Field Service Manual PDF

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

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

CAUTION may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
The following graphic symbols are used to give instructions that need to be observed.
Used to call the service technician attention to what is graphically represented

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

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

For replacement parts, always use the genuine parts specified in the manufac-
turers 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 manufacturers parts manual. Installing a fuse of a different
make or rating could lead to a possible fire. If a thermal fuse blows frequently,
the temperature control system may have a problem and action must be taken
to eliminate the cause of the problem.
5. Handle the power cord with care and never use a multiple outlet.
Do not break, crush or otherwise damage the power cord. Placing a heavy
object on the power cord, or pulling or bending it may damage it, resulting in a
possible fire or electric shock.
Do not use a multiple outlet to which any other appliance or machine is con-
nected.
Be sure the power outlet meets or exceeds the specified capacity.
6. Be careful with the high-voltage parts.
A part marked with the symbol shown on the left carries a high voltage. 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.
7. Do not work with wet hands.
Do not unplug or plug in the power cord, or perform any kind of service or
inspection with wet hands. Doing so could result in an electric shock.
8. Do not touch a high-temperature part.

A part marked with the symbol shown on the left and other parts such as the
exposure lamp and fusing roller can be very hot while the machine is energized.
Touching them may result in a burn.
Wait until these parts have cooled down before replacing them or any surround-
ing parts.
9. Maintain a grounded connection at all times. (This item may not apply in the USA.)
Be sure to connect the ground wire to the ground terminal even when 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.
10. Do not remodel the product.
Modifying this product in a manner not authorized by the manufacturer may
result in a fire or electric shock. If this product uses a laser, laser beam leakage
may cause eye damage or blindness.
P-2
11. Restore all parts and harnesses to their original positions.
To promote safety and prevent product damage, make sure the harnesses are
returned to their original positions and properly secured in their clamps and 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.
1-2. Caution
CAUTION
1. Precautions for Service Jobs.
A star washer and spring washer, if used originally, must be reinstalled. Omitting
them may result in contact failure which could cause an electric shock or fire.
When reassembling parts, make sure that the correct screws (size, type) are
used in the correct places. Using the wrong screw could lead to stripped
threads, poorly secured parts, poor insulating or grounding, and result in a 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.
2. Precautions for Servicing with Covers and Parts Removed.

Wherever feasible, keep all parts and covers mounted when energizing the
product.
If energizing the product with a cover removed is absolutely unavoidable, do not
touch any exposed live parts and use care not to allow your clothing to be
caught in the moving parts. Never leave a product in this condition unattended.
Never place disassembled parts or a container of liquid on the product. Parts
falling into, or the liquid spilling inside the mechanism could result in an electric
shock or fire.
Never use a flammable spray near the product. This could result in a fire.
Make sure the power cord is unplugged before removing or installing circuit
boards or plugging in or unplugging connectors.
Always use the interlock switch actuating jig to actuate an interlock switch when
a cover is opened or removed. The use of folded paper or some other object
may damage the interlock switch mechanism, possibly resulting in an electric
shock, injury or blindness.
P-3
3. Precautions for the Working Environment.
The product must be placed on a flat, level surface that is stable and secure.
Never place this product or its parts on an unsteady or tilting workbench when
servicing.
Provide good ventilation at regular intervals if a service job must be done in a
confined space for a long period of time.
Avoid dusty locations and places exposed to oil or steam.
Avoid working positions that may block the ventilation ports of the product.
4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, etc.)

Replace a rundown battery with the same type as specified in the manufac-
turers 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 users premises or attempt to try to discharge one.
5. Precautions for the Laser Beam. (Only for Products Employing a Laser)
Removing the cover marked with the caution label could lead to possible expo-
sure to the laser beam, resulting in eye damage or blindness. Be sure to unplug
the power cord before removing this cover.
If removing this cover while the power is ON is unavoidable, be sure to wear
protective laser goggles that meet specifications.
Make sure that no one enters the room when the machine is in this condition.
When handling the laser unit, observe the Precautions for Handling Laser
Equipment.
6. Precautions for storing the toner or imaging cartridge.
Be sure to keep the toner or imaging cartridge out of the reach of children. Lick-
ing the imaging cartridge or ingesting its contents is harmful to your health.
1-3. Other Precautions

When handling circuit boards, observe the HANDLING of PWBs.
The PC Drum is a very delicate component. Observe the precautions given in 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.
P-4
1-4. Used Batteries Precautions
ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturers instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
ATTENTION
Il y a danger dexplosion sil y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du mme type ou dun type quivalent recom-
mand par le constructeur.
Mettre au rebut les batteries usages conformment aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.
Udskiftning m kun ske med batteri af samme fabrikat og type.
Levr det brugte batteri tilbage til leverandren.
Finland, Sweden
VAROlTUS
Paristo voi rjht, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hvit kytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera anvnt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
P-5
1-5. Precautions for Service
When performing inspection and service procedures, observe the following precautions
to prevent mishandling of the machine and its parts.
Depending on the model, some of the precautions given in the following do not apply.
1. Precautions Before Service

When the user is using a word processor or personal computer from a wall outlet of the
same line, take necessary steps to prevent the circuit breaker from opening due to 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.
2. How to Use this Book

DIS/REASSEMBLY, ADJUSTMENT
To reassemble the product, reverse the order of disassembly unless otherwise specified.
TROUBLESHOOTING
If a component on a PWB or any other functional unit including a motor is defective, the
text only instructs you to replace the whole PWB or functional unit and does not give
troubleshooting procedures applicable within the defective unit.
All troubleshooting procedures contained herein assume that there are no breaks in the
harnesses and cords and all connectors are plugged into the right positions.
The procedures preclude possible malfunctions due to noise and other external causes.
3. Precautions for Service.

Keep all disassembled parts in good order and keep tools under control so that none will
be lost or damaged.
After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged motor or locking mechanism.
If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.
Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other 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.
P-6
4. Precautions for Dis/Reassembly
Be sure to unplug the copier from the outlet before attempting to service the copier.
The basic rule is not to operate the copier anytime during disassembly. If it is absolutely
necessary to run the copier with its covers removed, use care not to allow your clothing
to be caught in revolving parts such as the timing belt and gears.
Before attempting to replace parts and unplug connectors, make sure that the power
cord of the copier has been unplugged from the wall outlet.
Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the
Interlock Switch with the covers left open or removed.
While the product is energized, do not unplug or plug connectors into the circuit boards
or harnesses.
Never use flammable sprays near the copier.
A used battery should be disposed of according to the local regulations and never be dis-
carded casually or left unattended at the users premises.
When reassembling parts, make sure that the correct screws (size, type) and toothed
washer are used in the correct places.
5. Precautions for Circuit Inspection

Never create a closed circuit across connector pins except those specified in the text and
on the printed circuit.
When creating a closed circuit and measuring a voltage across connector pins specified
in the text, be sure to use the GND wire.
P-7
6. Handling of PWBs
During Transportation/Storage
During transportation or when in storage, new P.W. Boards must not be indiscriminately
removed from their protective conductive bags.
Do not store or place P.W. Boards in a location exposed to direct sunlight and high 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.
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.
7. Handling of Other Parts

The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
P-8
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3
C. Soak a small amount of either ethyl alcohol or 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
D. 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
NOTES
Even when the PC Drum is only locally dirtied, wipe the entire surface.
Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under
interior illumination.
If dirt remains after cleaning, repeat the entire procedure from the beginning one more
time.
9. Handling of the Imaging Cartridge

Only for Products Employing an Imaging Cartridge.
During Transportation/Storage
The storage temperature is in the range between 20C and +40C.
In summer, avoid leaving the Imaging Cartridge in a car for a long time.
Handling
Store the Imaging Cartridge in a place that is not exposed to direct sunlight.
Precautionary Information on the PC Drum Inside the Imaging Cartridge

Use care not to contaminate the surface of the PC Drum with oil-base solvent, 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.
P-10
DIS/REASSEMBLY,
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in memory.
12 Paper Misfeed indicator Lights up when a paper misfeed occurs in the copier.
Malfunction indicator Lights up when malfunction occurs in the copier.
13 Maintenance indicator Blinks or lights up when the time approaches that copier
needs maintenance service.
14 Add Paper indicator Lights up when paper source currently selected for use
runs out of paper.
15 Add Toner indicator Lights up when toner will soon run out.
16 Bypass Tray Size Press to select the size of the paper loaded in the Bypass
Select key Tray.
17 Zoom () key Press to change the zoom ratio in the range between
50 % and 200 % in 1 % increments.
What is shown on the Display changes from the number
of copies to be made to the zoom ratio.
18 Display Shows the number of copies to be made, the zoom ratio,
and other setting data.
19 10-key Pad Use to type in the number of copies to be made and any
other numeric data.
20 Access key Press when entering an account number.
Becomes valid only when Copy Track has been set.
21 Energy Saver key Press to set the copier into the Energy Saver mode.
22 Interrupt key Press to interrupt a copy job.
23 Panel Reset key Press to reset all copy functions and settings to their
defaults.
Holding down the key for 3 seconds or more will set the
copies into the Utility mode.
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2. UTILITY MODE
Utility Mode is used to make various settings according to the users need.
2-1. Settings in the Utility Mode
Number Description
U-1 Users Choice Mode
U-2 Drum Dehumidify Mode
U-3 Toner Replenisher Mode
U-4 Custom Size Input Mode
U-5 Administrator Mode
2-2. Utility Mode Setting Procedure

Procedure
1. Hold down the Panel Reset key for 3 seconds.
2. Using the 10-Key Pad, enter the code corresponding to the desired subfunction.
No.: 1 to 5
3. Press the Start key.
Exiting the Mode

