Minolta Di200 Service Manual
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Minolta Di200 Service Manual

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  • Page 1 Return to SubMenu 'L'L'L 'L 86$ DQG &DQDGD RQO\ 6(59,&( 0$18$/ > ),(/' 6(59,&(...
  • Page 2 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.
  • Page 3 4. Handle the power cord with care and never use a multiple outlet. • Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock.
  • Page 4 CAUTION 1. Precautions for Service Jobs • A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. • When reassembling parts, make sure that the correct screws (size, type) are used in the correct places.

  • Page 5: Other Precautions

    5. Precautions for the Laser Beam (Only for Products Employing a Laser) • 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.
  • Page 6 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 manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.
  • Page 7 Precautions for Service When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. Precautions Before Service •...
  • Page 8 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.
  • Page 9 Handling of PWBs 1. During Transportation/Storage: • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature.
  • Page 10 Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. •...
  • Page 11 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.
  • Page 12 INDEX (FIELD SERVICE) DIS/REASSEMBLY, ADJUSTMENT SWITCHES ON PWBs, TECH. REP. SETTINGS TROUBLESHOOTING...
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  • Page 76 SWITCHES ON PWBs, TECH. REP. SETTINGS 17196...

  • Page 78: Table Of Contents

    CONTENTS 1. CONTROL PANEL KEYS AND TOUCH PANEL ..........S-1 1-1. Control Panel Keys .................. S-1 1-2. Explanation of the Touch Panel ............... S-2 (1) Basis Screen ................... S-2 (2) Warning Screens ................S-3 2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ......S-4 2-1.
  • Page 79 7-4. Data/Conditions Cleared by Reset Switches ........... S-36 8. UTILITY MODE ....................S-37 8-1. Utility Mode selection Screen ..............S-37 8-2. User’s Choice Function Tree ..............S-37 8-3. Settings in the Utility Mode ..............S-38 9. SOFT SWITCH SET ..................S-39 9-1.

  • Page 80: Control Panel Keys And Touch Panel

    CONTROL PANEL KEYS AND TOUCH PANEL 1-1. Control Panel Keys 4015O038AA 1. Touch Panel 7. Access Mode Key • Shows various screens and message. • Press to enter the access number when Copy Track of the Administrator mode 2. Utility Key available.

  • Page 81: Explanation Of The Touch Panel

    1-2. Explanation of the Touch Panel Basis Screen The Basic screen is the initial screen that appears when the copier is turned ON. 4011P291CA 1. Supplementary Function Keys • The auxiliary, Density, Orig. Copy, and Basics keys are displayed. 2. Message Display •...

  • Page 82: Warning Screens

    Warning Screens The Warning screen may be a malfunction display, error display, warning display, or a cau- tion display. <Malfunction Display> <Error Display> Given when a malfunction occurs. Given when an error occurs. E.g.: Malfunctions that can be identified E.g.: Paper misfeed, door open, etc. with a specific code.

  • Page 83: Function Of Switches And Other Parts On Pwbs

    FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs 2-1. PWB Location PWB-A PWB-F 4011D095AA 2-2. PWB-A (Master Board) 4011D093AA Symbol Name Description Test Print Switch Produces the test pattern of Function F12. <Procedure> 1. Press S1 to let the copier start the output sequence.

  • Page 84: Pwb-F (Control Panel

    2-3. PWB-F (Control Panel) 4011D095AA Symbol Name Description SW37 Warm Restart Switch Used to enter the initial mode.

  • Page 85: Utility Mode

    UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 3-1. Utility Mode selection Screen • Press the Utility key on the control panel. 4011P294CA 3-2. Utility Mode Function Tree User’s Choice 1/6 User’s Choice 2/6 User’s Choice 3/6 User’s Choice User’s Choice 4/6...

  • Page 86: Settings In The Utility Mode

    3-3. Settings in the Utility Mode Touch Panel Setting Display User’s Choice User’s Choice is used to make various settings according to the user’s need. Meter Count Displays the counts of various counters. Copy Job Recall Permits programming of various functions, including copying jobs. User Management Permits setting of the various User Management functions.

  • Page 87: User's Choice Mode

    2. User's Choice Function Tree Memory Recall User’s Choice 1/6 Mixed Original Detection Language Selected Original Copy Default Auto Paper/Auto Size User’s Choice 2/6 Drawer Priority Special Paper Multiple-in-1 and Booklet Copy Zoom Auto Panel Reset Energy Save Mode User’s Choice Mode User’s Choice 3/6 Plug-In Counter,ID Key Reset Auto Power Off...
  • Page 88 3. Settings in the User's Choice Mode Touch Panel Setting (The default is Highlighted Display Memory Recall Select whether to enable or disable the Memory Recall function. Mixed Original Select the priority Mixed Original Detection mode that is automatically Detection selected when the Power Switch is turned ON or Panel Reset key pressed.
  • Page 89 Touch Panel Setting (The default is Highlighted Display Multiple-in-1 and Select whether to enable or disable recalling a default zoom ratio for Booklet Copy 2in1, 4in1, or Booklet Creation. Zoom Auto Panel Reset Select the time it takes the Auto Panel Reset function, which resets the panel settings when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated.
  • Page 90 Touch Panel Setting (The default is Highlighted Display 4in1 Copy Order Specify the default copying order in the 4in1 mode. Density Priority Specify the priority exposure mode that is selected automatically when the Power Switch is turned ON or the Panel Reset key pressed. <Density>...
  • Page 91 Touch Panel Setting (The default is Highlighted Display Intelligent Sorting Select whether to enable or disable the function that automatically switches between Sort and Non-Sort according to the number of orig- inals and the number of copy sets to be made. Applicable when the system is equipped with a finishing option and using an ADF or ADFR.
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  • Page 93: Admin. Management

    Admin. Management • The entry on the “Administrator # Input ” set using the Tech. Rep. mode permits the set- tings of the following functions. 1. Admin. Management Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2. Touch the “Admin. Management Mode” key. 3.
  • Page 94 Touch Panel Setting (The default is Highlighted Display 100 Accounts-1 100 Accounts-1 100 Accounts-2 • Copying is authorized only for the accounts, for which Access Codes have been programmed. 100 Accounts-2 • Permits the accounts, for which Access Codes have been pro- grammed, to make copies.

