28TAA

Step 1 2 3

Check Item Power source voltage is applied to DC Power Supply 1. DC 24 V is output from DC Power Supply 1 and DC Power Supply 2. There is an open-circuit in the harness from DC Power Supply 1 and DC Power Supply 2 to option connector.

Result NO NO YES

Action Check wiring. Change DC Power Supply 1. Change DC Power Supply 2. Change harness.

T-78

(3)

Only power cooling fan rotates. Relevant Electrical Parts

MSC Board (PWB-H) PIC Board (PWB-PIC)

DC power supply 1 (PU1)

PU1
PJ10PU1-6 (DC3.3 V) PJ10PU1-7 (DC3.3 V) PJ9PU1-6 (DC5 V) PJ8PU1-5 (DC5 V) PJ8PU1-6 (DC5 V)

PWB-H
PJ1H-1 PJ1H-2

PWB-PIC
PJPWR1-6 PJPWR1-5 PJPWR1-2 PJPWR1-1 PJPWR2-6

4004C32TAB

Step 1 2

Check Item Fuses (F2, F3) on DC power supply 1 are conducting. DC5 V is output from PJ8PU1-6 and PJ9PU1-6 on DC power supply 1, and DC 3.3 V is also output from PJ10PU1-6. DC3.3 V is input to PJ1H-1 on MSC board, and DC5 V is also input to PJ1H-2. DC5 V is input to PJPWR1-1/2 on PIC board, and DC3.3 V is also input to PJPWR1-5/6.

Result NO NO

Action Replace DC power supply 1. Replace DC power supply 1.

NO

Check wiring between PJ9/10 on DC power supply 1 and PJ1 on MSC board. Check wiring between PJ8/10 on DC power supply 1 and PJPWR1 on PIC board. Replace MSC board or PIC board.

NO

YES

T-78-1

(4)

Control panel indicators do not light. Relevant Electrical Parts

Master Board (PWB-1) MSC Board (PWB-H) IR PRIF board (PWB-D)

DC power supply 1 (PU1) PIC Board (PWB-PIC) Control panel (UN1)

Step 1 2 3 4 5

Check Item I/F cable between IR and engine is securely set. Fuse (F103) on DC power supply 1 is conducting. PJ18 on master board is securely set. Flat cable between MSC board and PIC board is securely set. PJ30 on control panel and PJ3 on IR PRIF board are securely set.

Result NO NO NO NO NO YES

Action Reset, or replace I/F cable. Replace DC power supply 1. Reset. Reset or replace flat cable. Reset. Replace master board, PIC board, IR PRIF board, MSC board or control panel.

T-78-2

4.
4-1.

IMAGE QUALITY PROBLEMS

Troubleshooting Image Quality Problems

This chapter is divided into two parts: Initial Check Items and Troubleshooting Procedure by a Particular Image Quality Problem. When an image quality problem occurs, first go through the Initial Check Items and, if the cause is yet to be identified, go to Troubleshooting Procedure by a Particular Image Quality Problem.

4-2.

Initial Check Items

1. First determine which of the following three is responsible for the image quality problem: the input system (IR), interface system, or the output system (printer). When an image quality problem occurs, possible causes that are likely to be responsible for it may be broadly grouped into the following three: those relating to the Scanner of the IR unit, the interface between the IR unit and printer, and the printer. As a procedure to isolate basic causes, you first let the printer produce test prints. If the image quality problem of the same sort is evident on the test patterns, then the printer is very likely to be responsible for it. If not, the cause is attributable to the Scanner of the IR unit or the interface. The next step to take to identify whether the problem is attributable to the IR Scanner or the interface is to produce IR test prints. If the problem of the same sort is evident on the test patterns, then the interface is probably responsible for it. If the same symptom does not occur on the test prints, then the IR Scanner is responsible for the problem.

IR Area

CCD Sensor

Image Processing Boad

IR Test print

I/F Area

I/F Cable

PIC Board

Printer Test print

Printer Area

LED Drive

4004T006CA

T-79

Step

Symptom

Check The faulty symptom occurs when a test print is produced with the following settings made: Test Print Gradation Pattern 4 Color. The faulty symptom occurs when a test print is produced with the following settings made: Test Print Halftone Pattern C M Y Bk Enter 64 in Density. Select Hyper. The faulty symptom occurs when a test print is produced with the following settings made: Test Print Halftone Pattern C M Y Bk Enter 0 in Density.

Result YES NO YES

Cause Printer To step 2 Printer

Ref. Page T-96

Gradation failure, density failure Uneven density, pitch noise, or image noise (lines, bands, spots, etc.)

T-96

NO

To step 2

YES

Printer

T-96

Foggy background

NO

To step 2

The faulty symptom occurs when a test print is produced with the Color reproducfollowing settings made: Test tion failure Print Color Sample Enter 255 in Density. Abnormal image The faulty symptom occurs when a test print is produced with the following settings made: Test Print IR Test Pattern.

YES NO YES NO

Printer To step 2 Interface IR

T-96

T-93 T-82

T-80

2. If the output system (printer) is responsible for the image quality problem, determine if it occurs with a single color of Y, M, C, or Bk, or four colors. By rule of thumb, if the problem occurs with a single color, the corresponding Imaging Unit is very likely to be faulty. If the problem occurs with four colors, the Transfer Belt and/or Fusing Unit are probably defective. The same problematic symptom occurs with each of the four colors, then the Transfer Belt, Image Transfer Rollers, and/or the Fusing Unit are responsible for it. If the symptom occurs with a single color, each Imaging Unit is responsible for it.

4 colors

Mono color

4004T008CA

Step

Symptom

Check The faulty symptom occurs with each of the four colors when a test print is produced with the following settings made: Test Print Gradation Pattern 4 Color. The faulty symptom occurs with each of the four colors when a test print is produced with the following settings made: Test Print Halftone Pattern C M Y Bk Enter 64 in Density. Select Hyper. he faulty symptom occurs with each of the four colors when a test print is produced with the following settings made: Test Print Halftone Pattern C M Y Bk Enter 0 in Density.

Result YES

Cause Printer 4 color Printer monocolor Printer 4 color Printer monocolor Printer 4 color Printer monocolor

Ref. Page T-114 T-96 T-114

Gradation failure, density failure

NO

Uneven density, pitch noise, or image noise (lines, bands, spots, etc.)

YES

NO

T-96

YES

T-114

Foggy background

NO

T-96

T-81

4-3.
(1)

Troubleshooting Procedure by a Particular Image Quality Problem

IR Scanner System: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD <Typical Faulty Images>

White lines in FD

White bands in FD

Colored lines in FD

Colored bands in FD

4011T015AA

4011T020AA

4011T017AA

4011T023AA

<Troubleshooting Procedure> Section Original Original Cover Original Glass Shading sheet Mirror, lens, Exposure Lamp, and reflectors System setting Left Image (Tech. Rep. function) IR Step 1 2 3 4 5 Check Item Original is damaged or dirty. Original Pad is dirty. Original Glass is dirty. Shading sheet is dirty. Mirror is dirty. Lens is dirty. Exposure Lamp is dirty. Reflectors are dirty. 6 7 S/No. of IR is correctly input. The Scanner starts reading the image at the position of 0 mm from the scale. The white lines/bands or colored lines/bands are blurry. The white lines/bands or colored lines/bands are clear and distinct. Result YES YES YES YES YES YES YES YES NO NO Clean. Wipe the surface clean with a soft cloth. Wipe the surface clean with a soft cloth. Clean. Clean. Clean. Clean. Re-input. Adjust the image reading position in the range of 10 mm. Change Scanner Assy. Change CCD Unit. Action Change original.