Press the Panel Reset key.
(1) Users Choice Mode (Display: U-1)

Users Choice is used to make various settings according to the users need.
1. Settings in the Users Choice Mode
Number Function Number Function

C-1 Mixed Orig. C18 Density (ADF)
C-2 Paper Priority C19 Print Density
C-3 Copy Priority C20 Paper Auto Detection (1st Tray)
C-4 Density Priority C21 Paper Auto Detection (2nd Tray)
C-5 Density Level (Auto) C22 Paper Auto Detection (3rd Tray)
C-6 Density Level (Manual) C23 Paper Auto Detection (4th Tray)
C-7 Output Priority C24 Paper Auto Detection (5th Tray)
C-8 Crisscross Mode C25 Paper Size Detection (1st Tray)
C-9 4in1 Copy Order C26 Paper Type (1st Tray)
C10 Book Binding Position C27 Paper Type (Bypass Tray)
C11 Margin Setting C28 Special Paper Setting (1st Tray)
C12 Erase Setting (Left) C29 Special Paper Setting (2nd Tray)
C13 Erase Setting (Upper) C30 Special Paper Setting (3rd Tray)
C14 Erase Setting (Frame) C31 Special Paper Setting (4th Tray)
C15 Auto Panel Reset C32 Special Paper Setting (5th Tray)
C16 Energy Saver C33 Special Paper Setting
(Multiple Bypass Tray)
C17 Auto Shut OFF
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3-3. Setting in the Tech.Rep.Mode
(1) Control Panel LED Check
The LEDs on the Control Panel are made to blink to check for any LED that has burned
out.
Any LED that is not blinking is considered to be out.
(2) Function
This function allows the Tech. Rep. to make the various function tests and adjustments.
Procedure
1. Enter the number corresponding to the function to be used from the 10-Key Pad.
2. Press the Start key.
Exiting the Mode

Press the Panel Reset key until the initial screen reappears.
Number Operation
Paper Passage Test
Correct paper passage (paper transport path) is checked without
involving any printing action.
This test is used to check for a paper misfeed and transport path.
F-1
Procedure
1. Select the paper source.
2. Press the Start key to start the paper passage cycle.
3. Press the Stop key to stop the paper passage cycle.
HV Output
F-2
This test is for factory adjustment only and should NOT be used.
ATDC Sensor Automatic Adjustment
Adjusts the output level of the ATDC Sensor.
F-8 This test is used when the copier is set up, developer is changed, and
the IU is replaced.
For details, see DIS/REASSEMBLY, ADJUSTMENT.
Test Pattern Output
Outputs a test pattern. (Halftone)
This test is used to determine whether the engine is responsible for
F12 an image problem which has occurred or the IR is responsible for it.
Procedure
1. Select the paper source.
2. Press the Start key to start the output sequence.
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Number Setting
Trouble Counter
Counts the number of malfunctions that have occurred at different
parts of the copier.
If all malfunction counters are 0, ALL and 0 alternate.
Display Description
1 Main Motor malfunction
2 Fusing Cooling Fan Motor malfunction
3 Power Supply Cooling Fan Motor malfunction
4 Toner Replenishing Motor malfunction
5 Faulty image transfer voltage
6 Warm-up failure
--6 7 Abnormally low fusing temperature
8 Abnormally high fusing temperature
9 Scanner Home Sensor malfunction
10 Tray Selecting Motor malfunction
11 Shift Motor malfunction
12 ATDC Sensor malfunction
13 ATDC adjustment failure
14 ASIC/memory malfunction
15 Polygon Motor malfunction
16 HSYNC detection failure
17 EEPROM malfunction
18 Exposure Lamp malfunction
Paper Size Counter

Counts the number of sheets of paper used according to the size and
type.
Display Description Display Description

1 A3 (L) 13 Letter (L)
2 B4 (L) 14 Letter (C)
3 A4 (L) 15 Invoice (L)
4 A4 (C) 16 Invoice (C)
--7 5 B5 (L) 17 Other size
6 B5 (C) 18 Paper enabling Auto Paper/
7 A5 (L) enabling auto tray switching
8 A5 (C) 19 Paper disabling Auto Paper/
9 FLS (L) enabling auto tray switching
10 Ledger (L) 20 Paper disabling Auto Paper/
11 1114 (L) disabling auto tray switching
12 Legal (L) 21 OHP
22 Thick paper
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(11) Memory Clear
This function is used to clear all data except that of the various electronic counters.
Procedure
1. Press the Start key to display CLr on the Display.
2. Press the Start key to blank out the Display.
Then, CLr will reappear.
3. Turn OFF and ON the Power Switch.
(12) Total Clear

This function is used to clear all data of the various electronic counters.
Procedure
1. Press the Start key to display tCL on the Display.
2. Press the Start key to blank out the Display.
Then, tCL will reappear.
3. Turn OFF and ON the Power Switch.
List of Types of Data to be Cleared

Clearing Method Door Memory Total
Data Cleared Open/Close Clear Clear
Jam display
Trouble display
Erratic operation/display
Utility (*1)
Tech. Rep. Mode (*2)
Security
Adjust
Job programs
Electronic counters
: Cleared : Not cleared
*1: Except Copy Track, Input Account, and Total Counter Display by Account.
*2: Except Marketing Area Setting and Serial No. Display.
(13) ADF Document Passage Test

This function is used to check for correct document passage through the ADF when a
document misfeed occurs.
Procedure
1. Load a stack of paper in the Document Feeding Tray.
2. Press the Start key to let the ADF start feeding the paper.
3. Press the Stop key to stop the sequence.
For details, see the relevant option service manual.
S-23
(14) ADF Original Glass Check
The original scanning area of the ADF is scanned to check for possible dirt or scratches
on the glass. The scanned area is produced as a copy.
Procedure
Press the Start key to start the sequence.
For details, see the relevant option service manual.
(15) Scanner Move Check

This function is used to check the Scanner Drive.
It is also used when securing the Scanner in position with the fixing pin (for transportation
of the machine).
Procedure
Press the Start key. This will move the Scanner to the left and stop.
(16) Serial No. Display

This function is used to display the serial number (consisting of 8 digits).
Procedure
Press the Start key to display the serial number.
E.g.: The Display shows Sn 12 345 678 in that order if the serial number is
12345678.
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1. INTRODUCTION
1-1. 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.
E.g.: Pattern 1
Step Check Result Action

1 NO
2
Go to the next step if you answered
YES.
E.g.: Pattern 2

YES
1
NO
2
Go to the next step if it checks
T-1
2. PAPER TRANSPORT FAILURE
2-1. Paper Misfeed Detection
(1) Outline
A paper misfeed is detected by detecting different states of signals (H, L) of several sen-
sors located near the paper take-up section and the Exit Paper Sensor.
The timings of the rising and falling edges of the paper take-up-related sensors and the
Exit Paper Sensor are monitored to detect a misfeed of paper being fed through the
copier.
The states (H, L) of the paper take-up-related sensors and the Exit Paper Sensor are
monitored to detect a sheet of paper left in the copier.
All drives are brought to an immediate stop when a paper misfeed or paper left in the
copier is detected.
2-2. Paper Misfeed

When a paper misfeed occurs, the control panel shows the misfeed location and paper
location.
Display
Misfeed Location
Indicator LED
4022T501AA
4022T503AA
4022T502AA
LED No. Code Misfeed/Paper Location Action Ref. Page

1 J01 Misfeed at the 1st Tray T-7
2 J02 Misfeed at the 2nd Tray T-11
3 J03 Misfeed at the 3rd Tray T-11
4 J04 Misfeed at the 4th Tray T-11
5 J05 Misfeed at the 5th Tray T-11
6 J06 Misfeed at the Bypass Tray T-7
T-2
LED No. Code Misfeed/Paper Location Action Ref. Page
2/3 J1 Misfeed on paper transport path between PC1 T-11
and PC12 (3rd Tray)
3/4 Misfeed on paper transport path between PC12 T-11
(3rd Tray) and PC12 (4th Tray)
4/5 Misfeed on paper transport path between PC12 T-11
(4th Tray) and PC12 (5th Tray)
7 J2 Misfeed at the PC Drum T-13
7 J3 Misfeed at the Fusing Unit T-16
8 J80 Original misfeed: ADF Separator See option
J81 Original misfeed: ADF registration service manual.
J83 Original misfeed: ADF exit
1/7 J Paper left: PC1 T-7
7 Paper left: PC3 T-16
2 Paper left: 2nd Tray Paper Take-Up Sensor T-11
3 Paper left: 3rd Tray Paper Take-Up Sensor T-11
4 Paper left: 4th Tray Paper Take-Up Sensor T-11
5 Paper left: 5th Tray Paper Take-Up Sensor T-11
8 Paper left: ADF See option
service manual.
6 byp Paper left: Manual Bypass Tray T-7
T-3
2-3. Misfeed Detection Sensor Layout
PC4*
PC3*
PC5*
PC3
PC1
PC2
PC12*
PC12*
PC12*
PC12*
Paper Path 4022T504AA
Copier
Symbol Name
PC1 Synchronizing Roller Sensor
PC2 Manual Feed Paper Sensor
PC3 Exit Paper Sensor
Paper Feed Cabinet (option)