  • Page 95: Tech. Rep. Mode

    TECH. REP. MODE • This mode is used by the Tech. Rep. to check, set, adjust, and/or program various ser- vice functions. 4-1. Tech. Rep. Mode Menu Screen 4011P296CA 4-2. Tech. Rep. Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2.
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  • Page 97  6HWWLQJ LQ WKH 7HFK 5HS 0RGH 7HFK 5HS 0RGH ‡ 7KLV IXQFWLRQ DOORZV WKH 7HFK 5HS WR PDNH YDULRXV VHWWLQJV DQG DGMXVWPHQWV  6\VWHP 6HW ‡ 6HW WKH HQYLURQPHQW IRU FRS\LQJ RSHUDWLRQV 7RXFK 3DQHO 6HWWLQJ 7KH GHIDXOW LV +LJKOLJKWHG 'LVSOD\ $XWR 3DSHU 6HOHFW WKH SDSHU VL]H VHOHFWLRQ VFKHPH IRU DXWRPDWLF RULJLQDO VL]H...
  • Page 98 2. Printer • Make the necessary adjustments of the printer (engine). Touch Panel Setting (The default is Highlighted Display Edge Erase Set the erase width on the leading, trailing, right, and left edge of the image. 0 to 5 mm ( 4 mm Loop Adjustment Set the length of the loop to be formed in paper before the Synchro-...
  • Page 99 3. ADFR • Make the necessary adjustments of ADFR. Note: • For details, see Option service manual. Touch Panel Setting (The default is Highlighted Display Original Stop Adjust the document stop position in each of the ADF modes. Position -7..................+7 Smaller Greater...
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  • Page 101 7RXFK 3DQHO 6HWWLQJ 7KH GHIDXOW LV +LJKOLJKWHG 'LVSOD\ 0DFKLQH 'LVSOD\V WKH PDFKLQH FRQILJXUDWLRQ VWDWXV &RQILJXUDWLRQ 7HFKQLFDO 0HPR (QWHU WKH VHULDO QXPEHU DQG RWKHU GDWD 2ULJLQDO 6L]H 6HOHFW ¦21§ ZKHQ WKH RSWLRQDO 2ULJLQDO 6L]H 'HWHFWLQJ 6HQVRU LV 'HWHFWLQJ PRXQWHG 2SWLRQ $GPLQLVWUDWRU ,QSXW ‡...
  • Page 102 Touch Panel Setting Display Counts the number of misfeeds that have occurred at different loca- tions in the copier. Display Display MCBJ System Manual Feed MCBJ Machine Only Vertical Transport 1st Drawer Separator 2nd Drawer Fusing 3rd Drawer Duplex Entrance 4th Drawer Duplex Feed 5th Drawer...

  • Page 103: Touch Panel Display

    Touch Panel Setting Display Display Description SADF No. of single feeds IR 1 No. of scan motions IR 2 No. of scan motions Job Tray No. of cycles of feeding paper out into Job Tray Toner Pages No. of pages equivalent to the no. of black dots on A4 original with B/W 5% Fusing Unit No.

  • Page 104: Function

    Touch Panel Setting Display Device Shows the numbers of prints for different applications. It also allows the Tech. Rep. to clear each counter. Display Description Copier No. of prints made by copier Printer No. of prints made by printer Report Print No.
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  • Page 106 RD Mode • Make the initial settings of the copier for the Data Terminal. 1. RD Mode Menu Function Tree ID Code CT-ID DT Setting DT-ID TEL. # Initial Transmisson RD Mode Maintenance Counter Clear Call Completion RAM Clear Dial Mode Common DT Auto Receive Result Code...

  • Page 107: Rom Version

    Touch Panel Setting (The default is Highlighted Display Initial Performs the initial transmission from the PPC to the Center to check Transmission for correct communication after the Data Terminal has been set up. Counter Clear Clears the spare counter. <Procedure> 1.
  • Page 108 6(&85,7< 02'( ‡ $OORZV WKH 7HFK 5HS WR VHW WKH YDULRXV FRXQWHUV  6HFXULW\ 0RGH 0HQX 6FUHHQ 3&$  6HFXULW\ 0RGH 6HWWLQJ 3URFHGXUH 3URFHGXUH!  6KRZ WKH 7HFK 5HS PRGH PHQX VFUHHQ  3UHVV WKH IROORZLQJ NH\V LQ WKLV RUGHU 6WRS ¡...