8 9

YES YES

T-82

(2)

IR Scanner System: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD <Typical Faulty Images> White lines in CD White bands in CD Colored lines in CD Colored bands in CD

4011T016AA

4011T021AA

4011T018AA

4011T022AA

<Troubleshooting Procedure> Section Original Original Cover Original Glass Flat cable Top Image (Tech. Rep. function) IR Step 1 2 3 4 5 Check Item Original is damaged or dirty. Original Pad is dirty. Original Glass is dirty. Flat cable terminal is connected properly. The Scanner starts reading the image at the position of 0 mm from the scale. The problem has been eliminated through the checks of steps up to 5. The problem is eliminated after the Scanner Assy has been replaced. Result YES YES YES NO NO Clean. Wipe the surface clean with a soft cloth. Clean terminal. Reconnect. Change flat cable. Adjust the image reading position in the range of 10 mm. Change Scanner Assy. Action Change original.

NO

NO

Change CCD Unit.

T-83

(3)

IR Scanner System: color spots <Typical Faulty Image> Color spots

CF
4011T027AA

<Troubleshooting Procedure> Section Original Original Cover Original Glass IR Step 1 2 3 4 Check Item Original is damaged or dirty. Original Pad is dirty. Original Glass is dirty. The problem has been eliminated through the checks of steps up to 3. The problem is eliminated after the Scanner Assy has been replaced. Result YES YES YES NO Clean. Wipe the surface clean with a soft cloth. Change Scanner Assy. Action Change original.

NO

Change CCD Unit.

T-84

(4)

IR Scanner System: fog <Typical Faulty Image> Fog

4011T004AA

<Troubleshooting Procedure> Section Warning display Step 1 Check Item Maintenance call mark S-2 (intensity adjustment failure) is displayed. Maintenance call mark S-1 (gain adjustment failure) is displayed. Original is damaged or dirty. Original Pad is dirty. Original Cover does not lie flat. Result YES Action Carry out remedial action procedures for S-2 as part of image stabilizer malfunction troubleshooting procedures. Carry out remedial action procedures for S-1 as part of image stabilizer malfunction troubleshooting procedures. Change original. Clean. Change Original Cover if it is deformed or hinges are broken. Wipe the surface clean with a soft cloth. Wipe the surface clean with a soft cloth. Clean. Clean. Clean. Clean. Change the exposure mode to Manual.

YES

Original Original Cover

3 4 5

YES YES YES

Original Glass Shading sheet Mirror, lens, Exposure Lamp, and reflectors Exposure setting (panel setting)

6 7 8

Original Glass is dirty. Shading sheet is dirty. Mirror is dirty. Lens is dirty. Exposure Lamp is dirty. Reflectors are dirty.

YES YES YES YES YES YES NO

The problem is eliminated after the exposure mode has been changed to Auto.

T-85

Section IR

Step 10

Check Item The problem has been eliminated through the checks of steps up to 9. The problem is eliminated after the Scanner Assy has been replaced.

Result NO

Action Change Scanner Assy.

11

NO

Change CCD Unit.

T-86

(5)

IR Scanner System: blurred image, blotchy image <Typical Faulty Image> Blurred image, blotchy image

4011T046AA

<Troubleshooting Procedure> Section Original Cover Original Glass IR Step 1 Check Item Original Cover does not lie flat. Result YES Action Change Original Cover if it is deformed or hinges are broken. Position Original Glass correctly. Check original loading position. Readjust with the Scanner/ Mirrors Carriage Positioning Jigs. Change Scanner Assy.

Original Glass tilts.

YES

Scanner is not aligned with the 2nd/3rd Mirrors Carriage. The problem has been eliminated through the checks of steps up to 3. The problem is eliminated after the Scanner Assy has been replaced.

YES

NO

NO

Change CCD Unit.

T-87

(6)

IR scanner system: Color shift, sync shift (lines in CD) <Typical Faulty Image>

CF
4011T039AA

<Troubleshooting Procedure> Section Original Cover Slide rails Scanner assy Step 1 Check Item Original Cover does not lie flat. Result YES Action Change Original Cover if it is deformed or hinges are broken. Clean, lubricate. Adjust scanner motor belt tension. Replace bush. Replace scanner motor. Correct or change. Change CCD Unit.

2 3

Foreign matter on rails. Scanner assy moves smoothly.

YES NO

Drive Cables IR

4 5

Cable kinks or is damaged. The problem has been eliminated through the checks of steps up to 4.

YES NO

T-88

(7)

IR Scanner System: moire <Typical Faulty Image> Moire

4011T040AA

<Troubleshooting Procedure> Section Original Original Step 1 2 Check Item Moire distortions occur. Moire distortions recur even after the orientation of original has been changed. Moire distortions recur even after the original mode has been changed. The problem has been eliminated through the checks of steps up to 3. Result YES YES Action Change original loading direction. Change the original mode (select one other than that resulted in moire). Select Gradation (mode optimized for gradation) or Resolution (that optimized for resolution). Change the zoom ratio.

Mode change

YES

NO

T-89

(8)

IR Scanner System: skewed image <Typical Faulty Image> Skewed image

CF
4011T048AA

<Troubleshooting Procedure> Section Original Original Glass 2nd/3rd Mirrors Carriage IR Step 1 2 Check Item Original is skew. Original Glass is in positive contact with the flat spring without being tilt. Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage. The problem has been eliminated through the checks of steps up to 3. The problem is eliminated after the Scanner Assy has been replaced. Result YES NO Action Reposition original. Reinstall the glass. Check the original loading position. Readjust with the Scanner/ Mirrors Carriage Positioning Jigs. Change Scanner Assy.

YES

NO

NO

Change CCD Unit.

T-90

(9)

IR Scanner System: distorted image <Typical Faulty Image> Distorted image

ABCDE ABCDE ABCDE ABCDE ABCDE

4011T045AA

<Troubleshooting Procedure> Section Installation Step 1 Check Item IR is installed on a level surface if mounted without any rack. Rack is installed on a level surface. Rack is tilt with a lot of play. 2nd/3rd Mirrors Carriage Scanner Motor IR 2 Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage. Scanner Motor turns smoothly. The problem has been eliminated through the checks of steps up to 3. The problem is eliminated after the Scanner Assy has been replaced. Result NO Reinstall. Action

NO YES YES

Reinstall. Adjust rack legs. Readjust with the Scanner/ Mirrors Carriage Positioning Jigs. Change belt. Change Scanner Motor. Change Scanner Assy.

3 4

NO NO

NO

Change CCD Unit.