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

Misfeed in Misfeed at 1st Tray J01, Open the Right Door or slide out
the copier misfeed at Multiple Bypass Tray J06, the 1st Tray, remove all sheets of
misfeed at Manual Bypass Tray J06, paper left inside, and close the
misfeed at PC Drum J2, Right Door.
misfeed at Fusing Unit J3,
paper left J - -
Paper wedged at Manual Bypass Tray Pull the paper wedged out of the
tray. (Removing the paper will
reset the misfeed display.)
Misfeed in the option: Remove all sheets of paper left
J02, J03, J04, J05, J1, J80, J81, and J83 inside and then raise and lower or
disconnect and reconnect the
option.
T-5
2-4. Types of Misfeed Detection and Detection Timings
The following lists the types of misfeed detection and detection timings for different 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.
NOTE
For the types of misfeed detection and detection timings of options, see the relevant
option service manual.
Misfeed at the Paper Take-Up Section
Type Detection Start Paper Detection

Misfeed at 1st Tray Paper Take-Up Solenoid (SL1) Synchronizing Roller Sensor
J01 energized (PC1) (L)
Misfeed at Manual Manual Bypass Solenoid (SL2) Synchronizing Roller Sensor
Bypass Tray J06 energized (PC1) (L)
Misfeed at Multiple Multiple Bypass Solenoid (SL21) Synchronizing Roller Sensor
Bypass Tray J06 energized (PC1) (L)
Misfeed at the PC Drum

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

Misfeed at Fusing Synchronizing Roller Sensor (PC1) Exit Paper Sensor (PC3) (T)
Unit J3 (T)
T-6
3. MISFEED TROUBLESHOOTING PROCEDURES
3-1. Misfeed at Copier Paper Take-Up J01 and Misfeed at Bypass
Tray J06
Relevant Electrical Parts

Synchronizing Roller Sensor (PC1) Manual Bypass Solenoid (SL2)
Manual Feed Paper Sensor (PC2) Multiple Bypass Solenoid (SL21)
Paper Take-Up Solenoid (SL1) Master Board (PWB-A)
PWB-A
MANUAL BYPASS SECTION Master Board
Manual Feed
Paper Sensor
Multiple Bypass
Multiple
Bypass Solenoid
CN26
Manual Feed
Bypass Solenoid
DRAWER SECTION
Paper Take-Up
Solenoid
TRANSPORT SECTION
Synchronizing
Roller Sensor PC1 ANODE
4022T522AA
Misfeed at 1st Tray J01 Troubleshooting Procedures

1 Paper meets product specifications. NO Change paper.
2 Paper is curled, wavy, or damp. YES Change paper.
Instruct user to load paper that
meets product specifications.
3 Edge Guide and Trailing Edge Stop NO Adjust as necessary.
are at correct position to accommo-
date paper.
T-7
4 Paper Take-Up Roller (1st Tray) is YES Clean or change.
dirty, scratched, deformed, or worn.
5 Paper Separator Roller (1st Tray) is YES Clean or change.
6 Paper Take-Up Roll drive shaft turns NO Reinstall the Paper Take-Up Roll
when the Start key is pressed. drive shaft.
Reinstall the Paper Take-Up Roll
drive gear and spring.
7 Paper Take-Up Solenoid (SL1) is NO Change Paper Take-Up Solenoid
operational when the Start key is (SL1).
pressed.
Check Procedure
Check voltage across a Master
Board (copier: PWB-A) pin and GND.
Voltage across PJ5A-2 and GND
In standby: DC24 V
When pressed: DC0 V
8 Synchronizing Roller Sensor (PC1) is NO Change Synchronizing Roller Sen-
operational. sor (PC1).
Check Procedure YES Change Master Board (copier:
Check voltage across a Master PWB-A).
Board (copier: PWB-A) pin and GND
when the sensor is blocked.
When blocked: DC5 V
When unblocked: DC0 V
Misfeed at Manual Bypass Tray J06 Troubleshooting Procedures

3 Paper Guides are at correct position NO Adjust as necessary.
to accommodate paper.
4 Transport Roller (Manual Bypass YES Clean or change.
Tray) is dirty, scratched, deformed, or
worn.
T-8
5 Manual Bypass Solenoid (SL2) is NO Change Manual Bypass Solenoid
pressed.
Check Procedure
In standby: DC24 V
When pressed: DC0 V
6 Manual Feed Paper Sensor (PC2) is NO Change Manual Feed Paper Sen-
Check Procedure
When blocked: DC0 V
When blocked: DC5 V
Misfeed at Multiple Bypass Tray J06 Troubleshooting Procedures

3 Paper Guides are at correct position NO Adjust as necessary.
to accommodate paper.
4 Paper Take-Up Roller drive shaft NO Reinstall.
(Multiple Bypass Tray) turns when
the Start key is pressed.
T-9
5 Multiple Bypass Solenoid (SL21) is NO Change Multiple Bypass Solenoid
pressed.
Check Procedure
In standby: DC24 V
When pressed: DC0 V
6 Paper Take-Up Roller (Multiple YES Clean or change.
Bypass Tray) is dirty, scratched,
deformed, or worn.
7 Separator Roller (Multiple Bypass YES Clean or change.
Tray) is dirty, scratched, deformed, or
worn.
When blocked: DC0 V
T-10
3-2. Misfeed at Paper Feed Cabinet Paper Take-Up and Transport
Section J02, J03, J04, J05, J1 (PF-120)

Paper Take-Up Solenoid (SL11) Master Board (PWB-A)
Synchronizing Roller Sensor (PC1) Control Board (PWB-A): PF-120
Paper Take-Up Sensor (PC12)
PJ6
PJ6A-1(PC1 ANODE)
PJ6A-2(GND)
Synchronizing
PJ6A-3(PC1 ON) PC1 Roller Sensor
PJ18A
PWB-A
Master Board
13
CN25
CN53
2nd Tray PJ1A PJ53
Paper
PJ3A-3B(DC5 V)
PJ3A-1A(SL11 ON) PJ3A-2B( PC12ON) Take-Up
SL11 PJ3A-2A(GND) PJ3A-1B(GND) PC12 Sensor
PWB-A
(PF-120)
PJ2APJ1A
13
3rd Tray PJ1A PJ53

Paper
CN53 PJ3A-3B(DC5 V)
PWB-A
(PF-120)
PJ2APJ1A
13
CN53
4th Tray PJ1A PJ53
PJ3A-3B(DC5 V) Paper
PWB-A
(PF-120)
PJ2APJ1A
13
CN53
5th Tray PJ1A PJ53
PJ3A-3B(DC5 V) Paper
PWB-A
(PF-120)
4022T543AA
T-11
Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05,
J1 (PF-120) Troubleshooting Procedures
Paper is not taken up at all.

3 Edge Guides and Trailing Edge Stop NO Adjust position as necessary.
are at correct position to accommo-
date paper.
4 Paper Take-Up Roller is dirty, YES Clean or change.
scratched, deformed, or worn.
5 Mylar is dirty, scratched, or deformed. YES Clean or change.
6 Separator Fingers are dirty or YES Clean or change.
deformed.
7 Paper guide plate is dirty or YES Clean or change.
deformed.
8 Paper Take-Up Solenoid (SL11) YES Change Paper Take-Up Solenoid
operation check: (SL11).
The voltage across PJ3A-1A on Con- NO Change Control Board (PF-120:
trol Board (PF-120: PWB-A) and PWB-A).
GND changes from DC0 V to DC24 V
when the Start key is pressed.
9 Paper Take-Up Sensor (PC12) oper- YES Change Control Board (PF-120:
ation check: PWB-A) and/or Master Board
The voltage across PJ3A-2 on Con- (copier: PWB-A).
trol Board (PF-120: PWB-A) and NO Correct actuator and/or change
GND is DC 5 V when the sensor is Paper Take-Up Sensor (PC12).
unblocked and DC 0 V when the sen-
sor is blocked.
Paper is stopped near the vertical transport section or Synchronizing Roller.

1 Vertical Transport Roller/Rollers are YES Clean or change.
dirty, deformed, or worn.
3 Synchronizing Roller Sensor (PC1) YES Change Master Board (copier:
operation check: PWB-A).
The voltage across PJ6A-3 on Mas- NO Correct actuator and/or change
ter Board (copier: PWB-A) and GND Synchronizing Roller Sensor
is DC5 V when the sensor is blocked (PC1).
and DC0 V when the sensor is
unblocked.
T-12
3-3. Misfeed at PC Drum J2

Synchronizing Roller Sensor (PC1) Synchronizing Roller Clutch (CL1)
Fusing Cooling Fan Motor (M3) Master Board (PWB-A)
PWB-A
Master Board
TRANSPORT SECTION
Synchronizing
Roller Clutch
Synchronizing
Roller Sensor PC1 ANODE
FUSING SECTION
Fusing Cooling
Fan Motor
4022T523AA
Misfeed at PC Drum J2 Troubleshooting Procedures

Paper is stopped at the Synchronizing Roller.

1 Synchronizing Rollers are dirty, YES Clean or change the Synchronizing
scratched, deformed, or worn. Rollers.
Clean or change the Paper Dust
Remover.
2 Loop length is set to an appropriate NO Adjust loop length using Tech. Rep.
value. Choice.
For details, see DIS/REASSEM-
BLY, ADJUSTMENT.
T-13
Check Procedure
When blocked: DC5 V
4 The following voltage is supplied to YES Change Synchronizing Roller
the Synchronizing Roller Clutch Clutch (CL1).
(CL1). NO Change Master Board (copier:
Check Procedure PWB-A).
In standby: DC24 V
When pressed: DC0 V
Paper is stopped at the PC Drum.

1 Image Transfer Roller is dirty. YES Clean or change.
2 PC Drum Paper Separator Fingers YES Clean or change.
are dirty, scratched, deformed, worn,
or damaged.
3 Charge Neutralizing Plate is dirty, YES Clean, correct, or change.
scratched, broken, or bent.
T-14
Paper is stopped at the transport section.

