TASKalfa 3500i, 4500i, 5500i, 6500i, 8000i Troubleshooting Manual

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Page 1

2012.3. 8 Revised

3.16Revised

3.19Revised

3.21Revised

4. 6 Revised

8.30 Revised

2013.11.18 3rd Edition

3500i/4500i/5500i/6500i/8000i

Troubleshooting Guide

Page 2

Content

Item Phenomeno

3500i/4500i/5500i 6500i/8000i Pages

Image Toner Color Dot / Color Mark

○ ○

4-5

Void Li ne / White Band

○ ○

6-9

Void Li ne / Blac k Band（V ertical B l ack S t ri pes）

○ ○

Image Smudges

○ ○

11-23

Light Image

○ ○

Edge Part Background

○ ○

Meas ure for Condensat i on

○ ○

DP-770　Tip50mm・End37mm　Character B l urring

○

27-28

Conveying

J0501～7 / J0523～7

○ ○

29-30

J051X

○ ○

J05X8/J44XX

○ ○

J0545 (PF-770)

○ ○

PF-770 Repair for the procedures s l ope c onfirm ation of TRAY PAPE R

○ ○

J1313 / J1314

○ ○

J150X/J1904

○ ○

J1512

○ ○

J341X（PF)

○ ○

J4103/ J4104

○ ○

Abnormal Sound/ J42XX/J40XX（ Add Interme di ate Motor Cover）

○

J42XX/Fixi ng S e paration Claw Tip Missing or Damaged

○

J421X / J460X / J470X

○ ○（J460Xのみ）

42-43

Torn Paper、J430X/431X/440X/471X, 60m m from bot tom edge

○

○ ○

J49XX / J50XX / J51XX / J600X

○ ○

46-54

J610X / J611X (DF)

○ ○

55-60

J631X / J641X / J650X (DF)

○ ○

61-63

J6510　（DF-790 Caution of Manual S ta ple)

○ ○

J6600 (DF)

○ ○

J6710 / J7710 (BF)

○ ○

J9020/J9030

○ ○

J9010 / J9011 / J9110 / J9300 / J9310 / J9400 / /J9600 / J961

○ ○

Dog Ears

○ ○

69-74

Paper W ri nkles

○ ○

75-76

BF-730/720/710　P a per Wrinkle Correspondence of 1 Sheets of Paper Whe n Fol ded in the Middle

○ ○

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Content

Item Phenomeno

3500i/4500i/5500i 6500i/8000i Pages

C-CALL C0640

○ ○

C2101

○ ○

C2201

○ ○

C510X

○ ○

C6000/C6030/C6050/C6200/C6230/C6250

○

C6020/C6220

○

C6020/C6030/Fix ing Roll er Fusing, Poor Fix i ng

○

C6030/C6050

○

C6600/C6720/F ixi n g Belt Da mage

○

86-90

C6620

○

C6730

○ ○

C6770

○

C6910

○ ○

C7101

○ ○

C9500/C9510/C9520/C0630/C0640/CF245　SATA Cable Fai l ture

○ ○

CF000/“Welcom e” S creen Lock

○ ○

CF040

○ ○

CF182/186

○ ○

Abnormal S ound F rom Developing Unit

○ ○

100

Abnormal S ound F rom F i x i ng Dri ve Unit

○

101-105

DP Mot or Dri ven Sound

○ ○

106

Others DP Si ze Detec t i on Error

○ ○

107

Disporsal Toner Bott l e

○

108

Time for maintenance.(T)

○ ○

109

Damage of Cassette Rail

○ ○

110-111

Abnormal Sound

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Black Dot / Black Marks

Image sample 1

１．126mm interval Black Dots (drum)

If one of several 126mm interval black dots appears randomly at sub scanning

direction, take the following measure.

(Image sample 1) (*there is the case that the black dots appearance becomes vertical line.)

a.Replace the DRUM ASSY (DK-6305/6705).

126mm

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Black Dot / Black Mark

2. 45mm interval Black dots

If 45mm interval paper appears at image in the sub

scanning direction, tak e the following measure.

a. Check whether the foreign subst ance are attached

on the developing roll er surface.

b. If the foreign substance attached, wipe off by the

clean cloth.

c. If no foreign substance attached or it will not be

disappeared after w iping off, replace t he devel oping unit.

Image

φ0.1～0.3ｍｍ

45mm

Above is to check the black dots on the paper by the Magnifying glass.

1. 38mm interval black dots, black marks (Charger r oller)

Take the follow ing measure if the 38mm inter v al bl ack dots or marks appear at the image In the sub scanning direction.

a. Check the 38mm interval to print out the test sample by U089 M ono4. b. Replace the MC-6705 after confirming the dots appears 38mm inter val . c. Execute U930 charger roller counter reset after replacing MC-6705.

38mm

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a. If the void image appear at solid part of prints out on U089 Color

Belt, refer to below “b” * If the vert ical streak image appear s at the

halftone, replace the dev elopi ng unit. b. Execute U140  AC Calib High Altitude c. Select “Altitude” and find the setting w hich the leak image does not

appear . * Avoid the setting far from the actual al ti tude. d. If the image will not be recovered, replace the developi ng uni t.

Image sample 1 ◇ Leak at the solid part

Void image appear at the solid part.

U89 Sample set Void imag e at Solid part

Image sample 2 ◇Leak at the halftone par t

Horizontal streaks appear at Halftone image.

U89 Sample set Horizontal streaks at halftone image

Void Line / White Band (Horizontal White Streaks)

1. Leak Image 1 (3500i、4500i)

Execute AC Calib Operation Autom atically

Select AC Calib High Altitude Setting

7550ci/6550ci

5550ci/4550ci

3550ci/3050ci

8000i/6500i

5500i

4500i/3500i

Page 7

a. If the void image appear at solid part of prints out on U089 Color

Belt, refer to below “b” * If the vert ical streak image appear s at the

halftone, replace the dev elopi ng unit. b. Check the value of U140 Sleeve AC (1) c. U140  Execute AC Calib（2）  Set “K” Off to On（3）  Execute（4）  Start d. Check whether the value of U140 Sleeve AC (3) becomes lower and the image is recovered. e. If the image will not be recovered, replace the developi ng uni t.

（3）

(4)

（1）

（2）

Image sample 1 ◇ Leak at the solid part

Void image appear at the solid part.

U89 Sample set Void imag e at Solid part

Image sample 2 ◇Leak at the halftone par t

Horizontal streaks appear at Halftone image.

U89 Sample set Horizontal streaks at halftone image

Void Line / White Band (Horizontal White Streaks)

1. Leak Image 2 (5500i、6500i、8000i)

Execute AC Calib Operation Autom atically

Select AC Calib High Altitude Setting

7550ci/6550ci

5550ci/4550ci

3550ci/3050ci

8000i/6500i

5500i

4500i/3500i

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Void Line / White Band

2. Horizontal white streaks (Image sample 1)

If 1.2mm interval horizontal streaks occur at

the gray image in the main scanning direction, take the following measure. *In case of this appearance at the machine’s rear side is more noticeable than at front.

a. Replace the LSU.

Image sample 1

About

1.2mm

Machine Front

Machine

Rear

Page 9

Void Line / White Band

3.Vertical White streaks (Image sample 1)

If vertical white streaks appears continuously and

linearly in the sub scanning direction, take the following measure.

a. Clean the cover glass on the LSU.

Image sample 1

Verti cal whi te streaks

Image sample 2

4. Vertical White lines (void image) (Image sample 2)

If the void image appears by wide width in the sub scanning direction, take the following measure.

a. Replace the LSU. (In case of the machine is produced before 2011 Oct.)

Page 10

1. Vertical Black streaks (Image sample 1)

It occurs continuously and linearly toward the paper feeding direction.

Please remove the transfer belt unit and check whether the transfer belt is cracked.

1. When the transfer belt is torn or cracked, please replace the drum unit and the transfer belt unit.

2．Check the firmware version (U019) and upgrade it higher than Upgrade Pack Ver. V4.00

Image sample 1

Void Line / Black Band

Vertical Black Streak

Condition of tear or crack on the transfer belt

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Image Smudges (1/13)

Image sample 2

View from bottom part of ejected paper

2.Image Smudges (Imag e samp le 2)

The smudges appears at the leading edge of ejected paper.