  • Page 109: Security Mode

    5-3. Settings in the Security Mode Touch Panel Setting (The default is Highlighted Display Total Counter Select the condition by which the Counter count is increased. 1 Copy per 1 copy cycle Mode 1 Multiple count-up according to paper size 1/2-sided Mode 2 copying Multiple count-up according to paper size 1/2-sided...
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  • Page 111: Adjust Mode

    ADJUST MODE • Used at the factory for making adjustments. 6-1. Adjust Mode Menu Screen C1166P002CA 6-2. Adjust Mode Setting Procedure <Procedure> 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop Start 3.

  • Page 112: Settings In The Adjust Mode

    6-4. Settings in the Adjust Mode Printer • Adjust functions relating to the printer. • Runs a test print sequence. Touch Panel Setting Display Registration (CD) Adjust registration in the CD direction on the engine side. -4.0........... 0...........+4.0 Smaller Greater Registration (FD) Adjust registration in the FD direction on the engine side 35 CPM...

  • Page 113: Initial Mode

    INITIAL MODE • Used to initialize the various service functions. 7-1. Initial Mode Menu Screen 4011P297CA 7-2. Initial Mode Setting Procedure <Procedure> 1. Press the Warm Restart switch. Then “.” appears at the center on the left side of the screen.
  • Page 114  6HWWLQJV LQ WKH ,QLWLDO 0RGH 7RXFK 3DQHO 6HWWLQJ 7KH GHIDXOW LV +LJKOLJKWHG 'LVSOD\ 0HPRU\ &OHDU &OHDUV DOO GDWD <HV 7RXFK 3DQHO $GM &RUUHFWV GHYLDWLRQ LQ WKH VHQVLWLYH DUHD RI WKH 7RXFK 3DQHO 3URFHGXUH! ‡ 6HTXHQWLDOO\ WRXFK WKH IRXU SRLQWV PDUNHG ZLWK RQ WKH VFUHHQ DV LQVWUXFWHG E\ WKH DUURZ 1RWH...
  • Page 115 7-4. Data/Conditions Cleared by Reset Switches Clearing Method Side Cover Trouble Memory Total Clear open/close Reset Clear Data Cleared Misfeed display – – Fusing – – Malfunction display Others – Erratic operation/display – – Job/Image – – – User’s Choice –...
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  • Page 117  6HWWLQJV LQ WKH 8WLOLW\ 0RGH 7RXFK 3DQHO 6HWWLQJ 'LVSOD\ 8VHU©V &KRLFH 8WLOLW\ 0RGH 6 0HWHU &RXQW 8WLOLW\ 0RGH 6 &RS\ -RE 5HFDOO 8WLOLW\ 0RGH 6 8VHU 0DQDJHPHQW 8WLOLW\ 0RGH 6 $GPLQ 8WLOLW\ 0RGH 6 0DQDJHPHQW 5HSRUW 3URWRFRO 7UDFH...
  • Page 118 62)7 6:,7&+ 6(7  6RIW 6ZLWFK ,QLWLDO 9DOXH 7DEOH ‡ 7KH FRQWHQWV RI WKH VRIW VZLWFKHV DUH GHVFULEHG PDLQO\ IRU PRGHV UHODWHG WR FRS\LQJ ‡ 7KH PDUN LQGLFDWHV D PRGH FRQWDLQLQJ LWHPV WKDW FDQ EH VHW DFFRUGLQJ WR WKH XVHU V ✽...
  • Page 119 9-2. Set Contents of Soft Switches NOTES • The contents of the software switches are described mainly for modes related to copying. • The mark indicates a mode containing items that can be set according to the user's choice, for example. •...
  • Page 120 Mode Initial value Bit: HEX: 01 Logic Function Description Simplex/Duplex 1-Sided 2-Sided Original Copy Default Bit6-5: 1-Sided 2-Sided Setting other inhibit Bit4-3: APS: Auto paper mode Auto Paper/Auto Size AMS: Auto magnification mode Setting inhibit Manual Sets the print form for overseas PC printing. Main Application Copy: All PC prints are output together after Copy...
  • Page 121 Mode Initial value Bit: HEX: 01 Logic Function Description Auto Panel Reset Bit7-0: Setting of whether or not auto clear takes place after the speci- 00000000 No Reset fied time from the end of copying or a key operation and also the 00000001 1 min.
  • Page 122 Mode Initial value 20-cpm Copier Bit: HEX: 1E 25-cpm Copier Bit: 35-cpm Copier HEX: 3C Logic Function Description Auto Power Off Bit7-0: • Setting of whether or not to cut OFF the power to the machine 00000000 after the specified time from the end of copying or a key 00000001 1 min.
  • Page 123 Mode Initial value Bit: HEX: 00 Logic Function Description Drawer Priority Bit7-4: Setting of paper source selected preferentially in the APS (auto 0000 1st Drawer paper mode) or the manual mode. 0001 2nd Drawer 0010 3rd Drawer 0011 4th Drawer 0100 5th Drawer Manual...
  • Page 124 Mode Initial value Bit: HEX: 44 Logic Function Description Default Copy Output Levels Bit7-6: Darker Selection of level in auto density mode. Normal Setting inhibit Lighter Fixed Setting change inhibit Density (ADF only) Normal: Black Image is read at the specified density. streak Normal Black streak prevention:...
  • Page 125 Mode Initial value Bit: HEX: 08 Logic Function Description Priority Sort Mode Bit7-6: Non Sort Selection of the paper exit mode that has priority when the paper sort exit system option is installed. Setting inhibit Group Can be set simultaneously with a mode other Priority Stapling Mode (copy) than "Non-sort"...
  • Page 126 0RGH ,QLWLDO YDOXH %LW +(; $ /RJLF )XQFWLRQ 'HVFULSWLRQ ,PDJH &RPSUHVVLRQ :KHQ %LW ,QGLFDWHV WKH PHPRU\ UHVHUYH 5HVHUYLQJ &DSDFLW\ ,Q 7KH &RS\ FDSDFLW\ SHU FRS\ FRQYHUWHG LQWR  0HPRU\ FRS\ LPDJH FRPSUHVVLRQ DQG UHVHUYHV PHPRU\ FDSDFLW\ EHIRUH  VWDUW RI VFDQQLQJ DFFRUGLQJ WR WKH  VHW FRPSUHVVLRQ FRUUHVSRQGLQJ WR WKH RULJLQDO XVHG...
  • Page 127 0RGH ,QLWLDO YDOXH %LW +(;  /RJLF )XQFWLRQ 'HVFULSWLRQ 6RXQG 9ROXPH 6HWWLQJ  0RQLWRU /LQH PRQLWRU WRQH YROXPH VHWWLQJ %LW ✽ 1R WRQH 7RQH FRS\ 6HWWLQJ 2WKHU LQKLELW 2ULHQWDWLRQ RI ,PDJHV :KHQ )LQ )DFLQJ 6HWV WKH RULHQWDWLRQ RI WKH LPDJH ZKHQ D ILQ LVKHU LV &RQQHFWHG FRS\ IDFLQJ HDFK...
  • Page 128 0RGH ,QLWLDO YDOXH %LW +(;  /RJLF )XQFWLRQ 'HVFULSWLRQ )L[HG 6HWWLQJ FKDQJH LQKLELW %LW  PP (GJH (UDVH :KHQ D %6 VFDQ LQFOXGLQJ $')5 LV SHUIRUPHG  PP ,Q WKH $36$06 PRGH H[DFWO\ WKH ZLGWK VHW IURP WKH  PP GHWHFWHG RULJLQDO VL]H IUDPH LV HUDVHG ,Q WKH PDQXDO PRGH H[DFWO\...
  • Page 129 Mode Initial value Bit: HEX: 08 Logic Function Description Total Counter Mode 1 Setting of total counter counting Bit7-6: (standard) method. Mode 2 (ME) Mode 3 Setting inhibit Size Counter Do not Setting of paper size to be Bit5-3: count counted by size counter.
  • Page 130 0RGH ,QLWLDO YDOXH %LW +(;  /RJLF )XQFWLRQ 'HVFULSWLRQ &RS\ &RS\ 6HWWLQJ RI WKUHVKROG YDOXH RI FRS\ NLW FRXQWHU 3OXJ,Q &RXQWHU 0DGH &\FOHV DQG YLHZLQJ FRXQW YDOXH .H\ &RXQWHU 8VH RI NH\ FRXQWHU RU YHQGRU 9HQGRU 0RGH 6HWV ZKLFK RI WKH NH\ FRXQWHU RU %LW FRXQWHU YHQGRU WR VHW ZKHQ WKHVH DUH...
  • Page 131 Mode Initial value Bit: HEX: 00 Logic Function Description 7 to 4 Fixed Setting change inhibit Image Quality Mode Adjustment Bit3-0: 0000 Setting of image density for print- (copy) ing. Enables setting of special image 1000 quality mode for Original Image Type of MODE 409 Bit4-1.