1 Transport guide plate is dirty, YES Clean or change.
scratched, deformed, worn, or dam-
aged.
2 The following voltage is supplied to YES Change Fusing Cooling Fan Motor
the Fusing Cooling Fan Motor (M3). (M3).
Check Procedure NO Change Master Board (copier:
During decelerated rotation: DC8 V
During full speed rotation: DC24 V
T-15
3-4. Misfeed at Fusing Unit J3

Exit Paper Sensor (PC3) Master Board (PWB-A)
Fusing Cooling Fan Motor (M3)
FUSING SECTION
Fusing Cooling
Fan Motor
PC3 ANODE
PAPER EXIT SECTION PWB-A

Exit Paper Master Board
Sensor
4022T511AA
Misfeed at Fusing Unit J3 Troubleshooting Procedures
Paper is stopped at the Fusing Unit.

1 Fusing guide plate is dirty, scratched, YES Clean or change.
deformed, worn, or damaged.
2 Fusing Paper Separator Fingers are YES Clean or change the Fusing Paper
dirty, scratched, deformed, or worn. Separator Fingers, or change
spring.
3 Fusing Rollers are dirty, scratched, YES Clean or change.
deformed, or worn.
Paper is stopped at the paper exit section.

1 Exit guide plate is dirty, scratched, YES Clean or change.
2 Transport Roller is dirty, scratched, YES Clean or change.
deformed, or worn.
3 Exit Roller/Rollers are dirty, YES Clean or change.
T-16
4 Exit Paper Sensor (PC3) is opera- NO Change Exit Paper Sensor (PC3).
tional. YES Change Master Board (copier:
When blocked: DC5 V
T-17
4. MALFUNCTION
The copiers CPU is equipped with a self-diagnostics function that, on detecting a malfunc-
tion, gives the corresponding malfunction code on the Display.
4-1. Detection Timing by Malfunction Code
Code Description Detection Timing

C0000 Main Motor malfunc- The Main Motor (M1) Lock signal remains HIGH for a
tion continuous 1-sec. period at any time 1 sec. after the
Main Motor has started turning.
C0045 Fusing Cooling Fan The Fusing Cooling Fan Motor (M3) Lock signal
Motor malfunction remains HIGH for a continuous 1-sec. period while
the Fusing Cooling Fan Motor is turning at full speed
or decelerated speed.
C004E Power Supply Cooling The Power Supply Cooling Fan Motor (M4) Lock sig-
Fan Motor malfunc- nal remains HIGH for a continuous 1-sec. period while
tion the Power Supply Cooling Fan Motor Remote signal
remains ON (for full-speed rotation) or OFF (for decel-
erated-speed rotation).
C0070 Toner Replenishing The Toner Bottle Home Position Sensor (PC7) out-
Motor malfunction puts a HIGH signal for a continuous 3.5-sec. period
while the Toner Bottle is turning.
The Toner Bottle Home Position Sensor (PC7) out-
puts a LOW signal for a continuous 2-sec. period
while the Toner Bottle is turning.
C0210 Abnormal image The image transfer voltage remains more than 100 V
transfer voltage for a continuous given period of time while the PC
Drum remains stationary.
C03FF Improperly set Adjust An incorrect setting is made of Adjust 11.
Mode 11
C0500 Warm-up failure It takes the surface temperature of the Left Fusing
Roller more than 35 sec. to reach 100 C since the
start of a warm-up cycle.
It takes the surface temperature of the Left Fusing
Roller more than 25 sec. to reach 140 C after it has
reached 100 C.
It takes more than 20 sec. for the warm-up cycle to be
completed after the surface temperature of the Left
Fusing Roller has reached 140 C.
C0510 Abnormally low fus- The surface temperature of the Left Fusing Roller
ing temperature remains lower than 120 C for a given period of time
while the copier is in a standby state.
The surface temperature of the Left Fusing Roller
remains lower than 120 C for a given period of time
during a print cycle.
C0520 Abnormally high fus- The surface temperature of the Left Fusing Roller
ing temperature remains higher than 240 C for a given period of time.
T-18
C0650 Faulty Scanner Home The Scanner Home Position Sensor (PC6) does not
Position Sensor go from HIGH to LOW when the Scanner Motor (M5)
is energized for a given number of steps after the
sequence to bring the Scanner back to its home posi-
tion has been started at the end of a scan motion and
during re-shading.
The Scanner Home Position Sensor (PC6) does not
go from LOW to HIGH when the Scanner Motor (M5)
is energized for a given number of steps after a scan
motion has been started at the end of a Scanner
Home Position Sensor home check scan motion and
during re-shading.
C0B60 Bin Switching Motor If the Upper Home Position Sensor is LOW during an
malfunction initial operation:
The Lower Home Position Sensor (PC33) is LOW
when the Bin Switching Motor (M1) starts turning for-
ward.
If the Lower Home Position Sensor (PC33) does not
go LOW at a time 2.5 sec. after the Bin Switching
Motor (M1) has started turning forward, the Bin
Switching Motor is kept deenergized for a given
period of time and then energized again to turn back-
ward. The Upper Home Position Sensor (PC32) does
not go LOW after the motor has started turning back-
ward.
The Upper Home Position Sensor (PC32) does not go
HIGH at a time 1 sec. after the Bin Switching Motor
(M1) has started turning forward.
When the Lower Home Position Sensor (PC33) goes
LOW, the Bin Switching Motor (M1) starts turning
backward. The Upper Home Position Sensor (PC32)
does not go LOW at a time 2.5 sec. after the motor
has started turning backward.
backward. The Lower Home Position Sensor (PC33)
does not go HIGH at a time 1 sec. after the motor has
started turning backward.
If the Lower Home Position Sensor is LOW during an
initial operation:
The Upper Home Position Sensor (PC32) does not go
LOW at a time 2.5 sec. after the Bin Switching Motor
(M1) has started turning backward.
The Lower Home Position Sensor (PC33) does not go
HIGH at a time 1 sec. after the Bin Switching Motor
(M1) has started turning backward.
T-19
C0B60 Bin Switching Motor If both the Upper Home Position Sensor and the Lower
malfunction Home Position Sensor are HIGH during an initial opera-
tion:
If the Lower Home Position Sensor (PC33) does not
go LOW at a time 2.5 sec. after the Bin Switching
Motor (M1) has started turning forward, the Bin
Switching Motor is kept deenergized for a given
period of time and then energized again to turn back-
ward. The Upper Home Position Sensor (PC32) does
not go LOW after the motor has started turning back-
ward.
backward. The Upper Home Position Sensor (PC32)
does not go LOW at a time 2.5 sec. after the motor
has started turning backward.
backward. The Lower Home Position Sensor (PC33)
does not go HIGH at a time 1 sec. after the motor has
C0B80 Shift Motor malfunc- The Home Sensor (S31) is LOW at a timing immedi-
tion ately before the Shift Motor (M1) starts turning back-
ward.
The Home Sensor (S31) is LOW after the lapse of a
given period of time after the Shift Motor (M1) has
C0F32 Faulty ATDC Sensor The measurement taken by the ATDC Sensor (UN1)
at a time 2.5 sec. after the Main Motor (M1) has
started turning is less than 3 % (greater than 4.98 V).
The measurement taken by the ATDC Sensor (UN1)
at a time 2.5 sec. after the Main Motor (M1) has
started turning is 19 % or more (1.41 V or less).
C0F33 Improperly adjusted The adjustment of the ATDC control voltage is not
ATDC Sensor completed within 1 sec. after sampling has started of
the ATDC Sensor (UN1) as part of an operation of
ATDC Sensor Automatic Adjustment.
The ATDC Sensor control voltage falls outside the
range of 5.39 V to 8.15 V during an operation of ATDC
Sensor Automatic Adjustment.
C1038 Engine connection Master Board (PWB-A) to Control Board (PWB-C) con-
failure nection failure
There is no acknowledge signal transmitted from the
Master Board (PWB-A) to Control Board (PWB-C) for
1.5 sec. or more.
An error command signal is transmitted from the Con-
trol Board (PWB-C) to Master Board (PWB-A).
An error status signal is transmitted from the Master
Board (PWB-A) to Control Board (PWB-C).
T-20
C1200 Faulty ASIC/memory ASIC/memory (for image and control) fault
A write or read error occurs with SRAM on the Control
Board (PWB-C).
C1300 Polygon Motor mal- Startup failure
function A LOW Polygon Motor (M2) Lock signal is not
detected within a given period of time that begins 1
sec. after the Polygon Motor has started turning.
Lock signal fault: Unstable after the first Lock signal has
been detected
For a period of 1 sec. after the first LOW Polygon
Motor (M2) Lock signal (first Lock) has been detected,
the next LOW Polygon Motor Lock signal is not
detected.
Lock signal fault: Lock signal out-of-timing
A LOW Polygon Motor (M2) Lock signal is not
detected for a continuous given period of time while
the rotation of the Polygon Motor remains stabilized.
Faulty Lock signal
A LOW Polygon Motor (M2) Lock signal is detected
for a given period of time or more when the Polygon
Motor remains deenergized.
C13F0 Faulty HSYNC Laser scanning system malfunction
The SOS Sensor does not detect a rising edge of
SOS within a given period of time after the Polygon
Motor (M2) has started turning and a laser output has
been started.
The SOS Sensor detects no rising edges of SOS
while VIA (image area control) is ON.
C1468 Faulty EEPROM EEPROM fault
Data cannot be written in EEPROM.
Data stored in EEPROM is wrong.
C14A3 IR fluorescent lamp The Exposure Lamp (LA2) of the Scanner fails to turn
fault ON.
The intensity of the Exposure Lamp is a predeter-
mined value or less during shading and re-shading.
T-21
4-2. Resetting Procedure by Malfunction Code
Code Description Resetting Procedure

