Minolta CF 1501/2001 SM

CF1501/CF2001

SERVICE MANUAL

[TROUBLESHOOTING]

INDEX (TROUBLESHOOTING)

UNIT REPLACEMENT MANUAL

TROUBLESHOOTING

P-1

Safety Precautions for Inspection and Service

When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety.

Depending on the model, some of the precautions given in the following do not apply.

Different markings are used to denote specific meanings as detailed below.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

The following graphic symbols are used to give instructions that need to be observed.

Used to call the service technician’s attention to what is graphically represented inside the marking (including a warning).

Used to prohibit the service technician’s from doing what is graphically repre-sented inside the marking.

Used to instruct the service technician’s to do what is graphically represented inside the marking.

1. Always observe precautions.

2. Before starting the procedures, be sure to unplug the power cord.

3. Use the specified parts.

WARNING

CAUTION

WARNING

• 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 precau-tions.

• Be sure to observe the “Safety Information” given in the Operator’s Manual.

• 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.

• For replacement parts, always use the genuine parts specified in the manufac-turer’s parts manual. Installing a wrong or unauthorized part could cause dielec-tric 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 manufacturer’s 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-2

4. Handle the power cord with care and never use a multiple outlet.

5. Be careful with the high-voltage parts.

6. Do not work with wet hands.

7. Do not touch a high-temperature part.

8. Maintain a grounded connection at all times. (This item may not apply in the USA.)

9. Do not remodel the product.

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

• 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 con-nected.

• Be sure the power outlet meets or exceeds the specified capacity.

• A part marked with the symbol shown on the left carries a high voltage. Touch-ing 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.

• 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.

• 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 surround-ing parts.

• Be sure to connect the ground wire to the ground terminal even when perform-ing 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.

• 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.

• To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and sad-dles 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.

P-3

1. Precautions for Service Jobs

2. Precautions for Servicing with Covers and Parts Removed

3. Precautions for the Working Environment

4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)

CAUTION

• 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 mal-function, 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.

• 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.

• 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.

• Replace a rundown battery with the same type as specified in the manufac-turer’s parts manual.

• Before installing a new battery, make sure of the correct polarity of the installa-tion or the battery could burst.

• Dispose of used batteries according to the local regulations. Never dispose of them at the user’s premises or attempt to try to discharge one.

P-4

5. Precautions for the Laser Beam (Only for Products Employing a Laser)

• When handling circuit boards, observe the “HANDLING of PWBs”.• The PC Drum is a very delicate component. Observe the precautions given in “HAN-

DLING 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 partic-

ular items, or software installation.

• Removing the cover marked with the following caution label could lead to possi-ble 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.”

ANGRInvisible laser radiation when open.

AVOID DIRECT EXPOSURETO BEAM

0947-7127-01

1144D270AA

1167P001AA

Other Precautions

P-5

ALL AreasCAUTION

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 manufacturer’s instructions.

GermanyVORSICHT!

Explosionsgefahr bei unsachgemäßem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.Entsorgung gebrauchter batterien nach Angaben des Herstellers.

FranceATTENTION

Ily a danger d’explosion s’ily a remplacement incorrec de la batterie.Remplacer uniquement avec une batterie du meme type ou d’un type équivalent recom-mande par le constructueur.Mettre au rebut les batteries usageés conformément aux instructions du fabricant.

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med bat-teri af samme fabrikat og type.Levér det brugte batteri tilbage til leverandøren.

NorwayADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

SwedenVARNING

Explosionsfara vid felaktigt batteribyte.Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-tillverkaren.Kassera använt batteri enligt fabrikantens instruktion.

FinlandVAROlTUS

Paristo voi räjähtää, los se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristo valmistajan ohjeiden mukaisesti.

Used Batteries Precautions

P-6

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.

• 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 over-loads.

• 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.

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.

• 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 sen-sors, 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.

Precautions Before Service

How to Use this Book

Precautions for Service

P-7

• 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 dis-

carded casually or left unattended at the user’s 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.

• 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.

Precautions for Dis/Reassembly

Precautions for Circuit Inspection

P-8

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 tem-

perature. • 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 elec-tricity.

• 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 dis-charge static electricity before touching the PWB.

• Note that replacement of a PWB may call for readjustments or resetting of particular items.

• The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

Handling of PWBs

Handling of Other Parts

P-9

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 –20°C and +40°C.• 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 pro-

tect 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, finger-

prints, 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 proce-dure.

Handling of the PC Drum

1. Place the PC Drum into one half of its carton.

1076D001

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 thor-oughly 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.

1076D002

P-10

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.

Only for Products Employing an Imaging Cartridge.1. During Transportation/Storage: • The storage temperature is in the range between –20°C and +40°C.• 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, finger-

prints, 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.

3. Soak a small amount of either ethyl alcohol or iso-propyl alcohol into a clean, unused Dust-Free Cot-ton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one con-tinuous 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 proce-dure 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 appropri-ate for cleaning.

1076D004

Handling of the Imaging Cartridge

TROUBLESHOOTING

18605

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CONTENTS1. INTRODUCTION .............................................................................................T-1

1-1. Reading the Text .....................................................................................T-12. I/O CHECK ......................................................................................................T-1

2-1. Electrical Components Check Procedure ................................................T-12-2. I/O Check List ..........................................................................................T-32-3. 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-112-5. Misfeed Detecting Sensor Layout ............................................................T-122-6. Types of Misfeed Detection and Detection Timing ..................................T-142-7. 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-373-1. Detection Timing by Warning Code .........................................................T-383-2. Detection Timing by Malfunction Code ....................................................T-403-3. Troubleshooting Procedures by Malfunction Code ..................................T-48

(1) C0000: Main Motor’s failure to turnC0001: Main Motor turning at abnormal timing ...............................T-48

(2) C0010: Imaging Unit Motor C’s failure to turnC0011: Imaging Unit Motor C turning at abnormal timingC0012: Imaging Unit Motor M’s failure to turnC0013: Imaging Unit Motor M turning at abnormal timingC0014: Imaging Unit Motor Y’s failure to turnC0015: Imaging Unit Motor Y turning at abnormal timingC0016: Imaging Unit Motor Bk’s failure to turnC0017: Imaging Unit Motor Bk turning at abnormal timing .............. T-49

(3) C0040: Fusing Cooling Fan Motor 1’s failure to turnC0046: Fusing Cooling Fan Motor 2’s failure to turnC004C: Ozone Ventilation Fan Motor’s failure to turnC004E: Power Supply Cooling Fan Motor’s failure to turn .............. T-51

(4) C0060: Fusing Drive Motor’s failure to turnC0061: 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

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C0204: Yellow PC Drum Charge Corona malfunctionC0206: Black PC Drum Charge Corona malfunction ......................T-58

(9) C0400: Exposure Lamp’s failure to turn ONC0410: Exposure Lamp turning ON at abnormal timing ..................T-60

(10) C0500: Heating Roller warm-up failureC0501: Lower Fusing Roller Heater Lamp warm-up failureC0510: Heating Roller abnormally low temperatureC0511: Lower Fusing Roller Heater Lamp abnormally low temperatureC0520: Heating Roller abnormally high temperatureC0521: Lower Fusing Roller Heater Lamp abnormally high temperature

.............................................................................................T-61(11) C0650: Scanner Home Sensor malfunction

C0660: Scanner overrun failure .......................................................T-63(12) C0990: LCC Lift-Up Motor malfunction

C0991: LCC Lift 1 ascent motion failureC0995: LCC Transport Motor malfunctionC0999: LCC Lift 2 ascent motion failure ..........................................T-65

(13) C0F30: Abnormally low toner density detected by Cyan ATDC Sensor/C0F31: Abnormally high toner density detected by Cyan ATDC SensorC0F32: Abnormally low toner density detected by Magenta ATDC Sensor/C0F33: Abnormally high toner density detected by Magenta ATDC SensorC0F34: Abnormally low toner density detected by Yellow ATDC Sensor/C0F35: Abnormally high toner density detected by Yellow ATDC Sensor

.............................................................................................T-67(14) C0F36: Abnormally low toner density detected by Black ATDC Sensor/

C0F37: Abnormally high toner density detected by Black ATDC Sensor .............................................................................................T-69

(15) C0F3A: Cyan ATDC Sensor adjustment failureC0F3B: Magenta ATDC Sensor adjustment failureC0F3C: Yellow ATDC Sensor adjustment failureC0F3D: Black ATDC Sensor adjustment failure ..............................T-70

(16) C13C8: New Transfer Belt Unit resetting failureC13CA: New Fusing Unit resetting failureC13CB: New Fusing Web Unit resetting failureC13CC: New Oil Coating Unit resetting failure ................................T-71

(17) C13D1: Cyan IU EEPROM failureC13D2: Magenta IU EEPROM failureC13D3: Yellow IU EEPROM failureC13D4: Black IU EEPROM failure ...................................................T-72

(18) C3310: CCD clamp/gain adjustment failure ....................................T-73(19) C3700: IR Cooling Fan Motor 1 turning at abnormal timing

C3710: IR Cooling Fan Motor 2 turning at abnormal timingC3720: Original Glass Cooling Fan Motor turning at abnormal timing

.............................................................................................T-74(20) C3A00: PIC communication error

C3A01: PIC Board malfunctionC3FFF: ROM contents fault detected upon start .............................T-75

iii

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-794-1. Troubleshooting Image Quality Problems ................................................T-794-2. Initial Check Items ...................................................................................T-794-3. 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

iv

(34) Printer 4-Color: void areas, white spots ...........................................T-126(35) Printer 4-Color: colored spots .......................................................... T-127(36) Printer 4-Color: oil lines, oil on copy ................................................T-129(37) Printer 4-Color: poor fusing performance, offset .............................T-130(38) Printer 4-Color: brush effect, blurred image ....................................T-131(39) Printer 4-Color: back marking .......................................................... T-132(40) 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 FailureP-8: Yellow Imaging Unit FailureP-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 FailureP-25: Yellow 1st Image Transfer ATVC FailureP-26: Black 1st Image Transfer ATVC FailureP-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

T-1

1. INTRODUCTION1-1. 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.

2. I/O CHECK2-1. Electrical Components Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular electrical com-ponent 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, mal-function, 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 elec-trical 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.

Pattern 1

Go to step 2 if you answered No.

Step Check Result Action

1 Is ..? YES Do this.

2

Pattern 2

Go to step 2 if it is checked okay.

Step Check Result Action

1 Is ..? YES Do this.

NO Check that.

2

T-2

<Electrical Component Check Procedure Through Checking Input Data>

ExampleWhen 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-3

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 indi-

vidual copier.

Previous Screen

Next Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Previous Screen

Next Screen

4004P047CA 4004P048CA

4004P049CA

4004P050CA

4004P051CA4004P052CA

4004P053CA

T-4

<I/O Check List>

Symbol Panel Display Part/Signal Name

Operation Characteris-tics/Panel Display Input

BoardIC

No.Port No.

CN/PJNo.

1 0

PC3 1st Drawer Set 1st Drawer Set Sensor

In position Out of position

Master Board

(PWB-I)

IC6 PG1 PJ17I-9A

PC6 Paper Empty

1st Drawer Paper Empty Sensor

Paper not present

Paper present

IC5 PI7 PJ3I-8A

PC4 Paper Near Empty

1st Drawer Paper Near-Empty Sensor

Blocked Unblocked IC6 PG0 PJ17I-6A

PC13 Double Feed

1st Drawer Double Feed Sensor

Paper present

Paper not present

IC6 PI0 PJ5I-8B

SW D 2nd Drawer

Set 2nd Drawer Set Switch


Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC102 Paper Empty

2nd Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


2nd Drawer Paper Near-Empty Sensor

Blocked Unblocked IC1 PB6 PJ3A-11A

PC101 Take-Up 2nd Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC105 Double Feed

2nd Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

SW D 3rd Drawer Set Drawer Set Switch In position Out of position

Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC2 Paper Empty

Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


Drawer Paper Near-Empty Sensor


PC1 Take-Up Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC5 Double Feed

Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

SW D 4th Drawer Set Drawer Set Switch In position Out of position

Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC2 Paper Empty

Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


Drawer Paper Near-Empty Sensor


PC1 Take-Up Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC5 Double Feed

Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

PC15 Manual Take-Up Manual Feed Paper Take-Up Sensor

Paper present

Paper not present

Master Board

(PWB-I)

IC6 PI5 PJ15I-7B

PC15 Set Manual Feed Paper Take-Up Sensor


IC5 PH4 PJ15I-10B

PC17 Paper Passage

Timing Roller

Synchronizing Roller Sensor

Paper present

Paper not present

IC1 P77 PJ14I-9B

PC10 Exit Exit Sensor Paper present

Paper not present

IC6 PI4 PJ3I-14A

PC19 Paper Passage

OHP Detect Sensor

OHP Detecting Sensor

OHP present

OHP not present

IC1 AN5 PJ14-2B

T-5

LS1 LCC Lift-Up 1 Lift-Up Sensor 1 At raised position

Not at raised

position

LCC Control Board

(PWB-A)

IC4 P74/ANI4

CN4A-6

LS2 Lift-Up 2 Lift-Up Sensor 2 At raised position

Not at raised

position

IC4 P73/ANI3

CN4A-9

RSEN Registration Registration Sensor Paper present

Paper not present

IC4 P22/INTP1

CN4A-2

S1 Paper Wait Paper Standby Position Sensor

At standby position

Not at standby position

IC4 P23/INTP2/

CI

CN3A-5

PPS0 Take-Up 1 LCC Paper Take-Up Sensor

Paper present

Paper not present

IC4 P24/INTP3

CN4A-11

PPS1 Take-Up 2 Paper Empty Sensor 1

Paper present

Paper not present

IC4 P25/INTP4/ASCK

CN3A-2

EMP Paper Empty

Paper Empty Sensor 2

Paper not present

Paper present

IC4 P72/ANI2

CN3A-8

RS1 Paper Near Empty 1

Paper Near Empty Sensor 1

Unblocked Blocked IC4 P75/ANI5

CN6A-12

RS2 Paper Near Empty 2

Paper Near Empty Sensor 2

Unblocked Blocked IC4 P76/ANI6

CN5A-5

PWB-A PI2

Duplex Set Duplex Unit Door Set Sensor (in PWB-A)