Clean the duct at insi de i f machine and the developing unit.

Refer to “3.Cleaning Procedure” for cleaning.

1.Image Smudges (Imag e samp le 1)

There is no periodicity and it occurs intermittently

in the paper conveyance direc tion. a. Clean the conveying guide. b. Clean the paper dust cleaner at the regist roller

section.

(-->)

Image sample 1

Cleaner

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(Stains on the conveying guide)

The stains occur at the outside of paper path.

3. Cleaning Procedure

Image Smudges (2/13)

a. Preparation before cleaning Remove the lower rear cover and toner box （Fig.1) Remove the developing unit and dr um unit

after detaching the inner unit .

Remove the toner box.

2 screws

Fig.1

b. Clean the conveying guide . Clean the paper feeding si de of the

conveying guide ( Fig .2)

At the nex t, r emove the conveying guide

(one each at front and rear), clean the back side of conveying g ui de ( F i g .3)

* For cleaning, use the dr y and soft cloth. (It

locates at the size indi cati on plate slot on 1st cassette.)

Clean the conveying guide

Screw

Fig.2

Fig.3

Page 13

Image Smudges (3/13)

c. Clean the toner exhaust duct at inside of

machine

While the developing unit is taken out and the

conveying guide i s removed, suct ion t he toner exhaust part at inside the machine where the toner exhaust duct of the developing unit connected with a cleaner. (Fig.4)

Note) Clean while paying attention not to scratch the gear and registration roller.

(Before cleaning) Tone is accumulating.

(-->) T oner Exhaust Aperture

Fig.4

d. Check the machine’s production month Check the production month from the

machine’s serial number on the rati ng l abel and clean it according to the production month.

・Before 2012/Feb. production machine. Refer to the cleaning procedure “e”

”g”

・After 2012 / Mar. pr oducti on model. Refer to the cleaning procedure “f” 

“g”

MACHINE No. N4P22*****

16 : 2011/6 17 : 2011/7 18 : 2011/8 19 : 2011/9 1X : 2011/10 1Y : 2011/11 1Z : 2011/12 21 : 2012/1 22 : 2012/2 23 : 2012/3 24 : 2012/4 25 : 2012/5

(Rating label)

(Way of refer to the production month)

N4P：Model Number It differs according to the model

22：Indicate 2012 Feb. production

Page 14

Image Smudges (4/13)

e. Clean the DUCT TONER UNIT

( In case of 2012 Feb. production machi ne) Clean the DUCT TONER UNIT with the vacuum

cleaner.

Procedure 1) Clean and suction the outlet of duct with cleaner for 1 min.

A cleaner ti p is put in and attracted from this direction. (If a opening is cover ed with a rag etc. so that the open air may not be attracted from a cleaner tip, toner can be attracted effectively.)

Page 15

Image Smudges (5/13)

Procedure 2) Remove the 302LF33012/DUCT FAN TONER from the machine and clean, suction it with the vacuum cleaner. Reattaching the seal after cleaning and cut the part of duct.

302LF33012/DUCT FAN TONER

Remove the duct with 2 screws

Lift up this part if it is detached.

Clean the removed duct

Clean after removing the duct too.

(Before cleaning ) Toner is accumulating.

Page 16

Re-attach with 302LF33201/SEAL TONER DUCT A (Chang e wi th 5mm thick sponge)

Cut the rib (claw) of the duct.

Procedure 3) Peel off the FILM of 302LF33012/DUCT FAN TONER and replace w ith 302LF94410 /PAR TS LID TONER FAN ASSY(ZG) SP

302LF94410/P AR TS LID TONER FAN ASSY(ZG) SP

FILM

302LF94410 is re-usable.

After this replacement, the level of unit is same as 2012 Mar. and after production model.

Please replace with the parts as shown in fig when 302LF94410/PARTS LID TONER FAN ASSY(ZG) SP.is available.

Image Smudges (6/13)

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f. Clean the DUCT TONER UNIT (In case of 2012 Mar and after production

machine) Clean suction the DUCT TONER UNIT with

the vacuum cleaner.

Procedure 1) Clean suction the duct outlet for 1 min with the vacuum cleaner.

Image Smudges (7/13)

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Procedure 2) Remove the 302LF33830/LID TONER FAN from the machine and clean suction it with the vacuum cleaner.

(Before cleaning ) Toner is accumulating.

LID TONER FAN

Remove it after releasing 3 pcs of snap-fit

Return the LID TONER FAN at ori g i nal posi ti on after cleaning

Image Smudges (8/13)

Page 19

(-->)

g. Replace the DISPOSAL TONER UNIT.

- Replace the following DISPOSAL TONER UNIT. 302LF94400 PARTS DISPOSAL UNIT(ZG) SP

- Clean suction the acc umulating toner at the DISPOSAL TONER UNIT inside or the FILTER.

Refer to the right figure for the c l eaning procedure. ( FILTER ) 302LC33240/FIL TER OPTION A (New type) 302LF33820/FILTER TONER (Old type)

Remove the LID from the DISPOSAL TONER

Old type (2 piles

sheets)

New type (2 layer

structure)

Clean the inner part of accumulating toner and filter after opening the DISPOSAL TONER UNIT.

When cleaning the old type Filter, Be careful for FILTER of the thinner side not to be inhaled by the cleaner due to two-sheet piles.

FILTER

Remove 3 pcs of screws Release 8pcs of snap-fit

Install the thick density side of FILTER at Fan side with (both sheets). There are not difference in performance between old and new 2 type of filters.

Image Smudges (9/13)

Page 20

FILTER 2

6500i/8000i

3500i/4500i/5500i

At cleaning the FILTER, the FILTER can be detached after removing the DF Rear Cover without releasing D F from the main body. After removing, clean or replace i t.

h. Clean the FIL TER

( FILTER ) 302LC33370/FILTER LEFT SIDE

Image Smudges (10/13)

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i. Clean the developing unit Clean the toner stain on t he r emov ed

developing unit.

(-->) Absorb the insi de toner w hile fitting the

nozzle of the vacuum c leaner to the toner waste aperture of the DUCT.

Clean the accumulating toner on the toner r eceiv er of the developing unit.

At rear side of the developing unit

Clean the toner at inside of developing cooling duct

Image Smudges (11/13)

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Image sample4

Image sample3

4.Image Smudges (Image sample 4)

Toner smudges at the 1st cassette (Image sample3) Toner smudges by the feed pulley when feeding the paper from the 1st cassette (Image sample4)

a. Clean the duct at inside if machine and the developing unit. *Refer to “3.Cleaning Procedure” for cleaning.

b. Please use the PARTS SEAL SET.ALL SP. *Refer to the service bulletin No. 2LF-0014(C171) for the detail information

Model Part No Description

8000i/6500i 302LF94451 PARTS SEAL SET ALL SP

5500i/4500i/3500i 302LH94341 PARTS SEAL SET ALL SP

Image Smudges (12/13)

Page 23

128mm

118mm

Toner stain・Bottom edge toner stain

5. Toner s tai n occ urs at the pos i ti on shown in the right fig, pleas e take the following measure. ( imag e sample A)

2. When toner stain occurs at about 20mm position from paper bottom edge, please take the following measure. (image sample B)

a. Replace the DV unit. ( DV-6305/6705:

302LH93034/302LF93034)

a. Replace the DV unit. ( DV-6305/6705:

302LH93034/302LF93034)

Image A

Image B

Feeding direction

(In case of A4)

It occurs in three places of either

It occurs in the range of about 20mm from paper bottom edge.

Image Smudges (13/13)

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Light Image

If the copy image becomes out of focus, take the following measure in

order. (Sample1)

1. Replace the ISU_LENS UN IT (P ARTS IMAGE SCANNER L SP： 302K993082)

2. Execute the scanner auto adjustment.

2-1. Place the designated adjustment original (Part No.:

7505000005) on the contact g lass .