C0000 Main Motor malfunction Turn OFF and ON the Power Switch.
C0045 Fusing Cooling Fan Motor mal-
function
C004E Power Supply Cooling Fan Motor
malfunction
C0070 Toner Replenishing Motor mal-
function
C0210 Abnormal image transfer voltage
C03FF Improperly set Adjust Mode 11 Set Adjust Mode 11 correctly and then
turn OFF and ON the Power Switch.
For details, see SWITCHES ON PWBs/
TECH. REP. SETTINGS.
C0500 Warm-up failure Turn ON the Power Switch with the Stop
C0510 Abnormally low fusing temperature key held down.
C0520 Abnormally high fusing tempera-

ture
C0650 Faulty Scanner Home Position Turn OFF and ON the Power Switch.
Sensor
C0B60 Bin Switching Motor malfunction
C0F32 Faulty ATDC Sensor
C0F33 Improperly adjusted ATDC Sensor
C1038 Engine connection failure
C1200 Faulty ASIC/memory
C1300 Polygon Motor malfunction
C13F0 Faulty HSYNC
C1468 Faulty EEPROM
C14A3 IR fluorescent lamp fault
T-22
4-3. Troubleshooting Procedures by Malfunction Code
(1) C0000: Main Motor malfunction

Main Motor (M1) Master Board (copier: PWB-A)
PWB-A
Master Board
PJ7A
Main Motor
PJ4
1
2
3
4
5
6
7
4022T525AA

1 Main Motor (M1) turns when the Start NO Check for overload.
key is pressed.
2 The following voltage is supplied to NO Change Main Motor (M1).
the Main Motor (M1) when the Start YES Change Master Board (copier:
key is pressed. PWB-A).
DC5 V when Main Motor (M1) is in
standby state
DC0 V when Main Motor (M1) is
energized
DC5 V when Main Motor (M1) is in
standby state
DC0 V when Main Motor (M1) is
energized
T-23
(2) C0045: Fusing Cooling Fan Motor malfunction

Fusing Cooling Fan Motor (M3) Master Board (copier: PWB-A)
PWB-A
Master Board
FUSING SECTION
Fusing Cooling
Fan Motor
4022T526AA

1 Fusing Cooling Fan Motor (M3) turns NO Check for overload.
when the Power Switch is turned ON.
2 The following voltage is supplied to YES Change Fusing Cooling Fan Motor
Check Procedure
DC8 V during rotation at deceler-
ated speed
DC24 V during rotation at full
speed
3 The following voltage is supplied to NO Change Fusing Cooling Fan Motor
DC0 V when energized
T-24
(3) C004E: Power Supply Cooling Fan Motor malfunction

Power Supply Cooling Fan Motor (M4) Master Board (copier: PWB-A)
PWB-A
Master Board
POWER SUPPLY SECTION

Power Supply
Cooling Fan Motor
4022T527AA

1 Power Supply Cooling Fan Motor NO Check for overload.
(M4) turns when the Power Switch is
turned ON.
2 The following voltage is supplied to YES Change Power Supply Cooling Fan
the Power Supply Cooling Fan Motor Motor (M4).
(M4).
Check Procedure
DC8 V during rotation at deceler-
ated speed
DC24 V during rotation at full
speed
3 The following voltage is supplied to NO Change Power Supply Cooling Fan
the Power Supply Cooling Fan Motor Motor (M4).
(M4). YES Change Master Board (copier:
T-25
(4) C0070: Toner Replenishing Motor malfunction

Toner Replenishing Motor (M6) Master Board (copier: PWB-A)
Toner Bottle Home Position Sensor (PC7)
PWB-A
DEVELOPING SECTION Master Board
Toner Replenishing
Motor
Toner Bottle Home PC7 ANODE
Position Sensor
4022T528AA

1 The coupling of the Toner Hopper NO Check for overload.
turns as the Toner Replenishing
Motor (M6) turns.
Check Procedure
Disengage the Toner Bottle
Release Lever.
Turn the Toner Bottle a half turn by
hand.
Turn ON the Power Switch.
2 The Toner Bottle Home Position Sen- NO Change Toner Bottle Home Posi-
sor (PC7) is operational. tion Sensor (PC7).
Check Procedure
when the Toner Replenishing Motor
(M6) turns.
Voltage across PJ19A-10 and
GND
DC0 V when unblocked
DC5 V when blocked
3 The following voltage is supplied to YES Change Toner Replenishing Motor
the Toner Replenishing Motor (M6). (M6).
when the Toner Replenishing Motor
(M6) turns.
DC0 V when deenergized
T-26
(5) C0210: Abnormal image transfer voltage

High Voltage Unit (HV1) Master Board (copier: PWB-A)
DEVELOPING SECTION
HV1 PWB-A
High Voltage Unit Master Board
Developing Bias
P.C/I.T._REM
I.T.Control Not Use
Image Transfer I.T.Voltage Monitor
P.C/I.T._REM
VG Voltage I.T.Control
I.T.Voltage Monitor
Charge Neutralizing Cloth
Photo Conductor
4022T529AA

1 C0210 reappears when the Power YES Change High Voltage Unit (HV1).
Switch is turned OFF and ON. Change Master Board (PWB-A).
T-27
(6) C0500: Warm-up failure
C0510: Abnormally low fusing temperature
C0520: Abnormally high fusing temperature

Fusing Heater Lamp (H1) Fusing Unit Interlock Switch (S2)
Thermistor (TH1) DC Power Supply (PU1)
Thermoswitch 1 (TS1) Master Board (copier: PWB-A)
PWB-A
Master Board
Not Use
Thermistor
FUSING SECTION
Thermo-
POWER SUPPLY SECTION
Fusing Heater Fusing Unit
Lamp switch 1 Interlock Switch PU1
R DC Power Supply
R CN2PU1
HEATER_N
Not Use
HEATER_L
4022T530AA
C0500: Warm-up failure; C0510: Abnormally low fusing temperature

1 Fusing Heater Lamp (H1) turns YES Go to step 3.
ON. NO Go to step 2.
2 Fusing Heater Lamp (H1) is open-cir- YES Change Fusing Heater Lamp (H1).
cuited.
Check Procedure
Check the resistance across both
ends of the Fusing Heater Lamp
(H1).
The Fusing Heater Lamp is open-cir-
cuited if the resistance is infinity.
3 Thermoswitch 1 (TS1) is operational. NO Change Thermoswitch 1 (TS1).
Check Procedure
Check the resistance across both
ends of the Thermoswitch 1 (TS1).
The Thermoswitch 1 is open-circuited
if the resistance is infinity.
T-28
4 Fusing Unit Interlock Switch (S2) is NO Change Fusing Unit Interlock
operational. Switch (S2).
Check Procedure YES Change DC Power Supply (PU1).
Check continuity across terminals
when the Fusing Unit Interlock
Switch (S2) is turned ON.
Across S2-1A and S2-1B
Across S2-2A and S2-2B
5 Thermistor (TH1) is open-circuited. YES Change Thermistor (TH1).
Check Procedure
Check the resistance across CN15-2
and CN15-3 on the Fusing Unit side
with CN15 disconnected.
The Thermistor is open-circuited if
the resistance is infinity.
6 The following voltages are supplied NO Change Master Board (copier:
from the Master Board (copier: PWB- PWB-A).
A).
Check Procedure
DC24 V when Fusing Heater Lamp
(H1) is OFF
(H1) is ON
GND
(H1) is OFF
(H1) is ON
C0520: Abnormally high fusing temperature

1 Thermistor (TH1) is dirty. YES Clean Thermistor (TH1).
2 Thermistor (TH1) is open-circuited. YES Change Thermistor (TH1).
Check the resistance across CN15-2 PWB-A).
and CN15-3 on the Fusing Unit side
with CN15 disconnected.
The Thermistor is open-circuited if
the resistance is infinity.
T-29
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Scanner Home
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(8) C0B60: Bin Switching Motor malfunction

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

1 Bin Switching Motor (JS-202: M1) NO Change Bin Switching Motor (JS-
turns when the Power Switch is 202: M1).
turned ON.
2 Tray is moved as the Bin Switching NO Reinstall motor unit.
Motor (JS-202: M1) operates.
3 Upper Home Position Sensor (JS- NO Change Upper Home Position Sen-
202: PC32) is operational. sor (PC32).
Check Procedure
Check voltage across a Main Board
(JS-202: PWB-A) pin and GND when
the sensor is blocked.
DC5 V when blocked
T-31
4 Lower Home Position Sensor (JS- NO Change Lower Home Position Sen-
202: PC33) is operational. sor (PC33).
Check voltage across a Main Board PWB-A).
(JS-202: PWB-A) pin and GND when
DC5 V when blocked
T-32
(9) C0B80 Shift Motor malfunction

Shift Motor (OT-103: M1) Main Board (OT-103: PWB-A)
Home Sensor (OT-103: S31) Master Board (copier: PWB-A)
OT-103 PWB-A
PWB-A Master
Main Board Board
OT-103 CN55
Shift Motor
PJ58 PJ3A
S31 ANODE
Home Sensor S31 S31 ON
Not Used
4022T536AA

1 Shift Motor (OT-103: M1) turns when NO Change Shift Motor (OT-103: M1).
the Power Switch is turned ON.
2 Exit Roller operates as the Shift NO Reinstall motor unit.
Motor (OT-103: M1) is energized.
3 Home Sensor (OT-103: S31) is oper- NO Change Home Sensor (OT-103:
ational. S31).
Check voltage across a Main Board PWB-A).
(OT-103: PWB-A) pin and GND when
DC5 V when blocked
T-33
(10) C0F32: Faulty ATDC Sensor
C0F33: Improperly adjusted ATDC Sensor

