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0.1 Getting to know this Service Manual

This manual is used as the standard service manual for WorkCentre 5022/5024.

•Publication Comment Sheet

Enter any comments and/or corrections regarding this service manual into the Publication Comment Sheet, and send it to the following department.

Solution Service & Operational Management CS Dept.

0.2 How to use the Service Manual

This manual describes the standard procedures for the servicing this product. Refer to Chapter 1 Service Call Procedure for efficient and effective servicing during maintenance calls.

For more information on the options, refer to the options manual.

0.2.1 Contents of Manual

This manual is divided into 10 chapters as described below.

•Chapter 1 Service Call Procedure

This chapter describes the general work and servicing procedures for the maintenance of this product.

•Chapter 2 Troubleshooting

This chapter describes the troubleshooting procedures other than image quality troubleshooting for this product.

•Chapter 3 Image Quality Troubleshooting

This chapter describes the image quality troubleshooting procedures for this product.

•Chapter 4 Disassembly/Assembly and Adjustment

This chapter describes the disassembly, assembly, adjustment and replacement procedures for components of this product.

•Chapter 5 Parts List

This chapter contains the spare parts information for this product.

•Chapter 6 General

This chapter contains the following information.

6.1Specifications

6.2Tools/Service Consumables/Consumables

6.3Service Data

6.5 Service Mode

6.8Fax-related Information

•Chapter 7 Wiring Data

This chapter contains the information about the Wiring Connector List/Locations, the Wiring Data, and the BSD for this machine.

•Chapter 8 Accessories (not yet issued)

•Chapter 9 Installation/Removal

This chapter contains the installation and removal procedures for this product and the options that are specific to it.

•Chapter 10 Mechanism & Functions Overview (not yet issued)

1.1 Before Starting the Servicing

1.1.1 Safety

To prevent any accident that may occur during a maintenance service, any warning or any caution regarding the servicing must be strictly observed. Do not perform any hazardous operation.

1.Power Supply

To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and disconnect the plug before starting the maintenance service. If the machine has to be switched ON, such as when measuring the voltage, take extra care not to get an electrical shock.

2.Drive Area

Never inspect, clear or lubricate the drive area such as chain belts, chain wheel or gears during the machine operation.

3.Heavy Parts

Position your hip lower when removing or installing heavy parts.

4.Safety Device

See that safety devices for preventing mechanical accidents, such as fuses, circuit breakers, interlock switches, etc., and those for protecting customers from injury, such as panels and covers, function properly. Modifications that hinder the function of any safety devices are strictly prohibited.

5.Installing and Removing Parts

The edge of parts and covers may be sharp, take care not to touch them. Be careful not to touch those parts, and wipe off any oil that may have adhered to your fingers or hands before servicing. When removing parts, cables, and etc. do not pull them out by force but remove them slowly.

6.CAUTION:

RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

7.Specified Tools

Follow the instruction when a tool is specified.

8.Cleaning the Toner and Developer

11.Harmful Laser

The customer or service personnel would not be exposed to any harmful laser during the usual copying or scanning of documents. However, if a customer finds that the lamp that is used for exposing documents is too bright when performing platen copy or scan, it is possible to block the light from the platen glass by covering the portion of the platen document area that is usually not used for copying or scanning documents.

1.1.2 Things to Take Note When Handling Customer Information

1.Handling of customer’s electronic information — samples of copy/print/received fax (paper data), log files (Activity Report), and etc.

Before you bring back any samples for the purpose of investigation/analysis, always obtain permission from the customer. Make sure to assure them that the data will not be used for any other purpose. When requesting for a retrieval application from the customer, either use the [Data Security Regulations: Annex 15 — Confidential Information/Personal Information Request Form (IS-019)] or use a letterhead that has been specified by the customer after obtaining their agreement.

2.Handling of a PWB, etc. that contains customer information.

Data such as Fax Address Numbers and URLs that are registered in the customer’s machine are all important customer information. These types of information are stored in the PWB, etc. within the machine. Take extra care when handling them.

a.In case of replacements, transfer the data to the new PWB and make sure that all data in the old parts is thoroughly erased before disposing it. Make sure that no important customer information gets leaked. (For details, refer to the preface in Chapters 4 and 5)

b.If a component was replaced and it was not found to be the cause of the malfunction, return it to the machine it came from. (For components that were temporarily installed/removed for troubleshooting, etc. clear the data using the CE Mode, etc.)

3.Security related NVM values that were changed during maintenance.