Duplex Control Board

- - PJ1A-3

PWB-A PI1

Paper passage 1

Duplex Unit Transport Sensor 1 (in PWB-A)

Paper present

Paper not present

- - PJ1A-12

PC1 Paper passage 2

Duplex Unit Transport Sensor 2

Paper present

Paper not present

- - PJ4A-3

PC1 Horizontal Trans. Unit

Horizontal Transport

Paper Sensor Paper not present

Paper present

Control Board

(PWB-A)

IC1IC1

P26P27

PJ15A-4PJ12-2

PC6 Rev. Empty Turnover Empty Detecting Sensor

Paper present

Paper not present

IC26IC1

PE3P22

PJ15A-12PJ13-2

PWB-B Mail Bin Sorter

Exit Section

Exit Sensor Board Paper present

Paper not present

IC1 P25 PJ6A-7

PWB-B 1st bin Empty

Non-Sort Bin Empty Sensor

Paper present

Paper not present

IC1 P40 PJ6A-5

PWB-D 2nd bin Empty

2nd Bin Empty Sensor

Paper present

Paper not present

IC1 P41 PJ7A-4A

PWB-D 3rd bin Empty

3rd Bin Empty Sensor

Paper present

Paper not present

IC1 P42 PJ7A-11A

PWB-D 4th bin Empty

4th Bin Empty Sensor

Paper present

Paper not present

IC1 P43 PJ7A-4B

PWB-D 5th bin Empty


Paper present

Paper not present

IC1 P44 PJ7A-11B

PWB-D 6th bin Empty


Paper present

Paper not present

IC1 P45 PJ8A-4A

PWB-D 7th bin Empty


Paper present

Paper not present

IC1 P46 PJ8A-11A

PWB-D 8th bin Empty


Paper present

Paper not present

IC1 P47 PJ8A-4B

PWB-D 9th bin Empty


Paper present

Paper not present

IC1 P23 PJ8A-11B

PWB-D 10th bin Empty


Paper present

Paper not present

P21 PJ9A-4

PWB-D



BoardIC

No.Port No.

CN/PJNo.

1 0

T-6

PWB-B Mail Bin Sorter

1st bin Full Non-Sort Bin Full Sensor

Blocked Unblocked Control Board

(PWB-A)

IC1 P70 PJ6A-4

PWB-D 2nd bin Full 2nd Bin Full Sensor Blocked Unblocked IC1 P71 PJ7A-1A

PWB-D 3rd bin Full 3rd Bin Full Sensor Blocked Unblocked IC1 P72 PJ7A-8A

PWB-D 4th bin Full 4th Bin Full Sensor Blocked Unblocked IC1 P73 PJ7A-1B


PWB-D 6th bin Full 6th Bin Full Sensor Blocked Unblocked IC1 P75 PJ8A-1A

PWB-D 7th bin Full 7th Bin Full Sensor Blocked Unblocked IC1 P76 PJ8A-8A



PWB-C 10th bin Full 10th Bin Full Sensor Blocked Unblocked IC1 P67 PJ9A-1

PC1 Finisher Exit (Non-sort)

1st Tray Exit Sensor Paper present

Paper not present

Control Board

(PWB-A)

IC26 PC4 PJ19A-6

PC3 Exit (Finisher)

Storage Sensor Paper present

Paper not present

IC26 PD0 PJ20A-3

PC4 Transport Upper

Upper Entrance Sensor

Paper present

Paper not present

IC26 PE6 PJ20A-9

PC2 Transport Lower

Lower Entrance Sensor

Paper present

Paper not present

IC26 PE7 PJ19A-8

PC6 Full (Non-sort)

1st Tray Full Detecting Sensor

Blocked Unblocked IC26 PC5 PJ19A-3

PC7 Full (Elev. Tray)

Elevator Tray Full Detecting Sensor

Blocked Unblocked IC26 PA7 PJ19A-12

PC5 Empty Finisher Tray Paper Detecting Sensor

Out of position

In position IC26 PD1 PJ25A-2

PWB-D Finisher Elevator Tray Upper Limit Sensor PQ

Paper present

Paper not present

IC26 PA6 PJ21A-2

PC8 Surface (Elev.)

Elevator Tray Paper Detecting Sensor

Blocked Unblocked IC26 PA5 PJ25A-9

PC9 Empty (Elev.)

CD Aligning Home Position Sensor

Blocked Unblocked IC26 PD2 PJ25A-6

PC14 Home (CD-Align)

Staple Home Position Sensor


PC12 Home (Stap. Unit)

Storage Roller Home Position Sensor


PC13 Hole (store roller)

Exit Rolls Home Position Sensor


- Home (Stapler 1)

Stapler Home 1 Blocked Unblocked IC1 P71, ANI1

PJ23A-2

- Empty St. 1 Needle

Stapler Empty 1 Blocked Unblocked IC1 P72, ANI2

PJ23A-4



BoardIC

No.Port No.

CN/PJNo.

1 0

T-7

- Finisher Self Priming S1

Stapler Self-Priming 1

Blocked Unblocked Control Board

(PWB-A)

IC1 P73, ANI3

PJ23A-3

- Home (Stapler 2)

Stapler Home 2 Blocked Unblocked IC1 P75, ANI5

PJ24A-2

- Empty St. 2 Needle

Staple Empty 2 Blocked Unblocked IC1 P76, ANI6

PJ24A-4

- Self Priming S2

Stapler Self-Priming 2

Blocked Unblocked IC1 P77, ANI7

PJ24A-3

S2S3

Elevate Tray

Raised/Lowered

Elevate Tray Raised/Lowered

ON OFF - - PJ4A-4

PC10 Home (Shift)

Shift Home Position Sensor


S4 Punch Hole Change

Hole Punch Position Switch

ON OFF IC28 PE2 PJ12A-3

PC15 Punch Speed

Punch Motor Pulse Sensor

Blocked Unblocked IC1 P21INPO

PJ13A-8

PC11 Shift Speed Shift Motor Pulse Sensor

Blocked Unblocked IC1 P24INPO

PJ25A-14

SW6 Dev. Cyan Toner Empty

Toner Empty Switch C

ON OFF Master Board

(PWB-I)

IC6 PH6 PJ5I-5A

SW7 Magenta Toner Empty

Toner Empty Switch M

ON OFF IC6 PH5 PJ5I-3A

SW8 Yellow Toner Empty

Toner Empty Switch Y

ON OFF IC6 PH4 PJ5I-1A

SW5 Black Toner Empty

Toner Empty Switch Bk

ON OFF IC6 PH7 PJ5I-5B

PC28 Transfer Belt

Transfer Unit

Separation

1st Image Transfer Retraction Position Sensor

Not Retracted

Retracted IC5 PI1 PJ17I-1A

- Set - In position Out of position

IC5 PE7 PJ4I-8

PC23 2nd Transfer

Transfer Unit

Separation

2nd Image Transfer Pressure Position Sensor

Not Retracted

Retracted IC5 PI2 PJ14I-6B

PC29 Toner Collect

Waste Toner

Waste Toner Full Detecting Sensor

Unblocked Blocked IC8 3Y PJ7I-7B

PC18 Toner Box Set

Waste Toner Bottle Set Sensor


IC5 PI4 PJ7I-5B

- Fusing Unit

Set Fusing Unit In position Out of position

IC5 PH5 PJ6I-7A

- Fusing Web Unit

Not used Not used Not used - - -

PC7 Fuser Roller Separation

Fusing Pressure Position Sensor

Pressed State other than pressed

IC5 PI6 PJ17I-3B

PC24 IR Home Sensor

Org. Detect Sensor At home Out of home

Image Process-

ing Board

(PWB-C)

- - PJ6C-2

SW10 Scanner Home Sensor

Org. Cover Size Reset Switch Lowered Raised - - PJ7D-2



BoardIC

No.Port No.

CN/PJNo.

1 0

T-8

PC25 Orig.Detect Sensor

15 Degree Sensor

Original Cover Detecting Sensor

Less than 15°

15° or more

Image Process-

ing Board

(PWB-C)

- - PJ2C-2B

PC30 Org. Detect Sensor 1

Original Size Detecting Sensor FD1

Original loaded,

not mounted

Original not loaded

- - PJ7C-1

PC31 Orig. DetectSensor 2


Original loaded,

not mounted

Original not loaded

- - PJ7C-7



Original loaded,

not mounted

Original not loaded

- - PJ7C-9



Original loaded,

not mounted

Original not loaded

- - PJ9C-3



Original loaded,

not mounted

Original not loaded

- - PJ9C-5


Original Size Detecting Sensor CD1

Original loaded,

not mounted

Original not loaded

- - PJ7C-12



Original loaded,

not mounted

Original not loaded

- - PJ7C-14



Original loaded,

not mounted

Original not loaded

- - PJ9C-10



BoardIC

No.Port No.

CN/PJNo.

1 0

T-9

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.

(1) Table #

4004P054CA

Vb-C/-M/-Y/-BkOutput 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 VIf 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

Vg-C/-M/-Y/-BkOutput table value of each PC Drum Charge Corona grid mesh, representing data appli-cable 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 VIf 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.

T-10

(2) Level History 1

(3) Level History 2

ATDC-C/-M/-Y/-BkDisplays 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 %AIDC1/2Displays 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

AIDC Sensor Adjust Value 1/2Displays the AIDC intensity adjustment val-ues.The values represent the intensity deter-mined through AIDC intensity control.The value is displayed in units of 1 step.Intensity range: 0 to 255

4004P058CA

T-11

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.

<Misfeed Display Resetting Procedure>

Display Misfeed/Paper Location Ref. Item No.

1 ADF take-up

See relevant Option Service Manual.

2 ADF transport

3 ADF turnover/exit

4 Horizontal Unit

5Mailbin/Finishing option transport/Finishing option exit

6 Mailbins

7 Duplex Unit transport (8)

8 Fusing/Exit (5)

9 2nd Image Transfer (4)

10 Manual Bypass take-up (2)

11 Vertical Transport/Duplex Unit take-up (3)

12 1st Drawer take-up (1)

13 2nd Drawer take-up (1)

143rd Drawer take-up/LCC take-up/LCC Lift 2 to 1 paper transport

(6) (7)

15 4th Drawer take-up (6) (7)

Misfeed in copier 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.)

Misfeed in option

3

2

1

4

512

13

14

15

10

11

11

11

6 11

9

8

7

4004P059CA

T-12

2-5. Misfeed Detecting Sensor Layout

• System Mounted with AD-14 and PF-117

Exit Sensor (PC10)

Duplex Unit Transport Sensor 1 (PI1)

Duplex Unit Transport Sensor 2 (PC1)

Manual Feed Paper Take-Up Sensor (PC15)

2nd Drawer Paper Take-Up Sensor (PC101)

LCC Registration Sensor (RSEN)

LCC Paper Take-Up Sensor (PPS0)

1st Drawer Double Feed Sensor (PC13)

2nd Drawer Double Feed Sensor (PC105)

Synchronizing Roller Sensor (PC17)

2/ OHP Detecting Sensor (PC19)

4011T055AA

T-13

• System Mounted with AD-14 and PF-118

Exit Sensor (PC10)

Synchronizing Roller Sensor (PC17)

Duplex Unit Transport Sensor 1 (PI1)

Duplex Unit Transport Sensor 2 (PC1)

Manual Feed Paper Take-Up Sensor (PC15)

2nd Drawer Paper Take-Up Sensor (PC101)

3rd Drawer Paper Take-Up Sensor (PC1)

4th Drawer Paper Take-Up Sensor (PC1)

OHP Detecting Sensor (PC19)

1st Drawer Double Feed Sensor (PC13)

2nd Drawer Double Feed Sensor (PC105)

3rd Drawer Double Feed Sensor (PC5)

4th Drawer Double Feed Sensor (PC5)

4011T056AA

T-14

2-6. Types of Misfeed Detection and Detection Timing

• The following lists the types of misfeed detection and detection timings for different mis-feed 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>

<Manual Bypass Take-Up Misfeed>

<Copier Vertical Transport Misfeed>

Type Detection Start Detection

Paper take-up failure detection

1st Drawer Paper Take-Up Clutch energized

Synchronizing Roller Sensor (L)

2nd Drawer Paper Take-Up Clutch energized

2nd Drawer Paper Take-Up Sensor (L)

1st Drawer size error detection

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

2nd Drawer size error detection


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]

Detection of paper left in 2nd Drawer

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

2nd Drawer Paper Take-Up Sensor activated


Bypass paper take-up failure detection

Manual Feed Paper Take-Up Sensor (L)


Manual bypass size error detec-tion

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

Detection of paper left in Manual Bypass Table


Manual Feed Paper Take-Up Sensor activated


2nd Drawer paper take-up failure



T-15

<2nd Image Transfer Misfeed>

<Exit Misfeed>

<PF-118 Paper Take-Up Misfeed>


2nd Image Transfer mis-feed detection

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

Exit Sensor (L)

Detection of paper left at 2nd Image Transfer


Synchronizing Roller Sensor activated, OHP Detecting Sensor activated


Exit misfeed Exit Sensor activated (L) Exit Sensor deactivated (T)

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

Detection of paper left at exit


Exit Sensor activated


3rd Drawer size error detection

3rd Drawer Paper Take-Up Sensor (L)

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 size error detection

4th Drawer Paper Take-Up Sensor (L)

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]

Detection of paper left in 3rd Drawer


3rd Drawer Paper Take-Up Sensor activated

Detection of paper left in 4th Drawer


4th Drawer Paper Take-Up Sensor activated

T-16

<PF-117 Paper Take-Up Misfeed>

<Duplex Paper Take-Up Misfeed>


LCC misfeed detection

LCC paper take-up request LCC Exit signal ON

Lift 2 to 1 mis-feed detection

LCC Paper Take-Up Request LCC Paper Take-Up Sensor activated, LCC Paper Empty Sensor 1 activated, Paper Standby Position Sensor acti-vated

LCC vertical transport mis-feed detection

LCC Exit signal ON 2nd Drawer Paper Take-Up Sensor (L)

LCC size error detection


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]

Detection of paper left in LCC


LCC Registration Sensor Paper-Left Misfeed signal ON


Duplex paper take-up mis-feed detection

Duplex paper take-up start Synchronizing Roller Sensor (L), Man-ual Feed Paper Take-Up Sensor (L)

Duplex trans-port misfeed detection

Duplex Unit Transport Sensor 1 (L)

Duplex Unit Transport Sensor 2 (L)

Detection of paper left in Duplex


Duplex Unit Transport Sensor 1 acti-vated, Duplex Unit Transport Sensor 2 activated

T-17

2-7. Misfeed Troubleshooting Procedures

(1) 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)

M13

PJ10512345678

PJ116

PC17

CL1

321

678

121

CN63

59 4

12 1

2112

CN55

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

PU1

PJ13I-7A(M13 LOCK)PJ13I-8A(M13 REM)

PJ13I-9A(M13 CLK)PJ13I-10A(DC5 V)PJ13I-11A(GND)PJ13I-12A(M13 CW/CCW)

PJ14I-7A(DC5 V)PJ14I-8A(GND)

PJ15I-10A(DC24 V)PJ15I-11A(CL1 REM)

PJ14I-9A(PC17 ON)

PWB-I

CL101

M101 321

14

CN61

23

21

CN1

12

4

PJ3A-13B(DC24 V)PJ3A-14B(CL101 REM)

PJ5A-4(–)B

PJ5A-2(–)APJ5A-3(B)

PJ5A-1(A)

PWB-A(2nd Tray)–

4004C16TAD

T-18

Copier Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is not taken up at all.