ATDC Sensor (UN1) Master Board (copier: PWB-A)
PWB-A
Master Board
DEVELOPING SECTION
ATDC Sensor
4022T533AA

1 Developer is not even in the Devel- YES Gently swing the IU in the horizon-
oper Mixing Chamber. tal direction to even out developer
in the Developer Mixing Chamber.
2 ATDC Sensor (UN1) is dirty with for- YES Clean ATDC Sensor (UN1).
eign matter (such as paper dust)
other than developer.
3 Foreign matter (such as paper dust) YES Remove foreign matter from the
is trapped in the Developer Mixing Developer Mixing Chamber.
Chamber.
4 The following voltages are supplied YES Change ATDC Sensor (UN1) and
from the Master Board (copier: PWB- developer.
A). NO Change Master Board (copier:
Board pin and GND when the Power
Switch is turned ON.
DC5.39 V to 8.15 V across PJ7A-8
and GND
DC1.41 V to 4.98 V across PJ7A-
10 and GND
T-34
(11) C1038: Engine connection failure

Master Board (copier: PWB-A) Control Board (copier: PWB-C)

1 C1038 reappears when the copier is YES Go to step 2.
turned OFF and ON again.
Check Procedure
Turn OFF and ON the Power Switch
to check to see if C1038 reappears.
2 The connection between Master YES Make good connection between
Board (copier: PWB-A) and Control Master Board (copier: PWB-A) and
Board (copier: PWB-C) is loose. Control Board (copier: PWB-C).
NO Change Control Board (copier:
PWB-C).
Change Master Board (copier:
PWB-A).
(12) C1200: Faulty ASIC/memory

Control Board (copier: PWB-C)

Check Procedure
2 Memory (U8) on Control Board YES Reinstall memory (U8).
(copier: PWB-C) is loose. NO Change Control Board (copier:
PWB-C).
T-35
(13) C1300: Polygon Motor malfunction (startup failure, Lock signal failure, faulty
Lock signal)
C13F0: Faulty HSYNC

Polygon Motor (M2) Master Board (copier: PWB-A)
PWB-A
Master Board
IR/PH SECTION
Polygon Motor
4022T534AA

1 C1300/C13F0 reappears when the YES Go to step 2.
copier is turned OFF and ON again.
Check Procedure
to check to see if C1300/C13F0 reap-
pears.
2 Polygon Motor (M2) connector YES Reconnect connector PJ13A.
PJ13A is loose.
3 The following voltage is supplied to YES Change PH Unit.
the Polygon Motor (M2). NO Change Master Board (copier:
Board (copier: PWB-A) and GND
DC5 V while Polygon Motor (M2) is
in standby state
DC0 V when Polygon Motor (M2) is
energized
T-36
(14) C1468: Faulty EEPROM

Control Board (copier: PWB-C)

Check Procedure
2 Memory (U29) on Control Board YES Reinstall memory (U29).
(copier: PWB-C) is loose. NO Change Control Board (copier:
PWB-C).
T-37
(15) C14A3: IR fluorescent lamp fault

Exposure Lamp (LA2) Control Board (copier: PWB-C)
Inverter Board (copier: PU2)
IR SECTION
PWB-C
PWB-J
Control Board
CCD Board
Not Used Not Used
PU2
Inverter Board
Exposure Lamp
LA2 H/V TERMINAL 1
Not Used
Not Used
H/V TERMINAL 2
CN1PU2 JP16C
4022T535AA
T-38
1 Exposure Lamp turns ON when the NO Go to step 3.
Power Switch is turned ON.
2 Exposure Lamp is abnormally lit NO Go to step 4.
(flickers or abnormally dark) when
the Power Switch is turned ON.
3 Inverter Board (copier: PU2) connec- YES Reconnect.
tor is loose. NO Change Exposure Lamp (LA2).
4 CCD Board (copier: PWB-J) connec- YES Reconnect.
tor is loose.
5 The following voltage is supplied YES Change Inverter Board (PU2).
from the Control Board (copier: PWB- NO Change Control Board (copier:
C). PWB-C).
Check Procedure
Check voltage across a Control
Board (copier: PWB-C) pin and GND
Voltage across JP16C-4 and GND
DC24 V when Exposure Lamp
(LA2) is OFF
DC0 V when Exposure Lamp (LA2)
is ON
T-39
(16) The copier does not turn ON.

Power Switch (S1) Control Board (copier: PWB-C)
DC Power Supply (PU1) Master Board (copier: PWB-A)
Control Panel (UN2)
PWB-C
Control Board
JP2UN2 JP4C
UN2
Control
Panel
Main Switch
Not Used
Not Used
Not Used PJ11C

Fusing 1 29
Heater Lamp Thermoswitch 1

2 30
HEATER_L
Not Used
HEATER_N 1 29
Fusing Unit
Interlock Switch PU1 2 30
DC Power Supply PJ1A

Front Door
InterLock Switch
Right Door
InterLock Switch
PWB-A
Master Boad
4022T545AA

1 A malfunction code appears when YES Go to step 2.
the Power Switch is turned ON. NO Go to step 3.
2 The malfunction is temporarily reset YES Perform the troubleshooting proce-
when the Power Switch is turned dure according to the malfunction
OFF and ON with the Stop key held code.
down.
T-40
3 Power supply voltage check NO Check wall outlet for volt-
Check Procedure age.
Check voltage across pins of DC Power Sup- Check power cord for
ply (PU1) when the Power Switch is turned continuity.
ON. Check Power Switch.
Voltage across CN1PU1-1 and CN1PU1-3
AC0 V when the Power Switch is OFF
Rated AC voltage when the Power Switch is
turned ON
4 Check of output of DC24 V to Control Board NO Check Front Door Inter-
(copier: PWB-C) lock Switch (S3).
Check Procedure Check Right Door Inter-
Check voltage across a Control Board (copier: lock Switch (S4).
PWB-C) pin and GND when the Power Switch Change DC power Supply
is turned ON. (PU1).
DC0 V when the Power Switch is OFF
DC24 V when the Power Switch is turned
ON
5 Check of output of DC24 V to Master Board NO Check Front Door Inter-
(copier: PWB-A) lock Switch (S3).
Check Procedure Check Right Door Inter-
Check voltage across a Master Board (copier: lock Switch (S4).
PWB-A) pin and GND when the Power Switch Change DC power Supply
ON
6 Check of output of DC 5 V to Master Board NO Change DC power Supply
(copier: PWB-A) (PU1).
Check Procedure
Check voltage across a Master Board (copier:
PWB-A) pin and GND when the Power Switch
is turned ON.
ON
7 Check of output of DC5 V to control panel NO Check Control Board
(UN2) (copier: PWB-C).
Check Procedure Change Master Board
Check voltage across a Control Board (copier: (copier: PWB-A).
PWB-C) pin and GND when the Power Switch Change DC power Supply
Voltage across JP4C-1 and GND YES Change Control Panel
DC0 V when the Power Switch is OFF (UN2).
DC5 V when the Power Switch is turned ON
T-41
5. IMAGE FAILURE
5-1. Image Failure Troubleshooting
In this chapter, troubleshooting is divided into initial checks and troubleshooting proce-
dures classified by image failures.
If any image failure has occurred, first make the initial checks, then proceed to the corre-
sponding image failure troubleshooting procedure.
5-2. Initial Checks

Determine if the failure is attributable to a basic cause or causes.
Section Step Check Result Action

Installation 1 The installation site complies NO Change the installation site.
site with the requirements speci-
fied in PRECAUTIONS FOR
INSTALLATION contained in
GENERAL.
Paper 2 Paper meets product specifi- NO Change paper for one that
cations. meets specifications.
Instruct user to use paper
that meets specifications and
is recommended.
3 Paper is damp. YES Change paper for one that is
dry.
Then, instruct user to use
paper that meets specifica-
tions and in how to store
paper.
Original 4 Original is placed correctly. NO Reposition original.
Instruct user in how to place
original correctly.
5 Original is written in light pen- YES Change original.
cil. Instruct user to use original
with appropriate image den-
sity.
6 Original is transparent (OHP YES Change original.
transparencies, etc.). Instruct user to use originals
that meet specifications.
7 Original Glass is dirty. YES Clean Original Glass.
8 Original Glass is scratched. YES Change Original Glass.
PM parts 9 The PM parts relating to YES Clean PM parts.
image formation have Change PM parts.
reached the end of cleaning/
replacement cycles.
T-42
Determine if the failure is attributable to an input system (IR) or output system (engine).
Check Result Action

Copy made at a reduced
ratio. Full-size copy Reduced copy
Input system
Original
1177T04YA
Full-size copy Reduced copy
1177T03YA
Output system
1177T05YA
T-43
5-3. Image Failure Samples
1. Blank copy 2. Black copy 3. Low image density
4. Foggy background or rough

image 5. Black streaks or bands 6. Black spots
7. Blank streaks or bands 8. Void areas 9. Smear on back
11. Gradation reproduc- 12. Periodically

10. Uneven image density tion failure uneven image
4022T542
T-44
5-4. Troubleshooting Procedures by Image Failure
(1) Blank copy