If any security related NVM values, such as polling, were set for test purposes, make sure you return them to their original values after the test. (E.g.: for the details on polling that is common to all machine types, refer to FTO 2-202)

4.When connecting our company machine to the customer’s network during maintenance, make sure that you have gone through the person-in-charge to obtain permission from the customer’s systems administrator (or person-in-charge) before proceeding.

5.Follow the safety guidelines established within the OpCo and ensure that customer data do not get leaked out when servicing.

1.1.3 Other Precautions

Pay attention to the following when performing maintenance service to avoid wrong or redundant servicing:

1.Reference Materials

Before performing maintenance servicing, read all relevant technical materials such as SB, FTI, or FTO to make a systematic approach.

2.Disassembling

Make sure to check the assembled condition before removing parts or disassembling the machine.

3.Installation/Adjustment

After the installation or adjustment is complete, check that no parts or tools are left inside or on the assemblies before using the machine.

4.Handling of replaced parts/consumables

Make sure that the replaced parts or consumables as well as their packaging materials are collected back to the Service Center.

For the separation and processing methods for the collected items, refer to the Common Technical Information No. 2-027 for all machines.

• Drum Cleaner

WARNING

Never discard the Drum Cleaner into a fire. Always keep it away from open flames to prevent it from catching and causing a fire. Always dispose of the Drum Cleaner after it is completely used up. For recyclable parts, fill the necessary items in the [U-TAG] and perform collection.

5.General Precautions

•Take care not to disturb the customer’s daily work.

•Place a drop cloth or paper on the floor of the service area to keep the site clean.

•Throw any trash generated during the maintenance service into a trash bag and bring them back to the Service Center.

•Record clearly the service details and the consumables and parts replaced at visit in the Machine Service Log.

1.2.2 Service Call Procedure

1.2.2.1 Initial Actions

1.Ask the operator(s) about the machine condition.

2.Record the billing meter readings.

3.Inspect any error copies, then check the machine.

4.Check the Service Log.

1.2.2.2 When UM is requested, perform the following:

1.Check the problem status by performing the Level 1 Troubleshooting in [Chapter 2 Troubleshooting].

2.Perform the applicable Level 2 Troubleshooting FIP in [Chapter 2 Troubleshooting].

3.If there are no applicable items, troubleshoot by referring to [Chapter 7 BSD].

4.Check the copy quality.

Make several sheets of copies using the Test Chart (499T 00247), then check the quality of the copies for problems.

5.Output the following [Error History Report] and check the [System Fail History] and [Paper Jam History] in order to understand the machine status.

a.Press the <Machine Status> button.

b.Select [Print Report], then press the <OK> button.

c.Select the [Error History Report], then press the<OK> button.

NOTE: When replacing parts that will incur cost to the customer, obtain the customer’s agreement before performing the replacement.

6.Repair all the secondary problems.

7.Perform TRIM Service.

1.2.2.3 When SM is requested, perform the following:

1.Check the copy quality.

Make several sheets of copies using the Test Chart (499T 00247), then check the quality of the copies for problems.

2.Output the [Error History Report] and check the [System Fail History] and [Paper Jam History] in order to understand the machine status.

•For how to output the [Error History Report], refer to [1.2.2.2 When UM is requested, perform the following:].

NOTE: When replacing parts that will incur cost to the customer, obtain the customer’s agreement before performing the replacement.

3.Perform TRIM Service.

1.2.2.4 Final Actions

1.Check overall operation/features.

2.Check the machine exterior and consumables.

3.Train the operator as required.

4.Complete the Service Log and Service Report.

5.Keep the copy samples with the Service Log.

1.3 Detailed Contents of the Service Call

1.3.1 Initial Actions

1.Ask the operator(s) about the machine condition.

•How often and where do paper jams have been occurring recently

•How is the copy quality

2.Record the copy meter readings.

3.Inspect any error copies, then check the machine.

4.Check the print samples from previous service calls and the Service Log.

1.3.2 Checking Reproducibility of Problem

1.Check the problem status by performing the Level 1 Troubleshooting in [Chapter 2 Troubleshooting].

2.Perform the applicable Level 2 Troubleshooting FIP in [Chapter 2 Troubleshooting].

3.If there are no applicable items, troubleshoot by referring to [Chapter 7 BSD].

1.3.3 Checking Copy Quality

1.Make several sheets of copies using the Test Chart (499T 00247), then check the quality of the copies.

1.3.4 TRIM Servicing

Perform TRIM servicing during a service call to maintain the machine performance.

1.Follow the TRIM Check List to perform the required TRIM items.

2.Check for parts that require periodical cleaning/replacement (consumables, parts) by referring to the TRIM Chec List, the Periodic Replacement Parts/Consumables List, and the Maintenance Report, and clean them if necessary. After a replacement, make sure that you enter the CE Mode and use [HFSI Read / Clear] to clear the applicable counter(s).

