KONICA MINOLTA EP4000, EP5000 TROUBLESHOOTING

1156SBT000AA

EP5000/EP4000

TROUBLESHOOTING

1139SBT0100A

1 INTRODUCTION

1139SBT0101A

1-1. General Precautions

1.When servicing the copier with its covers removed, use utmost care to prevent your hands, clothing, and tools from being caught in revolving parts including the chains and gears. When servicing the copier with the Lower Rear Cover removed, be sure to install the jig.

2.Before attempting to replace parts and unplugging connectors, make sure that the power cord of the copier has been unplugged from the wall outlet.

3.Never create a closed circuit across connector pins except those specified in the text and on the printed circuit.

4.When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the green wire (GND).

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

6.Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged.

1139SBT0102A

1-2. How to Use This Book

1.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.

2.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.

3.For the removal procedures of covers and parts, see DIS/REASSEMBLY, ADJUSTMENT.

4.The troubleshooting procedures are given in the order of greater frequency of trouble or order of operation.

5.The procedures preclude possible malfunctions due to noise and other external causes.

1139SBT0103A

1-3. 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 numerical order of steps and, if an item is checked okay, go to the next step.

Pattern 1

Step	Check Item	Result	Action
1	Is...?	YES	Do this.
2		↑
	Go to step 2 if you answered NO.

Pattern 2

Step Check Item		Result	Action
1	Is...?	YES	Do this.
		NO	Check that.

	2	↑
		Go to step 2 if it checks okay.

T-1

1151SBT0200A

2 I/O PORT CHECK

1156SBT0201A

2-1. Controlled Parts Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular controlled part is fully operational, this copier provides the following provision: checking the data of the I/O port of the board IC with the copier in the standby state (including a misfeed, malfunction, and closure failure condition) allows the Tech. Rep. to determine whether a signal is properly input to, and output from, a controlled part.

<Procedure>

1)On the circuit diagram accompanying the text, locate the I/O port of the controlled part which is probably defective when a misfeed or malfunction occurs.

2)Select the “IC Port Data Check” function of “I/O Check” in the Tech. Rep. mode and access the screen which contains the port identified in step 1 above. (See SWITCHES ON PWBs/TECH. REP. MODE.)

3)Change or check the input or output port data to determine whether the controlled part is operational and signals are properly input and output.

4)If the controlled part does not operate properly after changing the output port data, select “Controller Board Check” of “I/O Check” in the Tech. Rep. mode and determine whether the board is responsible for that malfunction or not.

Note: Only the output ports given on pages T-37 and 38 may be checked by “Controller Board Check” of “I/O Check” in the Tech. Rep. mode.

T-2

<Controlled Part Check Procedure by Changing Input Port Data>

Example: When a paper misfeed occurs in the paper take-up section of the copier, 1st Drawer Paper Take-Up Sensor PC56 is considered to be responsible for it.

<Procedure>

1)Remove the sheet of paper misfed and reset the misfeed.

2)From the I/O port check list, it is found that the H/L input signal to PC56 is supplied from PWB-A (IC3A) APB3.

3)Select “IC Port Check” from the I/O Check function in the Tech. Rep. mode and access the screen which includes the input ports of PWB-A (IC3A) APB3.

4)Check that the input port data of PWB-A (IC3A) APB3 on the screen is “H” (sensor being unblocked).

5)Move the PC56 actuator to block the sensor.

6)Return to the “I/O Check” basic screen once, select “IC Port Check” again, choose the screen which includes the APB3 input port data, and make sure that the data has changed from “H” to “L”.

L: PC56 is operational.

H: PC56 is faulty.

T-3

<Controlled Part Check Procedure by Changing Output Port Data>

Example: When a manual paper misfeed occurs, Manual Feed Paper Take-Up Clutch CL3 is considered to be responsible for it.

<Procedure>

1)Remove the sheet of paper misfed and reset the misfeed.

2)From the I/O port check list, it is found that the ON/OFF output signal of CL3 is supplied from PWB-A (IC5A) BPA1.

3)Select “IC Port Check” from the I/O Check function in the Tech. Rep. mode and access the screen which includes the output ports of PWB-A (IC5A) BPA1.

4)Check that the output port data of PWB-A (IC5A) BPA1 on the screen is “1” (CL3 is deenergized).

5)Touch the “CHANGE” key on the screen to change the data from “1” to “0”, causing CL3 to be energized for approx. 5 seconds. This allows you to determine whether the Clutch is “operational or faulty” by checking for the Clutch sound.

Operational: Sound produced.

Faulty: No sound produced.

6)If CL3 was not energized, make the “Controller Board Check” in the same mode (for some electrical parts only).

7)If the “ON” signal of CL51 is not output from PWB-A, the corresponding malfunction code is displayed.

*For CL3, “C0337” is displayed.

T-4

1156SBT0202A

2-2. I/O Port Check List

<Port Check Screens>

D The following screens are displayed in the standby mode but may not always be as shown below because some port data are undefined. (Copier+PF-205)