Step Check Item Result Action

1 Paper meets product specifications. NO Change paper.

2 Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater.

3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper.

NO Set as necessary.

4 Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter.

YES Clean or change.

5 Paper Lifting Plate is dirty, deformed, or scratched.


6 Separator Pad is deformed, worn, or dirty with paper dust or other foreign matter.


7 Separator Roll is deformed, worn, or dirty with paper dust or other foreign matter.


8 Paper take-up guide plate is dirty, deformed, or scratched.


9 Paper take-up guide plate is installed prop-erly.

NO Reinstall.

10 Paper Take-Up Roll turns when the Start key is pressed with the 1st Drawer selected.

NO Correct drive coupling (cou-pling engagement, position of drive transmitting pin).

11 1st Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 1st Drawer selected: the voltage across PJ15I-11A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES Check for overload. Change clutch.

NO Change Master Board.

12 Paper Take-Up Roll turns when the Start key is pressed with the 2nd Drawer selected.


13 2nd Drawer Paper Take-Up Clutch opera-tion 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 Change Control Board.

T-19

(2) Manual Bypass Take-Up Misfeed


Manual Feed Paper Take-Up Sensor (PC15)Manual Feed Paper Take-Up Clutch (CL13)

Synchronizing Roller Sensor (PC17)Synchronizing Roller Clutch (CL21)Master Board (PWB-I)

PJ116

PC17

CL21

CL3

321

PJ40

PC15

123

678

121

CN63

5

267

71

CN65

2112

CN30

2112

CN41

1

9 4

12 1

334455

88

11

CN33

22DC24 V


PJ14I-7B(DC5 V)PJ14I-8B(GND)PJ14I-9B(PC17 ON)

PJ15I-9A(CL3 REM)PJ15I-7B(PC15 ON)PJ15I-8B(GND)PJ15I-9B(DC5 V)

PWB-I

4004C17AD

T-20

Manual Bypass Take-Up Misfeed Troubleshooting Procedures

• Paper is not detected.



1 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).

YES Change Master Board.

NO Correct actuator. Check sen-sor connector connection. Change sensor.




3 Guide plate is dirty with paper dust, deformed, or scratched.


4 Manual Bypass Take-Up Roll is dirty with paper dust, deformed, or worn.


5 Manual Bypass Take-Up Roll turns when the Start key is pressed with the Manual Bypass Table used.

NO Correct drive coupling (drive transmitting gear engage-ment).

6 Manual Feed Paper Take-Up Clutch opera-tion 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.



T-21

• Paper is at a stop at the vertical transport section.



2 Synchronizing Rollers are dirty with paper dust, deformed, or worn.


3 Paper Dust Remover is deformed or worn. NO Change Paper Dust Remover Unit.

4 Paper Dust Remover is installed properly. NO Reinstall Paper Dust Remover Unit.

5 An adequate length of loop is formed before the Synchronizing Rollers.

NO Adjust “Paper Loop.” (See ADJUSTMENT.)

6 I/O check for Synchronizing Roller Sensor operation when the Manual Bypass Table is used: the voltage across PJ14I-9B on Mas-ter Board and GND is DC 0 V when the sen-sor is unblocked (paper present) and DC 5 V when the sensor is blocked.


NO Correct actuator. Check sen-sor connector connection. Change sensor.

7 Synchronizing Rollers turn when the Start key is pressed with the Manual Bypass Table used.


8 Synchronizing Roller Clutch operation when the Manual Bypass Table is used: the volt-age 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.



9 Size error display after the misfeed display has been reset.

YES Check paper size.

T-22

(3) Copier Vertical Transport Misfeed


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)

M13

PJ10512345678


PU1

PJ116

PC17

CL1

CL21

321

678

121

CN63

5

267

71

CN65

1

9 4

12 1

2112

CN55

2112

CN30

PJ14I-7A(DC5 V)PJ14I-8A(GND)



PJ14I-9A(PC17 ON)



PWB-I

PJ12

PC101

CL101

M101

321

321

14

CN61

23

21

CN1

12

4

PJ3A-3A(DC5 V)PJ3A-4A(GND)PJ3A-5A(PC101 ON)


PJ5A-4(–)B


PJ5A-1(A)

PWB-A(2nd Tray)–

4004C18TAD

T-23

Copier Vertical Transport Misfeed Troubleshooting Procedures

• Paper is at a stop at the vertical transport section.


1 Synchronizing Rollers are deformed or worn.

YES Check type of paper being used.

2 Paper dust deposits on Synchronizing Roll-ers.

YES Clean Synchronizing Rollers. Check Paper Dust Remover for proper function.

3 Paper Dust Remover is deformed or worn. YES Change Paper Dust Remover Unit.

4 Paper Dust Remover is installed properly. NO Reinstall Paper Dust Remover Unit.

5 An adequate length of loop is formed before the Synchronizing Rollers.

NO Adjust “Paper Loop.” (See ADJUSTMENT.)

6 Vertical transport guide plate is dirty, deformed, or scratched.


7 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.


NO Correct actuator. Check sen-sor connector for connection. Change sensor.

8 Synchronizing Rollers turn when the Start key is pressed with the 1st Drawer selected.


9 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.



10 2nd Drawer Vertical Transport Roller 1 is dirty with paper dust, deformed, or scratched.


11 2nd Drawer vertical transport guide plate is dirty, deformed, or scratched.


12 Synchronizing Rollers turn when the Start key is pressed with the 2nd Drawer selected.


13 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.



T-24

14 2nd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 2nd Drawer selected.

NO Correct drive coupling (cou-pling engagement, position of drive transmitting pin). Change motor. Change 2nd Drawer Control Board.


YES Check paper size. Check positioning of the Edge Guide and Trailing Edge Stop.


T-25

(4) 2nd Image Transfer Misfeed


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

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

M13

PJ10512345678

M14

PJ10612345678


PU1


PJ13I-9A(M13 CLK)PJ13I-10A(DC5 V)PJ13I-11A(GND)PJ13I-12A(M13 CCM/CM)



PWB-I

PJ116

PC17

321

PJ133

PC10

321

678

121

CN63

312213

CN17

59 4

12 1


PJ3I-12A(DC5 V)PJ3I-13A(GND)PJ3I-14A(PC10 ON)

4004C20TAB

T-26

2nd Image Transfer Misfeed Troubleshooting Procedures

• Paper is at a stop at the 2nd Image Transfer section.


1 Vertical transport guide plate is dirty, deformed, or scratched.


2 Image Transfer Roller Unit is not installed properly.

YES Reinstall.

3 Pre-Image Transfer Guide Plate is dirty, deformed, or scratched.Seal is separated.

YES Clean or change Image Transfer Roller Unit.

4 Transfer Belt is driven when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Reinstall Transfer Belt Unit.

5 Transfer Belt is deformed or damaged. YES Change Transfer Belt Unit.

6 Transfer Roller turns when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Reinstall Transfer Roller Unit.

7 Transfer Roller is dirty with paper dust or other foreign matter, deformed, or worn.

YES Clean or change Image Transfer Roller Unit.

8 Fusing Rollers turn when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Correct the installed position of Fusing Unit.

9 Paper winds around Transfer Belt. YES Readjust Paper Separator Fingers. Readjust “Top Mar-gin.”

10 Paper winds around Transfer Roller. YES Change Transfer Roller Unit.

11 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.



T-27

(5) Exit Misfeed


Exit Sensor (PC10)Fusing Drive Motor (M14)

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

M14

PJ10612345678


PU1



PJ3I-12A(DC5 V)PJ3I-13A(GND)PJ3I-14A(PC10 ON)

PWB-I

PJ133

PC10

321 13

31

CN17

22

4004C21TAA

T-28

Exit Misfeed Troubleshooting Procedures

• Paper is at a stop at the 2nd Image Transfer section.


1 Fusing guide plate is dirty, deformed, or damaged.


2 Fusing Rollers are dirty, deformed, or scratched.

YES Clean or change Fusing Unit.

3 Fusing Paper Separator Fingers are dirty, deformed, or worn.

YES Clean, correct, or change.

4 Fusing Exit Roller is dirty, deformed, or scratched.


5 Fusing Rollers turn when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Correct installed posi-tion of Fusing Unit. Change Fusing Unit.

6 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.



7 Exit Turnover Roller is dirty, deformed, or scratched.


8 Exit Turnover Roller turns when the Start key is pressed.

NO Correct drive coupling (roller position).

T-29

(6) PF-118 Paper Take-Up Misfeed


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

CL1

M1

321

PJ12

PC1

CL1

M1

321

321

14

CN61

23

21

CN73

12

4

321

14

CN61

23

21

CN73

12

4



PJ5A-4(–)B


PJ5A-1(A)

PWB-A(3rd Tray)–



PJ5A-4(–)B


PJ5A-1(A)

PWB-A(4th Tray)–

4004C22TAB

T-30

PF-118 Paper Take-Up Misfeed Troubleshooting Procedures





3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper.

NO Set as necessary.

4 Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter.


5 Paper Lifting Plate is dirty, deformed, or scratched.




7 Paper take-up guide plate is dirty, deformed, or scratched.


8 Paper take-up guide plate is installed prop-erly.

NO Reinstall.

9 Paper Take-Up Roll turns when the Start key is pressed with the 3rd Drawer selected.


10 3rd Drawer Paper Take-Up Clutch opera-tion 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.


NO Change 3rd Drawer Control Board.

11 3rd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 3rd Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment). Change motor. Change 3rd Drawer Control Board.

12 Paper Take-Up Roll turns when the Start key is pressed with the 4th Drawer selected.


13 4th Drawer Paper Take-Up Clutch opera-tion 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 Change 4th Drawer Control Board.

T-31

• Paper is at a stop at the Vertical Transport Rollers.

14 4th Drawer Paper Take-Up Motor turns when the Start key is pressed with the 4th Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment). Change motor. Change 4th Drawer Control Board.


1 Paper take-up guide plate or vertical trans-port guide plate is dirty or deformed.


2 Vertical Transport Rollers are dirty with paper dust, deformed, or worn.


3 I/O check for 3rd Drawer Paper Take-Up Sensor operation when the 3rd Drawer is used: the voltage across PJ3A-5A on Con-trol Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked.

YES Change 3rd Drawer Control Board.


4 Vertical Transport Roller 3 turns when the Start key is pressed with 3rd Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, clutch spring opera-tion).

5 I/O check for 4th Drawer Paper Take-Up Sensor operation when the 4th Drawer is used: the voltage across PJ3A-5A on Con-trol Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked.

YES Change 4th Drawer Control Board.


6 Vertical Transport Roller 4 turns when the Start key is pressed with 4th Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, clutch spring opera-tion).


YES Check paper size.


T-32

(7) PF-117 Paper Take-Up Misfeed


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

S1123

PJ7

RSEN123

PJ4

PPSO

BCL

HMOT

RCL

P2CL

P1CL

123

PJ4123456

12

CN14

21

12

CN13

21

12

CN12

21

12

CN11

21

CN3A-6(S1 LED)CN3A-5(S1 ON)CN3A-4(DC5 V)

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

CN4A-12(PPSO LED)CN4A-11(PPSO ON)

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

CN6A-6(HMOT CLK)CN6A-5(DC5 V)CN6A-4(HMOT SIG)CN6A-3(CTND)

CN6A-1(DC24 V)

CN7A-4(RCL ON)CN7A-3(DC24 V)

CN7A-6(P2CL ON)CN7A-5(DC24 V)

CN7A-8(P1CL ON)CN7A-7(DC24 V)

CN4A-10(DC5 V)

PWB-A(LCC Tray)

4004C23TAB

T-33

PF-117 Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is not taken up at all. (Lift 1)

• Paper is not taken up at all. (Lift 2)




3 Lift is dirty, deformed, or damaged. YES Clean or change.

4 Paper Take-Up Roll 1 is dirty, deformed, or scratched.


5 Paper Take-Up Roll 1 turns when the Start key is pressed with Lift 1 used.

NO Correct drive coupling (drive transmitting gear engage-ment, spring operation, belt tension).