2-2. Select “Targ et” on U 411 S canner Auto Adjustment 2-3. Select “Auto” and pr ess the s tar t key. 2-4. Select “Table (Chart1)”. 2-5. Select “ALL” for items to be ex ec uted. 2-6. Press the start key and start the auto adj us tment.

Refer to the service bull eti n No. 2LC-0026 (B314)

Original

Sample1

COPY

Page 25

Edge Part Background

１．If Paper Edge Background occurs, you will be required of the following as below.

■ Case of failure

During the continuous output, event does not occur until a few sheet of papers, but it may occur in the middle. The uneven density appears periodically at background image with developing sleeve pitch.. 3500i/4500i/5500i/6500i/8000i：45mm

■ How to Respond Check the Firmware and Upgrade to the Ver. 5.00 or above. Please run the calibration after upgrade it.

End Background occurs in the magnetic roller pitch

Sample 1：Case of failure （Monochrome Machine）

Page 26

Measure for condensation

<Phenomenon> Flowing image occ urs at pr i nti ng after power on if the inside machine is in cold condition. ( condens ati o n

image occurs)

1.Update the firmware abov e Pack.3. 07

2.Change refresh freq uency (mode) of U148

3.If the condensation occurs easily depends on installation environment (the temperature difference in the morning and day time is too large and high humidit y ) , set mode 2 in U148.

4.Set to Mode 3 if the condensation can not be eliminated at mode 2.

* Caution Refresh frequency will be increased if incr ement of mode number. Therefore, if it is pointed out that the

warm up period becomes longer, set to mode 1.

However , the ef fecti veness of this measures dec r eases in comparison with Mode2 in the case of set

Mode1, please ask the user understand to perform refresh operation manually at the time of the condensation occurs.

Mode Inner humidity <70% 70%≦ Inner humidity <80% 80%≦ Inner humidity <90% 90%≦ Inner humidity

0 0 time 0time 0time 0time

1 0 1 2 3

2 0 2 3 4

3 0 4 5 6

⇒Recomm ended

Refresh frequency in each mode

Page 27

DP-770 Character blur at 50mm l eadi ng edge, 37 mm bottom edge

<Phenomenon> Text Character is extended around 50mm from original leading edge and 37mm from bottom edge.

<Method of measure> Change the front and rear nip pressure at scanning the original during DP conveying and stabilizing the original conveying speed.

1.Change of the front nip pressure 1700g → 1200g 《Cut two coils》

Item 303LL24120:SPRING PULLEY CONV LEFT

2.1.Change of the rear nip pressure 900g → 500g 《Cut two and a half coils》

Item 303LL24130:SPRING PULLEY CONV R

1.Front scan spring

2.Rear scan spring

For 3500i/4500i/5500i

Page 28

DP-770 Character blur at 50mm l eadi ng edge, 37 mm bottom edge

<Procedure for modification

1. Detach the original mat and remove 6 screws (1screw for front cover left lower, 1screw for left cover, 4screws for scan rear sprint mount plate)

2. All of 5pcs springs at rear original scan are cut two and a half coils.

3. Remove the rear cover and left side stay by 2screws, then remove the screws in the bottom of it.

4. Remove the lower cover while sliding front side, then remove the metal plate by 4 screws.

5. Remove all of original scan front pulleys (5 pcs) and springs （3303LL24120:SPRING PULLEY CONV LEFT）are cut two coils.

6. Return it original position and execute DP feeding and DP scanned image checking.

3 4

For 3500i/4500i/5500i

Page 29

J0501 to 7 / J0523 to 7 (Misfeed JAM)

If above code display, take an action as referring to below procedure. a. If JAM paper or printout paper is like a Fig.1, replace the Roller of the Primary Feed. * The maintenance cycle for Primary Feed is 150K.*

b. Please adjust the pressure of the retard pulley based to the flow chart in next page if misfeed

occurs.

Affected Model :4500i,5500i,6500i,8000i

◆ Note ---- * Check the color of Roller to find the Old and New difference at the Primary Feed. *Rubber color : Black *Rubber color :Gray

・Feed-Roller 302K906350 PULLEY FEED 2AR07230 PULLEY SAPARATION ・Retard-Roller 302K906360 PULLEY RETAR D 302K906340 PULLEY RETARD ・Pickup-Roller 302K906370 PU LLEY PICKUP 302K906340 PULLEY RETARD

Refer to the service bulletin No. 2LC-0003(B105) for the detail information for Roller.

Fig.1 JAM Paper

Rubber color :Black

Rubber color: Gray

NEW OLD

Gray

Black

White White

Black Black

J0501 to 7 / J0523 to 7

( Misfeed)

Page 30

[Procedures for adjusting the pressure of the retard pulley (Flow chart)] Refer to the service bulletin No. 2LF-0015(C191) for the detail information

J0501 to 7 / J0523 to 7

( Misfeed)

Page 31

J051X Continuous Feeding JA M If J051X occurs, take an action as referring t o below

procedure.

a. Check the paper size (Fig.1)

Check whether the size of paper is set at the cassette and stated on

the JAM log of the Even Log is same or not.

If the paper size is different at “a” b. Check whether the position of cassette cur sor is properly set against the paper. ( Fig.2)

c. Check whether the cass ette is inserted into the end. d. After performing abov e “b” and “c”, the problem is not solved,

replace with the modification parts mentioning on the service bulletin No.2LC-0023(B287) (Fig.3)

If the paper size is matched at above “a” e. Check the paper is using other than specified (such a coated paper , inkjet paper)

f. Please adjust the pressure of the retard pulley. Decrease the adjusting plate by one level.

Affected Model :4500i,5500i,6500i,8000i PF-730,PF-740

Fig.1 Paper size check

Fig.2 Check the position

of the Cassette Cursor

Fig. 3 Item need to be replaced on SB:2LC-0023

J051X

Page 32

Check the firmware version. （Engine）

・8000i/6500i : 2LF_1000.002.005 ・5500i/4500i/3500i : 2LF_1000.002.005

J05x8/J44xx(JAM during Duplex printing)

JAM during Duplex printing

a. If the version is older than the righthand, upgrade the firmware to the latest version.

b. After above “a” action, if JAM is still not solved, Replace the Conveying Unit.

Refer to the service bulletin No. 2LC-0036(B402),2LC-0083(C126) for the detail information. Modified from the production machine of May, 2012 .

J05x8/J44xx(JAM duri ng Duplex pri nting)

Model Part No. Description

5500i/4500i 302LH94042 PARTS CONVEYING H UNIT(G) SP

3500i 302LL94012 PARTS CONVEYING L UNIT(G) SP

8000i/6500i 302LF94052 PARTS CONVEYING H UNIT(Z) SP

Page 33

J0545 (Misfeeding JAM PF-770)

J0545 (no paper feeding JAM PF-770) If J0545 occurs, take an action as referring to below procedure.

a. If JAM paper or printout paper is lik e a Fi g .1, replac e the Roller of the Primary

Feed. (Image sample 1)

b. Replace w ith 303NG9401 1 PARTS FEED UNIT SP if the producti on of

machine is before 2011 Dec.

c. At replacement, chec k or clear the count number of U901 Paper Feedi ng

Counter.

* The maintenance cycle for Primary Feed is 150K.*

Fig. 1 JAM Paper

For the detail, refer to the ser vice bulletin No. 3NG-004(C024) Affected machines：After 2012 Jan production

Image sample 1

d. If the TRAY PAPER for paper loading w as assembled by slanting condit ion, there is possibility of JAM0545 oc cur r i ng . In c ase of the pr obl em, check it according to the next page "Inclination check and recov er ing pr ocedure of PF 770 TRAY PAPER" and corrected. (There is a possibility that J0545/0555/1 305 /13 15 may occur.)