  • Page 132: Troubleshooting

    TROUBLESHOOTING 14413...
  • Page 134 CONTENTS 1. INTRODUCTION ..................... T-1 1-1. Reading the Text ..................T-1 2. I/O CHECK ...................... T-1 2-1. Electrical Components Check Procedure ..........T-1 2-2. I/O Check List ..................T-2 3. PAPER TRANSPORT FAILURE ..............T-8 3-1. Paper Misfeed ..................T-8 3-2.
  • Page 135 (1) Blank Copy ..................T-48 (2) Black Copy ..................T-49 (3) Low Image Density ................T-50 (4) Foggy Background ................T-51 (5) Black Streaks or Bands ..............T-52 (6) Black Spots ..................T-53 (7) Blank Streaks or Bands ..............T-54 (8) Void Areas ..................

  • Page 136: Introduction

    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.

  • Page 137: I/O Check List

    2-2. I/O Check List <I/O Check Screens> • The following screen is only typical and it may be different from what is shown on each individual copier. 4011T539CA <I/O Check List> Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC13...
  • Page 138 <I/O Check Screens> • The following screen is only typical and it may be different from what is shown on each individual copier. Printer “BackUp” “Next” 4011T540CA 4011T541CA “Next” “BackUp” “Next” “BackUp” 4011T543CA 4011T542CA...
  • Page 139 <I/O Check List> Printer Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Drawer 1st Drawer Set In position Out of Master IC1A PJ3A-5B Drawer Sensor position Board PWB-A PWB-H Double Double Feed Blocked *2 Unblocked IC1A PJ4A-2 Feed...
  • Page 140 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Take-up Paper Take-Up Paper Paper not Control IC1A PJ3A-5A Drawer Sensor present present Board PWB-A Paper Paper Near Empty Unblocked Blocked IC1A PJ3A-11A Near Sensor Empty Paper Paper Empty Sen- Paper not Paper...
  • Page 141 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Lift Level Lift-Up Sensor 1 At upper Not at IC4A P74/ CN4A-6 limit upper limit Control ANI4 Board Lift Level Lift-Up Sensor 2 At upper Not at IC4A P73/ CN4A-9...
  • Page 142 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board SIDE Doors/ LCC Side Door Set Sensor When When IC4A P34/ CN3A-12 Toner Cover opened closed Control Board FRONT LCC Front LCC Set Sensor Out of In position IC4A P35/ CN6A-9...