6 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.


NO Change LCC Control Board.




3 Lift is dirty, deformed, or damaged. YES Clean or change.

4 Paper Take-Up Roll 2 is dirty, deformed, or scratched.


5 Paper Take-Up Roll 2 turns when the Start key is pressed with Lift 2 used.

NO Correct drive coupling (drive transmitting gear engage-ment, spring operation, belt tension).

6 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.



T-34

• Paper is stationary at the Vertical Transport Roller.


1 Feed Roll is deformed, worn, or dirty with paper dust or other foreign matter.




3 Paper take-up guide plate is dirty, deformed, or damaged.


4 Vertical Transport Roller is dirty with paper dust, deformed, or worn.


5 Vertical transport guide plate is dirty or deformed.


6 I/O check for Paper Standby Position Sen-sor 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.

YES Change LCC Control Board.

NO Check sensor connector for connection. Change sensor.

7 Feed Roll turns when the Start key is pressed with the LCC Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, belt tension).

8 Separator Roll turns when the Start key is pressed with the LCC Drawer selected.

NO Correct drive coupling (spring operation).

9 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.



10 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.


NO Check sensor connector for connection. Change sensor.

11 Vertical Transport Rollers turn when the Start key is pressed with the LCC Drawer selected.


12 LCC Registration Clutch operation when the Start key is pressed with the LCC Drawer selected: the voltage across CN7A-4 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-35

(8) Duplex Paper Take-Up Misfeed


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)

4004C24TAD

PJ3A-1(–)B

PJ3A-3(–)A

PJ2A-1(–)B

PJ2A-3(–)A

PJ40

PC15

CL3

M1

M2

123

PJ10

PC1

321

PI1

21

CN41

12334455

88

11

CN33

22

DC24 V

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

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

PWB-I

PWB-APJ3A-2(B)

PJ3A-4(A)

PJ2A-2(B)

PJ2A-4(A)

4004C24TAD

T-36

Duplex Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is at a stop in the Duplex Unit transport section.

• Paper is at a stop at the Manual Bypass take-up section.


1 Transport Roller is dirty, deformed, or worn. YES Clean or change.

2 Transport Roll is dirty, deformed, or worn. YES Clean or change.

3 Transport guide is dirty, deformed, or dam-aged.


4 Torn piece of paper left at the transport sec-tion.

YES Clean.

5 Duplex Unit Transport Roller 1 turns when the Start key is pressed with the Duplex Unit used.


6 Switchback Motor turns when the Start key is pressed with the Duplex Unit used.

NO Correct drive coupling. Change motor. Change Duplex Control Board.





9 Duplex Unit Transport Motor turns when the Start key is pressed with the Duplex Unit used.

NO Correct drive coupling. Change motor. Change Duplex Control Board.


1 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.



2 Manual Bypass Paper Take-Up Roll is dirty with paper dust, deformed, or worn.


3 Manual Bypass Paper Take-Up Roll turns when the Start key is pressed with the Man-ual Bypass Table used.


4 Manual Feed Paper Take-Up Clutch opera-tion 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.



T-37

3. MALFUNCTIONSThe copier’s 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 tim-ing; 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-38

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 Fault Detection Timing

P-5 AIDC Sensor failure (AIDC Sensor 1)

• All readings of the detection points are 4.8 V or more or the selected reading is 1.0 V or less dur-ing AIDC Sensor intensity correction.

P-6 Cyan Imaging Unit failure • The results of converting the adjustment pattern reading to reflection density on paper fall short of the specified value during max. density adjustment (Vg/Vb adjustment).

• The ATDC Sensor output when 0 gradation mea-surement is taken is 253 (4.96 V) or more during γcorrection.

• The result of converting the adjustment pattern reading to reflection density on paper is 0.4 V or less.

P-7 Magenta Imaging Unit fail-ure

P-8 Yellow Imaging Unit failure

P-9 Black Imaging Unit failure

P-21 Color Shift Correction fail-ure (test pattern failure)

• The calculated value of the CD color shift correc-tion amount is more or less than the specified value.

• The calculated value of the FD color shift correc-tion amount is more or less than the specified value.

P-22 Color Shift Correction fail-ure (correction amount fail-ure)

• The CD registration distance is greater than the specified range during registration correction.

• The FD registration distance is greater than the specified range during registration correction.

• Skew correction amount is more than the specified value.

P-23 Cyan 1st Image Transfer ATVC Failure

• The average value of voltage readings taken by the ATVC adjustment circuit is less than 0.5 V dur-ing ATVC adjustment.

• The average value of voltage readings taken by the ATVC adjustment circuit is 0.5 V or more and less than 0.6 V during ATVC adjustment. Or there are five consecutive adjustment sequences, each exceeding 4.6 V. (ATVC adjustment is made when power is turned OFF and ON. A warning is issued through a minimum of five sequences of turning power OFF and ON.)

P-24 Magenta 1st Image Trans-fer 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

P-28 AIDC Sensor failure (AIDC Sensor 2)

• All readings of the detection points are 4.8 V or more or the selected reading is 1.0 V or less dur-ing AIDC Sensor intensity correction.

T-39

S-1 Gain adjustment failure • 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.

Code Fault Detection Timing

T-40

3-2. Detection Timing by Malfunction Code

Code Description Detection Timing

C0000 Main Motor’s failure to turn The Main Motor Lock signal remains faulty for a pre-determined continuous period of time while the Main Motor is turning.

C0001 Main Motor turning at abnormal timing

The Main Motor Lock signal remains faulty for a pre-determined continuous period of time while the Main Motor remains stationary.

C0010 Imaging Unit Motor C’sfailure to turn

The Lock signal remains faulty for a continuous 1-sec. period after the motor rotation has stabilized and before the motor starts decelerating.

C0011 Imaging Unit Motor C turn-ing at abnormal timing

The Lock signal remains faulty for a continuous 1-sec. period after the motor has completely stopped and before the motor starts accelerating.

C0012 Imaging Unit Motor M’sfailure to turn


C0013 Imaging Unit Motor M turn-ing at abnormal timing


C0014 Imaging Unit Motor Y’s fail-ure to turn


C0015 Imaging Unit Motor Y turn-ing at abnormal timing


C0016 Imaging Unit Motor Bk’sfailure to turn


C0017 Imaging Unit Motor Bk turning at abnormal timing


C0040 Fusing Cooling Fan Motor 2’s failure to turn

A Fusing Cooling Fan Lock signal is detected for a continuous 3-sec. period while Fusing Cooling Fan Motor 2 is turning.

C0046 Fusing Cooling Fan Motor 1’s failure to turn

A Fusing Cooling Fan Lock signal is detected for a continuous 3-sec. period while the Fusing Cooling Fan Motor is turning.

C004C Ozone Ventilation Fan Motor’s failure to turn

An Ozone Fan Lock signal is detected for a continu-ous 3-sec. period while the Ozone Ventilation Fan Motor is turning.

C004E Power Supply Cooling Fan Motor’s failure to turn

A Power Supply Cooling Fan Lock signal is detected for a continuous 3-sec. period while the Power Sup-ply Cooling Fan Motor is turning.

T-41

C0060 Fusing Drive Motor’s fail-ure to turn

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

C0061 Fusing Drive Motor turn-ing at abnormal timing

The Fusing Drive Motor Lock signal remains faulty for a predetermined continuous period of time while the Fusing Drive Motor remains stationary.

C0094 2nd Image Transfer Roller pressure/retraction failure

• The 2nd Image Transfer Pressure Position Sensor 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 Sen-sor is not activated (retracted position) within 3 sec. after the 1st Image Transfer Pressure/Retrac-tion Motor has started turning.

• The 1st Image Transfer Retraction Position Sen-sor is not deactivated (pressed position) within 1.5 sec. after the 1st Image Transfer Pressure/Retrac-tion Motor has started turning.

C0098 Fusing Roller pressure/retraction failure

• No change is observed in the encoder pulse even after the lapse of 0.5 sec. after the Fusing Pres-sure/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 Pres-sure/Retraction Motor has started turning for pres-sure direction during pressure control.

• The Fusing Pressure Position Sensor is not acti-vated (pressed position) even when 31 motor encoder pulses have been counted after the Fus-ing Pressure/Retraction Motor has started turning for pressure direction during pressure control.

C0200 Cyan PC Drum Charge Corona malfunction

The SCD signal remains inactive for a continuous 1-sec. period while charge corona is being output (i.e., the Remote signal is being turned ON).

C0202 Magenta PC Drum Charge Corona malfunction


C0204 Yellow PC Drum Charge Corona malfunction


C0206 Black PC Drum Charge Corona malfunction



T-42

C0400 Exposure Lamp’s failure to turn ON

A Lamp-Out Detection signal is ON after the lapse of 5 sec. after the Exposure Lamp has been turned ON.

C0410 Exposure Lamp turning ON at abnormal timing

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.

C0500 Heating Roller warm-up failure(Fusing Thermistor 1)

• Fusing Thermistor 1 does not detect a predeter-mined 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 Heater Lamp warm-up fail-ure(Fusing Thermistor 2)

• The temperature of Fusing Thermistor 2 does not reach 100 °C within 180 sec. after the warm-up cycle has started.

• 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 low temperature(Fusing Thermistor 1)

• The temperature of Fusing Thermistor 1 remains below 120 °C for 1 sec. or more in the standby 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 high temperature(Fusing Thermistor 1)

The temperature of Fusing Thermistor 1 remains above 220 °C for 1 sec. or more at all times.

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-43

C0650 Scanner Home Sensor malfunction

• 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.

C0660 Scanner overrun failure 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.

C0990 LCC Lift-Up Motor mal-function

See the relevant Option Service Manual.

C0991 LCC Lift 1 ascent motion failure

C0995 LCC Transport Motor mal-function

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 mech-anism malfunction

C0B48 Finishing option Exit Roll pressure/retraction failure

C0B4A Finishing option Storage Roller pressure/retraction failure


T-44

C0B50 Finishing option stapling mechanism 1

See the relevant Option Service Manual.

C0B54 Finishing option stapling mechanism 2

C0B73 Finishing option punch cam motor mechanism malfunction

C0B78 Finishing option punch selector motor mecha-nism malfunction

C0B80 Finishing option Shift Motor mechanism mal-function

C0BA0 Finishing option Elevator Tray drive failure

C0F30 Abnormally low toner den-sity detected by Cyan ATDC Sensor

Toner density that is 2 % or more lower than the tar-get level is detected ten consecutive times during a 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 tar-get level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence.

C0F32 Abnormally low toner den-sity detected by Magenta ATDC Sensor


C0F33 Abnormally high toner density detected by Magenta ATDC Sensor


C0F34 Abnormally low toner den-sity detected by Yellow ATDC Sensor


C0F35 Abnormally high toner density detected by Yellow ATDC Sensor


C0F36 Abnormally low toner den-sity detected by Black ATDC Sensor


C0F37 Abnormally high toner density detected by Black ATDC Sensor


C0F3A Cyan ATDC Sensor adjustment failure

Cyan ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C0F3B Magenta ATDC Sensor adjustment failure

Magenta ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C0F3C Yellow ATDC Sensor adjustment failure

Yellow ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.


T-45

C0F3D Black ATDC Sensor adjustment failure

Black ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C13C8 New Transfer Belt 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. After an image stabilization sequence is com-

pleted, 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.

C13CA New Fusing 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.


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







T-46

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-ure

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.

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.

C3310 CCD clamp/gain adjust-ment failure

• 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 = 0Dgain = 255

C3700 IR Cooling Fan Motor 1 turning at abnormal timing

A Lock signal is detected ten consecutive times 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-47

C3710 IR Cooling Fan Motor 2 turning at abnormal timing


C3720 Original Glass Cooling Fan Motor turning at abnormal timing


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 stabiliza-tion sequence or registration adjustment.

• There is an open-circuit in the communication har-ness between the PIC Board and Master Board.

• Either the PIC Board or Master Board is faulty.

C3A01 PIC Board malfunction The PIC Board is faulty.

C3FFF ROM contents fault detected upon start

The system fails to rewrite flash memory during updating.


T-48

3-3. Troubleshooting Procedures by Malfunction Code

(1) C0000: Main Motor’s failure to turn

C0001: Main Motor turning at abnormal timing

C0000: Main Motor’s failure to turn

C0001: Main Motor turning at abnormal timing


Main Motor (M13) Master Board (PWB-I)DC Power Supply 1 (PU1)


1 Main Motor turns when the Start key is pressed.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement).

2 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.

YES Change motor.


3 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.

NO Change DC Power Supply 1.


1 Main Motor rotation while it is being ener-gized: the voltage across PJ13I-7A on Mas-ter Board and GND remains DC 0 V.


NO Change motor.