T-91

(10) IR Scanner System: low image density, rough image <Typical Faulty Image> Low image density

4011T003AA

<Troubleshooting Procedure> Section Warning display Step 1 Check Item Maintenance call mark S-2 (intensity adjustment failure) is displayed. Maintenance call mark S-1 (gain adjustment failure) is displayed. Original sticks to Original Glass. Original Glass is dirty. Shading sheet is dirty. Mirror is dirty. Lens is dirty. Exposure Lamp is dirty. Reflectors are dirty. Exposure Lamp IR 7 The problem has been eliminated through the check of step 6. The problem is eliminated after the Exposure Lamp has been changed. The problem is eliminated after the Scanner Assy has been changed. Result YES Action Carry out remedial action procedures for S-2 as part of image stabilizer malfunction troubleshooting procedures. Carry out remedial action procedures for S-1 as part of image stabilizer malfunction troubleshooting procedures. Reposition original. Wipe the surface clean with a soft cloth. Wipe the surface clean with a soft cloth. Clean. Clean. Clean. Clean. Clean or change Exposure Lamp. Change Scanner Assy.

YES

Original Original Glass Shading sheet Mirror, lens, Exposure Lamp, and reflectors

3 4 5 6

YES YES YES YES YES YES YES NO

NO

NO

Change CCD Unit.

T-92

(11) IR Scanner System: defective ACS <Typical Faulty Image> Defective ACS
CF

Colored Area of Original

ABCDE ABCDE ABCDE ABCDE ABCDE

4011T052AA

Black-and-White Area of Original

<Troubleshooting Procedure> Section ACS Determination Level Adjust (Users Choice function) Step 1 Check Item ACS failure occurs. The problem persists even after the ACS Determination Level Adjust function has been changed. Result YES YES Action Change ACS Determination Level Adjust function. Change the original loading direction. Make manual settings according to the type of original. (If the original contains a colored area in one of its corners, the copier may fail to properly detect the colored area.)

T-93

(12) IR Control System: blank copy, black copy <Typical Faulty Images> Blank copy Black copy

4011T036AA

4011T035AA

<Troubleshooting Procedure> Section Cable connecting IR and printer Image Processing Board Connection between IR and printer Image Processing Board PIC Board Step 1 Check Item Connector is connected properly with no pins bent. Connectors on the Image Processing Board are connected properly. The problem has been eliminated through the check using IR test pattern. The problem is eliminated after the I/F connection cable has been changed. The problem has been eliminated through the checks of steps up to 4. Result NO Reconnect. Action

NO

Reconnect.

NO

Change I/F connection cable.

NO

Change Image Processing Board. Change PIC Board.

NO

T-94

(13) IR Control System: abnormal image <Typical Faulty Images> Abnormal image Abnormal image Abnormal image

ABCDE ABCDE ABCDE ABCDE ABCDE

4004T010AB 4011T053AA

ABCDE ABCDE ABCDE

Data on previous page

CF
4011T063AA

Data on current page

<Troubleshooting Procedure> Section Cable connecting IR and printer Cable connection between Fiery I/F board and PIC board Image Processing Board PIC Board Step 1 Check Item Connector is connected properly with no pins bent. Connectors are securely set. Result NO Reconnect. Action

NO

Reconnect.

Connectors on the Image Processing Board are connected properly. If the copy contains part of data on the previous page together with that on the current page, the expanded memory (rim) is properly mounted to the PIC Board. The problem has been eliminated as checked on IR test prints produced. The problem is eliminated after the interface connection cable has been changed. The problem is eliminated through the checks of steps up to 6.

NO

Reconnect.

NO

Reinstall expanded memory.

Connection between IR and printer Image Processing Board PIC Board

NO

Change interface connection cable. Change Image Processing Board. Change PIC Board.

NO

NO

T-95

(14) Printer Monocolor: white lines in FD, white bands in FD, colored lines in FD, colored bands in FD, white lines in CD, white bands in CD, colored lines in CD, colored bands in CD <Typical Faulty Images> White lines in FD White bands in FD Colored lines in FD Colored bands in FD

4011T015AA

4011T020AA

4011T017AA

4011T023AA

White lines in CD White bands in CD Colored lines in CD Colored bands in CD

4011T016AA

4011T021AA

4011T018AA

4011T022AA

<Troubleshooting Procedure> Section Image check Imaging Unit LED Assy Imaging Unit Step 1 2 3 4 5 6 Check Item Line or band is sharp. Line or band continues edge to edge. The surface of the PC Drum is scratched. The surface of the lens array is dirty. Dirty on the outside. Connectors and contact terminals make good connection between each Imaging Unit and LED Assy. Developing bias contact terminal makes good connection. The problem has been eliminated through the checks of steps up to 7. Result YES YES YES YES YES NO Action Go to step 4 Go to step 3 Change Imaging Unit. Clean with cleaning jig. Clean. Clean contact terminals. Reconnect.

7 8

NO NO

Clean contact terminal and check terminal position. Change Imaging Unit.

T-96

Section Transfer Belt Unit LED Assy

Step 9

Check Item The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced.

Result NO

Action Change Transfer Belt Unit.

10

NO

Change LED Assy.

T-97

(15) Printer Monocolor: uneven density in FD <Typical Faulty Images> Uneven density in FD Uneven density in FD Uneven density in FD (Void areas)

4011T031AA 4011T042AA 4004T011AA

<Troubleshooting Procedure> Section Image check Step 1 2 LPH rank High image density original 3 4 Check Item Edge of uneven density area is sharp. Void areas are visible. Rank indication of LED assy matches LPH setting. Uneven density in FD occurs at a pitch of 40 mm to 50 mm when a multi-copy cycle is run using an original with high image density (50 % or more). LED retracting lever is locked in position. The surface of the PC Drum is scratched. Dirty on the outside. The surface of the lens array is dirty. Cam gear operates properly. The problem has been eliminated through the checks of steps up to 9. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. Result YES YES NO YES Action Go to step 4 Check LED unit connector. Replace LED assy. Reset LPH rank. Feed 10 to 20 blank sheets of paper with no originals placed, as the Imaging Unit fails to keep up with a high demand for toner. Slide out the Imaging Unit and reinstall. Change Imaging Unit. Clean. Clean with cleaning jig. Change Transfer Belt Unit. The problem is eliminated after the Imaging Unit has been replaced. Change Transfer Belt Unit.

LED Assy Imaging Unit LED Assy Transfer Belt Unit Imaging Unit Transfer Belt Unit LED Assy

5 6 7 8 9 10

NO YES YES YES NO NO

11

NO

12

NO

Change LED Assy.

T-98

Section LED Unit

Step 13

Check Item The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem of uneven density in CD is eliminated after the PIC Board has been replaced.

Result NO

Action Change LED Unit.

PIC Board

14

NO

Change PIC Board.

High Voltage Unit 2

15

NO

Change High Voltage Unit 2.

T-99

(16) Printer Monocolor: uneven density in CD <Typical Faulty Images> Uneven density in CD Uneven density in CD

4011T032AA

4011T043AA

<Troubleshooting Procedure> Section LED Assy Imaging Unit LED Assy Transfer Belt Unit Step 1 2 3 4 5 Check Item LED retracting lever is locked in position. The surface of the PC Drum is scratched. Dirty on the outside. The surface of the lens array is dirty. Transfer Belt Unit makes positive contact with plates on rails. Cam gear operates properly. The problem has been eliminated through the checks of steps up to 6. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem of uneven density in CD is eliminated after the PIC Board has been replaced. Result NO YES YES YES NO Action Slide out the Imaging Unit and reinstall. Change Imaging Unit. Clean. Clean with cleaning jig. Check and correct contacts.