1.4TRIM Check List

C:Perform checking. Clean, replace, or feed if necessary.

O:Always perform cleaning and checking.

*: Always perform replacement service at the specified interval.

1.5 Periodic Replacement Parts/Consumables List

When servicing, check the number of copies and number of fed sheets for the consumables and parts that require periodical cleaning/replacement. Clean or replace them if necessary. The history can be checked by printing the Maintenance Report or by checking the approriate counter in [HFSI Read / Clear] in CE Mode (6.4.2.9 HFSI Read / Clear).

For the items that cannot be checked in CE Mode, clean or replace them according to the replacement intervals (standard PV).

CAUTION

Do not place the imaging materials, such as the Toner and the Drum, in the car for a long time.

NOTE: Clean the Platen Glass with a Platen Wax Cleaner 499D 00194 (194D) every 10K Feeds.

Table 1

2.2.2 Level 2 FIP

CHAIN 3

CHAIN 4

CHAIN 5

CHAIN 7

CHAIN 16

CHAIN 17

CHAIN 24

CHAIN 26

CHAIN 27

CHAIN 33

CHAIN 34

CHAIN 35

CHAIN 36

CHAIN 41

CHAIN 42

CHAIN 45

CHAIN 47

CHAIN 61

CHAIN 62

CHAIN 71

CHAIN 72

CHAIN 73

CHAIN 74

CHAIN 75

CHAIN 77

CHAIN 92

CHAIN 93

CHAIN 116

CHAIN 117

CHAIN 123

CHAIN 124

CHAIN 127

CHAIN 133

CHAIN 134

2.2.3 Other Failure FIP

2.1.1 How to Troubleshoot

Level 1 Troubleshooting:

•Level 1 Troubleshooting (Level 1 FIP) is the first step to diagnose a problem. Level 1 FIP asks you whether any Fault Code and other problematic symptoms exist, guiding you to Level 2 Troubleshooting or BSD to resolve the problem.

Level 2 Troubleshooting:

•Level 2 Troubleshooting is a diagnostic procedure of separating a problem by Fault Code, document/paper jam and other problematic symptoms. Performing a FIP or an appropriate procedure in the Check Procedure enables you to discover causes of a problem in a short period of time.

How to proceed with troubleshooting and Cautions:

•First, perform Level 1 FIP to categorize a problem. Second, proceed to an appropriate Level 2 FIP or BSD to resolve the problem. To find the causes of the problem using FIP or Check Procedure etc., thoroughly read the instructions and follow the procedure properly. Sometimes, when two or more causes exist, they cannot be identified at once, so the same FIP should be repeated. In this case, pay attention to a different judgment made in the process of the same FIP.

•For source voltage related problems, such as being unable to power up the machine, refer to ‘Other Failure FIP’ to proceed with the troubleshooting.

•The Check Procedure for general electrical parts (Motor, Solenoid/Clutch, Switch, Sensor etc.) may not be shown in each troubleshooting for some cases. In such cases, proceed to troubleshoot by referring to ‘Generic FIP’.

2.1.3 Glossary

The following terminology are used throughout the troubleshooting section. The meaning of these terminology must be fully understood when performing problem analysis.

Common terms:

•Fault Code

This 6-digit code appears when the machine has found problems.

•Actuate (Deactuate)

To mechanically push (release) the Actuator of the switch or the connected mechanical linkage.

•Block

To place a sheet of document or paper on the photo sensor surface for detection.

•Check

To visually check for operation failure of parts such as relay or mechanical linkage, and the failure status of the parts.

•Enter the CE Mode

To enter the CE Mode by following the procedure described in ‘How to Enter/Exit the CE Mode’ of Chapter 6.

•Check the connection for short circuit

Turn the power OFF. Measure the resistance between the wire and the frame using the ohm range of a tester.

•Check the connection for open circuit

Turn the power OFF. Measure the resistance between both ends of the wire using the ohm range of a tester.

•Input Check [xxx-xxx]/Output Check [xxx-xxx]

To enter the Component Check by following the procedure described in ‘How to Use the CE Mode’ of Chapter 6.

•Analog Monitor [xxx-xxx]

To enter the Analog Monitor by following the procedure described in ‘How to Use the CE Mode’ of Chapter 6.

•Check the voltage level

•PL 4.2

Refer to PL 4.2 in Chapter 5 Parts List.

2.2.1.1 Level 1 FIP

Procedure

Ask the operator about the problem. Did the operator operate the machine correctly?

YN

Explain the correct way to operate the machine to the operator.