M13

PJ10512345678


PU1



PWB-I

4004C01TAA

T-49

(2) C0010: Imaging Unit Motor C’s failure to turn

C0011: Imaging Unit Motor C turning at abnormal timing

C0012: Imaging Unit Motor M’s failure to turn

C0013: Imaging Unit Motor M turning at abnormal timing

C0014: Imaging Unit Motor Y’s failure to turn

C0015: Imaging Unit Motor Y turning at abnormal timing

C0016: Imaging Unit Motor Bk’s failure to turn

C0017: Imaging Unit Motor Bk turning at abnormal timing


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)

PJ12I-6B(Speed CHG)

CL11

CL12

CL14

CL13

PJ8PU1-4(DC5V)PJ8PU1-3(GND)PJ7PU1-2(DC24 V)PJ7PU1-6(GND)

PJ1Y-1(DC5V)PJ1Y-2(GMD)

PJ1Y-3(DC24 V)PJ1Y-4(GND)

PU1

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

PJ2Y-1(M15 REM)PJ2Y-2(M15 LOCK)

PJ2Y-3(Speed CHG)PJ2Y-4(CL11 REM)

PWB-I


PJ1M-1(DC5V)PJ1M-2(GMD)

PJ1M-3(DC24 V)PJ1M-4(GND)

PU1

PJ12I-8A(M16 REM)PJ12I-7A(M16 LOCK)PJ12I-6A(Speed CHG)PJ12I-5A(CL12 REM)

PJ2M-1(M16 REM)PJ2M-2(M16 LOCK)

PJ2M-3(Speed CHG)PJ2M-4(CL12 REM)

PJ1C-1(DC5V)PJ1C-2(GND)

PJ1C-3(DC24 V)PJ1C-4(GND)

PJ2C-1(M17 REM)PJ2C-2(M17 LOCK)

PJ2C-3(Speed CHG)PJ2C-4(CL13 REM)

PWB-I


PU1

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

PWB-I

PJ1K-1(DC5V)PJ1K-2(GND)

PJ1K-3(DC24 V)PJ1K-4(GND)

PJ2K-1(M18 REM)PJ2K-2(M18 LOCK)

PJ2K-3(Speed CHG)PJ2K-4(CL14 REM)


PU1

M15

M16

M17

M18

PJ12I-8B(M18 REM)PJ12I-7B(M18 LOCK)

PJ12I-5B(CL14 REM)

PWB-I

M15

M16

M17

M18

4004C02TAD

T-50

C0010, C0012, C0014, C0016

C0011, C0013, C0015, C0017


1 Imaging Unit Motor turns when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment, coupling engagement). Check that the LED Assy is locked in position.

2 Imaging Unit Motor rotation when the Start key is pressed:Cyan: the voltage across PJ12I-3B on Mas-ter 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 Mas-ter Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.



1 Imaging Unit Motor rotation while it is being energized:Cyan: the voltage across PJ12I-3B on Mas-ter 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 Mas-ter Board and GND remains DC 0 V.


NO Change motor.

T-51

(3) C0040: Fusing Cooling Fan Motor 1’s failure to turn

C0046: Fusing Cooling Fan Motor 2’s failure to turn

C004C: Ozone Ventilation Fan Motor’s failure to turn

C004E: Power Supply Cooling Fan Motor’s failure to turn

C0040


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)


1 Fusing Cooling Fan Motor 1 turns when the Start key is pressed.

NO Check connector for connec-tion. Check fan for overload.

2 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.


NO Change motor.

4004C03TAC

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

PJ14I-13A(M23 LOCK)PJ14I-12A(GND)PJ14I-11A(M23 ON)

PJ10I-14(M22 ON)PJ10I-15(M22 LOCK)

CN2HV3-2(GND)CN2HV3-3(M22 LOCK)

CN2HV3-1(M22 ON)

PJ13PU1-2(GND)PJ13PU1-3(M21 LOCK)

PJ13PU1-1(DC24 V)

PJ6PU1-8(GND)PJ6PU1-9(GND)

PJ6PU1-2(DC24 V)PJ6PU1-1(DC24 V)

PJ1I-4PJ1I-5

PJ1I-3PJ1I-2

M24

CN80123

321

M23

M22

M21

CN31123

321

CN77123

321

67

54

CN65123

321

4567

CN1HV3-1(M22 LOCK)CN1HV3-2(M22 ON)

HV3

PU1PWB-I

4004C03TAC

T-52

C0046

C004C

C004E


1 Fusing Cooling Fan Motor 2 turns when the Start key is pressed.


2 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.

YES Change motor.



1 Ozone Ventilation Fan Motor turns when the Start key is pressed.


2 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.


3 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 deener-gized and DC 0 V when the motor is ener-gized.

YES Change motor.

NO Change High Voltage Unit 3.


1 Power Supply Cooling Fan Motor turns when the Start key is pressed.


2 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.

YES Change motor.


T-53

(4) C0060: Fusing Drive Motor’s failure to turn

C0061: Fusing Drive Motor turning at abnormal timing

C0060

C0061


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


1 Fusing unit driver over-loaded. YES Correct cause of over-load.

2 Fusing Drive Motor turns when the Start key is pressed.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement).

3 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.

YES Change motor.


4 Fusing Drive 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.



1 Fusing Drive Motor rotation while it is being energized: the voltage across PJ13I-1A on Master Board and GND remains DC 0 V.


NO Change motor.

4004C04T

PJ13I-2A(M14 REM)

PJ13I-3A(M14 CLK)PJ13I-4A(DC5 V)PJ13I-5A(GND)PJ13I-6A(M14 CCW/CW)

PJ13I-1A(M14 LOCK)

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

M14

PJ106

21

89

34567

PU1

PWB-I

4004C04TAA

T-54

(5) C0094: 2nd Image Transfer Roller pressure/retraction failure

C0094


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

Master Board (PWB-I)


1 While the 2nd Image Transfer Pressure/Retraction Clutch is supposed to be deener-gized 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.

YES Check connector for connec-tion. Check for overload. Change clutch.


2 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).



CN1412

21

CN6512

7

7

1

6

CN631

5 84

6 7

1

9

PJ108

PC23

321

PJ1224

1

32

PJ14I-4B(DC5 V)PJ14I-5B(GND)


PJ14I-6B(PC23 ON)

PWB-I

CL15

12

12

4004C05TAB

T-55

(6) C0096: Image Transfer Belt pressure/retraction failure

C0096


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



1 1st Image Transfer Pressure/Retraction Motor turns during pressure/retraction oper-ation.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement). Change motor. Change Master Board.

2 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).



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

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

PWB-I

PJ109

CN46

PC28

321

654321

123456

M11

4004C06TAA

T-56

(7) C0098: Fusing Roller pressure/retraction failure


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

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

40


PJ14I-4A(M8 -)PJ14I-5A(M8 +)


PWB-I

PJ12021

PJ136

PC7

321

PJ134

PC8

321

M8

CN4123

123

45

45

24 24

4004C07TAC

T-57

C0098


1 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.

YES Check motor connector for connection. Change motor.


2 I/O check for Fusing Pressure Position Sen-sor 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.


NO Check sensor installation. Correct detecting plate. Check sensor connector for connection. Change sensor.

3 Fusing Pressure/Retraction Motor rotation when the Fusing Roller is pressed: the volt-age across PJ14I-5A on Master Board and GND is DC 0 V when the motor is deener-gized and DC 24 V when the motor is ener-gized.


4 I/O check for Fusing Pressure Position Sen-sor 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).



5 I/O check for Fusing Retraction Position Sensor operation while the Fusing Pres-sure/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.



T-58

(8) 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


Imaging Unit CImaging Unit MImaging Unit YImaging Unit Bk

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

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-12(D.C REM-K)

PJ9I-10(D.C REM-C)

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-11(D.C SCD-K)

PWB-I


PU1

PJ17-12PJ17-11

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

PJ17-10PJ17-9PJ17-8PJ17-7PJ17-6PJ17-5PJ17-4PJ17-3PJ17-2PJ17-1

HV1

4004C08TAB

T-59

C0200, C0202, C0204, C0206


1 Imaging Unit contact failure YES Correct or clean Imaging Unit contact.

2 High Voltage Unit 1 contact failure YES Correct or clean High Voltage Unit 1 contact.

3 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.

YES Change High Voltage Unit 1.


T-60

(9) C0400: Exposure Lamp’s failure to turn ON

C0410: Exposure Lamp turning ON at abnormal timing

C0400/C0410


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

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


1 Exposure Lamp conduction NO Change Exposure Lamp.

2 Temperature Fuse conduction NO Change Temperature Fuse.

3 Flat Cable conduction NO Check for correct installation or change.

4 The problem has been eliminated through the checks of steps up to 3.


5 Exposure Lamp turns ON and OFF cor-rectly after DC Power Supply 2 has been replaced.

NO Change Image Processing Board.

PJ8

PJ7

PJ1Z-1

PJ1Z-3

PWB-Z PWB-Z PU2F4

LA1

12 PJ2Z-5

PJ2Z-3

PJ2PU2-1(DC0 V)

PWB-CPJ2C-11BPJ2C-10BPJ2C-9BPJ2C-8BPJ2C-7B

PJ2PU2-3(DC70 V)

PJ3PU2-5(Lamp CNT)PJ3PU2-4(Lamp Down)PJ3PU2-3(Lamp REM)


4004C09TAB

T-61

(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


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

PJ6I-1B(TH1 ON)PJ6I-2B(GND)PJ6I-3B(TH2 ON)

PJ4PU1-2(N H1)PJ4PU1-1(L)

PJ4PU1-3(N H2)PJ4PU1-4(N H3)

PJ6I-4B(GND)

PJ2I-8(H3 ON)PJ2I-9(H2 ON)

PJ2I-10(H1 ON)

PJ12PU1-2(H1 ON)PJ12PU1-3(H2 ON)PJ12PU1-4(H3 ON)

PWB-I

PU1

CN41

12

1

1213 13

141514

15

17 1718 18

16 16

24 24

FUSINGUNIT

4004C27TAC

T-62

C0500, C0510

C0520

C0501, C0511

C0521


1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is infinity with CN4 (2P) disconnected.

YES Change Fusing Unit.


2 Heating Roller Heater Lamps turn ON. YES Change DC Power Supply 1. Change Master Board.

NO Change Fusing Unit.


1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 Ω (or close to 0) with CN4 (2P) discon-nected.




1 Fusing Unit condition: the resistance across CN4-17 and 18 on the Fusing Unit end is infinity with CN4 (2P) disconnected.



2 Lower Fusing Roller Heater Lamp turns ON. YES Change DC Power Supply 1. Change Master Board.



1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 Ω (or close to 0) with CN4 (2P) discon-nected.



T-63

(11) C0650: Scanner Home Sensor malfunction

C0660: Scanner overrun failure


Scanner Home Sensor (PC24)Scanner Motor (M1)

Scanner Motor Drive Board (PWB-IC)DC Power Supply 2 (PU2)Image Processing Board (PWB-C)

4004C11TAA

PJ26

PC24

321

M1

PJ38123

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

PJ3IC-1(U)PJ3IC-2(V)PJ3IC-3(W)

PJ2IC-6PJ2IC-5PJ2IC-4PJ2IC-3PJ2IC-2PJ2IC-1

PJ1IC-4PJ1IC-3PJ1IC-2PJ1IC-1

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

PJ2IC-7PJ2IC-8

PJ2C-4A(HOLD)PJ2C-5A(M1 CRNT SW1)PJ2C-6A(M1 CRNT SW2)PJ2C-7A(ENABLE)PJ2C-8A(RESET)PJ2C-9A(GND)

PJ2C-2A(CW/CCW)PJ2C-1A(CLK)

PWB-IC

PWB-C

PU2

4004C11TAA

T-64

C0650, C0660


1 Wire comes off. YES Wind wire.

2 Screw of scanner motor loose. YES Correct.

3 Tension in scanner belt. NO Adjust belt tension.

4 Connectors are connected properly on Scanner Motor Drive Board: PWB-IC PJ1IC, PJ2IC, and PJ3IC.

NO Check connectors for connec-tion.

5 Scanner Motor turns when the Start key is pressed.

NO Check connectors for connec-tion. Change motor. Change Scanner Motor Drive Board.

6 I/O check for Scanner Home Sensor: the voltage across PJ6C-2 on Image Process-ing Board and GND is DC 0 V (home posi-tion) when the sensor is blocked and DC 5 V when the sensor is unblocked.

YES Change Image Processing Board.

NO Check sensor for installation. Correct detecting plate. Check sensor connector for connection. Change sensor.

7 “IR Area” check:Malfunction when Power Switch is turned ON after “Top Image” has been set to 0 and “FD-Mag.” to 1.000.

NO Adjust “IR Area” data.

T-65

(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


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)

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

CN4A-9(LS2 ON)CN4A-8(GND)CN4A-7(DC5 V)

CN5A-2(E MOT/CCW)CN5A-1(E MOT/CW)

CN6A-6(H MOT CLK)CN6A-5(DC5 V)CN6A-4(H MOT SIG)CN6A-3(GND)

CN6A-1(DC24 V)

PWB-A

LS2

LS1

PJ3123

PJ6123

CN6A-9(FRONT ON)CN6A-8(GND)CN6A-7(DC5 V)FRONT

PJ1123

PJ5123

456

CN17

21

12

H MOT

E MOT

4004C12TAA

T-66

C0990

C0991

C0995

C0999


1 LCC Lift-Up Motor turns after the LCC Drawer has been slid into position while the LCC Drawer is being used.

NO Change motor. Change LCC Control Board.


1 Lift 1 ascends after the LCC Lift-Up Motor has been energized.

NO Correct drive coupling (one-way gear engagement, cou-pling engagement, spring operation, and belt tension).

2 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).


NO Check sensor for installation. Check sensor connector for connection. Change sensor.


1 LCC Lift-Up Motor turns when the Start key is pressed while the LCC Drawer is being used.

NO Change motor. Change LCC Control Board.


1 Lift 2 ascends after the LCC Lift-Up Motor has been energized.

NO Correct drive coupling (one-way gear engagement, cou-pling engagement, spring operation, and belt tension).

2 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).


NO Check sensor for installation. Check sensor connector for connection. Change sensor.

T-67

(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


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)

4004C13TAA

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)

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

PJ5I-8A(A-A3)

PJ5I-10A(B-B3)

PJ5I-7A(– A-A1)

PJ5I-9A(– B-B1)

PWB-ICN35

43

12

2314

CN50

1211

12

103948576675849310211112

CN36

43

12

2314

CN72

10

4

1

73829110

M10

M9

PWB-N3PJ90N3-4(TH3 OUT)

PJ90N3-3(GND)PJ90N3-2(DC5 V)

PJ90N3-1(UN35 REM)

PWB-N2PJ89N2-4(TH2OUT)


PJ89N2-1(UN34 REM)



PJ88N1-1(UN33 REM)

4004C13TAA

T-68

C0F30, C0F32, C0F34

C0F31, C0F33, C0F35


1 Image density is low. YES T-101

2 ATDC Sensor spring moving part operates properly.

NO Correct.