1156T016CA	1156T020CA

1156T017CA

1156T021CA

1156T018CA

1156T022CA

1156T019CA

1156T023CA

T-5

<I/O Port Check List>

	Copier	*The shaded areas of the following table indicate that the output check cannot be made by
		touching the Change key.
			Dis-				Operation Char-
	Sym-			IC	Port		acteristics/Panel		CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.		Display		No.
			Page
							H or 1	L or 0
	M1	Main Drive Motor/REM	2/8	IC4A	BPA2	f	OFF	ON	PJ18A-9
	↑	Main Drive Motor/lock	2/8	IC4A	BPB1		When	When	PJ18A-10
		signal					locked	turned
	M2	Scanner Motor/SCAN	3/8	IC4A	APC0	f	Stop	Scan	PJ8A-5
								cycle
	M3	Ventilation Fan Motor/	3/8	IC4A	BPC1	f	OFF	ON	PJ34A-1
		REM
	↑	Ventilation Fan Motor/	2/8	IC4A	BPB6		When	When	PJ34A-3
		lock signal					locked	turned
		Suction Fan Motor/se-					Turned	Turned
	M4		3/8	IC4A	BPC2	f	at high	at low	PJ15A-4
		lect signal
							speed	speed
	↑	Suction Fan Motor/lock	3/8	IC4A	BPC7		When	When	PJ15A-3
		signal					locked	turned
	M5	Original Glass Cooling	3/8	IC4A	BPC0	f	OFF	ON	PJ15A-5
		Fan Motor/REM
	↑	Original Glass Cooling	2/8	IC4A	BPB5		When	When	PJ15A-7
		Fan Motor/lock signal					locked	turned
	M8	Main Hopper Toner Re-	3/8	IC4A	BPC3	f	OFF	ON	PJ11A-4A
		plenishing Motor/REM
	M9	Sub Hopper Toner Re-	3/8	IC5A	APA2	f	OFF	ON	PJ11A-2A
		plenishing Motor/REM
		1st Drawer Paper Take-					Turn in-	Turn
	M11		3/8	IC5A	APA0	f		per-	PJ18A-1
		Up Motor					hibited
								mitted
		2nd Drawer Paper Take-					Turn in-	Turn
	M12		3/8	IC5A	APA1	f		per-	PJ18A-2
		Up Motor					hibited
								mitted
	M13	1st Drawer Paper Lift-Up	3/8	IC5A	APA4	f	OFF	ON (up)	PJ18A-5
		Motor (UP)
	↑	1st Drawer Paper Lift-Up	3/8	IC5A	APA5	f	OFF	ON	PJ18A-6
		Motor (DOWN)						(down)
	M14	2nd Drawer Paper	3/8	IC5A	APA6	f	OFF	ON (up)	PJ8A-7
		Lift-Up Motor (UP)
	↑	2nd Drawer Paper	3/8	IC5A	APA7	f	OFF	ON	PJ18A-8
		Lift-Up Motor (DOWN)						(down)
	M15	Fusing Section Cooling	3/8	IC4A	APC2	f	OFF	ON	PJ10A-1
		Fan Motor/REM

T-6

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		Fusing Section Cool-					When	When
	↑	ing Fan Motor/lock	3/8	IC4A	APB6				PJ10A-3
							locked	turned
		signal
	SL1	Separator Solenoid	2/8	IC4A	BPA0	f	OFF	ON	PJ11A-6A
	SL5	Exit/Duplex Switching	2/8	IC4A	BPA5	f	OFF	ON	PJ14A-6
		Solenoid
		Manual Feed Paper						ON
	SL51	Take-Up Solenoid	3/8	IC5A	BPA2	f	OFF		PJ15A-10
								(up)
		(UP)
		Manual Feed Paper						ON
	↑	Take-Up Solenoid	3/8	IC5A	BPA3	f	OFF		PJ15A-9
								(down)
		(DOWN)
	CL1	Paper Transport	2/8	IC4A	BPA3	f	OFF	ON	PJ14A-2
		Clutch
	CL2	Synchronizing Roller	2/8	IC4A	BPA4	f	OFF	ON	PJ14A-4
		Clutch
	CL3	Manual Feed Paper	3/8	IC5A	BPA1	f	OFF	ON	PJ15A-12
		Take-Up Clutch
		Duplex Unit Vertical					Paper	Paper
	PC12		3/8	IC5A	BPB0		not		PJ17A-8
		Transport Sensor						present
							present
	PC35	Toner Bottle Home	3/8	IC4A	BPC5		Un-	Blocked	PJ11A-9
		Position Sensor					blocked
		Manual Feed Paper					Paper	Paper
	PC51		3/8	IC5A	BPB1		not		PJ15A-14
		Empty Sensor						present
							present
		Transport Roller Sen-					Paper	Paper
	PC54		3/8	IC5A	BPB6		not		PJ19A-5
		sor						present
							present
		Paper Leading Edge					Paper	Paper
	PC55		3/8	IC5A	BPB5		not		PJ19A-2
		Detecting Sensor						present
							present
		1st Drawer Paper					Paper	Paper
	PC56		1/8	IC3A	APB3		not		PJ21A-5A
		Take-Up Sensor						present
							present
		2nd Drawer Paper					Paper	Paper
	PC57		1/8	IC3A	APB4		not		PJ21A-5B
		Take-Up Sensor						present
							present
	PC61	1st Drawer Set Sen-	1/8	IC3A	BPA5		Out of	In	PJ22A-2
		sor					position	position
	PC62	2nd Drawer Set Sen-	1/8	IC3A	APB5		Out of	In	PJ22A-6
		sor					position	position