Output all jobs that are stored in the memory. Turn the power OFF and ON. Is the UI display normal?

YN

Refer to [BSD (CH2.1)] and [2.2.3 Other Failure FIP] to repair the malfunction in UI display.

Check the Shutdown History. Refer to [6.5.2.1 Shutdown History] to display the Fault Code on the UI. Is the Fault Code displayed on the UI?

YN

Refer to [Troubleshooting] in the User Guide and repair the following errors.

•Problems With Hardware

•Problems With Image Quality

•Problems With Copy

•Problems With Printer

•Problems With Scanner

•Problems With Network

•In Case of Paper Jam

•In Case of Document Jam

Proceed to Level 2 Troubleshooting and perform the applicable FIP.

Status Indicator RAPs

2.2.1.1 Level 1 FIP

003-500 N-Up NG Out Of Range

BSD-ON:-

During 2-Up or 4-Up, the reduce/enlarge ration was not within the range of 25 to 400%.

Cause/Action

Press [Stop] on the UI Panel and change the settings.

003-754 IPS Overrun

BSD-ON:-

The IPS processing has overtook the Scan processing.

Cause/Action

This might be avoided by setting the R/E ratio to 99% or 101%. If this occurs frequently, obtain the document from the User and contact the Support Department for assistance.

003-795 AMS NG Out Of Range

BSD-ON:-

When [Reduce/Enlarge] is set to [Auto], the reduce/enlarge ratio was not within the range of 50 to 200%.

003-942 Not-Supported Doc Size

BSD-ON:-

During DADF Scan of a Copy, Scan and Fax sending Job, an unsupported document size was detected.

003-956 Not-Supported Doc Size

BSD-ON:-

During Platen Scan, an unsupported document size was detected.

Cause/Action

Press [Stop] on the UI Panel and change the document.

NOTE: When performing the operation again, the same Fault will occur if the user had proceeded without changing the document.

003-963 APS NG Out Of Range

BSD-ON:-

During Copy Job, when APS is selected, the image size obtained from document size x reduce/enlarge ratio was detected to be larger than the largest Standard Paper Size.

Cause/Action

Press [Stop] on the UI Panel and change the settings.

003-972 1Job Max Page Over

BSD-ON:-

During Copy Job or Scan Job, the number of pages that can be scanned has been exceeded.

Cause/Action

Press [Stop] on the UI Panel and reduce the number of document pages.

003-973 Auto Rotation NG Out Of Range

BSD-ON:-

During Copy Job, the following conditions were met.

•Rotation is required.

•The length of the image obtained by document x reduce/enlarge ratio is longer than 297 mm.

Cause/Action

Press [Stop] on the UI Panel and change the reduce/enlarge ratio.

005-122 DADF Simplex/Side 1 Pre Regi Sensor On Jam

BSD-ON: CH5.4

•After Pre-Feed started for the first sheet (DADF Feed Motor On (CW)) in Simplex and Duplex, the DADF Pre Regi Sensor did not turn ON within the specified time.

•After Pre-Feed started for the second sheet onwards (DADF Feed Motor On (CW)) in Duplex, the DADF Pre Regi Sensor did not turn ON within the specified time.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Feed Roll and Nudger Roll for foreign substances.

•The surface of the Feed Roll and Nudger Roll for wear.

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF Feed Clutch (Output Check [005-062]) for operation failure. (PL 56.7)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-123 DADF Simplex/Side 1 Regi Sensor On Jam

BSD-ON: CH5.5, CH5.4

The DADF Regi Sensor does not turn ON within the specified time after the DADF Pre Regi Sensor On.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Takeaway Roll and Regi Roll for foreign substances.

•The surface of the Takeaway Roll and Regi Roll for wear.

•The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF T/A Clutch (Output Check [005-098]) for operation failure. (PL 56.7)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-125/145 DADF Regi Sensor Off Jam/ DADF Regi Sensor Off Jam on Inverting

BSD-ON: CH5.5, CH5.4

[DADF Regi Sensor Off Jam]

After the DADF Pre Regi Sensor turned OFF at Scan operation, the DADF Regi Sensor did not turn OFF within the specified time.

[DADF Regi Sensor Off Jam on Inverting]

After the DADF Pre Regi Sensor turned OFF at Invert operation, the DADF Regi Sensor did not turn OFF within the specified time.

005-131/132 DADF Invert Sensor On Jam on Inverting/ DADF Invert Sensor On Jam

BSD-ON: CH5.5, CH5.4

[DADF Invert Sensor On Jam on Inverting]

After the DADF Regi Sensor turned ON at Invert operation, the DADF Invert Sensor did not turn ON within the specified time.