3 ATDC Sensor LED is dirty. YES Clean.

4 ATDC Sensor LED emits light properly. NO Check connector for connec-tion. Check harness.


NO Change Master Board.Replace ATDC sensor and IU.


1 ATDC Sensor window is dirty. YES Clean.

2 Bias voltage is properly applied to the ATDC Sensor window.

NO Check wiring.Check contact section.



T-69

(14) C0F36: Abnormally low toner density detected by Black ATDC Sensor/

C0F37: Abnormally high toner density detected by Black ATDC Sensor

C0F36

C0F37


Imaging Unit BkToner Replenishing Motor C/Bk (M9)



1 Image density is low. YES T-101

2 The problem has been eliminated through the check of step 1.

NO Check and correct Hopper.




1 Imaging Unit Bk is installed correctly. NO Check and correct ATDC drawer CN of imaging unit Bk.

2 Each of Imaging Unit Bk contacts makes good contact.

NO Clean or correct.

3 ATDC Sensor harness is open-circuited. YES Change Imaging Unit Bk.

PWB-ICN36

43

12

2314

M9

PJ13I-4BPJ13I-3BPJ13I-5BPJ13I-6B

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

Imaging Unit(Bk)

4004C26TAB

T-70

(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


ATDC Sensor C (PWB-N3)ATDC Sensor M (PWB-N2)ATDC Sensor Y (PWB-N1)Imaging Unit Bk

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

PWB-N3

CN50

1211

12

1039487

56

675843

910

211112

PJ13I-4BPJ13I-3BPJ13I-5B

PJ90N3-4(TH3 OUT)PJ90N3-3(GND)

PJ90N3-2(DC5 V)PJ90N3-1(UN35 REM)

Imaging Unit(Bk)

PWB-N2PJ89N2-4(TH2OUT)


PJ89N2-1(UN34 REM)



PJ88N1-1(UN33 REM)

PJ13I-6B

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)

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

PJ5I-8A(A-A3)

PJ5I-10A(B-B3)

PJ5I-7A(– A-A1)

PJ5I-9A(– B-B1)

PWB-ICN35

43

12

2314

CN36

43

12

2314

CN72

10

4

1

73829110

M10

M9

4004C25TAC

T-71

C0F3A, C0F3B, C0F3C

COF3D

(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


1 ATDC Sensor window is dirty. YES Clean.

2 Imaging Unit window for ATDC Sensor is dirty.

YES Clean.

3 LED retracting lever is locked in position. NO Slide out the Imaging Unit and then reinstall.


NO Check ATDC Sensor connec-tor. Change ATDC Sensor.

5 The problem is eliminated after the ATDC Sensor has been replaced.

NO Change Imaging Unit.

6 The problem is eliminated after the Imaging Unit has been replaced.



1 Imaging unit Bk is installed correctly. NO Check and correct ATDC drawer CN of imaging unit Bk.

2 Trouble in COF3D is indicated again. YES Change Imaging Unit.


NO Check harness. Check con-nector for connection. Change Master Board.


1 Each unit is installed properly in the copier (good contact connection).


NO Reinstall.

T-72

(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


1 Imaging Unit is installed properly. NO Reinstall.

2 Connector between the Imaging Unit and copier is dirty.

YES Clean.





T-73

(18) C3310: CCD clamp/gain adjustment failure

Clamp/Gain Adjustment Values

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 differ-

ence of up to 30 is allowed between RO and RE, between GO and GE, and between BO and BE.

C3310


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

CCD Sensor Board (PWB-A)Image Processing Board (PWB-C)

RO RE GO GE BO BE

Clamp 130 130 130 130 130 130

RO RE GO GE BO BE

Gain 160 160 170 170 160 160

Lamp Adjust-ment Value

135


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

2 There is a wide difference between the clamp and gain adjustment values, the value being close to “0” or “255.”

YES Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board.

3 Clamp adjustment value exceeds the allow-able range.

YES Reinstall covers, as extrane-ous light is the cause of the problem.

4 The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great.

YES Clean lens, mirrors, CCD sur-face, shading sheet, and related parts.

5 The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small.

YES Reinstall covers, as extrane-ous light is the cause of the problem.Change Scanner, as the reflectors are deformed.

T-74

(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

C3700

C3710

C3720


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)


1 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.


NO Change motor.


1 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.


NO Change motor.


1 Original Glass Cooling Fan Motor rotation: the voltage across PJ2C-6B on Image Pro-cessing Board and GND remains DC 0 V while the motor is turning.


NO Change motor.


PJ2C-5B(GND)PJ2C-6B(M2 LOCK)

PJ2C-4B(M2 REM)

M4

CN22123

321

M3

CN2123

321

PJ6C-5(GND)PJ6C-6(M3 LOCK)

PJ6C-4(M3 REM)

PJ6C-8(GND)PJ6C-9(M4 LOCK)

PJ6C-7(M4 REM)

PJ1C-1PJ1C-2

M2

CN3123

321

PWB-C

PU2

4004C19TAB

T-75

(20) C3A00: PIC communication error

C3A01: PIC Board malfunction

C3FFF: ROM contents fault detected upon start

C3A00

C3A01

C3FFF


1 Harnesses and connectors connecting PIC Board to Master Board are in good condi-tion.

NO Change harnesses. Recon-nect connectors.


NO Change PIC Board.

3 The problem is eliminated after the PIC Board has been replaced.



1 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.

YES Change PIC Board.


1 This malfunction occurs when an attempt is made to update firmware (rewriting of flash ROM).

YES Try downloading again.



T-76

3-4. Malfunctions related to power supply

(1) Power is not turned ON.


DC power supply 2 (PU2)


1 Power cooling fan rotates when main switch is turned ON.

NO T-77

2 Power voltage is applied to IR power plug when main switch is turned ON.

NO T-78-1

3 Scanner operates and exposure lamp lights when main switch is turned ON.

NO Replace power supply 2.

YES T-78-2

T-77

(2) Engine and IR are not turned ON.


Master Board (PWB-1) DC power supply 1 (PU1)


1 Power voltage is supplied to power outlet. NO Secure power supply.

2 Power voltage is supplied to PJ3PU1 and 2 on DC power supply 1.

NO Check wiring between power outlet and PJ3PU1.

3 Fuse (F1) on DC power supply 1 is conduct-ing.

NO Replace DC power supply 1.

4 DC 5 V is output from PJ11PU1-2/12 on DC power supply 1.

NOReplace DC power supply 1.

5 DC 5 V is input to PJ1I-6/7 on master board.

NO Check wiring between PJ11PU1 on DC power sup-ply and PJ1I on master board.

YES Replace master board.

PJ1I-7

PJ1I-6

PJ3PU1-1

PJ3PU1-2

N BkW

L

PWB-IPJ11PU1-12(DC5 V)PJ11PU1-2(DC5 V)

PU1

11

CN12CN88

22PG1

4004C31TAB

T-78

(3) No Power is Supplied to Options.


DC Power Supply 1 (PU1) DC Power Supply 2 (PU2)


1 Power source voltage is applied to DC Power Supply 1.

NO Check wiring.

2 DC 24 V is output from DC Power Supply 1 and DC Power Supply 2.

NO Change DC Power Supply 1. Change DC Power Supply 2.

3 There is an open-circuit in the harness from DC Power Supply 1 and DC Power Supply 2 to option connector.

YES Change harness.

PJ5PU1-2(DC24 V) CN60-11CN60-5

CN62-2CN62-1

CN82-1CN83-1CN82-2CN83-2

CN5-11CN5-5

PJ5PU1-3(GND)


PJ5PU1-6(DC24 V)


PJ7PU1-5(GND)

PU1 Sorter

Duplex

Tray

ADFPU2

L

N

4004C28TAA

T-78-1

(3) Only power cooling fan rotates.


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

DC power supply 1 (PU1)


1 Fuses (F2, F3) on DC power supply 1 are conducting.


2 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.


3 DC3.3 V is input to PJ1H-1 on MSC board, and DC5 V is also input to PJ1H-2.

NO Check wiring between PJ9/10 on DC power supply 1 and PJ1 on MSC board.

4 DC5 V is input to PJPWR1-1/2 on PIC board, and DC3.3 V is also input to PJPWR1-5/6.

NO Check wiring between PJ8/10 on DC power supply 1 and PJPWR1 on PIC board.

YES Replace MSC board or PIC board.

PJPWR1-6PWB-PIC

PWB-HPU1PJ1H-1

PJ1H-2

PJPWR1-5

PJPWR1-2

PJPWR1-1

PJPWR2-6PJ8PU1-6(DC5 V)

PJ8PU1-5(DC5 V)

PJ9PU1-6(DC5 V)

PJ10PU1-7(DC3.3 V)

PJ10PU1-6(DC3.3 V)

4004C32TAB

T-78-2

(4) Control panel indicators do not light.


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)


1 I/F cable between IR and engine is securely set.

NO Reset, or replace I/F cable.

2 Fuse (F103) on DC power supply 1 is con-ducting.


3 PJ18 on master board is securely set. NO Reset.

4 Flat cable between MSC board and PIC board is securely set.

NO Reset or replace flat cable.

5 PJ30 on control panel and PJ3 on IR PRIF board are securely set.

NO Reset.

YES Replace master board, PIC board, IR PRIF board, MSC board or control panel.

T-79

4. IMAGE QUALITY PROBLEMS4-1. Troubleshooting Image Quality Problems

• This chapter is divided into two parts: “Initial Check Items” and “Troubleshooting Proce-dure 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 Items1. First determine which of the following three is responsible for the image quality prob-

lem: the input system (IR), interface system, or the output system (printer).When an image quality problem occurs, possible causes that are likely to be responsi-ble 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 responsi-ble for the problem.

CCD Sensor

Printer Test print

IR Test printImage Processing Boad

PIC Board

I/F Cable

LED Drive

IR Area

I/F Area

Printer Area

4004T006CA

T-80

Step Symptom Check Result CauseRef. Page

1

Gradation fail-ure, density failure

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” → “Gradation Pattern” → “4Color.”

YES Printer T-96

NO To step 2 –

Uneven den-sity, pitch noise, or image noise (lines, bands, spots, etc.)

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.”

YES Printer T-96

NO To step 2 –

Foggy back-ground

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 “Den-sity.”

YES Printer T-96

NO To step 2 –

Color reproduc-tion failure

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” → “Color Sample” → Enter “255” in “Density.”

YES Printer T-96

NO To step 2 –

2Abnormal image

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” → “IR Test Pattern.”

YES Interface T-93

NO IR T-82

T-81

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.

Step Symptom Check Result CauseRef. Page

1

Gradation fail-ure, density failure

The faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” →

“Gradation Pattern” → “4 Color.”

YESPrinter 4 color

T-114

NOPrinter mono-color

T-96

Uneven den-sity, pitch noise, or image noise (lines, bands, spots, etc.)

The faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” →

“Halftone Pattern” → “C → M → Y → Bk” → Enter “64” in “Density.” →

Select “Hyper.”

YESPrinter 4 color

T-114


T-96

Foggy back-ground

he faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” →

“Halftone Pattern” → “C → M → Y → Bk” → Enter “0” in “Density.”

YESPrinter 4 color

T-114


T-96

4 colors

Mono color

4004T008CA

T-82

4-3. Troubleshooting Procedure by a Particular Image Quality

Problem(1) IR Scanner System: white lines in FD, white bands in FD, colored lines in FD,

and colored bands in FD

<Typical Faulty Images>

<Troubleshooting Procedure>

Section Step Check Item Result Action

Original 1 Original is damaged or dirty. YES Change original.

Original Cover

2 Original Pad is dirty. YES Clean.

Original Glass

3 Original Glass is dirty. YES Wipe the surface clean with a soft cloth.

Shading sheet

4 Shading sheet is dirty. YES Wipe the surface clean with a soft cloth.

Mirror, lens, Exposure Lamp, and reflectors

5 Mirror is dirty. YES Clean.

Lens is dirty. YES Clean.

Exposure Lamp is dirty. YES Clean.

Reflectors are dirty. YES Clean.

System setting

6 S/No. of IR is correctly input. NO Re-input.

Left Image (Tech. Rep. function)

7 The Scanner starts reading the image at the position of 0 mm from the scale.

NO Adjust the image reading position in the range of ±10 mm.

IR 8 The white lines/bands or col-ored lines/bands are blurry.

YES Change Scanner Assy.

9 The white lines/bands or col-ored lines/bands are clear and distinct.

YES Change CCD Unit.

White lines in FD Colored lines in FDWhite bands in FD Colored bands in FD

4011T015AA 4011T020AA 4011T017AA 4011T023AA

T-83

(2) IR Scanner System: white lines in CD, white bands in CD, colored lines in CD,

and colored bands in CD





OriginalCover


OriginalGlass


Flat cable 4 Flat cable terminal is con-nected properly.

NO Clean terminal. Reconnect. Change flat cable.

Top Image (Tech. Rep. function)

5 The Scanner starts reading the image at the position of 0 mm from the scale.

NO Adjust the image reading position in the range of ±10 mm.

IR 6 The problem has been elimi-nated through the checks of steps up to 5.

NO Change Scanner Assy.

7 The problem is eliminated after the Scanner Assy has been replaced.

NO Change CCD Unit.

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

4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-84

(3) IR Scanner System: color spots

<Typical Faulty Image>




OriginalCover


OriginalGlass





NO Change CCD Unit.

C F

Color spots

4011T027AA

T-85

(4) IR Scanner System: fog




Warning display

1 Maintenance call mark S-2 (intensity adjustment failure) is displayed.

YES Carry out remedial action pro-cedures for S-2 as part of image stabilizer malfunction troubleshooting procedures.