TRAY PAPER

Page 34

PF-770 Check & Recovery for Slating of TRAY PAPER

1. Remove the STOPPER DECK.

2. Check the right and left slanting condition of the TRAY PAPER surface.

Turn the SHAFT LIFT and adjust the top part of STAY DECK SIDE becomes the same flat surface level with the TRAY PAPER at the FEED UNIT side. In that height position, check that the TRAY PAPER surface of the opposite FEED UNIT side is lower than the STAY DECK SIDE top part. In addition, the height of STAY DECK SIDE is the same height at the FEED UNIT side and opposite FEED UNIT side.

1) If the opposite FEED UNIT side is lower than the FEED UNIT side････OK

3. Check there is not slanting between the front and rear of the TRAY PAPER.

Turn the SHAFT LIFT and when the top surface of the TRAY PAPER is aligned with the convex part of FRAME DECK REAR and FRAME F L,

1)Same flat height level at front and rear  OK

2)If it has about 5mm difference height between front and rear  NG

STOPPER DECK

Clearance (about 5mm)

SHAFT LIFT

STAY DECK SIDE

Same flat level

FEED UNIT side

TRAY PAPER

Feeding direction

FEED UNIT side

STAY DECK SIDE

Opposite FEED UNIT side

TRAY PAPER

FRAME F L

FRAME DECK REAR

TRAY PAPER

Same height at front / rear  OK

About 5mm

About 5mm difference between front and rear height  NG

<Recovery Procedure> If above item 2 and 3 is NG, the following re-assembling is necessary.

At checking of above item 3, if the TRAY PAPER lower side is not normal, it has a possibility that the ball is out of position as shown in the NG figure, re-assembly of the wire is necessary. In the case of NG above item 2, it has a possibility that the ball is out of position at both of front and rear, re-assembly of an front and rear wire is necessary.

OK : A ball terminal

goes into the hole

of shaft.

NG: A ball terminal

is out of shaft.

Black color

WIRE

* As shown in the right figure, make it a ball terminal go into the hole of SHAFT within PULLEY LIFT WIRE DRUM at the time of re-assembly. Be cautions especially at the time of the assembly of a black wire.

SHAFT LIFT ASSY

WIRE LIFT L black color

PULLEY LIFT WIRE DRUM

Opposite FEED UNIT side

Page 35

1. If J1313/J1314 occurs, take the measure as referring to the following.

a. Check whether installing 302K99 41 30 PARTS GUIDE FEED MIDDLE ASSY SP is proper.  The unit is not set properly, reinstall it.

b. Check whether 302K994430 PARTS ROLLER FEED LOW SP is rotating without power on the clutch. * refer to the procedure-1

 If the clutch is rotating, change the clutch cable wi r ing treatment. * refer to the procedure-2 c. If JAM is not solved after changing the clutch c abl e wiring, replace the 302K99 41 30 PARTS GUIDE FEED MIDDLE ASSY SP unit.

J1313/J1314

c. Push in the wires inside of the machine through the hole on the metal plate where the wire fastener was fitted. *Then, take care the connector at the feed drive unit side not to be loose.

b. Cut the snap-fit part not to refit after the measures

a. Remove the snap-fit wire fastener from the side plate that is fitted to the machine frame in the feed drive unit.

Procedure-2

Procedure-1

Check this installation part whether properly fitted.

1. While opening the feed cover, turn on this SW

2. Execute U032 Check Clutch Operation to select “MOTOR”.

3. Check this roller is not rotated. *If rotating, the clutch is on without operating.

Page 36

J150X/J1904

【Phenomenon】 The paper conveying actuator is scraped for a long usage, J1904 and J150X occurs due to sensor detection failure depending on the paper. 【How to respond】 Replace the actuator (ACTUATOR FEED LOW 302N706500) when the problem occurred.

【Service Bulletin】 2LC-0123（D148）

(500-sheet cassette feed section for the main machine)

Paper conveying sensor (PCS/PFPCS2)

Changed the shape of the paper detection parts

(Before) (After)

Page 37

J1512

【Phenomenon】 The cassette 4 paper may not stop before the feed sensor (middle sensor at vertical conveying) and the sensor may be turned on while the cassette 2 paper stays at the registration for duplex feed.

【Change】 Paper waiting position for the next feeding paper after feeding paper from the cassette 2 is changed. (About 50mm before the current position) Upgrade to the latest F/W. （Upgrade Pack Ver. V5.00 or above）

【Service Bulletin】 2LC-0116(D089)

Page 38

PF-780

If J341X occurs, take the measure as referring to

the following.

If the ACTUEATOR of SMPCS1 is slow to return to the

home position, it occurs.

a. Replace the actuator spring w ith 303NL06510 SPRING ACTUEATOR PI

b. If PF-730 for the 6th/7th cassette is installed and after

replacing the above spring, JAM still occurs , c heck whether the 303NF06100 ROLLER CONVEYING VF is

moving the thrust dir ecti on.

If the movement of unit is heavy, re-install the 303NJ31040

PLATE DECK JOINT located at right side while making the edge of (1) contacting with FRAME REAR, shift lower direction of arrow (2).

Shape of modified spring

Shift it smoothly this thrust direction

ROLLER CONVEYING VF

１

２

303NJ31040 PLATE DECK JOINT

Refer to service bulletin No. 3NJ-0001（B354）for the detail Affected machines：After 2011 Oct . production

Refer to service bulletin No. 3NL-0001(C059)for the detail Affected machines：After 2012 Feb production

J341X

Replace with 303NL06510 SPRING ACTUATOR PI

PF-730

Page 39

J4103/4104

Check whether a cor ner of A4 paper runs on the bump with a step of 1 1x8. 5 siz e. When paper runs on, set paper correctly. Please adhesive the regulation sheet: PARTS SHEET STOPPER A4 SP(303NF94170) as needed. *If paper seriously runs on, C1100/11 10 may occur.

１．When J4103/4104 oc cur at t he ti me of A4 size paper feed from

the large-capacity deck 3 or 4, please take the following measure.

Page 40

Abnormal Sound/J42XX/J40XX（Add Intermediate Mot or Cover）

【Phenomenon】 The abnormal noise may be heard or the Jam (J42XX／J40XX) may occur if the gear of the middle roller drive motor is worn with toner spillage.

Model：TASAalfa8000i／6500i

【How to respond】 The cover (302N724020：COVER MOTOR MIDDLE) is added to prevent the gear wear.

【Service Bulletin】 2K9-0040（D153）

For 6500i/8000i

PARTS GUIDE FEED REGIST ASSY SP

Groove width of the shaft (1.3±1mm -> 0.8±0.1mm)

Cut washer (t=1.0 -> t=0.5)

Added Cover

* Fixed together with the

metal plate (Y) with the screw

Metal plate (Y)

Page 41

J42XX/ The separation cla w cracks or comes off

J42xx occurred frequently, replace w ith the new claws or new parts when the separation claw cracks or comes off. Single Item ：302FT20120 SEP ARATOR ASSY Assembly ：302LH94370 P ARTS SEP ARATOR ASSY SP

If the claw is broken in half, please change to the new claw (claw that is integrated).

【Service Bulletin】：2LH-0016 (D159)

For 3500i/4500i/5500i

(Before)

(After)

The claw and holder are joined

Unifying the claw and hold prevents the crack at the joint part

The claw may crack or come off from the joint part

Page 42

If J421X/J460X/J470X occurs.

1. In case of JAM at the shift guide of the exit unit part, take the following measure.

a. Increase the clearance between the housing and the shi ft guide, attach the foll ow ing s pacers (No.1: 3pcs in one set ) on the driving plate.