6 Imaging Unit Transfer Belt Unit LED Assy 7

NO NO

Change Transfer Belt Unit. Change Imaging Unit.

NO

Change Transfer Belt Unit.

NO

Change LED Assy.

LED Unit

10

NO

Change LED Unit.

PIC Board

11

NO

Change PIC Board.

High Voltage Unit 2

12

NO

Change High Voltage Unit 2.

T-100

(17) Printer Monocolor: low image density <Typical Faulty Image> Low image density

4011T003AA

<Troubleshooting Procedure> Section Level History 1 (Tech. Rep. function) Step 1 2 3 Check Item Check ATDC data. AIDC output value is around 4.5 V. Check Vg and Vb values. Color Vb: Around 400 V Vg: Around 500 V Black Vb: Around 800 V Vg: Around 900 V Low ATDC and low Vg and Vb Low ATDC and high Vg and Vb ATDC falling within specified range and low Vg and Vb ATDC falling within specified range and high Vg and Vb LED Assy Imaging Unit 5 6 LED retracting lever is locked in position. Imaging unit, LED assy side connector and contact section are dirty. Dirty on the outside. The surface of the lens array is dirty. Color ATDC sensor windows and contacts on both LED assy side and IU side are dirty. Transfer Belt Unit makes positive contact with plates on rails. Cam gear operates properly. Shutters of IU and hopper open. Result NO Action Go to next step. Clean AIDC Sensor. Check Transfer Belt for damage. Go to next step.

Level History data check results

YES YES YES YES NO YES

Go to step 5. Go to step 12. Go to step 5. Go to step 9. Slide out the Imaging Unit and reinstall. Clean.

7 LED Assy ATDC Sensor window Transfer Belt Unit Imaging unit 8 9

YES YES YES

Clean. Clean with cleaning jig. Clean. Change ATDC. Change Imaging Unit. Check and correct contacts. Change Transfer Belt Unit. After re-set, replenish toner.

10 11 12

NO NO NO

T-101

Section Hopper Unit

Step 13 14 15

Check Item Connectors are loose. Gear is cracked. Toner empty lever and/or detecting switch are defective. T/C is normal after toner is replenished. Data after three cycles of Gradation Adjust falls within the specified range. Max: 0 100 Highlight = 0 60 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After the Reset + Stabilizer sequence has been completed, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Density and PRT Highlight. Thereafter, run Stabilizer again. The problem has been eliminated through the checks of steps up to 20. The problem has been eliminated through the checks of steps up to 21. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the PIC Board has been replaced.

Result YES YES YES NO Reconnect.

Action Replace gear or hopper unit. Replace hopper unit. Replace detecting switch. Replace toner replenishing motor or hopper unit. Run another cycle of Gradation Adjust. Go to next step if it does not still make data okay. Go to next step.

Toner replenishing Gradation Adjust (Tech. Rep. function) PRT Max Density (Tech. Rep. function) PRT Highlight (Tech. Rep. function) Reset + Stabilizer (Tech. Rep. function)

16

17

NO

18

NO

19

NO

Go to next step.

20

NO

Go to next step.

ATDC Sensor

21

NO

For color, change ATDC Sensor and Imaging Unit at once. For black, change Imaging Unit. Change Imaging Unit.

Imaging Unit Transfer Belt Unit LED Assy

22

NO

23

NO

Change Transfer Belt Unit.

24

NO

Change LED Assy.

LED Unit

25

NO

Change LED Unit.

PIC Board

26

NO

Change PIC Board.

High Voltage Unit 2

27

NO

Change High Voltage Unit 2.

T-102

(18) Printer Monocolor: gradation reproduction failure <Typical Faulty Images> Gradation reproduction failure Gradation reproduction failure

4011T034AA

4011T029AA

<Troubleshooting Procedure> Section Original mode LED Assy Imaging Unit Imaging Unit LED Assy ATDC Sensor window Step 1 2 3 4 5 6 Check Item Original type and screen pattern are selected properly. LED retracting lever is locked in position. Imaging Unit and LED Assy connectors are dirty. Dirty on the outside. The surface of the lens array is dirty. The color ATDC Sensor window on the LED Assy and the ATDC Sensor window on the Imaging Unit are dirty. AIDC output value is around 4.5 V. Result NO YES YES YES YES YES Action Change screen pattern. Slide out the Imaging Unit and reinstall. Clean. Clean. Clean with cleaning jig. Clean.

Level History 1 (Tech. Rep. Function) Gradation Adjust (Tech. Rep. function) PRT Max Density (Tech. Rep. function)

NO

Clean AIDC Sensor. Check Transfer Belt for damage.

Data after three cycles of Gradation Adjust falls within the specified range. Max: 0 100 Highlight = 0 60 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabilization.

NO

Run another cycle of Gradation Adjust. If the specifications are not met yet, go to next step. Go to next step.

NO

T-103

Section PRT Highlight (Tech. Rep. function) Reset + Stabilizer (Tech. Rep. function)

Step 10

Check Item After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After the Reset + Stabilizer sequence has been completed, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Density and PRT Highlight. Thereafter, run Stabilizer again. The problem has been eliminated through the checks of steps up to 11. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the PIC Board has been replaced.

Result NO

Action Go to next step.

11

NO

Go to next step.

Imaging Unit LED Assy

12

NO

Change Imaging Unit.

13

NO

Change LED Assy.

LED Unit

14

NO

Change LED Unit.

PIC Board

15

NO

Change PIC Board.

High Voltage Unit 2

16

NO

Change High Voltage Unit 2.

T-104

(19) Printer Monocolor: foggy background <Typical Faulty Image> Foggy background

4011T004AA

<Troubleshooting Procedure> Section Level History 1 (Tech. Rep. function) Step 1 2 3 Check Item ATDC data is within 1 % of the target value. AIDC output value is around 4.5 V. Vg and Vb values are correct. Color Vb: Around 400 V Vg: Around 500 V Black Vb: Around 800 V Vg: Around 900 V High ATDC and low Vg and Vb High ATDC and high Vg and Vb ATDC falling within specified range and low Vg and Vb ATDC falling within specified range and high Vg and Vb LED Assy Imaging Unit ATDC Sensor window High Voltage Unit 2 Gradation Adjust (Tech. Rep. function) 5 6 7 8 9 10 LED retracting lever is locked in position. Imaging Unit and LED Assy connectors are dirty. Dirty on the outside. The color ATDC Sensor window on the LED Assy is dirty. High Voltage Unit 2 connector is connected properly. Data after three cycles of Gradation Adjust falls within the specified range. Max: 0 100 Highlight = 0 60 Result NO NO NO Readjust. Clean AIDC Sensor. Check Transfer Belt for damage. Go to next step. Action

Level History data check results

YES YES YES YES NO YES YES YES NO NO

Go to step 16. Go to step 5. Go to step 20. Go to step 5. Slide out the Imaging Unit and reinstall. Clean. Clean. Clean. Change ATDC. Change Imaging Unit. Reconnect. Run another cycle of Gradation Adjust. Go to next step if it does not still make data okay.

T-105

Section Background Voltage Margin (Tech. Rep. function) PRT Max Density (Tech. Rep. function) PRT Highlight (Tech. Rep. function) Reset + Stabilizer (Tech. Rep. function)

Step 11

Check Item After Background Voltage Margin has been adjusted, run Stabilizer to reflect the adjustment value in image stabilization. After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After the Reset + Stabilizer sequence has been completed, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Density and PRT Highlight. Thereafter, run Stabilizer again. The problem has been eliminated through the checks of steps up to 14. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after High Voltage Unit 2 has been replaced.