T-7

			Dis-				Operation Charac-
	Sym-			IC	Port		teristics/Panel Dis-			CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.		play			No.
			Page
							H or 1	L or 0
		1st Drawer Vertical					Paper	Paper
	PC63		1/8	IC3A	APB6		not			PJ21A-8A
		Transport Sensor						present
							present
		2nd Drawer Vertical					Paper	Paper
	PC64		1/8	IC3A	APB7		not			PJ21A-8B
		Transport Sensor						present
							present
		1st Drawer Lift-Up					Not at	At	up-
	PC65		1/8	IC3A	APB1		upper			PJ21A-2A
		Sensor						per limit
							limit
		2nd Drawer Lift-Up					Not at	At	up-
	PC66		1/8	IC3A	APB2		upper			PJ21A-2B
		Sensor						per limit
							limit
	PC67	1st Drawer Lift-Up	1/8	IC3A	APC0		Un-	Blocked		PJ23A-2
		Motor Pulse Sensor					blocked
	PC68	2nd Drawer Lift-Up	1/8	IC3A	APC1		Un-	Blocked		PJ23A-5
		Motor Pulse Sensor					blocked
		1st Drawer Lower					Not at	At lower
	PC69	Limit Position Sen-	1/8	IC3A	BPA2		lower			PJ24A-5
									limit
		sor					limit
		2nd Drawer Lower					Not at	At lower
	PC70	Limit Position Sen-	1/8	IC3A	BPA3		lower			PJ24A-6
									limit
		sor					limit
	PC72	Paper Size Detect-	2/8	IC3A	BPB6		Size not	Size de-		PJ25A-2
		ing Sensor 5					detected	tected
	PC73	Paper Size Detect-	2/8	IC3A	BPB7		Size not	Size de-		PJ25A-5
		ing Sensor 6					detected	tected
	PC81	Scanner Reference	2/8	IC4A	APC4		Not at	At home		PJ8A-4
		Position Sensor					home
		1st Drawer Paper					Paper	Paper
	PC101		1/8	IC3A	APC2		not			PJ23A-9
		Empty Sensor						present
							present
		2nd Drawer Paper					Paper	Paper
	PC102		1/8	IC3A	APC3		not			PJ23A-12
		Empty Sensor						present
							present
	PC111	Original Cover	2/8	IC4A	APB5		Raised	Lowered		PJ12A-1
		Detecting Sensor
	PC112	Toner Hopper Home	3/8	IC5A	BPB7		Not at	At home		PJ11A-9B
		Position Sensor					home
	CNT1	Total Counter/REM	1/8	IC1A	P55	f	Normally	When		PJ13A-6
								counting
	↑	Total Counter/Set	2/8	IC4A	APB7		Out of	In	posi-	−
							position		tion

T-8

			Dis-				Operation Charac-
	Sym-			IC	Port		teristics/Panel Dis-		CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.		play		No.
			Page
							H or 1	L or 0
								When
	CNT2	Plug-In Counter/REM	1/8	IC1A	P44	f	Normally	count-	PJ28A-9
								ing
	↑	Plug-In Counter/Set	3/8	IC5A	BPC3		Out of	In	PJ28A-7
							position	position
	H1	Fusing Heater Lamp	1/8	IC1A	P57	f	OFF	ON	PJ33A-2
	H3	Paper Dehumidifying	1/8	IC1A	P45	f	ON	OFF	PJ4A-5
		Heater
	RY1	Main Relay	1/8	IC1A	P46	f	ON	OFF	PJ4A-3
	LA1	Exposure Lamp/AVR	1/8	IC1A	P61	f	OFF	ON	PJ8A-13
		REM
	LA2	Main Erase Lamp/	2/8	IC4A	BPA1	f	OFF	ON	PJ12A-3
		REM
	LA2	Main Erase Lamp/	2/8	IC4A	APC7		OFF	ON	PJ12A-5
		failure detection
	S1	Power Switch	1/8	IC1A	P53		OFF	ON	PJ4A-1
	S21	Front Door Interlock	1/8	IC1A	P51		OFF	ON	PJ4A-4
		Switch
	S22	Right Upper Door	3/8	IC5A	BPB2		OFF	ON	PJ16A-2
		Interlock Switch
	S23	Left Upper Door	3/8	IC5A	BPC6		OFF	ON	PJ16A-4
		Interlock Switch
							Paper	Paper
	S53	Paper Exit Switch	3/8	IC4A	BPB2			not	PJ20A-12
							present
								present
		Paper Size Detecting					Size yet	Size de-
	S61		1/8	IC3A	BPA6		to be de-		PJ26A-2
		Switch 1						tected
							tected
		Paper Size Detecting					Size yet	Size de-
	S62		1/8	IC3A	BPA7		to be de-		PJ26A-4
		Switch 2						tected
							tected
		Paper Size Detecting					Size yet	Size de-
	S63		2/8	IC3A	BPB4		to be de-		PJ26A-7
		Switch 3						tected
							tected
		Paper Size Detecting					Size yet	Size de-
	S64		2/8	IC3A	BPB5		to be de-		PJ26A-9
		Switch 4						tected
							tected
		Toner Empty					Toner	Toner
	S106		3/8	IC1A	BPC6		still avail-		PJ11A-8B
		Detecting Switch						empty
							able

T-9

			Dis-				Operation Charac-
	Sym-			IC	Port		teristics/Panel Dis-			CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.			play		No.
			Page
							H or 1		L or 0
	UN5	1st Drawer Paper	1/8	IC3A	BPA0		OFF		ON	PJ24A-3
		Descent Key
	↑	Manual Down	1/8	IC3A	APC4	f	OFF		ON	PJ24A-1
		Display 1
	UN6	2nd Drawer Paper	1/8	IC3A	BPA1		OFF		ON	PJ24A-4
		Descent Key
	↑	Manual Down	1/8	IC3A	APC5	f	OFF		ON	PJ24A-2
		Display 2
	PWB-G	AIDC Sensor Board/	2/8	IC4A	APA4	f	OFF		ON	−
		AIDC REM