*302LC94660(PARTS FILM SPACER EXIT SET SP) １SET *Refer to the service bulletin: 2LC-0037(B405)

■Affected machine’s serial number

J421X / J460X / J470X (1/2)

5500i

KDJ ▲KDA KDA(AK) ▲CPY CS(AK) ▲KDA GSA ▲KDBR ▲KDA 220V

1102LH9JP0 1102LH2US0 1102LH2US2 1102LH2CS0 1102LH2CS1 1102LH2US1 1102LH2BR0 1102LH4US0

N3W1Y00307 N3X1Z02903 NWN1Y00001 NHJ1Z00472 NWM1Y00001 NLR2100106 NJC1Z00026 NHZ1Z00008

KDE ▲UTAX ▲OLIVETTI KDAU KDCN ▲KDKR KDTW ▲KDHK

1102LH3NL0 1102LH3UT0 1102LH3LV0 1102LH3AS0 1102LH3KS0 1102LH3KR0 1102LHTTW0 1102LH3HK0

N3Y1Y02250 N411Z00865 NK31Z00221 NextPdct NKR1Z00101 NMS1Z00106 NJS1Y00030 NJ61Z00046

KDID ▲KDSG KDTH Philcopy

1102LH3ND0 1102LH3SG0 1102LH3TH0 1102LH4PH0 NHZ1Y00006 NJ91Z00198 NJ31Y00176 NextPdct

4500i

▲KDJ KDA KDA(AK) ▲CPY CS(AK) KDA GSA KDBR ▲KDA 220V

1102LJ9JP0 1102LJ2US0 1102LJ2US2 1102LJ2CS0 1102LJ2CS1 1102LJ2US1 1102LJ2BR0 1102LJ4US0 N421Z00668 N431Y02336 NWQ1Y00001 NHK1Z00485 NWP1Y00001 NextPdct NJB1Z00040 NHR1Z00017

KDE ▲UTAX ▲OLIVETTI KDAU KDCN ▲KDKR ▲KDTW ▲KDHK

1102LJ3NL0 1102LJ3UT0 1102LJ3LV0 1102LJ3AS0 1102LJ3KS0 1102LJ3KR0 1102LJTTW0 1102LJ3HK0 N441Y02505 N461Z01265 NK41Z00321 NextPdct NKS1Z00101 NMT1Z00091 NJT1Z00093 NJ51Z00128

▲KDID ▲KDSG ▲KDTH Philcopy

1102LJ3ND0 1102LJ3SG0 1102LJ3TH0 1102LJ4PH0

NHY1Z00015 NJ81Z00373 NJ21Z00106 NextPdct

3500i

KDJ KDA ▲CPY ▲KDA GSA KDBR KDA 220V KDE UTAX

1102LL9JP0 1102LL2US0 1102LL2CS0 1102LL2US1 1102LL2BR0 1102LL4US0 1102LL3NL0 1102LL3UT0 N471Y00539 N481Y04077 NHL1Z00712 NLT2100181 NJA1Y00051 NextPdct N491Y02575 N4B1Y02215

▲OLIVETTI KDAU ▲KDCN ▲KDKR ▲KDTW KDHK ▲KDID ▲KDSG

1102LL3LV0 1102LL3AS0 1102LL3KS0 1102LL3KR0 1102LLTTW0 1102LL3HK0 1102LL3ND0 1102LL3SG0 NK51Z00381 NextPdct NKU2100301 NMU1Y00732 NJU1Z00024 NextPdct NHX1Z00022 NJ71Z00067

KDTH Philcopy

1102LL3TH0 1102LL4PH0

NextPdct NextPdct

Page 43

■Removal procedure for the exit drive unit

3500i/4500i/5500i/6500i/8000i b. When the entire paper is not damaged at JAM.

Since there is a possibility of incorrect detection of the sensor, please replace the sensor in the inside of the

eject unit, or the eject unit.

* Sensor：7NXGP1A73LCH01(SENSOR OPT.) Eject unit：302LH94271（PARTS EXIT UNIT B SP） * Measurement time : April 2012 (after March 2012 production lot, the sensor selection is executed.)

J421X / J460X / J470X (2/2)

Page 44

J421X(Fuser exit sensor stay jam)

【Service Bulletin】 2K9-0021(C155)

【Permanent support】 Exit guide rib shape change + fixing cover ribs added Sept 2013 - production: corresponding time

Item Number Item Name 302K994C40 PARTS CUT-WASHER 6 SET SP

＊Set bundling 2 pcs of the cut washer

In the case of J421X occurs, check the fuser guide shape of the fixing, it will be required the following.

排出ｶﾞｲﾄﾞ形状対応方法

ｶｯﾄﾜｯｼｬｰを以下支点部に追加して下さい。

・機械前側支点部：1枚

・機械後側支点部：2枚

ｶｯﾄﾜｯｼｬｰを以下支点部に追加して下さい。

・機械後側支点部：2枚

For 6500i/8000i

Shape of Fuser exit guide

How to respond

Added 2 cut washers to the fulcrum of the fuser exit guide.

・Machine front fulcrum:1pc ・Machine back fulcrum:2pc s

Please add to the fulcrum below the cut washer. ・Machine back fulcrum:2pc s

New Fuser Cover

Cut washer mounting position

Cut washer

Exit guide

Cut washer

Fuser cover

Add rib

Page 45

Paper tear, J430X/431X/440X/471X, Horizontal line at 60mm

from bottom edge

（Phenomenon1）

If the leading edge of the actuator switching the switchback sensor is hooked with the center hole of 3-hole pre-punched paper when the paper is turned over with the duplex printing, the paper may be torn or the paper jam (J430X/431X/440X/471X) may occur depending on paper thickness. (If the paper is torn, the following phenomenon 2 may occur at the same time.)

a Replace the EXIT UNIT (PARTS EXIT UNIT B SP :302LH94272) 3500i/4500i/5500i：PARTS EXIT UNIT B SP (302LH94272)

6500i/8000i ：PARTS EXIT UNIT A SP(302K994662)

（Phenomenon2）

the horizontal line on the image of the paper rear side. a Check the most updated firmware version and version up the firmware.

Check the Firmware version and version up to above FW PACK V4.00.

1. During usage of a pre-punch paper with 3 holes, if paper tear/JAM and horizontal line at 60mm from bottom edge occur, please take the following measure.

[Restriction when using 3-hole pre-punched pap er] Please kee p and perform the following restrictions when using 3-hole pre-punched paper even if performing

the corrective measures.

1.The length of the punched hole in the paper feeding directio n o n 3-hole pr e-punch ed paper must be 8mm or less.

 If the punching hole is longer than 8mm in lengthwise, the leading edge of the actuator switching the

switchback sens o r falls down the center hole o f th e paper when turning over the paper in duplex printing and as the result, the punched hole may be torn or the paper jam may occur.

(Phenomenon 1: Tear/jam of the paper at the switchback section)

2.The distance between the hole of 3-hole pre-punched paper and the paper rear end must be 15mm or less.

 If the punched hole is farther than 15mm from the paper rear end, the interval to the next fed paper

becomes short and then the regist drive stops though the paper doesn’t pass through yet. As the result, the horizontal line a p p ears on the image. (Phenomenon 2: Horizontal line on the image of the paper rear side.)

3.Don’t eject 3-hole pre-punched paper to the JS-731 (right job separator).

 The JAM 470x/471x may occur due to chattering of the fuser eject sensor if trying to eject 3-hole pre-

punched paper to the JS-731.

Page 46

1. Check whether the positioning of bridge conveying-in unit is inserted into the positioning hole of the drive unit.

 If it is not inserted into the positioning hole.

ａ.While being careful not to contact with the tray in following fig, insert the

positioning boss of AK conveying-in unit into the positioning hole of the drive unit.

Positioning with the drive unit

Contact part of the tray

If J49XX/J50XX/J51XX/J600X occurs, check the following item 1 to 7.

2. Check whether the positioning hole of the bridge drive un it is damaged.

 If it is damaged, replace the AK drive unit (following item number.)

Broken

Normal

No. Old New item number Parts name Q’ty 1

303NB94200 PARTS DRIVE UNIT SP

J49XX / J50XX / J51XX / J600X (1/9)

Page 47

3. Check the positioning cutout part (red circle at below fig.) at the left slider section of the bridge conveying unit is fitted to red round mark on the slider section.

■Affected machine’s serial number is below

№ Old New Parts No Parts name Q’ty 1 302LF28770

2LF28770

SHEET HINGE STOPPER

(Right) (Wrong)

Clearance

4. Check whether the leverage of upper conveying guide on the bridge conveying unit is not detached.

 if it is detached, add the below parts as referring the procedure mentioning next page.