Result NO

Action Go to next step.

12

NO

Go to next step.

13

NO

Go to next step.

14

NO

Go to next step.

Imaging Unit LED Assy

15

NO

Change Imaging Unit.

16

NO

Change LED Assy.

High Voltage Unit 2 PIC Board

17

NO

Change High Voltage Unit 2.

18

NO

Change PIC Board.

T-106

(20) Printer Monocolor: void areas, white spots <Typical Faulty Images> Void areas White spots

4011T008AA 4011T030AA

<Troubleshooting Procedure> Section Image check Imaging Unit Imaging Unit Hopper Unit Imaging Unit LED Assy Step 1 Check Item There are void areas at the front side or high density section. The surface of the PC Drum is scratched. Dirty on the outside. Foreign matter or caked toner in the Hopper. The problem has been eliminated through the checks of steps up to 4. The problem is eliminated after the Imaging Unit has been replaced. Result NO T-101 Action

2 3 4 5

YES YES YES NO

Change Imaging Unit. Clean. Remove foreign matter. Change Imaging Unit.

NO

Change LED Assy.

T-107

(21) Printer Monocolor: colored spots <Typical Faulty Image> Colored spots

CF
4011T027AA

<Troubleshooting Procedure> Section Imaging Unit Step 1 2 3 LED Assy Imaging Unit LED Assy 4 5 Check Item Developing bias contact terminal makes good connection. The surface of the PC Drum is scratched. Dirty on the outside. The surface of the lens array is dirty. The problem has been eliminated through the checks of steps up to 4. The problem is eliminated after the Imaging Unit has been replaced. Result NO YES YES YES NO Action Clean contact terminal and check terminal position. Change Imaging Unit. Clean. Clean with cleaning jig. Change Imaging Unit.

NO

Change LED Assy.

T-108

(22) Printer Monocolor: blurred image <Typical Faulty Image> Blurred image

4011T046AA

<Troubleshooting Procedure> Section LED Assy Step 1 2 3 Imaging Unit 4 5 Check Item LED retracting lever is locked in position. The surface of the lens array is dirty. LED Unit positioning pin is loose. Dirty on the outside. The problem has been eliminated through the checks of steps up to 4. The problem is eliminated after the Imaging Unit has been replaced. Result NO YES YES YES NO Action Slide out the Imaging Unit and reinstall. Clean with cleaning jig. Change LED Assy. Clean. Change Imaging Unit.

LED Assy

NO

Change LED Assy.

T-109

(23) Printer Monocolor: blank copy, black copy <Typical Faulty Images> Blank copy Black copy

4011T035AA

4011T036AA

<Troubleshooting Procedure> Section Imaging Unit Step 1 Check Item Coupling of Imaging Unit drive mechanism is installed properly. The PC Drum Charge Corona voltage contact or PC Drum ground contact of the Imaging Unit is connected properly. Connector is connected properly. The problem has been eliminated through the check of step 3. The problem is eliminated after High Voltage Unit 2 has been replaced. The problem is eliminated after the PIC Board has been replaced. Result NO Action Check and correct drive transmitting coupling. Change Imaging Unit. Check, clean, or correct the contact.

NO

High Voltage Unit 2

3 4

NO NO

Reconnect. Change High Voltage Unit 2.

PIC Board

NO

Change PIC Board.

LED Unit

NO

Change LED Unit.

T-110

(24) Printer Monocolor: 0.5 to 1.0-mm-pitch uneven image <Typical Faulty Image> 0.5 to 1.0-mm-pitch uneven image

4004T012CA

<Troubleshooting Procedure> Section LED Assy Imaging Unit LED Assy Step 1 2 Check Item LED retracting lever is locked in position. The problem has been eliminated through the check of step 1. The problem is eliminated after the Imaging Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. Result NO NO Action Slide out the Imaging Unit and reinstall. Change Imaging Unit.

NO

Change LED Assy.

LED Unit

NO

Change LED Unit.

T-111

(25) Printer Monocolor: 2-mm-pitch uneven image <Typical Faulty Image> 2-mm-pitch uneven image

2 mm

4011T059AA

<Troubleshooting Procedure> Section Imaging Unit Step 1 Check Item The drive mechanisms for spent toner conveying and Imaging Unit are dirty. The problem has been eliminated through the check of step 1. Result YES Clean. Action

NO

Change Imaging Unit.

T-112

(26) Printer Monocolor: 94-mm-pitch uneven image <Typical Faulty Images> 94-mm-pitch uneven image 94-mm-pitch uneven image 94-mm-pitch uneven image

94 mm

94 mm

94 mm

4011T047AD

4011T057AA

4011T058AA

<Troubleshooting Procedure> Section Imaging Unit Step 1 2 3 Check Item The surface of the PC Drum is scratched. 94-mm-pitch uneven image occurs on the image. The problem has been eliminated through the checks of steps up to 2. Transfer Belt Unit drive gear is intact. Transfer Roller is damaged. Result YES YES NO Action Change Imaging Unit. Store the Imaging Unit in a dark place overnight. Change Imaging Unit.

Transfer Belt Unit Transfer Roller Unit

4 5

NO YES

Correct. Change Transfer Belt Unit. Change Transfer Roller Unit.

T-113

(27) Printer 4-Color: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD <Typical Faulty Images> White lines in FD White bands in FD Colored lines in FD Colored bands in FD

4011T015AA

4011T020AA

4011T017AA

4011T023AA

<Troubleshooting Procedure> Section Transfer Belt Unit Step 1 Check Item Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Cleaning Blade is not effective in removing toner completely. Transfer Roller is dirty or scratched. There is foreign matter on paper path. Image Transfer Paper Separator Fingers are damaged or dirty. Paper dust accumulates on Paper Dust Remover. Fusing Belt is dirty or scratched. Fusing Entrance Guide Plate is dirty or damaged. Fusing Paper Separator Fingers are dirty. Web is properly taken up. Oil exudes more than appropriate. Result YES Action Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean or change Transfer Belt Unit. Change Transfer Roller Unit. Remove foreign matter. Clean or change.

YES

3 Transfer Roller Unit Paper path 4 5 6

YES YES YES YES

7 Fusing Unit 8 9 10 Fusing Web Unit Oil Coating Unit 11 12

YES YES YES YES NO YES

Clean. Change Fusing Unit. Clean or change. Clean. Change Fusing Web Unit. Change Oil Coating Unit.

T-114

Section Transfer Roller Unit Transfer Belt Unit LED Assy

Step 13

Check Item The problem has been eliminated through the checks of steps up to 12. The problem is eliminated after the Transfer Belt Cleaner has been cleaned. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the Paper Dust Remover has been replaced.

Result NO

Action Change Transfer Roller Unit.

14

NO

Change Transfer Belt Unit.

15

NO

Change LED Assy.

LED Unit

16

NO

Change LED Unit.

Paper Dust Remover PIC Board

17

NO

Change Paper Dust Remover.

18

NO

Change PIC Board.