[DADF Invert Sensor On Jam]

After the DADF Regi Sensor turned ON in the Scan operation, the DADF Invert Sensor did not turn ON within the specified time.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Regi Roll, Out Roll, and Exit Roll for foreign substances.

•The surface of the Regi Roll, Out Roll, and Exit Roll for wear.

•The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Out Roll for foreign substances.

•The surface of the Out Roll for wear

•The DADF Invert Sensor (Input Check [005-211]) for operation failure. (PL 56.10)

•The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-134/139 DADF Invert Sensor Off Jam on Inverting/ DADF Invert Sensor Off Jam

BSD-ON: CH5.5, CH5.4

[DADF Invert Sensor Off Jam on Inverting]

During the Invert operation where there is a next document, after the DADF Regi Sensor turned OFF, the DADF Invert Sensor did not turn OFF within the specified time.

[DADF Invert Sensor Off Jam]

During the Simplex and Duplex Scan operation, after the DADF Regi Sensor turned OFF, the DADF Invert Sensor did not turn OFF within the specified time.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Out Roll and Exit Roll for foreign substances.

•The surface of the Out Roll and Exit Roll for wear.

•The DADF Invert Sensor (Input Check [005-211]) for operation failure. (PL 56.10)

•The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip Release Solenoid (Output Check [005-072])). (PL 56.7)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-135 DADF Side 2 Pre Regi Sensor On Jam

BSD-ON: CH5.5, CH5.4

After the DADF Feed Motor started the reverse rotation at Invert operation, the DADF Pre Regi Sensor did not turn ON within the specified time.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Exit Roll for foreign substances.

•The surface of the Exit Roll for wear

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-048]) for operation failure. (PL 56.6)

•The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip Release Solenoid (Output Check [005-072])). (PL 56.7)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-136 DADF Side 2 Regi Sensor On Jam

BSD-ON: CH5.5, CH5.4

After the DADF Pre Regi Sensor turned ON at Invert operation, the DADF Regi Sensor did not turn ON within the specified time.

005-147 DADF Pre Regi Sensor Off Jam on Inverting

BSD-ON: CH5.5, CH5.4

After the DADF Feed Motor started the reverse rotation at Invert operation, the DADF Pre Regi Sensor did not turn OFF within the specified time.

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Exit Roll, Takeaway Roll, and Regi Roll for foreign substances.

•The surface of the Exit Roll, Takeaway Roll, and Regi Roll for wear.

•The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

•The DADF T/A Clutch (Output Check [005-098]) for operation failure. (PL 56.7)

•The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip Release Solenoid (Output Check [005-072])). (PL 56.7)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

Cause/Action

Check the following:

•Transportation failure due to foreign substance on the document path.

•The surface of the Exit Roll, Takeaway Roll, Regi Roll, and Out Roll for foreign substances.

•The surface of the Exit Roll, Takeaway Roll, Regi Roll, and Out Roll for wear.

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The DADF Feed Motor (Output Check [005-048/008] (CCW/CW)) for operation failure. (PL 56.6)

•The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip Release Solenoid (Output Check [005-072])). (PL 56.7)

•The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-196 Size Mismatch Jam on No Mix-Size

BSD-ON: CH5.4, CH5.2

The 2nd sheet or later of the document was detected to be of a different size conpared to the 1st sheet (the length of the document’s 2nd sheet or later in SS direction is longer).

Cause/Action

1.Check the size of the document that was fed by the User.

2.If the error is not cleared, check the following:

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation failure. (PL 56.11)

3.If no problem is found, replace the DADF PWB. (PL 56.2)

005-197 Prohibit Combine Size Jam

BSD-ON: CH5.4

A Mixed Size document was detected.

Cause/Action

Explain to the User that Mixed Size is not supported.

005-198/199 Too Short Size Jam/ Too Long Size Jam

BSD-ON: CH5.4, CH5.2

[Too Short Size Jam]

It was detected that the document length in Slow Scan direction is shorter than the specifications (Simpex: 85 mm, Duplex: 110 mm).

[Too Long Size Jam]

It was detected that the document length in Slow Scan direction is at the specifications (Simpex: 1275 mm, Duplex: 480.1 mm) or longer.

Cause/Action

Check the size of the document that was fed by the user. If it is within the permitted length for DADF transport, check the following:

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation failure. (PL 56.11)

If no problem is found, replace the DADF PWB. (PL 56.2)

005-210 DADF Download Fail

BSD-ON: CH1.3

When the IISS starts up (including at Power ON/Sleep recovery), it was detected that the DADF is in Download Mode.