【Service Bulletin】2LF-0004(B355)

Refer to the service bulletin：2LC-0034(B395)

[Conveying unit fixing]

AK eject unit slide rail

AK carry-in unit

Machine front side

J49XX / J50XX / J51XX / J600X (2/9)

8000i

KDA CPY KDA GSA KDBR KDA 220V I KDE UTAX OLIVETTI

1102LF2US0 1102LF2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 1102LF3LV0

From nex t From next

production produc tion

KDAU KDCN KDKR KDTW KDSG

1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0

From nex t

production

6500i

KDA CPY KDA GSA KDBR KDA 220V I KDE UTAX OLIVETTI

1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 1102LG3LV0

From nex t From next

production

KDAU KDCN KDKR KDTW KDSG

1102LG3AS0 1102LG3KS0 1102LG3KR0 1102LGTTW0 1102LG3SG0

From nex t (-->)

production NJR2100003

N4U1Y00818

NHG1Y00207

NHH1Y00006

N4V1Y00423

N4X1Y00183

NK21Y00021

NKQ1Y00021

NMR1Y00009

NJL1Y00084

N4P1X00646

NHE1X00173

NHF1X00011

N4Q1X00421

N4S1X00067

NK11X00024

NKP1X00011

NMQ1X00013

(-->)

NJQ2100002

NJK1X00073

Page 48

■The film attached procedure

J49XX / J50XX / J51XX / J600X (3/9)

Page 49

5. Check the material of roller at the bridge conveying-in unit (Fig.1)  If it is old type shown in right fig, replace the roller.

Fig 1

№ Old New Item Number Parts Name Q’ty 1 302LF94010

2LF94010

PARTS ROLLER RELAY MIDDLE SP

2 302LF94030

2LF94030

PARTS ROLLER RELAY EXIT SP

■ Affected machine’s serial number is below

【Service bulletin】3NB-0001(B235)

J49XX / J50XX / J51XX / J600X (4/9)

Page 50

7. Check whether the screw fixed boss, positioning boss of the Rail installing section at the bridge

relay exit unit is broken.  If it is broken, replace the relay exit unit.

No. Old New Parts No Parts name Q’ty 1 303NB94174

3NB94174

PARTS RELAY EXIT SP 1

6. Check there is any breakage at the hook hang part of the bridge relay exit unit. (Right fig.)  If it is broken, replace the relay exit unit.

No. Old New Parts No Parts name Q’ty

303NB94174 3NB94174

PARTS RELAY EXIT SP

【Service bulletin】2LC-0034(B395)

J49XX / J50XX / J51XX / J600X (5/9)

Page 51

8. Check the bushin g o f th e Bridge Exit Unit (Fig.1)  If it is old type shown in right fig, replace the bushing according

to the replacement procedure (refer to the next page).

Fig 1

№ Old New Item

Number

Parts Name Q’ty

1 302K324450

2K324450

BUSH 6 6

■ Affected machine’s serial number is below

【Service bulletin】2LC-0059(C038)

J49XX / J50XX / J51XX / J600X (6/9)

8000i

KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX

1102LF2US0 1102LF2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 N4P1600107 NHE1600041

1st production NJE1600001 NHF1700001 N4Q1500041 N4S1500001

OLIVETTI KDAUS KDCN KDKR KDTW KDSG

1102LF3LV0 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0 NK11600001 N4R1600012 NKP1800001

NMQ1700001 NJQ1900001 NJK1500001

6500i

KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX

1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 N4U1500102 NHG1500021 1st production

NJD1500001 NHH1700001 N4V1500021 N4X1500001

OLIVETTI KDAU KDCN KDKR KDTW KDSG

1102LG3LV0 1102LG3AS0 1102LG3KS0 1102LG3KR0 1102LGTTW0 1102LG3SG0 NK21600001 N4W1500001 NKQ1800001 NMR1700001 NJR1900001 NJL1500001

Page 52

■Replacement procedure for the bushing

J49XX / J50XX / J51XX / J600X (7/9)

Page 53

9. Check whether the check whether the paper conveying guide fulcrum for the bridge exit unit has separated or n o t. (fig.1).

 If it is separated, install the following parts （Fig 2) a. install it to the front and rear stay while holding the upper cover of exit unit. b. Check whether the paper conveying guide does not come off and the fulcrum parts is not separated.

Fig 1

№ Old New Parts Items Parts Name Q’ty

1 302LF28240

2LF28240

GUIDE RELAY EXIT RIGHT

【Service Bulletin】2LC-0015(B221)

Fig 2

J49XX / J50XX / J51XX / J600X (8/9)

Page 54

10.Check whether the rib (blue color round mark on the right fig) of the conveying guide of the bridge exit unit is broken or not.  In case of breakage, replace the below part No.1 to 3 as referring to the service bulletin “2LC-0068(C076)

11. After performing above items 1 to 10, JAM still occurs, replace the bridge conveying unit, bridge relay exit unit.

*Bush ⇒ Bearing

No. Old New Parts No Parts name Q’ty 1

303NB94241 3NB94241

PARTS GUIDE UPPER UNIT SP

２

303NB94174 3NB94174

PARTS RELAY EXIT SP

No. Old New Parts No Parts name Q’ty

1 303NB94174

3NB94174

PARTS RELAY EXIT SP 1

2 302LF28621

2LF28621

+PLATE REINFORCEMENT EXIT

3 302LF28840

2LF28840

+SPRING-COMPRESSION RELAY EXIT

【Service bulletin】2LC-0068(C076)

J49XX/J50XX/J51XX/J600X (9/9)

【Service bulletin】2LC-0059(C038)

Page 55

1. Add the films to the holes (2 locations )on the conveying unit. (Fig.1)

Affix the film (No.1) to the designated location at fig after

cleaning w her e to affix it on the conveying uni t. ( F i g .2)

No. Old New Parts No Parts name Q’ty 1 302LF28820

2LF28820

SHEET RERAY LOWER

Sample1 Fig 1

Fig 2

【Service bulletin】2LC-0034(B395)

■ Affected machine’s serial number is below

If J6100/J6110 occurs, check the following item 1 to 3.

J6100 / J61 10 (DF) (1/6)

8000i (2LF)

▲K DJ ▲ KDA ▲CPY KDA GSA KDBR ▲KDA 220V ▲ KDE ▲UTAX

1102LF9JP0 1102LF2US0 1102LF2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 N4N2100074 N4P2100809 NHE2100219 NLP NextPdct NextPrdct NHF2100013 N4Q2100481 N4S2100111

▲OL IVETTI KDAU KDCN ▲KDKR ▲K DTW KDSG

1102LF3LV0 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0 NK12100036 NextPrdct NextPrdct NMQ2100022 NJQ2100002 NextPrdct

6500i (2LG)

▲K DJ KDA CPY KDA GSA KDBR ▲KDA 220V KDE UTA X

1102LG9JP0 1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 N4T2100122 N4U1Z00959 NHG1Z00248 NLQ NextPdct NextPrdct NHH2100014 N4V1Z00575 N4X1Z00236

▲OL IVETTI KDAU KDCN ▲KDKR ▲K DTW ▲KDSG

1102LG3LV0 1102LG3AS0 1102LG3KS0 1102LG3KR0 1102LGTTW0 1102LG3SG0 NK22100037 NextPrdct NextPrdct NMR2100017 NJR2100003 NJL2100088

Page 56

J6100 / J61 10 (DF) (2/6)

■Affected machine’s serial number is below

№ Old New Parts No Parts name Q’ty 1 302LF28770

2LF28770

SHEET HINGE STOPPER

2. Check whether the leverage of upper conveying guide on the bridge conveying unit is not detached.

 if it is detached, add the below parts as referring the procedure mentioning next page.