T-115

(28) Printer 4-Color: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD <Typical Faulty Images> White lines in CD White bands in CD Colored lines in CD Colored bands in CD

4011T016AA

4011T021AA

4011T018AA

4011T022AA

<Troubleshooting Procedure> Section Transfer Belt Unit Step 1 Check Item Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Transfer Roller is dirty or scratched. There is foreign matter on paper path. Fusing Belt is dirty or scratched. Oil exudes more than appropriate. Paper dust accumulates. The problem has been eliminated through the checks of steps up to 7. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. Result YES Action Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Change Transfer Roller Unit. Remove foreign matter. Change Fusing Unit. Change Oil Coating Unit. Clean. Change Transfer Roller Unit.

YES

Transfer Roller Unit Paper path Fusing Unit Oil Coating Unit Paper Dust Remover Transfer Roller Unit Transfer Belt Unit LED Assy

3 4 5 6 7 8

YES YES YES YES YES NO

NO

Change Transfer Belt Unit.

10

NO

Change LED Assy.

LED Unit

11

NO

Change LED Unit.

T-116

Section Paper Dust Remover PIC Board

Step 12

Check Item The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the Paper Dust Remover has been replaced.

Result NO

Action Change Paper Dust Remover.

13

NO

Change PIC Board.

T-117

(29) Printer 4-Color: uneven density in FD <Typical Faulty Images> Uneven density in FD Uneven density in FD

4011T031AA

4011T042AA

<Troubleshooting Procedure> Section Transfer Belt Unit Step 1 Check Item Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Terminal is dirty. Transfer Roller is installed properly. Transfer Roller is dirty or scratched. The problem has been eliminated through the checks of steps up to 5. The problem is eliminated after the Transfer Roller Unit has been replaced. Result YES Action Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean. Reinstall. Change Transfer Roller Unit. Change Transfer Roller Unit.

YES

3 Transfer Roller Unit 4 5 6

YES NO YES NO

Transfer Belt Unit

NO

Change Transfer Belt Unit.

T-118

(30) Printer 4-Color: uneven density in CD <Typical Faulty Images> Uneven density in CD Uneven density in CD

4011T032AA

4011T043AA

<Troubleshooting Procedure> Section Transfer Belt Unit Step 1 Check Item Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Terminal is dirty. Transfer Roller is installed properly. Transfer Roller is dirty or scratched. The problem has been eliminated through the checks of steps up to 5. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. Result YES Action Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean. Reinstall. Change Transfer Roller Unit. Change Transfer Roller Unit.

YES

3 Transfer Roller Unit 4 5 6

YES NO YES NO

Transfer Belt Unit High Voltage Unit 2

NO

Change Transfer Belt Unit.

NO

Change High Voltage Unit 2.

T-119

(31) Printer 4-Color: low image density <Typical Faulty Image> Low image density

4011T003AA

<Troubleshooting Procedure> Section Paper Step 1 Check Item Paper is damp. Result YES Action Change paper to one just unwrapped from its package. Install Paper Dehumidifying Heater. Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean. Reinstall. Change Transfer Roller Unit. Correct or change.

Transfer Belt Unit

Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Terminal is dirty. Transfer Roller is installed properly. Transfer Roller is dirty or scratched. Charge Neutralizing Cloth is not separated and ground terminal is connected properly. Sensor is dirty. Data after three cycles of Gradation Adjust falls within the specified range. Max: 0 100 Highlight = 0 60 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabilization.

YES

YES

4 Transfer Roller Unit 5 6 Paper path 7

YES NO YES NO

AIDC Sensor Gradation Adjust (Tech. Rep. function) PRT Max Density (Tech. Rep. function)

8 9

YES NO

Clean with blower brush. Run another cycle of Gradation Adjust. If the specifications are not met yet, go to next step. Go to next step.

10

NO

T-120

Section PRT Highlight (Tech. Rep. function) Reset + Stabilizer (Tech. Rep. function)

Step 11

Check Item After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After the Reset + Stabilizer sequence has been completed, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Density and PRT Highlight. Thereafter, run Stabilizer again. The problem has been eliminated through the checks of steps up to 12. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the PIC Board has been replaced.

Result NO

Action Go to next step.

12

NO

Go to next step.

Transfer Roller Unit Transfer Belt Unit LED Unit

13

NO

Change Transfer Roller Unit.

14

NO

Change Transfer Belt Unit.

15

NO

Change LED Unit.

PIC Board

16

NO

Change PIC Board.

High Voltage Unit 2

17

NO

Change High Voltage Unit 2.

T-121

(32) Printer 4-Color: poor color reproduction <Typical Faulty Image> Poor color reproduction

4011T050AA

<Troubleshooting Procedure> Section Paper Step 1 Check Item Paper is damp. Result YES Action Change paper to one just unwrapped from its package. Install Paper Dehumidifying Heater. Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean. Reinstall. Change Transfer Roller Unit. Clean with blower brush. Run another cycle of Gradation Adjust. If the specifications are not met yet, go to next step. Go to next step.

Transfer Belt Unit

Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Terminal is dirty. Transfer Roller is installed properly. Transfer Roller is dirty or scratched. Sensor is dirty. Data after three cycles of Gradation Adjust falls within the specified range. Max: 0 100 Highlight = 0 60 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabilization. After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization.

YES

YES

4 Transfer Roller Unit 5 6 AIDC Sensor Gradation Adjust (Tech. Rep. function) PRT Max Density (Tech. Rep. function) PRT Highlight (Tech. Rep. function) 7 8

YES NO YES YES NO

NO

10

NO

Go to next step.

T-122

Section Reset + Stabilizer (Tech. Rep. function)

Step 11

Check Item After the Reset + Stabilizer sequence has been completed, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Density and PRT Highlight. Thereafter, run Stabilizer again. The problem has been eliminated through the checks of steps up to 11. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Unit has been replaced. The problem is eliminated after the PIC Board has been replaced.

Result NO

Action Go to next step.

Transfer Roller Unit Transfer Belt Unit LED Unit

12

NO

Change Transfer Roller Unit.

13

NO

Change Transfer Belt Unit.

14

NO

Change LED Unit.

PIC Board

15

NO

Change PIC Board.

High Voltage Unit 2

16

NO

Change High Voltage Unit 2.

T-123

(33) Printer 4-Color: incorrect color image registration <Typical Faulty Image> Incorrect color image registration

CF
4011T049AA

<Troubleshooting Procedure> Section Warning display Step 1 Check Item Warning display of P-5 (AIDC Sensor 2 failure) or P-28 (AIDC Sensor 1 failure) is displayed. Vibration is given to copier after Power Switch has been turned ON. LED retracting lever is locked in position. Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Drive coupling to the copier is dirty. The surface of the PC Drum is scratched. Transfer Roller is installed properly. Transfer Roller is dirty or scratched. Detecting lever operates smoothly. Shorting connector for speed correction is securely set. Problem is solved after checking step 11. Result YES Action Carry out remedial action procedures for P-5 or P-28 as part of image stabilizer malfunction troubleshooting procedures. Turn OFF and ON Power Switch. Slide out the Imaging Unit and reinstall. Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Clean. Change Imaging Unit. Reinstall. Change Transfer Roller Unit. Replace detecting sensor. Replace fusing unit. Re-set. Re-adjust fusing speed.