  • Page 143: Paper Transport Failure

    PAPER TRANSPORT FAILURE 3-1. Paper Misfeed • When a paper misfeed occurs, the Touch Panel shows the corresponding message, mis- feed location, and paper location. Misfeed location display display Paper location 15 11 15 11 4011T544CA 4011T545CA Display Misfeed/Paper Location Ref.
  • Page 144 If a communications error occurs between MFB2 Board and Master Board during a copy cycle, it forces a paper misfeed condition ( displayed on the Touch Panel). If that hap- pens, check the circuit between MFB2 Board and Master Board for proper connection and, if it is intact, replace the board.

  • Page 145: Size Error

    3-2. Size Error • The following warning screen appears if the actual size of the paper loaded in a paper source differs from the paper size set for that particular paper source. 1st to 5th Drawer Manual Bypass 4011T546CA 4011T547CA 1st to 5th Drawer: A size error is indicated by a highlighted paper source in the copier overview display.

  • Page 146: Misfeed Detection Sensor Layout

    3-3. Misfeed Detection Sensor Layout Paper Exit Sensor PC3 Duplex Unit Door Set Sensor PC1 Duplex Unit Trans- port Sensor PC2 Synchronizing Roller Sensor PC2 Manual Feed Paper Take-Up Sensor PC8 Paper Take-Up Sensor PC101 4011T548CA The Duplex Unit is standard on the 35-cpm copier. A fixed paper size cassette is standard for the 2nd Drawer of the 25-cpm and 35-cpm copier.

  • Page 147: Types Of Misfeed Detection And Detection Timings

    3-4. 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.
  • Page 148 Duplex Turnover/Take-Up Misfeed Type Detection Start Detection Leading edge detection by Paper Exit Sensor (T) Duplex Unit Transport Sen- Duplex Unit Transport Sen- sor (L) Paper take-up failure detec- Duplex Unit Transport Sen- Synchronizing Roller Sensor tion sor (L) Paper left Power Switch ON / Misfeed Duplex Unit Transport Sen- reset...
  • Page 149 3-5. Misfeed Troubleshooting Procedures 1st Drawer Take-Up Misfeed Relevant Electrical Parts 1st Drawer Paper Take-Up Solenoid SL1 Master Board PWB-A Synchronizing Roller Sensor PC2 PWB-A PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) CN10 PJ3A-13B (SL1 ON) PJ3A-12B (DC24 V) 4011T513AA T-14...
  • Page 150 1st Drawer Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. Edge Guide and Trailing Edge Stop are at cor- Set as necessary.
  • Page 151 Manual Bypass Take-Up Misfeed Relevant Electrical Parts Manual Feed Paper Take-Up Clutch CL2 Manual Feed Paper Take-Up Sensor PC8 Synchronizing Roller Sensor PC2 Master Board PWB-A PWB-A CN36 CN14 PJ23 PJ2A-8A (DC24 V) PJ2A-9A (CL2 ON) PJ2A-8B (GND) PJ2A-7B (PC8 ON) PJ40 PJ2A-6B (DC5 V) PJ3A-6A (GND)
  • Page 152 Manual Bypass Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. Edge Guides are at the correct position along Set as necessary.

  • Page 153: Separator/Fusing/Exit Misfeed

    Separator/Fusing/Exit Misfeed Relevant Electrical Parts Paper Exit Sensor PC3 Synchronizing Clutch CL1 Synchronizing Roller Sensor PC2 Master Board PWB-A PWB-A CN23 PJ24 PJ3A-1A (DC24 V) PJ3A-2A (CL1 ON) PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) PJ3A-11A (GND) PJ3A-12A (PC3 ON) PJ3A-13A (DC5 V) 4011T515AA T-18...
  • Page 154 Separator/Fusing/Exit Misfeed Troubleshooting Procedures • Paper is at a stop near the Synchronizing Roller. Step Check Result Action Pre-Image Transfer Guide Plate is dirty or YES Clean or change. deformed. Synchronizing Rollers are dirty, deformed, or YES Clean or change. worn.