【Service bulletin】2LF-0004(B355)

8000i

KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX OLIVETTI

1102LF2US0 1102LF2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 1102LF3LV0

From nex t From next

production production

KDAU KDCN KDKR KDTW KDSG

1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0

From nex t

production

6500i

KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX OLIVETTI

1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 1102LG3LV0

From nex t From next

production

KDAU KDCN KDKR KDTW KDSG

1102LG3AS0 1102LG3KS0 1102LG3KR0 1102LGTTW0 1102LG3SG0

From nex t (-->)

production NJR2100003

N4U1Y00818

NHG1Y00207

NHH1Y00006

N4V1Y00423

N4X1Y00183

NK21Y00021

NKQ1Y00021

NMR1Y00009

NJL1Y00084

N4P1X00646

NHE1X00173

NHF1X00011

N4Q1X00421

N4S1X00067

NK11X00024

NKP1X00011

NMQ1X00013

(-->)

NJQ2100002

NJK1X00073

Page 57

■The film attached procedure

J6100 / J61 10 (DF) (3/6)

Page 58

2. Replace the GUID E FEED LOWER with the No.1 P ARTS GUIDE FEED ASSY which the No.3 PET Film is attached on.

No. Old Parts No. New Parts No Parts name Q’ty 1 303NB94250 PARTS GUIDE FEED ASSY SP 1 2 303NB07020 303NB07021 +GUIDE FEED LOWER 1 3 303NB07190 +SHEET FEED IN C 2

3. Check whether the paper corner folding or scrat chi ng oc cur s at the Punch unit (Sample1, Sample2)

a. Upgrade the firmware (as set.)

3NB_9200.004.007 and after 3NK_9A00.003.004 and after

b, If the serial number of unit is before below

number, replace the Punch Unit.

PH-7A：N361703776 and after PH-7B：N351700282 and after PH-7C：N371701264 and after PH-7D：NMY1700042 and after

Paper is caught by the convex of welding part at the Punch unit upper guide conveying surface.

Scratch mark

Corner Folding (small fold)

Sample 2

Sample 1

The leading edge of paper (11 inch width rear side) is caught at the hole of Punch unit upper guide plate.

J6100 / J61 10 (DF) (4/6)

Affix it 0 to1mm from R end

Convex

Conveying surface

Page 59

J6100 / J61 10 (DF) (5/6)

4、If the paper stop before the conveying-in roller and there is no damage on paper, check whether the paper

is caught by the STAY PUNCH.

a. Add the PET Films on the middle part of cutout of the STAY PUNCH.

STAY PUNCH

№ Old Parts Item New Parts Items Parts Name Q’ty 1 303NB07140 SHEET ROLLER FEED 2

Adhesive position for Both sided Tape

Adhesive position

Page 60

J6100/J6110 (DF) （6/6）

5. When select A4 paper size at the manual bypass tray, be careful below item. If the actual direction of A4(Let ter)s iz e paper set on the manual by pass tray is not same as setting the direction by

the operation panel, JAM6110 may occur after feeding is started . Therefore, please inst ruct user about the setting method of manual bypass size.

Page 61

J631X / J641X / J650X (1/3)

1. Corner folding at paper leading edge or curling JAM (Image sample 1)

– It occurs since lower curled paper is caught by the cursor. a. Replace the cursor.

2. Paper trail end folding JAM (Image sample 2)

It occurs since the opening of the Bundle discharge unit is (b) slanting or (c) narrower. (b) Correct the balance of the Bundle discharge unit. (Check the front and rear opening balance by both pulleys while opening the Bundle Discharge Unit by executing U240 MOTOR-EjectUnlock(30） (c ) Place the MOUNT PI UPPER GUIDE

(a) Replace the cursor

303NB36031 CURSOR L MIDDLE TRAY 303NB36041 CURSOR R MIDDLE TRAY Affected from：2012 Jan production

Ref.No.3NB-0017(C025)

(b) Correct the Gear mesh

View from main tray side

Inside of process tray (Paper trail end side)

Corner folding

MOUNT PI UPPER GUIDE

Ref.No.3NB-0011(B403)

Image sample1

Image sample 2

3. JAM when the JAM paper occurs at J631* is not existed at the Processing section.

d. Check whether the Actuator (DF middle sensor) is operating smoothly without any problem.

Actuator (DF middle sensor)

DF-790 DF-770

Page 62

4.curling JAM at paper leading edge (Image sample 3)

Due to paper downward curl, the leading edge of paper is round at the inner

part of the process tray and JAM occurs.

a. Please affix the films.

Image sample3

Inside of process tray （Paper tray leading side)

(a)Affix the films 303NC24050 SHEET CONVEYING 2pcs

Ref.No.3NC-0002(C179)

J631X / J641X / J650X (2/3)

Page 63

J631X/J641X/J650X (DF) (3/3)

【Service Bulletin】 3NC-0002（C179）

【Phenomenon】 When ejecting 45 to 50 sheets of paper bundle of A4R or Letter-R, it may bound and the 1st sheet of the next bundle may be caught up at the paper guide. Then, the J6311 jam may occur.

【Hot to respond】 The tension of the spring is increased that pulls up the paper holder guide.

Eject guide (303NB3652-)

Eject roller

Eject pulley

Spring

Paper holder guide (303NB3622

Page 64

J6510 （DF-790 Caut ion of Manual Staple)

【Notes】 When inserting the paper, please make sure that the paper hold hand is away from the paper during staple operation. When you perform the manual staple operations when they hold the paper by hand, paper jam (J6510) will occur.

Please do not perform the manual staple

operating with that held the paper by hand.

Page 65

J6600 (DF-770/790)

1. JAM after paper stops at the paper conveying path (a) The leading edge of paper is caught by the Feedshift guide 1

(b)Paper is fed to the direction2 instead of the direction1.

(a) Check the assembling condition of the Feedshift guide1. Check the shaft of Feedshift guide 1 is firmly inserted into the lever of DF feedshift

solenoid 1. In case of out of location, insert the shaft into level as shown in below photo.

DF feedshift solenoid 1

Feedshift guide 1

Page 66

J6710/J7710（BF)

BF lock lever

ＤＦ fix pin

1. J6710/7710 occurs, t ake the following measure.

a. The JAM paper is stopped before reaching the BF.

No. Old New Parts No Parts name Q’ty 1 303ND02280 303ND02281 FULCRUM PLATE

RELEASE

2 303ND02360 PIN HOOK BOOKLET 2

OLD→NEW

2. DF hook pin

OLD→NEW

1. Fulcrum pin for BF lock lever

Paper stop position

 If the gears are not engaged, replace the fulcrum pin (1) of BF lock lever, DF hook pin (2).

b. Check whether the mesh of gears is not engaged or not after

setting the BF into the DF.

Page 67

J9020/J9030

<Treatment 1> The function can be stopped after setting is OFF.

< Treatment 2> If the user request below demand, Keep U460 set ON and do not stop this detection function. a. Reduce the original damage in case of setting the stapled originals wrongly on DP. b. Prevent missing page due to multi feeding (except DF-771)

Download the firmware higher than Service Upgrade Pack Ver. V3.03

[System menu]  [Common]  [Error handling setting]  [Original skew or multi feeding]

Check firmware version by U019 MAIN：Ver.003.077 MMI ：Ver.003.074

Output the maintenance report from the maintenance mode U000 and if the count of J9020（skew original feed detection))/J9030(muti feeding detection) *1 is frequent, perform below either t reat men t 1 or 2. *1 DP-771 has no

J9030 detection function.

Before Higher

Detect Stop the function

[Stop feeding by error ] [Ignore]

User can be selected whether set on this detection function.

Perform the maintenance mode U460 (Adjust Feed Sensor ) to stop this detection function. <Procedure> (It can be performed when DP is installed.)

[U460 Adjust Feed Sensor]  [DP]  [on/off Config]  [ON  OFF]  [Start

]

Page 68

Check the maintenance report or U903 (JAM counter), check whether bel ow counter are counted up. 8000i/6500i//DP-771： J9010 J901 1 J9110 J9300 J9310 J9400 J9600 DP-770 ： J9010 J9110 J9600 J 9610

Check the DP firmw ar e version at U019 8000i/6500i//DP-771:3M4_9500.007.002 DP-770 : 3NV_9500.005.001

No count Count up

2.J9010 J901 1 J9110 J9300 J9310 J9400 J9600 J9610 occurs, take the following measure.