Machine condition LED Assy Transfer Belt Unit

YES

3 4

NO YES

YES

6 Imaging Unit Transfer Roller Unit 7 8 9 Fusing speed detection section 10 11 12

YES YES NO YES NO NO NO

T-124

Section Paper Loop (Tech. Rep. function)

Step 13

Check Item If incorrect registration occurs in the main scanning (CD) or sub-scanning (FD) direction, it is evident on the first copy and onward. Paper skews a lot.

Result YES

Action Readjust Paper Loop.

Color Shift Correction (Tech. Rep. function)

14

YES

Adjust Color Shift Correction (Bk). After the correction has been made, adjust PRT Area (Top Margin, Left Margin, and Dup. Left Margin) and then check skew again. If the problem persists, repeat these steps. Change Transfer Roller Unit.

Transfer Roller Unit Transfer Belt Unit LED Assy

15

The problem has been eliminated through the checks of steps up to 14. The problem is eliminated after the Transfer Belt Cleaner has been cleaned. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the LED Assy has been replaced. The problem is eliminated after the LED Unit has been replaced.

NO

16

NO

Change Transfer Belt Unit.

17

NO

Change LED Assy.

LED Unit

18

NO

Change LED Unit.

PIC Board

19

NO

Change PIC Board.

T-125

(34) Printer 4-Color: void areas, white spots <Typical Faulty Images> Void areas White spots

4011T008AA 4011T030AA

<Troubleshooting Procedure> Section Transfer Belt Unit Step 1 Check Item Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. There is dirt, dent or scratch on transfer belt. There is dirt, dent or scratch on transfer belt. There is foreign matter on paper path. Pre-Image Transfer Guide Plate is damaged or dirty. Paper dust accumulates on Paper Dust Remover. Charge Neutralizing Cloth is not separated and ground terminal is connected properly. The problem has been eliminated through the checks of steps up to 7. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. Result YES Action Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Change Transfer Roller Unit. Remove foreign matter. Clean or change. Clean. Correct or change.

YES

Transfer Roller Unit Paper path

3 4 5 6 7

YES YES YES YES NO

Transfer Roller Unit Transfer Belt Unit Paper Dust Remover

NO

Change Transfer Roller Unit.

NO

Change Transfer Belt Unit.

10

NO

Change Paper Dust Remover.

T-126

(35) Printer 4-Color: colored spots <Typical Faulty Image> Colored spots

CF
4011T027AA

<Troubleshooting Procedure> Section Imaging Unit Transfer Belt Unit Step 1 2 Check Item The surface of the PC Drum is scratched. Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. Transfer Belt is dirty or scratched. Transfer Roller is dirty or scratched. There is foreign matter on paper path. Paper dust accumulates on Paper Dust Remover. Fusing Belt is dirty or scratched. Web is properly taken up. The problem has been eliminated through the checks of steps up to 8. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the Fusing Web Unit has been replaced. Result YES YES Action Change Imaging Unit. Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged. Change Transfer Roller Unit. Remove foreign matter. Clean. Change Fusing Unit. Change Fusing Web Unit. Change Transfer Roller Unit.

YES

Transfer Roller Unit Paper path

4 5 6

YES YES YES YES NO NO

Fusing Unit Fusing Web Unit Transfer Roller Unit Transfer Belt Unit Fusing Web Unit Oil Coating Unit

7 8 9

10

NO

Change Transfer Belt Unit.

11

NO

Change Fusing Web Unit.

12

NO

Change Oil Coating Unit.

T-127

Section Fusing Unit

Step 13

Check Item The problem is eliminated after the Oil Coating Unit has been replaced.

Result NO

Action Change Fusing Unit.

T-128

(36) Printer 4-Color: oil lines, oil on copy <Typical Faulty Images> Oil lines Oil on copy

4011T019AA

4011T054AA

<Troubleshooting Procedure> Section Paper Oil Coating Unit Fusing Unit Fusing Web Unit Step 1 2 3 4 5 6 Check Item Problem is solved after printing a few sheets of copy. Oil exudes more than appropriate. Oil Coating Roller is scratched. Fusing Belt is dirty or scratched. Web is properly taken up. The problem has been eliminated through the checks of steps up to 5. The problem is eliminated after the Fusing Web Unit has been replaced. The problem is eliminated after the Oil Coating Unit has been replaced. Result NO YES YES YES NO NO Action Go to next step. Change Oil Coating Unit. Change Oil Coating Unit. Change Fusing Unit. Change Fusing Web Unit. Change Fusing Web Unit.

Oil Coating Unit Fusing Unit

NO

Change Oil Coating Unit.

NO

Change Fusing Unit.

T-129

(37) Printer 4-Color: poor fusing performance, offset <Typical Faulty Images> Poor fusing performance Offset

CF CF CF
4004T002AA 4004T003AA

<Troubleshooting Procedure> Section Paper Step 1 Check Item Paper type is wrong. Result YES Action Change paper type. Change paper type select lever. Re-install. Change Fusing Web Unit. Change Oil Coating Unit. Change Oil Coating Unit. Readjust.

Fusing Web Unit Oil Coating Unit Fuser Nip (Tech. Rep. function) Fuser Temp. (Tech. Rep. function) Fusing Web Unit Oil Coating Unit Fusing Unit

2 3 4 5 6

Fusing web unit is correctly installed. Web is properly taken up. Oil exudes more than appropriate. Oil Coating Roller is scratched. Nip width meets the specifications: 7 0.5 mm. Changing fusing temperature eliminates the problem of poor fusing performance and offset. The problem has been eliminated through the checks of steps up to 7. The problem is eliminated after the Fusing Web Unit has been replaced. The problem is eliminated after the Oil Coating Unit has been replaced.

NO NO YES YES NO

NO

Go to next step.

NO

Change Fusing Web Unit.

NO

Change Oil Coating Unit.

10

NO

Change Fusing Unit.

T-130

(38) Printer 4-Color: brush effect, blurred image <Typical Faulty Images> Brush effect Blurred image

4004T004AA

4011T046AA

<Troubleshooting Procedure> Section Paper Step 1 Check Item Paper is damp. Result YES Action Change paper to one just unwrapped from its package. Install Paper Dehumidifying Heater. Change paper type. Clean. Change Fusing Unit. Change Fusing Web Unit. Change Oil Coating Unit. Change Oil Coating Unit. Readjust.

2 Fusing Unit 3 4 Fusing Web Unit Oil Coating Unit Fuser Nip (Tech. Rep. function) Fuser Speed (Tech. Rep. function) Fusing Web Unit Oil Coating Unit Fusing Unit 5 6 7 8

Paper type is wrong. Fusing Entrance Guide Plate is dirty. Fusing Belt is dirty or scratched. Web is properly taken up. Oil exudes more than appropriate. Oil Coating Roller is scratched. Nip width meets the specifications: 7 0.5 mm. Brush effect or blurred image is evident on different types of paper. The problem has been eliminated through the checks of steps up to 9. The problem is eliminated after the Fusing Web Unit has been replaced. The problem is eliminated after the Oil Coating Unit has been replaced.

YES YES YES NO YES YES NO

YES

Readjust.

10

NO

Change Fusing Web Unit.

11

NO

Change Oil Coating Unit.

12

NO

Change Fusing Unit.