Output system 1 Imaging Unit is installed correctly. NO Reinstall.
2 Connector between the Imaging YES Clean.
Unit and copier is dirty.
3 PH Shutter (located along the YES Correct or reinstall.
laser path between the PH Unit
and PC Drum) is not in correct
position or malfunctions.
4 PH Unit connectors PJ12A and YES Reconnect.
PJ13A are loose.
5 Image Transfer Roller Assy is NO Reinstall.
installed correctly.
6 Image transfer current contact is YES Clean, correct, or
dirty, broken, or bent. change.
7 Developing bias contact is dirty, YES Clean, correct, or
broken, or bent. change.
8 High Voltage Unit (HV1) connec- YES Reconnect.
tors CN1HV1 and CN2HV1 are
loose.
9 The following voltage is supplied YES Change IU.
from the Master Board (copier: Change PH Unit.
PWB-A). Change High Volt-
Check Procedure age Unit (HV1).
Check voltage across a Master NO Change Master
Board pin and GND when the Board (copier:
Start key is pressed. PWB-A).
GND
DC14 V in standby state
DC0 V when Start key is
pressed
Input system 1 CCD Board (PWB-J) connector YES Reconnect.
JP7C is loose.
2 Control Board (copier: PWB-C) YES Reconnect.
connector PJ1A is loose. NO Change Control
Board (copier:
PWB-C).
Change Master
Board (copier:
PWB-A).
T-45
(2) Black copy

Output 1 PC Drum Charge Corona grid mesh and YES Reinstall.
system Comb Electrode are loose.
2 PC Drum Charge Corona contact is dirty, YES Correct or change.
scratched, folded, bent, or damaged.
3 Grid bias contact is dirty, folded, or bent. YES Clean, correct, or
change.
4 PC Drum ground contact is dirty, YES Clean, correct, or
scratched, bent, or damaged. change.
5 High Voltage Unit (HV1) connectors YES Reconnect.
CN1HV1 and CN2HV1 are loose.
6 PH Unit connectors PJ12A and PJ13A YES Reconnect.
are loose.
7 The following voltage is supplied from YES Change IU.
the Master Board (copier: PWB-A). Change PH Unit.
Check Procedure Change High Volt-
Check voltage across a Master Board age Unit (HV1).
pin and GND when the Start key is NO Change Master
pressed. Board (copier:
Voltage across PJ8A-8 and GND PWB-A).
DC0 V when Start key is pressed
Input 1 Exposure Lamp turns ON when the NO Go to step 3.
system Power Switch is turned ON.
2 Exposure Lamp is abnormally lit (flickers NO Go to step 4.
or abnormally dark) when the Power
3 Inverter Board (copier: PU2) connector YES Reconnect.
is loose. NO Change Exposure
Lamp.
4 CCD Board (copier: PWB-J) connector is YES Reconnect.
loose.
5 Control Board (copier: PWB-C) connec- YES Reconnect.
tor PJ1A is loose.
6 The following voltage is supplied from YES Change Inverter
the Control Board (copier: PWB-C). Board (PU2).
Check Procedure Change CCD Unit.
Check voltage across a Control Board NO Change Control
(copier: PWB-C) pin and GND when the Board (copier:
Power Switch is turned ON. PWB-C).
DC24 V when Exposure Lamp (LA2) is
OFF
DC0 V when Exposure Lamp (LA2) is
ON
T-46
(3) Low image density

Output 1 Image density changes after Toner YES Replenish the supply of
system Replenisher has been run. toner using Toner
Toner Replenisher of Utility Replenisher.
2 Image density changes after ID Adjust- YES Readjust.
ment and VG Adjustment have been For more details, see
made. SWITCHES ON PWBs/
TECH. REP. SET-
TINGS.
3 Image transfer current contact is dirty, YES Clean, correct, or
folded, or bent. change.
4 Developing bias contact is dirty, folded, YES Clean, correct, or
or bent. change.
5 High Voltage Unit (HV1) connectors YES Reconnect.
CN1HV1 and CN2HV1 are loose.
6 ATDC Sensor (UN1) is dirty with foreign YES Clean.
matter (such as paper dust) other than
developer.
7 The following voltages develop from the NO Change ATDC Sensor
ATDC Sensor (UN1). (UN1) and then change
Check Procedure developer.
Check voltage across a Master Board
pin and GND when the Power Switch is
turned ON.
and GND
and GND
8 The following voltage is supplied from YES Change IU.
the Master Board (copier: PWB-A). Change High Voltage
Check Procedure Unit (HV1).
Check voltage across a Master Board NO Change Master Board
pin and GND when the Start key is (copier: PWB-A).
pressed.
DC0 V when Start key is pressed
T-47
Input 1 Shading sheet reading portion (the por- YES Clean.
system tion on the backside of the Original
Glass to which Original Width Scale is
affixed) is dirty.
2 CCD Board (copier: PWB-J) connector YES Reconnect.
is loose.
tor PJ1A is loose. NO Change Control Board
(copier: PWB-C).
Change Master Board
(copier: PWB-A).
T-48
(4) Foggy background or rough image

Output 1 Image condition changes after ID YES Readjust.
system Adjustment and VG Adjustment have For more details, see
been made. SWITCHES ON PWBs/
TECH. REP. SET-
TINGS.
2 PC Drum surface and the areas in con- YES Clean or change.
tact with Ds Collars are dirty with foreign
matter, or deformed or worn.
3 Main Erase (LA1) is dirty. YES Clean.
4 Grid bias contact is dirty, scratched, YES Clean, correct, or
deformed, worn, or damaged. change.
5 ATDC Sensor (UN1) is dirty with foreign YES Clean.
matter (such as paper dust) other than
developer.
6 The following voltages develop from the NO Change ATDC Sensor
ATDC Sensor (UN1). (UN1) and then change
Check voltage across a Master Board
pin and GND when the Power Switch is
turned ON.
and GND
and GND
7 The following voltage is supplied from YES Adjust Db.
the Master Board (copier: PWB-A). For details, see DIS/
Check Procedure REASSEMBLY,
Check voltage across a Master Board ADJUSTMENT.
pin and GND when the Start key is Change Main Erase
pressed. (LA1).
Voltage across PJ8A-8 and GND Change PC Drum.
DC14 V in standby state Change IU.
DC0 V when Start key is pressed Change High Voltage
Unit (HV1).
NO Change Master Board
(copier: PWB-A).
Input 1 Original Glass is dirty. YES Clean.
system 2 Scanner mirrors are dirty. YES Clean.
3 Exposure Lamp (LA2) is dirty. YES Clean.
4 CCD Unit lens and CCD surface are YES Clean.
dirty.
Check Procedure
Remove lens cover to check for possible
contamination.
T-49
Input 5 Exposure Lamp is abnormally lit (flickers NO Go to step 7.
system or abnormally dark) when the Start key
is pressed.
CN1PU2 is loose. NO Change Exposure
Lamp (LA2).
PJ7C is loose. NO Change Inverter Board
(PU2).
Change Control Board
(copier: PWB-C).
T-50
(5) Black streaks or bands

Output 1 PC Drum is dirty or scratched. YES Clean or change.
system 2 Foreign matter (such as paper dust) YES Remove foreign matter,
sticks to the Cleaning Blade of IU or the correct, or change.
blade curves upward.
3 DB of IU is plugged with foreign matter YES Remove foreign matter.
(such as paper dust).
4 PC Drum Charge Corona grid mesh and YES Clean or change.
Comb Electrode are dirty, scratched,
deformed, damaged, or out of position.
5 Left Fusing Roller is dirty or scratched. YES Clean or change.
6 PH window of the PH Unit is dirty or YES Clean or change.
scratched. NO Change IU.
Input 1 Original Glass is dirty, scratched, worn, YES Clean or change.
system or damaged.
2 Shading sheet reading portion (the por- YES Clean.
tion on the backside of the Original
affixed) is dirty.
3 Scanner mirrors are dirty, scratched, or YES Clean or change.
damaged.
4 Exposure Lamp (LA2) is dirty. YES Clean or change.
5 CCD Unit lens and CCD surface are YES Clean or change.
dirty or scratched.
Check Procedure
contamination.
is loose.
tor PJ1A is loose. NO Change CCD Unit.
(copier: PWB-C).
T-51
(6) Black spots

Output 1 Toner is present along the paper path. YES Clean.
system 2 PC Drum is dirty or scratched. YES Clean or change.
3 Tip of the PC Drum Paper Separator YES Clean or change.
Finger is dirty, scratched, deformed,
worn, or damaged.
4 Left Fusing Roller is dirty or scratched. YES Clean or change.
5 Tip of the Fusing Paper Separator Fin- YES Clean or change Fus-
ger is dirty, scratched, deformed, worn, ing Paper Separator
or damaged. Fingers and finger
springs.
6 Image condition changes after VG YES Readjust.
Adjustment has been made. For details, see
SWITCHES ON PWBs/
TECH. REP. SET-
TINGS.
Input 1 Original Glass is dirty or scratched. YES Clean.
system 2 CCD Board (copier: PWB-J) connector YES Reconnect.
is loose.
(copier: PWB-C).
T-52
(7) Blank streaks or bands

Output 1 PC Drum ground terminal is dirty, YES Clean, correct, or
system scratched, deformed, or damaged. change.
3 PC Drum Charge Corona grid mesh and YES Clean, correct, or
Comb Electrode are dirty, scratched, change.
deformed, or damaged.
4 Post-fusing guide plate is dirty, YES Clean or change.
scratched, deformed, worn, or dam-
aged.
5 PH window of the PH Unit is dirty, YES Clean or change.
scratched, or damaged. NO Change IU.
system or damaged.
affixed) is dirty.
damaged.
dirty or scratched.
Check Procedure
contamination.
is loose.
(copier: PWB-C).
T-53
(8) Void areas