  • Page 155: Paper Take-Up/Transport Misfeed (2Nd Fixed Paper Size Cassette

    Paper Take-Up/Transport Misfeed (2nd Fixed Paper Size Cassette/PF-118/PF- 119) Relevant Electrical Parts Paper Take-Up Clutch CL1 Power Supply Unit PU1 Paper Take-Up Sensor PC1 Control Board PWB-A Synchronizing Roller Sensor PC2 Master Board PWB-A I/C Motor M1 PWB-A CN83 PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) CN93...
  • Page 156 3DSHU 7DNH8S7UDQVSRUW 0LVIHHG QG )L[HG 3DSHU 6L]H &DVVHWWH3)3) 7URX EOHVKRRWLQJ 3URFHGXUHV ‡ 3DSHU LV QRW WDNHQ XS DW DOO 6WHS &KHFN 5HVXOW $FWLRQ 3DSHU PHHWV SURGXFW VSHFLILFDWLRQV &KDQJH SDSHU 3DSHU LV FXUOHG ZDY\ RU GDPS <(6 &KDQJH SDSHU ,QVWUXFW XVHU LQ FRUUHFW SDSHU VWRUDJH (GJH *XLGH DQG 7UDLOLQJ (GJH 6WRS DUH DW FRU 6HW DV QHFHVVDU\...
  • Page 157 • Paper is at a stop at the vertical transport section or near the Synchronizing Roller. Step Check Result Action Vertical Transport Roller is dirty, deformed, or YES Clean or change. worn. Vertical transport guide plate is dirty or YES Clean or change. deformed.
  • Page 158 Paper Take-Up Misfeed (PF-117) Relevant Electrical Parts LCC Paper Take-Up Sensor PPS0 Separator Clutch BCL Paper Empty Sensor 1 PPS1 Registration Clutch RCL Paper Standby Position Sensor S1 LCC Control Board PWB-A Registration Sensor RSEN Control Board PWB-A Paper Take-Up Clutch 1 P1CL Master Board PWB-A Paper Take-Up Clutch 2 P2CL CN83...
  • Page 159 3DSHU 7DNH8S 0LVIHHG 3) 7URXEOHVKRRWLQJ 3URFHGXUHV ‡ 0LVIHHG LV GHWHFWHG ZKHQ WKH FDVVHWWH LV VOLG LQ 6WHS &KHFN 5HVXOW $FWLRQ 3DSHU PHHWV SURGXFW VSHFLILFDWLRQV &KDQJH SDSHU 3DSHU LV FXUOHG ZDY\ RU GDPS <(6 &KDQJH SDSHU ,QVWUXFW XVHU LQ FRUUHFW SDSHU VWRUDJH 3DSHU 7DNH8S 5ROOHU LV GLUW\ GHIRUPHG RU <(6 &OHDQ RU FKDQJH ZRUQ...
  • Page 160 ‡ 3DSHU LV QRW WDNHQ XS DW DOO 6WHS &KHFN 5HVXOW $FWLRQ 3DSHU PHHWV SURGXFW VSHFLILFDWLRQV &KDQJH SDSHU 3DSHU LV FXUOHG ZDY\ RU GDPS <(6 &KDQJH SDSHU ,QVWUXFW XVHU LQ FRUUHFW SDSHU VWRUDJH )HHG 5ROOHU DQG 6HSDUDWRU 5ROOHU DUH GLUW\ <(6 &OHDQ RU FKDQJH GHIRUPHG RU ZRUQ 3DSHU WDNHXS JXLGH SODWH LV GLUW\ RU GHIRUPHG...

  • Page 161: Duplex Turnover/Take-Up Misfeed

    Duplex Turnover/Take-Up Misfeed (AD-15) Relevant Electrical Parts Paper Exit Sensor PC3 Duplex Unit Turnover Motor M1 Synchronizing Roller Sensor PC2 Duplex Unit Transport Motor M2 Manual Feed Paper Take-Up Clutch CL2 Duplex Unit Control Board PWB-A Duplex Unit Transport Sensor PC2 Master Board PWB-A PWB-A PJ2A-1A (DC24 V)
  • Page 162 'XSOH[ 7XUQRYHU7DNH8S 0LVIHHG $' 7URXEOHVKRRWLQJ 3URFHGXUHV ‡ 3DSHU LV DW D VWRS QHDU WKH H[LW VHFWLRQ 6WHS &KHFN 5HVXOW $FWLRQ 3DSHU ([LW 5ROOHU LV GLUW\ GHIRUPHG RU ZRUQ <(6 &OHDQ RU FKDQJH 'XSOH[ 8QLW 7UDQVSRUW 5ROOHU5ROO  LV GLUW\ <(6 &OHDQ RU FKDQJH GHIRUPHG RU ZRUQ 3DSHU ([LW 6HQVRU RSHUDWLRQ FKHFN WKURXJK ,2 &KHFN DFWXDWRU...
  • Page 163 ‡ 3DSHU LV DW D VWRS LQVLGH WKH 'XSOH[ XQLW 6WHS &KHFN 5HVXOW $FWLRQ 'XSOH[ 8QLW 7UDQVSRUW 5ROOHU5ROOHU  LV GLUW\ <(6 &OHDQ RU FKDQJH GHIRUPHG RU ZRUQ 0DQXDO )HHG 3DSHU 7DNH8S 5ROOHU LV GLUW\ <(6 &OHDQ RU FKDQJH GHIRUPHG RU ZRUQ 'XSOH[ 8QLW 7UDQVSRUW 6HQVRU RSHUDWLRQ FKHFN <(6 &KHFN VWHS  WKURXJK ,2 FKHFN...

  • Page 164: Malfunction

    MALFUNCTION The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. Malfunction Resetting Procedure • For all malfunctions except fusing-related ones, turn OFF, then ON the Power Switch or open and close the Side Cover.
  • Page 165 Code Description Detection Timing C0510 Abnormally low fusing • The fusing temperature remains 105 °C or less for a temperature continuous 0.1-sec. period or more during the standby state or printing. • The fusing temperature remains a level lower than the following temperature for a continuous 2-min.
  • Page 166 Code Description Detection Timing C0B38 Shift Motor drive mal- function C0B48 Exit Roller/Rolls Spacing Motor drive malfunction C0B4A Storage Roller/Rolls Spacing Motor drive mal- function C0B4D Paper Holding Tray Motor drive malfunction C0B4E Finisher Tray Motor drive malfunction C0B50 Stapling Motor 1 drive malfunction / Stapling See the relevant option service manual.
  • Page 167 Code Description Detection Timing C1300 Polygon Motor malfunc- <Faulty start detection> tion • The Lock signal is not detected at any time during a given period of time 1 sec. after the Polygon Motor has been energized. <Faulty Lock signal detection> •...