T-10

PF-205

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		Vertical Transport					Turn in-	Turn	PJ12A-1~
	M21		4/8	IC1A	PB3	f		per-
		Drive Motor					hibited		4
								mitted
		3rd Drawer Paper					Turn in-	Turn	PJ11A-1~
	M22		4/8	IC1A	PB1	f		per-
		Take-Up Motor					hibited		4
								mitted
		4th Drawer Paper					Turn in-	Turn	PJ10A-1~
	M23		4/8	IC1A	PB0	f		per-
		Take-Up Motor					hibited		4
								mitted
	M24	3rd Drawer Paper	4/8	IC1A	PA0	f	−	ON (up)	PJ9A-8B
		Lift-Up Motor
	↑	3rd Drawer Paper	4/8	IC1A	PA1	f	OFF	ON	PJ9A-7B
		Lift-Up Motor						(down)
	M25	4th Drawer Paper Lift-	4/8	IC1A	PA2	f	−	ON (up)	PJ9A-2A
		Up Motor
	↑	4th Drawer Paper Lift-	4/8	IC1A	PA3	f	OFF	ON	PJ9A-1A
		Up Motor						(down)
	PC11	Lower Left Door	4/8	IC2A	PB1		Out of	In	PJ3A-2
		Sensor					position	position
		Duplex Unit Turnover					Paper	Paper
	PC13		4/8	IC2A	PB0		not		PJ3A-5
		Path Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC17		4/8	IC1A	PC3		not		PJ7A-5
		Sensor 3						present
							present
	PC18	Lower Right Door	4/8	IC1A	PE2		Out of	In	PJ7A-2
		Sensor					position	position
		3rd Drawer Paper					Not at	At up-
	PC19		4/8	IC1A	PG3		upper		PJ6A-12
		Lift-Up Sensor						per limit
							limit
		3rd Drawer Paper					Paper	Paper
	PC20		4/8	IC1A	PC0		not		PJ6A-2
		Empty Sensor						present
							present
		3rd Drawer Paper					Paper	Paper
	PC21		4/8	IC1A	PE3		not		PJ6A-9
		Take-Up Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC22		4/8	IC1A	PC2		not		PJ6A-5
		Sensor 4						present
							present
		4th Drawer Paper Lift-					Not at	At up-
	PC23		4/8	IC1A	PF3		upper		PJ8A-8
		Up Sensor						per limit
							limit

T-11

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		4th Drawer Paper					Paper	Paper
	PC24		4/8	IC1A	PD0		not		PJ8A-2
		Empty Sensor						present
							present
	PC25	3rd Drawer Set	4/8	IC1A	PG2		Out of	In	PJ9A-2B
		Sensor					position	position
	PC26	4th Drawer Set	4/8	IC1A	PF2		Out of	In	PJ9A-7A
		Sensor					position	position
		3rd Drawer Paper					Un-
	PC27	Lift-Up Motor Pulse	4/8	IC1A	PC1				PJ9A-5B
							blocked	Blocked
		Sensor
		4th Drawer Paper Lift-					Un-
	PC28	Up Motor Pulse	4/8	IC1A	PD1				PJ9A-4A
							blocked	Blocked
		Sensor
		4th Drawer Paper					Paper	Paper
	PC29		4/8	IC2A	PB3		not		PJ8A-5
		Take-Up Sensor						present
							present
		Large Capacity Toner					Paper	Paper
	PC31	Collecting Box Set	4/8	IC2A	PC3		not		PJ2A-2
								present
		Sensor					present

T-12

PF-105

			Dis-				Operation Char-
	Sym-			IC	Port		acteristics/Panel		CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.		Display		No.
			Page
							H or 1	L or 0
		Vertical Transport					Turn in-	Turn
	M21		5/8	IC1A	PB3	f		per-	PJ12A-1~4
		Drive Motor					hibited
								mitted
		3rd Drawer Paper					Turn in-	Turn
	M22		5/8	IC1A	PB1	f		per-	PJ11A-1~4
		Take-Up Motor					hibited
								mitted
	M26	Main Tray Elevator	5/8	IC1A	PA2	f	Up/stop	Down	PJ4A-6B
		Motor
	↑	Main Tray Elevator	5/8	IC1A	PA3	f	Down/	Up	PJ4A-7B
		Motor					stop
	M27	Paper Shift Motor	5/8	IC1A	PA0	f	Trans-	Return	PJ4A-4B
							fer/stop
	↑	Paper Shift Motor	5/8	IC1A	PA1	f	Return/	Transfer	PJ4A-5B
							stop
	M28	Shift Gate Motor	5/8	IC1A	PB2	f	OFF	ON	PJ4A-2B
		Shift Tray Paper					Paper	Paper
	PC1		5/8	IC1A	PD1		not		PJ4A-4A
		Empty Sensor						present
							present
		Main Tray Lower					Not at	At
	PC2		6/8	IC2A	PC1		lower	lower	PJ4A-9A
		Position Sensor
							limit	limit
	PC3	Shifter Home	6/8	IC2A	PC0		Not at	At home	PJ4A-8A
		Position Sensor					home
		Shifter Return					Not at	At
	PC4		6/8	IC2A	PD1		returned	returned	PJ4A-7A
		Position Sensor
							position	position
	PC5	Elevator Motor	5/8	IC1A	PF2		Un-		PJ4A-5A
		Pulse Sensor					blocked	Blocked
	PC6	Shift Motor Pulse	5/8	IC1A	PD0		Un-		PJ4A-3A
		Sensor					blocked	Blocked
	PC7	3rd Drawer Set	6/8	IC1A	PG2		Out of	In	PJ5A-2
		Sensor					position	position
	PC11	Lower Left Door	6/8	IC2A	PB1		Out of	In	PJ3A-2
		Sensor					position	position
		Duplex Unit Turn-					Paper	Paper
	PC13		6/8	IC2A	PB0		not		PJ3A-5
		over Path Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC17		5/8	IC1A	PC3		not		PJ7A-5
		Sensor 3						present
							present
	PC18	Lower Right Door	5/8	IC1A	PE2		Out of	In	PJ7A-2
		Sensor					position	position