2 Maintenance call mark S-1 (gain adjustment failure) is dis-played.



OriginalCover


5 Original Cover does not lie flat. YES Change Original Cover if it is deformed or hinges are bro-ken.

OriginalGlass


Shading sheet







Exposure setting (panel set-ting)

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

NO Change the exposure mode to Manual.

Fog

4011T004AA

T-86




NO Change CCD Unit.


T-87

(5) IR Scanner System: blurred image, blotchy image




OriginalCover


OriginalGlass

2 Original Glass tilts. YES Position Original Glass cor-rectly. Check original loading position.

IR 3 Scanner is not aligned with the 2nd/3rd Mirrors Carriage.

YES Readjust with the Scanner/Mirrors Carriage Positioning Jigs.

4 The problem has been elimi-nated through the checks of steps up to 3.



NO Change CCD Unit.

Blurred image, blotchy image

4011T046AA

T-88

(6) IR scanner system: Color shift, sync shift (lines in CD)




Original Cover


Slide rails 2 Foreign matter on rails. YES Clean, lubricate.

Scanner assy

3 Scanner assy moves smoothly. NO Adjust scanner motor belt ten-sion. Replace bush. Replace scanner motor.

Drive Cables

4 Cable kinks or is damaged. YES Correct or change.


NO Change CCD Unit.

C FC F

4011T039AA

T-89

(7) IR Scanner System: moire




Original 1 Moire distortions occur. YES Change original loading direc-tion.

Original 2 Moire distortions recur even after the orientation of original has been changed.

YES Change the original mode (select one other than that resulted in moire).

Mode change

3 Moire distortions recur even after the original mode has been changed.

YES Select “Gradation” (mode optimized for gradation) or “Resolution” (that optimized for resolution).


NO Change the zoom ratio.

4011T040AA

Moire

T-90

(8) IR Scanner System: skewed image




Original 1 Original is skew. YES Reposition original.

OriginalGlass

2 Original Glass is in positive contact with the flat spring without being tilt.

NO Reinstall the glass. Check the original loading position.

2nd/3rd Mirrors Car-riage

3 Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage.





NO Change CCD Unit.

C F

Skewed image

4011T048AA

T-91

(9) IR Scanner System: distorted image




Installation 1 IR is installed on a level sur-face if mounted without any rack.

NO Reinstall.

Rack is installed on a level sur-face.

NO Reinstall.

Rack is tilt with a lot of play. YES Adjust rack legs.

2nd/3rd Mirrors Car-riage

2 Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage.


Scanner Motor

3 Scanner Motor turns smoothly. NO Change belt. Change Scan-ner Motor.




NO Change CCD Unit.

Distorted image

4011T045AA

ABCDEABCDEABCDEABCDEABCDE

T-92

(10) IR Scanner System: low image density, rough image




Warning display

1 Maintenance call mark S-2 (intensity adjustment failure) is displayed.


2 Maintenance call mark S-1 (gain adjustment failure) is dis-played.


Original 3 Original sticks to Original Glass.

YES Reposition original.

OriginalGlass


Shading sheet







Exposure Lamp

7 The problem has been elimi-nated through the check of step 6.

NO Clean or change Exposure Lamp.

IR 8 The problem is eliminated after the Exposure Lamp has been changed.


9 The problem is eliminated after the Scanner Assy has been changed.

NO Change CCD Unit.

Low image density

4011T003AA

T-93

(11) IR Scanner System: defective ACS




ACS Deter-mination Level Adjust (User’sChoicefunction)

1 ACS failure occurs. YES Change ACS Determination Level Adjust function.

The problem persists even after the ACS Determination Level Adjust function has been changed.

YES Change the original loading direction. Make manual set-tings according to the type of original. (If the original con-tains a colored area in one of its corners, the copier may fail to properly detect the colored area.)

Defective ACS

ABCDECF

ABCDEABCDEABCDEABCDE

Colored Area of Original

Black-and-White Area of Original

4011T052AA

T-94

(12) IR Control System: blank copy, black copy




Cable con-necting IR and printer

1 Connector is connected prop-erly with no pins bent.

NO Reconnect.

Image Pro-cessing Board

2 Connectors on the Image Pro-cessing Board are connected properly.

NO Reconnect.

Connection between IR and printer

3 The problem has been elimi-nated through the check using IR test pattern.

NO Change I/F connection cable.


4 The problem is eliminated after the I/F connection cable has been changed.


PIC Board 5 The problem has been elimi-nated through the checks of steps up to 4.


Blank copy Black copy

4011T036AA 4011T035AA

T-95

(13) IR Control System: abnormal image




Cable con-necting IR and printer

1 Connector is connected prop-erly with no pins bent.

NO Reconnect.

Cable con-nection between Fiery I/F board and PIC board

2 Connectors are securely set. NO Reconnect.


3 Connectors on the Image Pro-cessing Board are connected properly.

NO Reconnect.

PIC Board 4 If the copy contains part of data on the previous page together with that on the cur-rent page, the expanded mem-ory (rim) is properly mounted to the PIC Board.

NO Reinstall expanded memory.

Connection between IR and printer

5 The problem has been elimi-nated as checked on IR test prints produced.

NO Change interface connection cable.


6 The problem is eliminated after the interface connection cable has been changed.


PIC Board 7 The problem is eliminated through the checks of steps up to 6.


ABCDEABCDEABCDEABCDEABCDE

Abnormal image

4011T053AA

CF

ABCDEABCDEABCDE

Abnormal image

Data on previous page

Data on current page

4011T063AA

Abnormal image

4004T010AB

T-96

(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




Image check

1 Line or band is sharp. YES Go to step 4

2 Line or band continues edge to edge.

YES Go to step 3

Imaging Unit

3 The surface of the PC Drum is scratched.

YES Change Imaging Unit.

LED Assy 4 The surface of the lens array is dirty.

YES Clean with cleaning jig.

Imaging Unit

5 Dirty on the outside. YES Clean.

6 Connectors and contact termi-nals make good connection between each Imaging Unit and LED Assy.

NO Clean contact terminals. Reconnect.

7 Developing bias contact termi-nal makes good connection.

NO Clean contact terminal and check terminal position.



White lines in FD White bands in FD Colored lines in FD Colored bands in FD


4011T015AA 4011T020AA 4011T017AA 4011T023AA

4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-97

Transfer Belt Unit


NO Change Transfer Belt Unit.

LED Assy 10 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Assy.


T-98

(15) Printer Monocolor: uneven density in FD




Image check

1 Edge of uneven density area is sharp.

YES Go to step 4

2 Void areas are visible. YES Check LED unit connector. Replace LED assy.

LPH rank 3 Rank indication of LED assy matches LPH setting.

NO Reset LPH rank.

High image density original

4 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).

YES 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.

LED Assy 5 LED retracting lever is locked in position.

NO Slide out the Imaging Unit and reinstall.

Imaging Unit






Transfer Belt Unit

9 Cam gear operates properly. NO Change Transfer Belt Unit.

Imaging Unit


NO The problem is eliminated after the Imaging Unit has been replaced.

Transfer Belt Unit




NO Change LED Assy.

Uneven density in FD Uneven density in FD

4011T031AA

4011T042AA

Uneven density in FD (Void areas)

4004T011AA

T-99

LED Unit 13 The problem is eliminated after the LED Assy has been replaced.

NO Change LED Unit.

PIC Board 14 The problem is eliminated after the LED Unit has been replaced.


High Volt-age Unit 2

15 The problem of uneven density in CD is eliminated after the PIC Board has been replaced.



T-100

(16) Printer Monocolor: uneven density in CD






Imaging Unit






Transfer Belt Unit

5 Transfer Belt Unit makes posi-tive contact with plates on rails.

NO Check and correct contacts.


Imaging Unit



Transfer Belt Unit




NO Change LED Assy.


NO Change LED Unit.




12 The problem of uneven density in CD is eliminated after the PIC Board has been replaced.


Uneven density in CD Uneven density in CD

4011T032AA 4011T043AA

T-101

(17) Printer Monocolor: low image density




Level His-tory 1 (Tech. Rep. function)

1 Check ATDC data. - Go to next step.

2 AIDC output value is around 4.5 V.

NO Clean AIDC Sensor. Check Transfer Belt for damage.

3 Check Vg and Vb values.Color Vb: Around 400 V

Vg: Around 500 VBlack Vb: Around 800 V

Vg: Around 900 V

- Go to next step.

Level His-tory data check results

4 Low ATDC and low Vg and Vb YES Go to step 5.

Low ATDC and high Vg and Vb YES Go to step 12.

ATDC falling within specified range and low Vg and Vb

YES Go to step 5.

ATDC falling within specified range and high Vg and Vb

YES Go to step 9.



Imaging Unit

6 Imaging unit, LED assy side connector and contact section are dirty.

YES Clean.




ATDC Sen-sor window

9 Color ATDC sensor windows and contacts on both LED assy side and IU side are dirty.

YES Clean. Change ATDC. Change Imaging Unit.

Transfer Belt Unit

10 Transfer Belt Unit makes posi-tive contact with plates on rails.

NO Check and correct contacts.


Imaging unit

12 Shutters of IU and hopper open.

NO After re-set, replenish toner.

Low image density

4011T003AA

T-102

Hopper Unit 13 Connectors are loose. YES Reconnect.

14 Gear is cracked. YES Replace gear or hopper unit.

15 Toner empty lever and/or detecting switch are defective.

YES Replace hopper unit. Replace detecting switch.

Toner replenish-ing

16 T/C is normal after toner is replenished.

NO Replace toner replenishing motor or hopper unit.

Gradation Adjust (Tech. Rep. function)

17 Data after three cycles of Gra-dation Adjust falls within the specified range.Max: 0 ±100Highlight = 0 ±60

NO Run another cycle of Grada-tion Adjust. Go to next step if it does not still make data okay.

PRT Max Density (Tech. Rep. function)

18 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabiliza-tion.

NO Go to next step.

PRT High-light (Tech. Rep. func-tion)

19 After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization.

NO Go to next step.

Reset + Stabilizer (Tech. Rep. function)

20 After the Reset + Stabilizer sequence has been com-pleted, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Den-sity and PRT Highlight. There-after, run Stabilizer again.

NO Go to next step.

ATDC Sen-sor


NO For color, change ATDC Sen-sor and Imaging Unit at once. For black, change Imaging Unit.

Imaging Unit



Transfer Belt Unit




NO Change LED Assy.


NO Change LED Unit.







T-103

(18) Printer Monocolor: gradation reproduction failure




Originalmode

1 Original type and screen pat-tern are selected properly.

NO Change screen pattern.


YES Slide out the Imaging Unit and reinstall.

Imaging Unit

3 Imaging Unit and LED Assy connectors are dirty.

YES Clean.

Imaging Unit




ATDC Sen-sor window

6 The color ATDC Sensor win-dow on the LED Assy and the ATDC Sensor window on the Imaging Unit are dirty.

YES Clean.

Level His-tory 1 (Tech. Rep. Function)





NO Run another cycle of Grada-tion Adjust. If the specifica-tions are not met yet, go to next step.



NO Go to next step.

Gradation reproduction failure Gradation reproduction failure

4011T034AA 4011T029AA

T-104



NO Go to next step.



NO Go to next step.

Imaging Unit



LED Assy 13 The problem is eliminated after the Imaging Unit has been replaced.

NO Change LED Assy.


NO Change LED Unit.







T-105

(19) Printer Monocolor: foggy background




Level His-tory 1 (Tech. Rep. function)

1 ATDC data is within ±1 % of the target value.

NO Readjust.



3 Vg and Vb values are correct.Color Vb: Around 400 V

Vg: Around 500 VBlack Vb: Around 800 V

Vg: Around 900 V

NO Go to next step.

Level His-tory data check results

4 High ATDC and low Vg and Vb YES Go to step 16.

High ATDC and high Vg and Vb

YES Go to step 5.

ATDC falling within specified range and low Vg and Vb

YES Go to step 20.

ATDC falling within specified range and high Vg and Vb

YES Go to step 5.



Imaging Unit

6 Imaging Unit and LED Assy connectors are dirty.

YES Clean.


ATDC Sen-sor window

8 The color ATDC Sensor win-dow on the LED Assy is dirty.

YES Clean. Change ATDC. Change Imaging Unit.


9 High Voltage Unit 2 connector is connected properly.

NO Reconnect.



NO Run another cycle of Grada-tion Adjust. Go to next step if it does not still make data okay.

Foggy background

4011T004AA

T-106

Back-ground Voltage Margin (Tech. Rep. function)

11 After Background Voltage Mar-gin has been adjusted, run Stabilizer to reflect the adjust-ment value in image stabiliza-tion.

NO Go to next step.



NO Go to next step.



NO Go to next step.



NO Go to next step.

Imaging Unit




NO Change LED Assy.


17 The problem is eliminated after the LED Assy has been replaced.


PIC Board 18 The problem is eliminated after High Voltage Unit 2 has been replaced.



T-107

(20) Printer Monocolor: void areas, white spots




Image check

1 There are void areas at the front side or high density sec-tion.

NO T-101

Imaging Unit



Imaging Unit


Hopper Unit 4 Foreign matter or caked toner in the Hopper.

YES Remove foreign matter.

Imaging Unit




NO Change LED Assy.

Void areas White spots

4011T008AA

4011T030AA

T-108

(21) Printer Monocolor: colored spots




Imaging Unit

1 Developing bias contact termi-nal makes good connection.

NO Clean contact terminal and check terminal position.






Imaging Unit




NO Change LED Assy.

C F

Colored spots

4011T027AA

T-109

(22) Printer Monocolor: blurred image






2 The surface of the lens array is dirty.


3 LED Unit positioning pin is loose.

YES Change LED Assy.

Imaging Unit





NO Change LED Assy.