Cause/Action

Perform the DADF software download.

005-275/280 DADF RAM Test Fail/ DADF EEPROM Fail

BSD-ON: CH1.3

[DADF RAM Test Fail]

The DADF PWB RAM failed during the Read/Write operation. (At Power ON)

[DADF EEPROM Fail]

Write failure to DADF EEPROM or communication failure with EEPROM was detected.

Cause/Action

1.Turn the power OFF and ON.

2.If the problem persists, replace the DADF PWB. (PL 56.2)

005-305 DADF Feeder Cover Interlock Open

BSD-ON: CH5.1

The DADF Feeder Cover Interlock Switch was opened during DADF operation.

Cause/Action

1.Check the DADF Feeder Cover for mismatch.

2.Check the DADF Feeder Cover Interlock Switch (Input Check [005-212]) for operation failure. (PL 56.6)

3.If no problem is found, replace the DADF PWB. (PL 56.2)

005-500 DADF Download Flash Write Error

BSD-ON: CH1.3

Failed to write into the Flash ROM during DAFD Download.

Cause/Action

1.Turn the power OFF and ON.

•If the device starts up normally

Check the FW Version of the DADF. If the FW Version is not the expected version, turn OFF the power, start up the device in Download Mode, and then try to download again. If the problem persists, replace the DADF PWB. (PL 56.2)

•If the device does not start up normally

Turn OFF the power and start up the device in Download Mode. If the device can start up in Download Mode, try to download the FW again. If the problem persists, replace the DADF PWB. (PL 56.2)

If it cannot start up in Download Mode, replace the DADF PWB. (PL 56.2)

005-907/908/913 DADF Pre Regi Sensor/DADF Regi Sensor/DADF Invert Sensor Static Jam

BSD-ON: CH5.5, CH5.4

Paper was detected by the applicable sensor at Power ON, Feeder Cover Interlock Close, or DADF Open Sensor Close.

Cause/Action

1.Check the applicable sensor for remaining paper, the Actuator for return failure, contamination on sensor, and etc.

2.Check the applicable sensor for operation failure.

•DADF Pre Regi Sensor (Input Check[005-206]) (PL 56.14)

•DADF Regi Sensor (Input Check[005-110]) (PL 56.14)

•DADF Invert Sensor (Input Check[005-211]) (PL 56.10)

3.If no problem is found, replace the DADF PWB. (PL 56.2)

005-940 DADF No Original Fail

BSD-ON: CH5.1

It was detected that the document was pulled out during document feed.

Cause/Action

Reload the document.

005-948 SS-Size Mismatch Jam on No Mix-size

BSD-ON: CH5.4, CH5.2

In No Mix mode, it was detected that a document with a shorter size in Slow Scan (SS) direction was transported from the DADF.

Cause/Action

1.Check the size of the document that was fed by the User.

2.If the error is not cleared, check the following:

•The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

•The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation failure. (PL 56.11)

3.If no problem is found, replace the DADF PWB. (PL 56.2)

007-270 Tray 1 Paper Size Switch Broken

BSD-ON: CH7.1

The Tray 1 Size Sensor open circuit was detected. (The AD value is at its largest.)

NOTE: If this is already detected, it will be displayed on the UI Panel when a Job is being performed.

Initial Actions

Refer to the BSD and check the related connectors of the target electrical parts for partial connections.

007-272 Tray 3 Paper Size Switch Broken

BSD-ON: CH7.3

The Tray 3 Size Sensor open circuit was detected. (The AD value is at its largest.)

NOTE: If this is already detected, it will be displayed on the UI Panel when a Job is being performed.

Initial Actions

Refer to the BSD and check the related connectors of the target electrical parts for partial connections.

Cause/Action

Check the following:

•The connection between the Tray 1 Paper Size Switch J109 and the ESS/MCU PWB J414 for open circuit, short circuit, and poor contact.

•Tray 1 Paper Size Switch: Analog Monitor [072-050]/Input Check [072-114] (PL 9.1)

•The Tray 1 paper guide mechanism for damage and foreign substances.

•The Tray 1 Paper Size Switch for damage, improper installation, and Actuator operation failure.

If no problems are found, replace the ESS/MCU PWB (PL 18.3).

Cause/Action

Check the following:

•The connection between the Tray 3 Paper Size Switch J820 and the 2TM PWB J548 for open circuit, short circuit, and poor contact.

•Tray 3 Paper Size Switch: Analog Monitor [072-052]/Input Check [072-110] (PL 11.1)

•The Tray 3 paper guide mechanism for damage and foreign substances.

•The Tray 3 Paper Size Switch for damage, improper installation, and Actuator operation failure.