T-13

			Dis-				Operation Char-
	Sym-			IC	Port		acteristics/Panel		CN/PJ
		Parts/Signal Name	play			I/O
	bol			No.	No.		Display		No.
			Page
							H or 1	L or 0
		3rd Drawer Paper					Not at	At
	PC19		6/8	IC1A	PG3		upper	upper	PJ6A-12
		Lift-Up Sensor
							limit	limit
		3rd Drawer Paper					Paper	Paper
	PC20		5/8	IC1A	PC0		not		PJ6A-2
		Empty Sensor						present
							present
		3rd Drawer Paper					Paper	Paper
	PC21		5/8	IC1A	PE3		not		PJ6A-9
		Take-Up Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC22		5/8	IC1A	PC2		not		PJ6A-5
		Sensor 4						present
							present
		Large Capacity					Out of	In
	PC31	Toner Collecting Box	4/8	IC2A	PC3				PJ2A-2
							position	position
		Set Sensor
	PC34	Shift Gate Position	5/8	IC1A	PC1		Un-		PJ4A-1B
		Sensor					blocked	Blocked
		Lower Position					Not at	At lower
	PC35		6/8	IC2A	PB3		lower		PJ4A-2A
		Sensor						limit
							limit
		Main Tray Paper					Paper	Paper
	PWB-E		5/8	IC1A	PF3		not		PJ4A-6A
		Empty Board						present
							present
	UN21	Drawer Paper	6/8	IC2A	PC2		OFF	ON	PJ4A-10A
		Descent Key
	SL41	3rd Drawer Lock	6/8	IC2A	PA1	f	OFF	ON	PJ5A-5
		Solenoid

T-14

AD-9

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
	M31	Duplex Unit Drive	7/8	IC1G	PB3	f	OFF	ON	PJ6G-2
		Motor
	↑	Duplex Unit Drive	7/8	IC1G	PE1		When	When	PJ6G-1
		Motor/lock signal					locked	turned
	CL31	Duplex Unit Paper	7/8	IC1G	PA3	f	OFF	ON	PJ2G-7
		Take-Up Clutch
	SL31	Duplex Unit Gate	7/8	IC1G	PH1	f	OFF	ON	PJ3G-5
		Switching Solenoid
	SL32	Duplex Unit Rear	7/8	IC1G	PH0	f	OFF	ON	PJ3G-7
		Finger Solenoid
	SL33	Duplex Unit Pick-Up	7/8	IC1G	PB2	f	OFF	ON	PJ2G-12
		Solenoid
	PC8	Duplex Gate Home	7/8	IC1G	PE0		Not at	At home	PJ7G-2
		Position Sensor					home
		Front/Rear Edge					Not at
	PC9	Guide Plate Home	7/8	IC1G	PC3			At home	PJ7G-5
							home
		Position Sensor
		Duplex Unit Paper					Paper	Paper
	PC14		7/8	IC1G	PC1		not		PJ3G-2
		Entry Sensor						present
							present
		Duplex Unit Paper					Paper	Paper
	PC15		7/8	IC1G	PC2		not		PJ2A-4
		Empty Sensor						present
							present
		Duplex Unit Paper					Paper	Paper
	PC16		7/8	IC1G	PC0		not		PJ2G-9
		Take-Up Sensor						present
							present

T-15

C-301

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
	HMOT	Elevator Motor	8/8	IC1A	PH0	f	Down/	Up	CN5A-2
							stop
	↑	Elevator Motor	8/8	IC1A	PH1	f	Up/stop	Down	CN5A-1
	PWB-B	Paper Plate Descent	8/8	IC1A	PG1		OFF	ON	CN2A-2
		Switch Board
	EMP-						Paper	Paper
		Paper Empty Sensor	8/8	IC1A	PC1			not	CN2A-5
	SEN						present
								present
							Paper	Paper
	KSEN	Paper Feed Sensor	8/8	IC1A	PG0			not	CN2A-3
							present
								present
	LEV-	Paper Plate Raised	8/8	IC1A	PC0		Not up-	At up-	CN2A-6
	SEN	Position Sensor					per limit	per limit
	LOW-	Paper Plate Lowered					Not at	At lower
			8/8	IC1A	PG3		lower		CN3A-5
	SEN	Position Sensor						limit
							limit
	DSEN	Cassette Door	8/8	IC1A	PG2		Out of	In posi-	CN3A-2
		Sensor					position	tion
	SET-	Set Sensor	8/8	IC1A	PC2		Out of	In	CN2A-4
	SEN						position	position

T-16

PF205 : MC

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		Vertical Transport					Turn in-	Turn	PJ12A-1~
	M21		6/8	IC1A	PB3	f		per-
		Drive Motor					hibited		4
								mitted
		3rd Drawer Paper					Turn in-	Turn	PJ11A-1~
	M22		6/8	IC1A	PB1	f		per-
		Take-Up Motor					hibited		4
								mitted
		4th Drawer Paper					Turn in-	Turn	PJ10A-1~
	M23		6/8	IC1A	PB0	f		per-
		Take-Up Motor					hibited		4
								mitted
	M24	3rd Drawer Paper	6/8	IC1A	PA0	f	OFF	ON (up)	PJ9A-8B
		Lift-Up Motor
	↑	3rd Drawer Paper	6/8	IC1A	PA1	f	OFF	ON (up)	PJ9A-7B
		Lift-Up Motor
	M25	4th Drawer Paper	6/8	IC1A	PA2	f	OFF	ON (up)	PJ9A-2A
		Lift-Up Motor
	↑	4th Drawer Paper	6/8	IC1A	PA3	f	OFF	ON (up)	PJ9A-1A
		Lift-Up Motor
	PC11	Lower Left Door	6/8	IC2A	PB1		Out of	In	PJ3A-2
		Sensor					position	position
		Duplex Unit Turn-					Paper	Paper
	PC13		6/8	IC2A	PB0		not		PJ3A-5
		over Path Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC17		6/8	IC1A	PC3		not		PJ7A-5
		Sensor 3						present
							present
	PC18	Lower Right Door	6/8	IC1A	PE2		Out of	In	PJ7A-2
		Sensor					position	position
		3rd Drawer Paper					Not at	At
	PC19		6/8	IC1A	PG3		upper	upper	PJ6A-12
		Lift-Up Sensor
							limit	limit
		3rd Drawer Paper					Paper	Paper
	PC21		6/8	IC1A	PE3		not		PJ6A-9
		Take-Up Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC22		6/8	IC1A	PC2		not		PJ6A-5
		Sensor 4						present
							present
		4th Drawer Paper					Not at	At
	PC23		6/8	IC1A	PF3		upper	upper	PJ8A-8
		Lift-Up Sensor
							limit	limit
	PC25	3rd Drawer Set	6/8	IC1A	PG2		Out of	In	PJ9A-2B
		Sensor					position	position
	PC26	4th Drawer Set	6/8	IC1A	PF2		Out of	In	PJ9A-7A
		Sensor					position	position