T-131

(39) Printer 4-Color: back marking <Typical Faulty Images> Back marking Back marking

CF
4011T009AA 4011T051AA

<Troubleshooting Procedure> Section Transfer Roller Unit Paper path Fusing Unit Step 1 2 3 4 Transfer Belt Unit Transfer Roller Unit Transfer Belt Unit Oil Coating Unit Fusing Web Unit Fusing Unit 5 Check Item Transfer Roller is scratched or dirty. There is foreign matter on paper path. Fusing Entrance Guide Plate is scratched or dirty. Lower Fusing Roller is scratched or dirty. Fingerprints, oil, or other foreign matter is evident on the Transfer Belt. The problem has been eliminated through the checks of steps up to 5. The problem is eliminated after the Transfer Roller Unit has been replaced. The problem is eliminated after the Transfer Belt Unit has been replaced. The problem is eliminated after the Oil Coating Unit has been replaced. The problem is eliminated after the Fusing Web Unit has been replaced. The problem is eliminated after the Fusing Unit has been replaced. Result YES YES YES YES YES Action Change Transfer Roller Unit. Remove foreign matter. Clean or change. Change Fusing Unit. Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Change Transfer Roller Unit.

NO

NO

Change Transfer Belt Unit.

NO

Change Oil Coating Unit.

NO

Change Fusing Web Unit.

10

NO

Change Fusing Unit.

High Voltage Unit 2

11

NO

Change High Voltage Unit 2.

T-132

(40) Printer 4-Color: 75-mm-pitch uneven image, 200-mm-pitch uneven image <Typical Faulty Images> 75-mm-pitch uneven image 200-mm-pitch uneven image

75 mm 200 mm

4011T062AA

4011T061AA

<Troubleshooting Procedure> Section Oil Coating Unit Fusing Unit Step 1 Check Item Oil Coating Roller is damaged when 75-mm-pitch uneven image occurs. Fusing Belt is damaged when 200-mm-pitch uneven image occurs. Result YES Action Change Oil Coating Unit.

YES

Change Fusing Unit.

T-133

(41) Printer 4-Color: 94-mm-pitch uneven image <Typical Faulty Images> 94-mm-pitch uneven image 94-mm-pitch uneven image 94-mm-pitch uneven image

94 mm

94 mm

94 mm

4011T047AD

4011T057AA

4011T058AA

<Troubleshooting Procedure> Section Imaging Unit Step 1 2 3 Check Item The surface of the PC Drum is scratched. 94-mm-pitch uneven image occurs on the image. The problem has been eliminated through the checks of steps up to 2. Transfer Belt Unit drive gear is intact. Transfer Roller is damaged. Result YES YES NO Action Change Imaging Unit. Store the Imaging Unit in a dark place overnight. Change Imaging Unit.

Transfer Belt Unit Transfer Roller Unit

4 5

NO YES

Correct. Change Transfer Belt Unit. Change Transfer Roller Unit.

T-134

4-4.
(1)

Image Stabilizer Malfunction

P-5: AIDC Sensor Failure (AIDC Sensor 2) P-28: AIDC Sensor Failure (AIDC Sensor 1)

Step 1 2

Check Item AIDC Sensor Shutter operates properly. The area on the Transfer Belt facing the AIDC Sensor is dirty.

Result NO YES Correct.

Action Clean the dirty area with a soft cloth. If it is seriously contaminated, use the specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Change Transfer Belt Unit. Reinstall. Reconnect.

3 4

The area on the Transfer Belt facing the AIDC Sensor is scratched. AIDC Sensor is mounted at an inappropriate position or connectors are not connected properly. AIDC Sensor window is dirty. Value changes when AIDC Sensor output value is varied. P-6: Cyan Imaging Unit Failure P-7: Magenta Imaging Unit Failure P-8: Yellow Imaging Unit Failure P-9: Black Imaging Unit Failure

YES YES

5 6

YES NO YES

Clean. Change AIDC Sensor. Change PIC Board.

(2)

Step 1 2 3 4 5 6 7 8

Check Item PRT Max Density (Tech. Rep. Function) is correct. Density during correction is normal. Imaging Unit is being driven. T/C is unusually low as found through checking. AIDC Sensor window is dirty. Imaging Unit connector contact is dirty. The problem has been eliminated through the checks of steps up to 6. The problem is eliminated after the Imaging Unit has been replaced.

Result NO NO NO YES YES YES NO NO Readjust. Readjust.

Action

Check and correct drive coupling. Check Hopper. Clean. Clean. Change Imaging Unit. Change Transfer Belt Unit.

T-135

(3) Step 1

P-21: Color Shift Correction Failure (Test Pattern Failure) Check Item Produce a test pattern. Result Action Go to step 2 if the image on the Transfer Belt is correct. Go to step 4 if the image density is low. Clean the dirty area with a soft cloth. If it is seriously contaminated, use the specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.) Change Transfer Belt Unit.

The area on the Transfer Belt facing the AIDC Sensor is dirty.

YES

The area on the Transfer Belt facing the AIDC Sensor is scratched.

YES

(4) Step 1 2 3

P-22: Color Shift Correction Failure (Correction Amount Failure) Check Item LED retracting lever is locked in position. AIDC Sensor is installed slantwise. Vertical Transport Guide is installed slantwise. Result NO YES YES Action Slide out the Imaging Unit and then reinstall. Reinstall. Correct.

(5)

P-23: Cyan 1st Image Transfer ATVC Failure P-24: Magenta 1st Image Transfer ATVC Failure P-25: Yellow 1st Image Transfer ATVC Failure P-26: Black 1st Image Transfer ATVC Failure P-27: 2nd Image Transfer ATVC Failure

Step 1 2 3

Check Item Transfer Belt Unit contact makes positive contact with High Voltage Unit contact. The problem has been eliminated through the check of step 1. The problem is eliminated after the Transfer Belt Unit has been replaced.

Result NO NO NO

Action Clean or correct. Change Transfer Belt Unit. Change High Voltage Unit 2. Change Master Board.

T-136

(6)

S-1: CCD Gain Adjustment Failure

Clamp/Gain Adjustment Values RO Clamp Gain Lamp Adjustment Value 130 RO 160 RE 130 RE 160 GO 130 GO 170 135 GE 130 GE 170 BO 130 BO 160 BE 130 BE 160

Clamp: Allowable up to 100 of the above values. Gain: Allowable up to 90 of the above values for R and B; allowable up to 50 of the above values for G. Exposure Lamp adjustment value: Allowable in the range between 64 and 192. Step 1 2 Check Item There is a wide difference between the clamp and gain adjustment values, the value being close to 0 or 255. Clamp adjustment value exceeds the allowable range only slightly. The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great. The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small. S-2: Intensity Adjustment Failure Check Item Original Glass, mirrors, CCD surface, and Main and Auxiliary Reflectors are dirty. Exposure Lamp is dirty or has discolored. Result YES NO Action Clean or change; then, turn ON Power Switch. Change Exposure Lamp. Change CCD Sensor Board. Result YES Action Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board. Reinstall covers, as extraneous light is the cause of the problem. Clean lens, mirrors, CCD surface, shading sheet, and related parts. Reinstall covers, as extraneous light is the cause of the problem.

Check that each of the values displayed on the screen falls within the above range.

YES

YES

YES

(7) Step 1

T-137

Copyright 2001 MINOLTA Co., Ltd.

Use of this manual should be strictly supervised to avoid disclosure of confidential information.

MINOLTA Co., Ltd.

7662-4004-22 01011200