Output 1 Foreign matter is present along the YES Remove foreign matter.
system paper path.
2 Paper dust plugs up the Paper Dust YES Clean or change.
Remover.
3 PC Drum Charge Corona, grid mesh, YES Reinstall.
and Comb Electrode are loose.
4 PC Drum Charge Corona contact is YES Clean, correct, or
dirty, scratched, deformed, worn, or change.
damaged.
5 Developing Roller is dirty, scratched, YES Clean or change.
6 Toner is even on Sleeve/Magnet Roller. NO Adjust DB.
For details, see DIS/
REASSEMBLY,
ADJUSTMENT.
7 Developer is not even in the Developer YES Even out developer in
Mixing Chamber of IU. the Developer Mixing
Chamber.
9 Image Transfer Roller is dirty, scratched, YES Clean, correct, or
10 Image Transfer Roller Assy is installed NO Reinstall.
correctly.
11 Charge Neutralizing Plate is dirty, YES Clean, correct, or
scratched, folded, or bent. change.
12 Left Fusing Roller is dirty, scratched, YES Clean or change.
deformed, or worn. NO Change IU.
T-54
(9) Smear on back

Output 1 Toner is spilled over area inside copier. YES Clean interior.
system 2 Toner is present along the paper path. YES Clean.
3 Right Fusing Roller is dirty, scratched, or YES Clean or change.
damaged.
4 Image Transfer Roller is dirty. YES Clean or change.
5 Grid bias contact is dirty, scratched, YES Clean, correct, or
NO Change High Voltage
Unit (HV1).
Change Master Board
(copier: PWB-A).
T-55
(10) Uneven image density

Output 1 PC Drum ground plate is dirty, YES Clean, correct, or
system scratched, deformed, worn, or dam- change.
aged.
2 PC Drum Charge Corona grid mesh and YES Clean, correct, or
Comb Electrode are dirty, scratched, change.
deformed, worn, damaged, or loose.
3 Image Transfer Roller is dirty, scratched, YES Clean or change.
4 Sleeve/Magnet Roller is dirty, scratched, YES Clean or change.
5 Toner is even on Sleeve/Magnet Roller. NO Adjust DB.
For details, see DIS/
REASSEMBLY,
ADJUSTMENT.
6 Developer is not even in the Developer YES Even out developer in
Mixing Chamber of IU. the Developer Mixing
Chamber.
NO Change IU.
Change Master Board
(copier: PWB-A).
system or damaged.
affixed) is dirty.
damaged.
dirty or scratched.
Check Procedure
contamination.
6 Exposure Lamp is abnormally lit (flickers NO Go to step 8.
or abnormally dark) when the Power
Lamp (LA2).
is loose.
T-56
Input 9 Control Board (copier: PWB-C) connec- YES Reconnect.
system tor PJ1A is loose. NO Change CCD Unit.
(copier: PWB-C).
T-57
(11) Gradation reproduction failure

Output 1 PC Drum is dirty. YES Clean.
system 2 Image Transfer Roller is dirty, scratched, YES Clean or change.
3 PH Unit connectors PJ12A and PJ13A are YES Reconnect.
loose.
4 PH window of PH Unit is dirty. YES Clean.
5 ATDC Sensor (UN1) is dirty with foreign mat- YES Clean.
ter (such as paper dust) other than devel-
oper.
6 The following voltages develop from the NO Change ATDC
ATDC Sensor (UN1). Sensor (UN1) and
Check voltage across a Master Board pin YES Change Master
and GND when the Power Switch is turned Board (copier:
ON. PWB-A).
DC5.39 V to 8.15 V across PJ7A-8 and
GND
DC1.41 V to 4.98 V across PJ7A-10 and
GND
T-58
Input 1 Original Glass is dirty, scratched, worn, or YES Clean or change.
system damaged.
2 Shading sheet reading portion (the portion on YES Clean.
the backside of the Original Glass to which
Original Width Scale is affixed) is dirty.
3 Scanner mirrors are dirty, scratched, or dam- YES Clean or change.
aged.
5 CCD Unit lens and CCD surface are dirty or YES Clean or change.
scratched.
Check Procedure
Remove lens cover to check for possible con-
tamination.
6 Exposure Lamp is abnormally lit (flickers or NO Go to step 8.
abnormally dark) when the Start key is
pressed.
Lamp (LA2).
loose.
9 Control Board (copier: PWB-C) connector YES Reconnect.
PJ1A is loose. NO Change CCD Unit.
Change Control
Board (copier:
PWB-C).
(12) Periodically uneven image

Output 1 IU is securely fastened using the dedi- NO Secure in position.
system cated fixing screws.
2 PH Unit is securely fastened using the NO Secure in position.
dedicated fixing screws.
3 IU drive mechanism is dirty or damaged. YES Clean or change.
4 PC Drum surfaces in contact with Ds Col- YES Clean or change.
lars and drive mechanism are dirty,
5 Synchronizing Roller drive mechanism is YES Clean or change.
6 Fusing Unit drive mechanism is dirty, YES Clean or change.
scratched, deformed, or worn. NO Change Master Board
(copier: PWB-A).
T-59
Input 1 Scanner Motor (M5) is securely fastened NO Secure in position.
system using the dedicated fixing screws.
2 Scanner Motor (M5) drive mechanism is YES Clean or change.
dirty or damaged.
3 Timing belt of the scanner drive mecha- YES Remove foreign mat-
nism is dirty with foreign matter or out of ter or reinstall belt.
correct position.
4 Scanner drive mechanism pulley is dirty YES Remove foreign mat-
with foreign matter, scratched, deformed, ter or change.
worn, or damaged.
5 Scanner Drive Cables are wound incor- YES Re-wind Scanner
rectly. Drive Cables.
6 Scanner rails and bushings are dirty with YES Clean or change.
foreign matter, scratched, deformed,
worn, or damaged.
7 Scanner moves smoothly. NO Lubricate the Scan-
Check Procedure ner rails.
Gently move the Scanner by hand to Reinstall Scanner.
check for smooth operation.
loose.
9 Control Board (copier: PWB-C) connector YES Reconnect.
PJ1A is loose. NO Change CCD Unit.
Change Control
Board (copier: PWB-
C).
T-60
6. OTHER ERROR CODES
When an error that does not fall into the category of paper transport failure or malfunc-
tion, a corresponding error code is displayed in the Display.
4022T503AA
4022T505AA

tnr Toner empty stop Change Toner Bottle.
nP Paper size is physically changed of Load paper of the size originally
the paper source currently selected loaded in the paper source being
for use while a copy cycle is being used.
run. Turn OFF and ON the Power Switch.
Copier does not find paper of the Load the paper source with paper of
appropriate size when a copy cycle is the appropriate size.
run using the ADF and in the Mixed Turn OFF and ON the Power Switch.
Original and Auto Paper mode.
oL Front Door, Right Door, or Side Door Close the open door or lower the
is open. ADF.
oU ADF is raised.
oA ADF document take-up door is open.
H11 Scan image memory overrun Turn OFF and ON the Power Switch.
H2 The length of the paper set does not Load paper of the correct size again
match that of the paper actually taken according to the set paper size.
up and fed in. Turn OFF and ON the Power Switch.
For copier tray: Slide out and in the
paper tray in which the size error has
occurred.
For Manual Bypass Tray: Place paper
in the Manual Bypass Tray.
For Multiple Bypass Tray: Unload
paper from the Multiple Bypass Tray,
then reload it back again.
H3 JS-202 exit capacity exceeded Remove paper that has been fed out.
J9 JS-202 Bin Switching Motor error (Job Remove paper from the tray.
Tray is unable to return to its home Turn OFF and ON the Power Switch.
position because paper left in the tray)
T-61
PLG Plug-In Counter not plugged in Plug in the Plug-In Counter.
Change setting in Security mode.
For details, see SWITCHES ON
PWBs/TECH. REP. SETTINGS.
Err A numeral outside the specified set- Automatically reset 1 sec. after the
ting range is entered. error display is given.
Turn OFF and ON the Power Switch.
Blank Mechanical total counter not con- Connect the mechanical total counter
nected and then turn OFF and ON the Power
Switch.
Change setting in Security mode.
For details, see SWITCHES ON
nc1 Maintenance Counter count value Enter a count value again.
reached (the set count of the Mainte- For details, see SWITCHES ON
nance Counter is reached) PWBs/TECH. REP. SETTINGS.
nc2 IU life stop mode (the life value of the Initialize the counter value.
Maintenance Counter is reached) For details, see SWITCHES ON
T-62
Copyright
2001 MINOLTA CO., LTD.
Use of this manual should be strictly supervised to

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

Field Service Manual PDF

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Service Manual

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

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Used to call the service technician attention to what is graphically represented

Used to instruct the service technician to do what is graphically represented

4. Use the specified parts.

8. Do not touch a high-temperature part.

2. Precautions for Servicing with Covers and Parts Removed.

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

1-3. Other Precautions

1. Precautions Before Service

2. How to Use this Book

3. Precautions for Service.

5. Precautions for Circuit Inspection

7. Handling of Other Parts

D. Using the SAME face of the Pad, repeat the proce-

9. Handling of the Imaging Cartridge

Precautionary Information on the PC Drum Inside the Imaging Cartridge

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2-1. Settings in the Utility Mode

2-2. Utility Mode Setting Procedure

Exiting the Mode

(1) Users Choice Mode (Display: U-1)

1. Settings in the Users Choice Mode

Number Function Number Function

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Exiting the Mode

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Paper Size Counter

Display Description Display Description

(12) Total Clear

List of Types of Data to be Cleared

(13) ADF Document Passage Test

(15) Scanner Move Check

(16) Serial No. Display

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Step Check Result Action

Step Check Result Action

2-2. Paper Misfeed

LED No. Code Misfeed/Paper Location Action Ref. Page

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