T-17

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		4th Drawer Paper					Paper	Paper
	PC29		6/8	IC2A	PB3		not		PJ8A-5
		Take-Up Sensor						present
							present
		Large Capacity Ton-					Out of	In
	PC31	er Collecting Box Set	6/8	IC2A	PC3				PJ2A-2
							position	position
		Sensor
		3rd Drawer Paper					Un-
	PC67	Lift-Up Motor Pulse	6/8	IC1A	PC1				PJ9A-5B
							blocked	Blocked
		Sensor
		4th Drawer Paper					Un-
	PC68	Lift-Up Motor Pulse	6/8	IC1A	PD1			Blocked	PJ9A-4A
							blocked
		Sensor
		3rd Drawer Lower					Not at	At
	PC69		7/8	IC2A	PD1		lower	lower	PJ4A-7A
		Position Sensor
							limit	limit
		4th Drawer Lower					Not at	At
	PC70		7/8	IC2A	PC0		lower	lower	PJ4A-8A
		Position Sensor
							limit	limit
		3rd Drawer Paper					Paper	Paper
	PWB-E1		6/8	IC1A	PC0		not		PJ4A-4A
		Empty Board						present
							present
		4th Drawer Paper					Paper	Paper
	PWB-E2		6/8	IC1A	PD0		not		PJ4A-3A
		Empty Board						present
							present
	UN5	3rd Drawer Paper	7/8	IC2A	PC1		OFF	ON	PJ4A-9A
		Descent Key
	UN6	4th Drawer Paper	7/8	IC2A	PC2		OFF	ON	PJ4A-10A
		Descent Key

T-18

PF-5D/AD-8

			Dis-				Operation Char-
				IC	Port		acteristics/Panel		CN/PJ
	Symbol	Parts/Signal Name	play			I/O
				No.	No.		Display		No.
			Page
							H or 1	L or 0
		Vertical Transport					Turn in-	Turn	PJ12A-1~
	M21		4/8	IC1A	PB3	f		per-
		Drive Motor					hibited		4
								mitted
	M31	Duplex Unit Drive	7/8	IC1G	PB3	f	OFF	ON	PJ5G-2
		Motor
	↑	Duplex Unit Drive	7/8	IC1G	PE1		When	When	PJ5G-1
		Motor/lock signal					locked	turned
	CL31	Duplex Unit Paper	7/8	IC1G	PA3	f	OFF	ON	PJ2G-7
		Take-Up Clutch
	SL31	Duplex Unit Gate	7/8	IC1G	PH1	f	OFF	ON	PJ3G-5
		Switching Solenoid
	SL32	Duplex Unit Rear	7/8	IC1G	PH0	f	OFF	ON	PJ3G-7
		Finger Solenoid
	SL33	Duplex Unit Pick-Up	7/8	IC1G	FB2	f	OFF	ON	PJ2G-12
		Solenoid
	PC8	Duplex Gate Home	7/8	IC1G	PE0		Not at	At home	PJ7G-2
		Position Sensor					home
		Front/Rear Edge					Not at
	PC9	Guide Plate Home	7/8	IC1G	PC3			At home	PJ7G-5
							home
		Position Sensor
	PC11	Lower Left Door	5/8	IC2A	PB1		Out of	In	PJ3A-2
		Sensor					position	position
		Duplex Unit Turnover					Paper	Paper
	PC13		5/8	IC2A	PB0		not		PJ3A-5
		Path Sensor						present
							present
		Duplex Unit Paper					Paper	Paper
	PC14		7/8	IC1G	PC1		not		PJ3G-2
		Entry Sensor						present
							present
		Duplex Unit Paper					Paper	Paper
	PC15		7/8	IC1G	PC2		not		PJ2G-4
		Empty Sensor						present
							present
		Duplex Unit Paper					Paper	Paper
	PC16		7/8	IC1G	PC0		not		PJ2G-9
		Take-Up Sensor						present
							present
		Vertical Transport					Paper	Paper
	PC17		5/8	IC1A	PC3		not		PJ7A-5
		Sensor 3						present
							present
	PC18	Lower Right Door	5/8	IC1A	PE2		Out of	In	PJ7A-2
		Sensor					position	position
		Large Capacity Toner					Out of	In
	PC31	Collecting Box Set	5/8	IC2A	PC3				PJ2A-2
							position	position
		Sensor

T-19

1151SBT0300A

3 PAPER TRANSPORT FAILURE

1156SBT0301A

3-1. Paper Misfeed

When a paper misfeed occurs, the Touch Panel shows the corresponding message, misfeed location and paper location.

Blinking	There is a misfeed at
Light	that location.
	There might be a
Steady	sheet of paper
Light	stopped at that
	location.