  • Page 168: Troubleshooting Procedures By Malfunction Code

    4-2. Troubleshooting Procedures by Malfunction Code C0000: Main Motor malfunction C0010: I/C Motor malfunction C0045: Cooling Fan Motor malfunction C004C: Ozone Fan Motor malfunction C004E: Power Unit Cooling Fan Motor malfunction C0070: Main Hopper Toner Replenishing Motor malfunction Relevant Electrical Parts Main Motor M2 Power Unit Cooling Fan Motor M4 I/C Motor M1...
  • Page 169 C0000 Step Check Result Action Main Motor operation check: the voltage YES Check various parts for across PJ1-3 of the Main Motor and GND possible overload. changes from DC5 V to DC0 V when the Side Change Main Motor. Cover is opened and closed. Change Master Board.
  • Page 170 C0070 Step Check Result Action Main Hopper Toner Replenishing Motor opera- YES Check step 3. tion check: • Remove the Lower Rear Cover. • Unlock the Toner Bottle Lock Lever. • Block the Toner Bottle Cover Sensor. • Turn the Toner Bottle a half turn by hand. The Toner Bottle turns when the Toner Bottle Cover Sensor is unblocked under the above conditions.

  • Page 171: C0214: Abnormal Image Transfer Voltage

    C0214: Abnormal image transfer voltage Relevant Electrical Parts Power Supply Unit PU1 Master Board PWB-A High Voltage Unit PU2 PJ9PU1-1 (DC5 V) PJ9PU1-2 (GND) CN11 DC24 V CN1PU2-1 (DC24 V) CN1PU2-2 (GND) CN1PU2-3 (GND) CN1PU2-4 (DC5 V) CN17 PWB-A PJ15A-4A (P.C./I.T. REM) CN2PU2-4 (P.C./I.T.

  • Page 172: C0510: Abnormally Low Fusing Temperature

    C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Fusing Roller Heater Lamp H1 Side Cover Interlock Switch 2 S3 Fusing Roller Thermistor TH1 Power Supply Unit PU1 Fusing Roller Thermostat TS1 Master Board PWB-A Fusing Roller Heater Lamp Fuse TF1 PWB-A CN25...
  • Page 173 C0500,C0510 Step Check Result Action Fusing Roller Heater Lamp turns ON when the Check step 3 and onward. Side Cover is opened and closed. The resistance of Fusing Roller Thermistor YES Change Fusing Roller (across CN25-2 and 3 on the Fusing Unit end) Thermistor.

  • Page 174: C0650: Faulty Scanner Home Position Sensor

    C0650: Faulty Scanner Home Position Sensor 1 C0651: Faulty Scanner Home Position Sensor 2 Relevant Electrical Parts Scanner Home Position Sensor 1 PC12 BCR Board BCR Scanner Home Position Sensor 2 PC13 MFB2 Board MFB2 Scanner Motor M10 Master Board PWB-A CN33 PC12 CN32...
  • Page 175 C0650,C0651 Step Check Result Action Scanner Motor operation check: Select func- YES Check step 3 and onward. tions in the following order: Tech. Rep. Mode → Movement Check → Scanner; set “+1000” in “Relative Position” and touch “Set”; the Scan- ner moves at this time.

  • Page 176: C0991: Lift 1 Ascent Motion Failure

    C0990: LCC Lift-Up Motor failure to turn C0991: Lift 1 ascent motion failure C0995: LCC Transport Motor failure to turn C0999: Lift 2 ascent motion failure C099D: LCC communication error Relevant Electrical Parts LCC Lift-Up Motor EMOT Power Supply Unit PU1 Lift-Up Sensor 1 LS1 LCC Control Board PWB-A Lift-Up Sensor 2 LS2...
  • Page 177 C0990 Step Check Result Action The voltage across CN1A-15 on LCC Control YES Change LCC Lift-Up Board and GND is DC24 V. Motor. Change LCC Control Board. Change Control Board. Change Master Board. Fuse is conducting. YES Change Power Supply Unit.
  • Page 178 C0999 Step Check Result Action Lift-Up Sensor 2 operation check through I/O YES Check step 3 and onward. check Lift-Up Sensor 2 operation check: the voltage YES Change LCC Control across CN4A-9 on LCC Control Board and Board. GND is DC5 V when the sensor is blocked and Change Control Board.

  • Page 179: C0F32: Faulty Atdc Sensor C0F33: Atdc Adjustment Failure

    C0F32: Faulty ATDC Sensor C0F33: ATDC adjustment failure Relevant Electrical Parts ATDC Sensor UN2 Master Board PWB-A Power Supply Unit PU1 CN11 PWB-A CN50 PJ18 PJ6A-1 (UN2 CONTROL) PJ6A-2 (DC24 V) PJ6A-3 (UN2 ON) PJ6A-4 (GND) PJ6PU1-5 (DC5 V) 4011T512AA C0F32,C0F33 Step Check...

  • Page 180: C10Xx To C13Xx

    C10XX to C13XX • These malfunctions are concerned with faulty symptoms as they mainly relate to soft- ware, hardware, and communications. Code Action C1038 1. Check the connection between Master Board and MFB2 Board. 2. Reset the malfunction and turn OFF and ON the Power Switch. 3.

  • Page 181: The Copier Does Not Turn On

    The Copier Does not Turn ON. Relevant Electrical Parts Power Switch S1 Touch Panel UN1 Power Supply Unit PU1 MFB2 Board MFB2 Panel Board PWB-F Master Board PWB-A Inverter Board 2 PU3 • Touch Panel indicates nothing. Step Check Result Action Power supply voltage check: the voltage across Check the power outlet...