If no problems are found, replace the 2TM PWB (PL 11.6).

010-311 Fusing Unit Center Thermistor Defect

BSD-ON: CH10.2

An open circuit abnormality (the AD value of the STS is equivalent to the open circuit value) of the Heat Roll Center Thermistor was detected.

010-312 Fusing Unit Rear Thermistor Defect

BSD-ON: CH10.2

An open circuit abnormality (the AD value of the STS is equivalent to the open circuit value) of the Heat Roll Rear Thermistor was detected.

Procedure

Turn OFF the power and disconnect the Heat Roll Center Thermistor connector P/J600. Measure the resistance between the Heat Roll Center Thermistor J600 pin-1 and J600 pin-2. Is the resistance infinite?

YN

Reconnect the connector P/J600 and measure the resistance between the ESS/MCU PWB J403 pin-1 and J403 pin-2. Is the resistance infinite?

Y N

Replace the ESS/MCU PWB (PL 18.3).

Check the following connections for open circuits and poor contacts.

•Between ESS/MCU PWB J403-1 and Heat Roll Center Thermistor P600-4

•Between ESS/MCU PWB J403-2 and Heat Roll Center Thermistor P600-3

Replace the Fusing Unit. (PL 7.1)

Procedure

Turn OFF the power and disconnect the Heat Roll Rear Thermistor connector P/J600. Measure the resistance between the Heat Roll Rear Thermistor J600 pin-3 and J600 pin-4. Is the resistance infinite?

YN

Reconnect the connector P/J600 and measure the resistance between the ESS/MCU PWB J403 pin-3 and J403 pin-4. Is the resistance infinite?

Y N

Replace the ESS/MCU PWB (PL 18.3).

Check the following connections for open circuits and poor contacts.

• Between ESS/MCU PWB J403-3 and Heat Roll Rear Thermistor P600-2

• Between ESS/MCU PWB J403-4 and Heat Roll Rear Thermistor P600-1

Replace the Fusing Unit. (PL 7.1)

010-320 Over Heat Temperature Fail

BSD-ON: CH10.2, CH10.1

A high temperature error was detected at the Center Thermistor (245 degrees C or higher) or the Rear Thermistor (270 degrees C or higher).

NOTE: To clear this Fail, first remove the cause, next clear the value of NVM [744-040] (Over Heat Temp Fail) to ‘0’, and then turn the power OFF then ON. The relationship between the displayed value and the Thermistor that detected the high temperature error is as follows:

•0: Normal

•1: High Temperature Error of Heat Roll Center Thermistor

•2: High Temperature Error of Heat Roll Rear Thermistor

Cause/Action

Check the following:

•The Center Thermistor or the Rear Thermistor for dropped parts, sensor contamination, and foreign substances blocking the sensor.

•The Heat Roll for wound up, stuck paper.

•The Heat Roll Center Thermistor (Analog Monitor [010-050]) for operation failure.

•The Heat Roll Rear Thermistor (Analog Monitor [010-051]) for operation failure.

•The Heater Rod for operation failure.

If no problem is found, replace the following parts in sequence:

•Fusing Unit (PL 7.1)

•LVPS (PL 18.3)

•ESS/MCU PWB (PL 18.3)

010-327 Fusing Unit On Time Fail

BSD-ON: CH10.2, CH10.1

Any of the following was detected:

•The Heater Rod did not turn OFF within the specified time after the Heater Rod On.

•After power ON, the temperature of the Fusing Unit does not reach the specified value within the specified time.

Cause/Action

Check the following:

•The Heater Rod for operation failure.

•The connection between the LVPS J511 and the Fusing Unit P10 for open circuit and poor contact

•The Center Thermistor for dropped parts, sensor contamination, and foreign substances blocking the sensor.

•The Heat Roll for wound up, stuck paper.

If no problem is found, replace the following parts in sequence:

•Fusing Unit (PL 7.1)

•LVPS (PL 18.3)

•ESS/MCU PWB (PL 18.3)

010-379 Fusing Unit Hot Not Ready Return Time Fail

BSD-ON: CH10.2

The High Temperature Not Ready state is not cleared even after the Recovery Time (NVM) has passed.

Cause/Action

•Turn the power OFF and ON. If the problem persists, the Fusing Unit could be malfunctioning.

Replace the Fusing Unit. (PL 7.1)

010-392 NOHAD Fan Defect

BSD-ON: CH10.3

NOHAD Fan failure was detected. When the NOHAD Fan Fail signal indicating an abnormality of the Fan was monitored at the specified time interval, it was found to have failed the specified number of times or higher in a row.