1149T002CA

			*When option is installed
Blinking/Steady LED	Misfeed/Paper Location		Ref. Page
	Multi Bypass take-up and transport		T-22
	Transport/separator		T-20
	Fusing/exit		T-24
	Copier take-up/vertical transport		T-17,18
,	Paper Feed Cabinet take-up/vertical transport T-25 to 28			*
,	Duplex Unit vertical transport		T-30	*
	1st Drawer take-up		T-17
	2nd Drawer take-up		T-17
	3rd Drawer take-up		T-25 to 28	*
	4th Drawer take-up		T-26	*
	Duplex Unit take-up		T-32,33	*
,	Duplex Unit storage		T-31	*
	ADF take-up		−	*
	ADF transport		−	*
	ADF turnover/exit		−	*
	Sorter		−	*
	LCC		−	*
<Display Resetting Method>
When misfeed occurs in the copier			Open and close the Front Door.
When misfeed occurs in the option (except Du-		Raise and lower the option, or slide the option
plex Unit)		away from, and back up against, the copier.

T-20

<Misfeed Detecting Sensor Layout>

*When options (PF-205+AD-9) are installed

Paper Exit Sensor (S53)

Paper Leading Edge Detecting

Sensor (PC54)

*Duplex Unit

Vertical Transport

Sensor (PC12)

*Duplex Unit

Paper Entry

Sensor (PC14)

*Duplex Unit

Turnover Path

Sensor (PC13)

Transport Roller Sensor (PC54)

1st Drawer Vertical Transport Sensor (PC63)

1st Drawer Paper Take-Up Sensor (PC56)

2nd Drawer Vertical Transport Sensor (PC64)

2nd Drawer Paper Take-Up Sensor (PC57)

*Vertical Transport Detection Sensor 3 (PC17)

*Vertical Transport Detection Sensor 4 (PC22)

*Duplex Unit

Paper Take-up

Sensor (PC16)

1156T001AB

*Duplex Unit Paper	*3rd Drawer	*4th Drawer
Empty Sensor	Paper Take-up	Paper Take-up
(PC15)	Sensor (PC21)	Sensor (PC29)

T-21

1156SBT0302A

3-2. Misfeed Detection Types and Detection Timings

D The following table lists the types of misfeed detection classified by the misfeed locations and their corresponding detection timings.

Note: For the misfeed detection types and detection timings in the options, see the Service Manual for the options.

<Copier Paper Take-up Misfeed>

Type	Detection Timing
Paper take-up failure	1st Drawer Paper Take-Up Sensor PC56 is not blocked (L) even after
detection	the lapse of approx. 2.2 sec. after 1st Drawer Paper Take-Up Motor M11
	has been energized.
	2nd Drawer Paper Take-Up Sensor PC57 is not blocked (L) even after
	the lapse of approx. 2.2 sec. after 2nd Drawer Paper Take-Up Motor
	M12 has been energized.
Paper take-up trailing	PC56 is not unblocked (H) even after the lapse of T (which varies for
edge detection	paper sizes) after it has been blocked (L).
	PC57 is not unblocked (H) even after the lapse of T (which varies for
	paper sizes) after it has been blocked (L).
Paper take-up leading	1st Drawer Vertical Transport Sensor PC63 is not blocked (L) even after
edge detection	the lapse of approx. 2 sec. after PC56 has been blocked (L).
	2nd Drawer Vertical Transport Sensor PC64 is not blocked (L) even
	after the lapse of approx. 2 sec. after PC57 has been blocked (L).

Leading edge detection by Transport Roller Sensor PC54

PC54 is not blocked (L) even after the lapse of approx. 1.3 sec. after PC63 has been blocked (L).

PC54 is not blocked (L) even after the lapse of approx. 1.7 sec. after PC64 has been blocked (L).

<Multi-Bypass Misfeed>

Type	Detection Timing
Paper take-up failure	PC54 is not blocked (L) even after the lapse of approx. 2.5 sec. after
detection	Manual Feed Paper Take-Up Clutch CL3 has been energized.

<Transport/Separator Misfeed>

Type	Detection Timing
Trailing edge detection by	PC54 is not unblocked (H) even after the lapse of T (which varies for
Transport Roller Sensor	paper sizes) after the TRON signal has been input.
PC54
Leading edge detection by	PC55 is not blocked (L) even after the lapse of approx. 1.2 sec. after
Paper Leading Edge De-	PC54 has been blocked (L).
tecting Sensor PC55
Trailing edge detection by	PC55 is not unblocked (H) even after the lapse of approx. 1.2 sec. after
PC55	PC54 has been unblocked (H).

T-22

<Fusing/Exit Misfeed>

Type	Detection Timing
Leading edge detection by	S53 is not deactuated even after the lapse of approx. 2 sec. after the
Paper Exit Switch S53	TRON signal has been input.
Trailing edge detection by	S53 is not actuated even after the lapse of approx. 2.5 sec. after PC55
S53	has been unblocked (H).

T-23

1156SBT0303A

3-3. Misfeed Clearing Procedures

1156SBT030301A

1) Copier Paper Take-Up Misfeed

Relevant Electrical Parts

D 2nd Drawer Paper Take-Up Sensor PC57	D 1st Drawer Paper Take-Up Motor M11
D 1st Drawer Vertical Transport Sensor PC63	D 2nd Drawer Paper Take-Up Motor M12
D 2nd Drawer Vertical Transport Sector PC64	D Paper Transport Clutch CL1
D Transport Roller Sensor PC54	D Power Supply Board PWB−C
	D Master Board PWB-A