  • Page 182: Image Failure

    IMAGE FAILURE 5-1. Image Failure Troubleshooting • 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...

  • Page 183: Troubleshooting Procedures Classified By Image Failure

    5-3. Troubleshooting Procedures Classified by Image Failure Blank Copy <Typical Faulty Images> 4011T516AA Section Step Check Result Action Developing Unit is driven properly. Correct or change drive coupling mechanism. Image transfer current contact terminal YES Clean or change. is dirty or deformed. Developing bias contact terminal is YES Clean or change.

  • Page 184: Black Copy

    Black Copy <Typical Faulty Images> When engine is faulty. When IR is faulty. 4011T517AA 4011T537AA Section Step Check Result Action Comb Electrode contact terminal is YES Clean or change. dirty or deformed. Grid voltage contact terminal is dirty or YES Clean or change. deformed.

  • Page 185: Low Image Density

    Low Image Density <Typical Faulty Images> 4011T518AA Section Step Check Result Action Image transfer current contact terminal YES Clean or change. is dirty or deformed. Developing bias contact terminal is Clean or change. dirty or deformed. Select functions in the following order: YES Make setting again.

  • Page 186: Foggy Background

    Foggy Background <Typical Faulty Images> When engine is faulty. When IR is faulty. 4011T519AA 4011T538AA Section Step Check Result Action Sunlight or any other extraneous light YES Protect the copier from — enters the copier. extraneous light. PC Drum is dirty. YES Clean.

  • Page 187: Black Streaks Or Bands

    Black Streaks or Bands <Typical Faulty Images> 4011T520AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. PC Drum is dirty. YES Clean. Engine Fusing Rollers are dirty or scratchy. YES Clean or change. Change I/C. Change Master Board.

  • Page 188: Black Spots

    Black Spots <Typical Faulty Images> 4011T521AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. PC Drum is dirty. YES Clean. Fusing Rollers are dirty or scratchy. YES Clean or change. Comb Electrode contact terminal is YES Clean or change.

  • Page 189: Blank Streaks Or Bands

    Blank Streaks or Bands <Typical Faulty Images> 4011T522AA Section Step Check Result Action Image Transfer Roller is dented or YES Change. scratchy. PC Drum is dirty. YES Clean. Engine Fusing Rollers are dirty or scratchy. YES Clean or change. PH Assy window glass is dirty. YES Clean.

  • Page 190: Void Areas

    Void Areas <Typical Faulty Images> 4011T523AA Section Step Check Result Action PC Drum is dirty. YES Clean. Image Transfer Roller is dented or Change. scratchy. Engine Fusing Rollers are scratchy or YES Clean or change. deformed. Change I/C. Change Master Board. Original Glass is dirty.

  • Page 191: Smear On Back

    Smear on Back <Typical Faulty Images> 4011T524AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. Engine Image Transfer Roller is dirty. YES Clean. Fusing Rollers are dirty. YES Clean. T-56...

  • Page 192: (10) Uneven Image Density

    (10) Uneven Image Density <Typical Faulty Images> 4011T525AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Engine Change I/C. Change Master Board. Mirror, lens, and/or Original Glass are YES Clean. dirty. Shading sheet is dirty. YES Clean.

  • Page 193: (11) Gradation Reproduction Failure

    (11) Gradation Reproduction Failure <Typical Faulty Images> 4011T526AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Engine Change I/C. Change Master Board. Mirror, lens, and/or Original Glass are YES Clean. dirty. Shading sheet is dirty. YES Clean.

  • Page 194: (12) Rough Image

    (12) Rough Image <Typical Faulty Images> 4011T527AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Image transfer current contact terminal YES Clean or change. is dirty or deformed. Toner has caked or is contaminated YES Remove foreign matter.

  • Page 195: (13) Periodically Uneven Image

    (13) Periodically Uneven Image <Typical Faulty Images> 4011T528AA Section Step Check Result Action Developing Unit is driven properly. Correct or change drive coupling mechanism. PC Drum and Image Transfer Roller Correct or change drive are driven properly. coupling mechanism. Synchronizing Roller is driven properly. Correct or change drive coupling mechanism.

  • Page 196: Abort Codes

    ABORT CODES • The copier displays an abort code on the Touch Panel as it becomes unable to process tasks properly through its software control. Abort Code 4011T536AA 6-1. List of Abort Codes • When the system program is aborted, the copier attempts to restart it automatically. If it fails to restart the program, check the electrical component, unit, option, and connection relating to the specific type of the abort condition.
  • Page 197 Description Code Relevant Electrical Components, Units, and Options Scanner control sys- 0x00c00000 MFB2 Board, BCR Board, Inverter Board 1, AF-9, tem failure to 0x00c0ffff AFR-17 Scanner control sys- 0x00c10000 MFB2 Board, BCR Board, Inverter Board 1, AF-9, tem failure to 0x00c2ffff AFR-17 Scanner control sys- 0x00c30000...
  • Page 198 Description Code Relevant Electrical Components, Units, and Options Function sequence 0x01100400 MFB2 Board system failure to 0x011004ff OS message pro- 0x02000000 cessing system fail- MFB2 Board, FPLAN Board, CEN Board to 0x020fffff Network processing 0x03000000 MFB2 Board, FPLAN Board, CEN Board system failure to 0x030fffff T-63...
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