Cause/Action

1.Check the NOHAD Fan (Output Check [042-002]) for operation failure. (PL 4.1)

2.Check the NOHAD Fan for foreign substances.

3.If no problem is found, replace the ESS/MCU PWB (PL 18.3).

016-346 Fax Parameter Incorrect

BSD-ON:-

Parameter Error received from the Fax Board. Self Diagnostic: Parameter Error received.

Cause/Action

1.Turn the power OFF and ON.

2.Print out the Error Report and then replace the Fax PWB (PL 18.5).

3.Re-send the Fax or request for the customer to receive one.

016-372 File Access Error

BSD-ON:-

Unable to access the files that had been stored in the device for some reasons (access refused, etc.).

Cause/Action

1.Turn the power OFF and ON.

2.Install a firmware with the correct version.

3.If the problem persists, replace the ESS/MCU PWB. (PL 18.3)

1.Turn the power OFF and ON.

(If the contents of the Flash ROM is corrupted, the machine will boot up in Emergency Boot Download mode after Power ON.)

2.If the problem persists, replace the ESS/MCU PWB (PL 18.3).

1.Turn the power OFF and ON.

2.If the problem persists, replace the ESS/MCU PWB (PL 18.3).

Cause/Action

1.Turn the power OFF and ON.

2.If the problem persists, replace the following parts in sequence:

•ESS/MCU PWB (PL 18.3)

•UI PWB (PL 1.10)

Cause/Action

1.Turn the power OFF and ON.

2.If the problem persists, replace the following parts in sequence:

•Control Panel (PL 1.10)

•ESS/MCU PWB (PL 18.3)

016-570 No Response from USB-Host for Scan Job

BSD-ON: CH3.3

When any of the following has occurred as Scan to PC (USB) is in progress.

•The command from the PC was disrupted for 5 seconds.

•The machine has detected a communication error with the USB Device.

•The sending of commands to the PC remained unsuccessful even when 500 ms has passed. (The time-out time is the time calculated from the size of the data being sent only when sending image data.)

Cause/Action

1.Press [Stop] on the UI Panel.

2.Check the connection of the USB Cable between this machine and the PC.

3.Check the status (is it powered OFF, frozen, etc.) of the PC.

016-571 No Response from USB-Host for Print Job

BSD-ON: CH3.3

When any of the following has occurred as USB Print or Download data interpretation is in progress.

•The command from the PC was disrupted for 2 minutes.

•The machine has detected a communication error with the USB Device.

•The sending of commands to the PC remained unsuccessful even when 500 ms has passed.

NOTE: This Fault will clear automatically. (It will not be displayed on the UI Panel)

Cause/Action

1.Check the connection of the USB Cable between this machine and the PC.

2.Check the status (is it powered OFF, frozen, etc.) of the PC.

016-598 E-mail Message Size Over

BSD-ON:-

During Scan to E-mail, the maximum attachment size was exceeded at the 1st page.

Cause/Action

1.Press [Stop] on the UI Panel.

2.Delete the contents of the attached data.

3.Enter the Diag and input NVM [840-167].

Adjust the limit value of attachment size for Scan to E-mail.

4.Lower the resolution setting.

5.Change the document type.

6.Change the output color.

016-742/744 Download File Error/ Download File Check

Sum Error

BSD-ON:-

[Download File Error]

It was detected that there is an error with either the file format of the Download File, the Device Identifier, the Device Serial Number, or the Target Device Character String.

[Download File Check Sum Error]

The Download File checksum error was detected.

Cause/Action

1.Turn the power OFF and ON.

2.Install a firmware with the correct version.

016-749/799 HBPL or XPJL Syntax Error/ Print Instruction Fail

BSD-ON:-

[HBPL or XPJL Syntax Error]

When the Print Job data interpretation is in progress, an illegal command that cannot be ignored was received from the Client driver.

[Print Instruction Fail]

During the Print Job, the Job cannot be executed with the specified combination of print parameters (Stored File Size, Paper Size, Paper Tray, Duplex Settings, Output Tray, and etc.).

NOTE: During Continuous Print, this error will not occur until the paper that immediately precedes the paper where the applicable image is supposed to be printed on has been output successfully.

Cause/Action

1.Press [Stop] on the UI Panel.

2.Check whether the Printer Driver that is being used is the correct one.

3.Check whether the specified print parameters are correct.

016-759 Copy Counter Full

BSD-ON:-

During Multi Account Mode, any of the following has occurred:

•The general user that is logged in has reached the allotted maximum print count.

•A general user that has reached the allotted maximum print count has logged in.

Cause/Action

1.Press [Stop] on the UI Panel.

2.Clear the count for the user.