1156C01TAA

T-24

!Copier Paper Take-Up Misfeed Clearing Procedure

Symptom	Step	Check Item	Result	Action
D Paper is not taken		Does the paper being used		Instruct the user to use the
up at all.	1	meet product specifica-	NO	paper that meets product
		tions?		specifications.
D Paper is stationary		Is the paper curled, waved,		Change the paper. Instruct
before the Paper	2	or damp?	YES	the user in how to store the
Take-Up Sensor.				paper.
		Is the Trailing Edge Stop or		Position the edge stop and
	3	Edge Guide in good posi-	NO	guide to meet the paper
		tion?		size.
		Are the Paper Take-Up Roll		Clean or change the Paper
	4	and Separator Roll de-	YES	Take-Up Roll and/or Sepa-
		formed, worn, or dirty with		rator Roll.
		paper dust?
		Is the Paper Take-Up Motor		Check the motor for over-
	5	(M11, M12) turning when	NO	load.
		the Start key is pressed?
		Run the “Controller/Board	YES	Change PWB-A.
	6	Check.” Is either of the
				Change M11, M12, or
		malfunction codes C032A	NO
		and C032B displayed?		PWB-C.
Paper is stationary		Are the Vertical Transport		Clean or change the Verti-
at the Vertical Trans-	1	Rollers deformed, worn, or	YES	cal Transport Rollers.
port Section.		dirty with paper dust?
		Does PC63 operate proper-		Check the PC63 actuator
		ly?		for operation and, if it
	2	Using the IC Port Data	NO	checks okay, change PC63.
		Check function, make an in-
		put port check on PWB-A
		(IC3A) APB6.
		Does PC64 operate proper-		Check the PC64 actuator
		ly?		for operation and, if it
	3	Using the IC Port Data	NO	checks okay, change PC64.
		Check function, make an in-
		put port check on PWB-A
		(IC3A) APB7.
		Does PC56 operate proper-		Check the PC56 actuator
		ly?		for operation and, if it
	4	Using the IC Port Data	NO	checks okay, change PC56.
		Check function, make an in-
		put port check on PWB-A
		(IC3A) APB3.
		Does PC57 operate proper-		Check the PC57 actuator
		ly?		for operation and, if it
	5	Using the IC Port Data	NO	checks okay, change PC57.
		Check function, make an in-
		put port check on PWB-A
		(IC3A) APB4.

Does PC54 operate properly?

6Using the IC Port Data Check function, make an input port check on PWB-A (IC5A) BPB6.

YES	Change PWB-A.

		Check the PC54 actuator
	NO	for operation and, if it
		checks okay, change PC54.

T-25

Symptom	Step	Check Item	Result	Action
Paper is stationary		Does CL1 operate proper-		Check the drive transmis-
at the Vertical Trans-		ly?		sion path.
port Section	7	Using the IC Port Data	YES
		Check function, set the data
		of PWB-A (IC4A) BPA3 to
		“0.”
		Run the “Controller Board	YES	Change PWB-A.
	8	Check.” Is the malfunction
			NO	Change CL1.
		code “C0321” displayed?

T-26

1156SBT030302A

2) Transport/Separator Misfeed

Relevant Electrical Parts

D Transport Roller Sensor PC54	D Separator Solenoid SL1
D Paper Leading Edge Detecting Sensor PC55	D Suction Fan Motor M4
D Paper Transport Clutch CL1	D High Voltage Unit HV1
D Synchronizing Roller Clutch CL2	D Master Board PWB-A

1156C02TAA

T-27

!Transport/Separator Misfeed Clearing Procedure

	Symptom	Step	Check Item	Result	Action
	Paper is station-		Is the paper curled, waved or		Change the paper. Instruct
	ary at the Syn-	1	damp?	YES	the user in how to store the
	chronizing Roll-				paper.
	er.
			Does CL2 operate properly?		Check the drive transmis-
		2	Using the IC Port Data Check	YES	sion path.
			function, set the data of PWB-A
			(IC4A) BPA4 to “0.”
			Run the “Controller Board	YES	Change PWB-A.
		3	Check.” Is the malfunction code
				NO	Change CL2.
			“C0320” displayed?
			Is an adequate length of loop		Adjust the loop length using
		4	formed before the Synchroniz-	NO	the “Loop Adjust (Drawer)”
			ing Roller?		function of “Tech. Rep.
					Choice.”
			Does PC55 operate properly?	YES	Change PWB-A.
			Using the IC Port Data Check
		5			Check the PC55 actuator for
			function, make an input port
				NO	operation and, if it checks
			check on PWB-A (IC5A) BPB5.
					okay, change PC55.
	Paper is station-	1	Is the Pre-Image Transfer Guide	YES	Correct, clean, or change
	ary near the PC		Plate deformed or dirty?		the guide plate.
	Drum.
			Are the Image Transfer/Paper		Clean or change the wires.
		2	Separator Corona wires deterio-	YES
			rated or dirty?
			Is the paper guide at the Paper		Clean or change the paper
		3	Separator Corona deformed or	YES	guide.
			dirty?
			Are the Synchronizing Rollers		Clean or change the Syn-
		4	deformed, worn, or dirty with pa-	YES	chronizing Rollers.
			per dust?
			Run the “Controller Board	YES	Change PWB-A.
			Check.” Is the malfunction code
		5			Change the Image Transfer/
			“C031D” or ”C031E” displayed?
				NO	Paper Separator Coronas
					Assy or HV1.
	Paper is wedged	1	Are the Paper Separator Fin-	YES	Clean or change the Paper
	at the Paper		gers deformed or dirty?		Separator Fingers.
	Separator Fin-
			Does SL1 operate properly?		Check the drive transmis-
	gers.
			Using the IC Port Data Check		sion path.
		2		YES
			function, set the data of PWB-A
			(IC4A) BPA0 to “0.”
			Run the “Controller Board	YES	Change PWB-A.
		3	Check.” Is the malfunction code
				NO	Change SL1.
			“C0324” displayed?

T-28

	Symptom	Step	Check Item	Result	Action
	Paper is station-	1	Do the Suction Belts turn when	NO	Check the drive gears and
	ary on the Suc-		the Main Drive Motor runs?		timing belt.
	tion Belts.
			Does M4 operate properly?	YES	Check the Suction Belts.
			Using the IC Port Data Check
		2	function, set the data of PWB-A
					Change M4 or PWB-A.
			(IC4A) BPC2 to “0.” Does M4	NO
			then run at full speed?

T-29