Blurred image

4011T046AA

T-110

(23) Printer Monocolor: blank copy, black copy




Imaging Unit

1 Coupling of Imaging Unit drive mechanism is installed prop-erly.

NO Check and correct drive trans-mitting coupling. Change Imaging Unit.

2 The PC Drum Charge Corona voltage contact or PC Drum ground contact of the Imaging Unit is connected properly.

NO Check, clean, or correct the contact.


3 Connector is connected prop-erly.

NO Reconnect.



PIC Board 5 The problem is eliminated after High Voltage Unit 2 has been replaced.


LED Unit 6 The problem is eliminated after the PIC Board has been replaced.

NO Change LED Unit.

Blank copy Black copy

4011T035AA 4011T036AA

T-111

(24) Printer Monocolor: 0.5 to 1.0-mm-pitch uneven image






Imaging Unit




NO Change LED Assy.


NO Change LED Unit.

0.5 to 1.0-mm-pitch uneven image

4004T012CA

T-112

(25) Printer Monocolor: 2-mm-pitch uneven image




Imaging Unit

1 The drive mechanisms for spent toner conveying and Imaging Unit are dirty.

YES Clean.



2 mm

2-mm-pitch uneven image

4011T059AA

T-113

(26) Printer Monocolor: 94-mm-pitch uneven image




Imaging Unit



2 94-mm-pitch uneven image occurs on the image.

YES Store the Imaging Unit in a dark place overnight.



Transfer Belt Unit

4 Transfer Belt Unit drive gear is intact.

NO Correct. Change Transfer Belt Unit.

Transfer Roller Unit

5 Transfer Roller is damaged. YES Change Transfer Roller Unit.

4011T047AD

94 mm 94 mm94 mm

94-mm-pitch uneven image 94-mm-pitch uneven image

4011T057AA 4011T058AA


T-114

(27) Printer 4-Color: white lines in FD, white bands in FD, colored lines in FD, and

colored bands in FD




Transfer Belt Unit

1 Fingerprints, oil, or other for-eign matter is evident on the Transfer Belt.

YES Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.)

2 Transfer Belt is dirty or scratched.

YES Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged.

3 Cleaning Blade is not effective in removing toner completely.

YES Clean or change Transfer Belt Unit.


4 Transfer Roller is dirty or scratched.

YES Change Transfer Roller Unit.

Paper path 5 There is foreign matter on paper path.


6 Image Transfer Paper Separa-tor Fingers are damaged or dirty.


7 Paper dust accumulates on Paper Dust Remover.

YES Clean.

Fusing Unit 8 Fusing Belt is dirty or scratched.


9 Fusing Entrance Guide Plate is dirty or damaged.


10 Fusing Paper Separator Fin-gers are dirty.

YES Clean.

Fusing Web Unit

11 Web is properly taken up. NO Change Fusing Web Unit.

Oil Coating Unit

12 Oil exudes more than appropri-ate.

YES Change Oil Coating Unit.

White lines in FD White bands in FD Colored bands in FDColored lines in FD

4011T015AA 4011T020AA 4011T017AA 4011T023AA

T-115



NO Change Transfer Roller Unit.

Transfer Belt Unit

14 The problem is eliminated after the Transfer Belt Cleaner has been cleaned.



NO Change LED Assy.


NO Change LED Unit.

Paper Dust Remover

17 The problem is eliminated after the LED Unit has been replaced.

NO Change Paper Dust Remover.

PIC Board 18 The problem is eliminated after the Paper Dust Remover has been replaced.



T-116

(28) Printer 4-Color: white lines in CD, white bands in CD, colored lines in CD, and

colored bands in CD




Transfer Belt Unit












Oil Coating Unit



Paper Dust Remover

7 Paper dust accumulates. YES Clean.




Transfer Belt Unit

9 The problem is eliminated after the Transfer Roller Unit has been replaced.



NO Change LED Assy.


NO Change LED Unit.


4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-117

Paper Dust Remover

12 The problem is eliminated after the LED Unit has been replaced.


PIC Board 13 The problem is eliminated after the Paper Dust Remover has been replaced.



T-118

(29) Printer 4-Color: uneven density in FD




Transfer Belt Unit





3 Terminal is dirty. YES Clean.


4 Transfer Roller is installed properly.

NO Reinstall.





Transfer Belt Unit



Uneven density in FD Uneven density in FD

4011T031AA

4011T042AA

T-119

(30) Printer 4-Color: uneven density in CD




Transfer Belt Unit








NO Reinstall.





Transfer Belt Unit




8 The problem is eliminated after the Transfer Belt Unit has been replaced.


Uneven density in CD Uneven density in CD

4011T032AA 4011T043AA

T-120

(31) Printer 4-Color: low image density




Paper 1 Paper is damp. YES Change paper to one just unwrapped from its package. Install Paper Dehumidifying Heater.

Transfer Belt Unit








NO Reinstall.



Paper path 7 Charge Neutralizing Cloth is not separated and ground ter-minal is connected properly.

NO Correct or change.

AIDC Sen-sor

8 Sensor is dirty. YES Clean with blower brush.






NO Go to next step.

Low image density

4011T003AA

T-121



NO Go to next step.



NO Go to next step.




Transfer Belt Unit



LED Unit 15 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Unit.







T-122

(32) Printer 4-Color: poor color reproduction





Transfer Belt Unit








NO Reinstall.



AIDC Sen-sor

7 Sensor is dirty. YES Clean with blower brush.






NO Go to next step.



NO Go to next step.

Poor color reproduction

4011T050AA

T-123



NO Go to next step.




Transfer Belt Unit



LED Unit 14 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Unit.







T-124

(33) Printer 4-Color: incorrect color image registration




Warning display

1 Warning display of P-5 (AIDC Sensor 2 failure) or P-28 (AIDC Sensor 1 failure) is dis-played.

YES Carry out remedial action pro-cedures for P-5 or P-28 as part of image stabilizer mal-function troubleshooting pro-cedures.

Machine condition

2 Vibration is given to copier after Power Switch has been turned ON.

YES Turn OFF and ON Power Switch.



Transfer Belt Unit





6 Drive coupling to the copier is dirty.

YES Clean.

Imaging Unit





NO Reinstall.



Fusing speed detection section

10 Detecting lever operates smoothly.

NO Replace detecting sensor. Replace fusing unit.

11 Shorting connector for speed correction is securely set.

NO Re-set.

12 Problem is solved after check-ing step 11.

NO Re-adjust fusing speed.

C FC F

Incorrect color image registration

4011T049AA

T-125

Paper Loop (Tech. Rep. function)

13 If incorrect registration occurs in the main scanning (CD) or sub-scanning (FD) direction, it is evident on the first copy and onward.

YES Readjust Paper Loop.

Color Shift Correction (Tech. Rep. function)

14 Paper skews a lot. 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.




Transfer Belt Unit

16 The problem is eliminated after the Transfer Belt Cleaner has been cleaned.



NO Change LED Assy.


NO Change LED Unit.




T-126

(34) Printer 4-Color: void areas, white spots




Transfer Belt Unit



2 There is dirt, dent or scratch on transfer belt.



3 There is dirt, dent or scratch on transfer belt.




5 Pre-Image Transfer Guide Plate is damaged or dirty.



YES Clean.

7 Charge Neutralizing Cloth is not separated and ground ter-minal is connected properly.

NO Correct or change.




Transfer Belt Unit



Paper Dust Remover



Void areas White spots

4011T008AA4011T030AA

T-127

(35) Printer 4-Color: colored spots




Imaging Unit



Transfer Belt Unit











YES Clean.



Fusing Web Unit





Transfer Belt Unit



Fusing Web Unit


NO Change Fusing Web Unit.

Oil Coating Unit

12 The problem is eliminated after the Fusing Web Unit has been replaced.

NO Change Oil Coating Unit.

C F

Colored spots

4011T027AA

T-128

Fusing Unit 13 The problem is eliminated after the Oil Coating Unit has been replaced.



T-129

(36) Printer 4-Color: oil lines, oil on copy




Paper 1 Problem is solved after printing a few sheets of copy.

NO Go to next step.

Oil Coating Unit



3 Oil Coating Roller is scratched. YES Change Oil Coating Unit.



Fusing Web Unit




Oil Coating Unit





Oil lines

4011T019AA

Oil on copy

4011T054AA

T-130

(37) Printer 4-Color: poor fusing performance, offset




Paper 1 Paper type is wrong. YES Change paper type.Change paper type select lever.

Fusing Web Unit

2 Fusing web unit is correctly installed.

NO Re-install.


Oil Coating Unit




Fuser Nip (Tech. Rep. function)

6 Nip width meets the specifica-tions: 7 ±0.5 mm.

NO Readjust.

Fuser Temp. (Tech. Rep. function)

7 Changing fusing temperature eliminates the problem of poor fusing performance and offset.

NO Go to next step.

Fusing Web Unit



Oil Coating Unit





C F

C F

Offset

4004T003AA

C F

Poor fusing performance

4004T002AA

T-131

(38) Printer 4-Color: brush effect, blurred image





2 Paper type is wrong. YES Change paper type.

Fusing Unit 3 Fusing Entrance Guide Plate is dirty.

YES Clean.

4 Fusing Belt is dirty or scratched.


Fusing Web Unit


Oil Coating Unit




Fuser Nip (Tech. Rep. function)

8 Nip width meets the specifica-tions: 7 ±0.5 mm.

NO Readjust.

Fuser Speed (Tech. Rep. function)

9 Brush effect or blurred image is evident on different types of paper.

YES Readjust.

Fusing Web Unit



Oil Coating Unit





Blurred imageBrush effect

4011T046AA4004T004AA

T-132

(39) Printer 4-Color: back marking





1 Transfer Roller is scratched or dirty.




Fusing Unit 3 Fusing Entrance Guide Plate is scratched or dirty.


4 Lower Fusing Roller is scratched or dirty.


Transfer Belt Unit






Transfer Belt Unit



Oil Coating Unit



Fusing Web Unit

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


Fusing Unit 10 The problem is eliminated after the Fusing Web Unit has been replaced.



11 The problem is eliminated after the Fusing Unit has been replaced.


4011T009AA

Back marking

CF

Back marking

4011T051AA

T-133

(40) Printer 4-Color: 75-mm-pitch uneven image, 200-mm-pitch uneven image




Oil Coating Unit

1 Oil Coating Roller is damaged when 75-mm-pitch uneven image occurs.


Fusing Unit 2 Fusing Belt is damaged when 200-mm-pitch uneven image occurs.



75 mm

200 mm

4011T062AA 4011T061AA

T-134

(41) Printer 4-Color: 94-mm-pitch uneven image




Imaging Unit



2 94-mm-pitch uneven image occurs on the image.

YES Store the Imaging Unit in a dark place overnight.



Transfer Belt Unit

4 Transfer Belt Unit drive gear is intact.

NO Correct. Change Transfer Belt Unit.


5 Transfer Roller is damaged. YES Change Transfer Roller Unit.


4011T047AD

94 mm 94 mm94 mm


4011T057AA 4011T058AA

T-135

4-4. Image Stabilizer Malfunction

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

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

(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


1 AIDC Sensor Shutter operates properly. NO Correct.

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

YES Clean the dirty area with a soft cloth. If it is seriously con-taminated, use the specified solvent. (See DIS/REASSEM-BLY, ADJUSTMENT.)

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

YES Change Transfer Belt Unit.

4 AIDC Sensor is mounted at an inappropriate position or connectors are not connected properly.

YES Reinstall. Reconnect.

5 AIDC Sensor window is dirty. YES Clean.

6 Value changes when AIDC Sensor output value is varied.

NO Change AIDC Sensor.

YES Change PIC Board.


1 PRT Max Density (Tech. Rep. Function) is correct.

NO Readjust.

2 Density during γ correction is normal. NO Readjust.

3 Imaging Unit is being driven. NO Check and correct drive cou-pling.

4 T/C is unusually low as found through checking.

YES Check Hopper.

5 AIDC Sensor window is dirty. YES Clean.

6 Imaging Unit connector contact is dirty. YES Clean.





T-136

(3) P-21: Color Shift Correction Failure (Test Pattern Failure)

(4) P-22: Color Shift Correction Failure (Correction Amount Failure)

(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


1 Produce a test pattern.

-

Go to step 2 if the image on the Transfer Belt is correct. Go to step 4 if the image den-sity is low.

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

YES Clean the dirty area with a soft cloth. If it is seriously con-taminated, use the specified solvent. (See DIS/REASSEM-BLY, ADJUSTMENT.)

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

YES Change Transfer Belt Unit.


1 LED retracting lever is locked in position. NO Slide out the Imaging Unit and then reinstall.

2 AIDC Sensor is installed slantwise. YES Reinstall.

3 Vertical Transport Guide is installed slant-wise.

YES Correct.


1 Transfer Belt Unit contact makes positive contact with High Voltage Unit contact.

NO Clean or correct.




NO Change High Voltage Unit 2. Change Master Board.

T-137

(6) S-1: CCD Gain Adjustment Failure

Clamp/Gain Adjustment Values

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.

(7) S-2: Intensity Adjustment Failure

RO RE GO GE BO BE

Clamp 130 130 130 130 130 130

RO RE GO GE BO BE

Gain 160 160 170 170 160 160

Lamp Adjustment Value 135


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

2 There is a wide difference between the clamp and gain adjustment values, the value being close to “0” or “255.”

YES Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board.

3 Clamp adjustment value exceeds the allow-able range only slightly.


4 The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great.

YES Clean lens, mirrors, CCD sur-face, shading sheet, and related parts.

5 The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small.



1 Original Glass, mirrors, CCD surface, and Main and Auxiliary Reflectors are dirty.Exposure Lamp is dirty or has discolored.

YES Clean or change; then, turn ON Power Switch.

NO Change Exposure Lamp. Change CCD Sensor Board.

Copyright2001 MINOLTA Co., Ltd.

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

MINOLTA Co., Ltd. 7662-4004-22 01011200

Documents

Minolta CF 1501/2001 SM