Download the DP firmware

Before

After

J9010/J9011/J9110/J9300/J9310/J9400/J9600/J9610

Page 69

1.If it occurs at lower tray ejecting , per form below a, b. (at DF-770 install: A tray eject/ at DF-790 installed: A, B

tray eject)

a. Add the films to the holes (2 locations )on the conveying

unit. (Fig.1)

Affix the film (No.1) to the designated location at fig after

cleaning w her e to affix it on the conveying uni t. ( F i g .2)

No. Old New Parts No Parts name Q’ty 1 302LF28820

2LF28820

SHEET RERAY LOWER

Sample1 Fig 1

Fig 2

【Service bulletin】 2LC-0034(B395)

■ Take the measure at the production machines after 2011 Nov.

If Corner Folding occurs at paper , check below item.

Corner Folding (1/6)

Page 70

■Affected machine’s serial number is below

No. Old New Parts No Parts name Q’ty 1 302LF28770

2LF28770

SHEET HINGE STOPPER

b. Check whether the leverage of upper conveying guide on the bri dge conveying unit is not detached.

 if it is detached, add the below parts as referring the procedure mentioning nex t page.

Corner Folding (2/6)

【Service bulletin】 2LF-0004(B355)

Page 71

■The film attached procedure

Corner Folding (3/6)

Page 72

2. If it occurs at ejecting paper to upper tray (at DF-770 ins tal l : B tr ay eject/ at DF-790 installed: C tray eject), replace with new guide (No.1) which is affixed the films or the Relay exit unit (No,2).

No. Old New Parts No Parts name Q’ty

1 303NB94190

3NB94190

PARTS GUIDE RELAY EXIT SHEFT SP

2 302LF94173

2LF94173

PARTS RELAY EXIT SP 1

【Service bulletin 】2LH-0005(B445)

■Affected machine’s serial number is below.

AK-730

右仕様以外

KMKR KTST UTAX/TA OLIVETTI

1703NB0UN0 1703NB0KR0 1703NB0KS0 1703NB0UT0 1703NB0LV0

N341Y17217 NEM1Y00012 NLL2100056 NKM1Y02982 NKH1Y00215

KDA CPY KDA CPY

1102LJ2US2 1102LJ2CS1 1102LH2US2 1102LH2CS1 NWQ1Y00001 NWP1Y00001 NWN1Y00001 NWM1Y00001

▲TASKalfa4500i (AK)

▲TASKalfa5500i (AK)

Corner Folding (4/6)

Page 73

Corner Folding (5/6)

Page 74

Corner Folding (6/6)

Page 75

Perform above service bulletin measurement contents.

If the paper creasing like a below image occu rs f r equ ent l y, check as referring to below procedure.

Paper Creasing (1/2)

Ref.No. 2LC-0013(B213)

<Check the image sample> On the image sample of creased paper, spread out the creased part and check if toner is not transferred to the creased

If the paper is above creasing condition, check whether modified guide below photo is equipped or not.

YES

Add the modification guide (refer to next age for i nstal l ati on)

■ PARTS REGIST GUIDE SET SP (No1) components parts---A to D

No.

Old Part

No.

New Part

No.

Description

Q’ty

Old New

1 ----------

302LC94690

2LC94690

PARTS REGIST GUIDE SET SP

- 1

Page 76

[The procedures to install the guide]

1. Remove the conveying unit.

2. Remove 2 of the screws that fix the middle feed plate.

3. Remove the middle feed plate after rotating it downward as in the figure right.

4. Overlay the film (A) bundled in the parts set (No.1) on the film (X) affixed on the paper senor as shown in figure.*Clean where to affix the film.

Fold the leading edge of the film (A) and affix it

toward inner side using a flat-blade

screwdriver, etc. [Note] Take care of the tool not to touch the paper

sensor. Securely fold the film or mis-sensing may occur.

<Note> Check if the film is not warped toward Z before fitting the guide (C) (No.2). If warped so, correct the warpage.

6. Fit the middle feed plate (B)

7.Put the guide (C)(No.2) on the middle feed plate (B) and fix them with M3x10 screw (D)(Total 2 points) *Check the guide (No.2) does not run over the emboss

Paper Creasing (2/2)

Page 77

BF-730/720/710 Measure for Paper creasing when a sheet of

paper is fed after middle folding

【Phenomenon】 When center-folding or tri-folding one sheet of paper with the downward bending (toward the CF blade side) at its central part, the paper center part of paper may be creased or damaged due to the paper’s bent part pinched up by the CF rollers and the CF blade.

【How to Respond】 When the below phenomenon occurs, please execute the following 1 to 3 in order. １．Set the positions of the paper length guide and the paper width guides in the paper cassette in order to properly fit the paper size.

２．Turn the papers in the paper cassette over and reinstall it. (The grade of the paper’s bending may be slightly improved) ３．Replace the CF blade (303J124142：BLADE MID PRESSING) with the new one.

【Service Bulletin】 3ND-0008（C296）

[Cross-section view of the center-folding unit]

CF rollers

CF blade (No.1): CF blade lifts up to fold the paper (indicated with the blue line in the above figure) when center-folding or tri-folding the paper.

<View from the arrow X> (Before: Below is the state of lifting up the CF blade)

(After)

CF roller

Old CF blade

New CF blade

Protrusion is added

Bent part

Paper

If the CF rollers pinch up the paper's bent part that cannot be passed to the other area due to pressing two points marked Y by

the CF blade lifting up, the paper may

be creased or damaged.

Page 78

C0640 （HDD error）

C0640 display on the operation panel LC D at turning on the main sw.

Check the cable, connecter bet ween H DD and Main PCB. (check poor connection, break, damage <Connect applicable for main PCB>

5500i/4500i/3500i ： YC1、YC27

Replace the cable

Check abnormal sound (rattling sound) during driving HDD

Initialize HDD: *

1. Execute U024.

2. Select “FULL” and start format.

3. Power OFF/ON.

Replace HDD

HDD Item code 5500i/4500i/3500i ：

302LH93070 PARTS STORAGE DEVICE SP

HDD related cable item code： 5500i/4500i/3500i ：

302K946A10 WIRE HDD POWER 302K946A20 WIRE HDD DATA1

* HDD initialize : Stored data in HDD wi l l be erased after this format.

NG NG

Page 79

1. In case of abnormal sound occurs

a. Replace the DLP UNIT . b. Re-assemble it as referring to below attenti on 1.

2. In case of no abnormal sound (developing driv e possible) a. Remove the INNER UNIT. b. Check the CASS SHUTTER of the DLP U NI T. c. If the parts is broken, replace the DLP UNIT.（Fig.1) d. Re-assemble it as referring to below attention 1.

3. In case of not applicable above 1,2. a. It is possible of error at the DLP motor. Check the DLP motor.

C2101(Developing Motor Error)

Normal Break (bend)

CASS SHUTTER

Fig.1

When pushing in the CASS LOCK release LEVER at the INNER UNIT, there is a case not to push in smoothly . In that case, without pushing in by force, re-install the INNER UNIT while shifting it by right-hand side and fix. If it pushes into INNER UNIT forcefully, the lock release cannot be done normally, C2101, C7101, and unusual sound occur again and DLP UNIT may damage.

The measure against below condition was taken after 2011 Oct. production. Therefore, below action is not necessary if the production month is O ct. and after.

attention 1

There is a possibility that DLP is LOCKing by jam in the developing powder outlet etc. (It may be accompanied by the unusual rattling sound lik e no engagement of gears and C7101)

Page 80

C22XX（Drum Motor Error）

If C22XX(drum motor error) occurs, take the following

measure.

a. Remove the DRUM unit from machine. b. Check the drum rotation (refer to Fig1) In case of no rotation, replace the drum unit

 skip to “e”. c. Check rotation of the drum spiral roller (refer to Fig2) In case of no rotation, replace the drum unit,  skip to “e”. d. Replace the engine PCB. e. Check the Firmwar e ver si on and version up to above

Upgrade Pack Ver. V3.03.

<Fig2 Check Spiral Roller Rotation Check whether the spiral roller is rotating when turning the

drum manually.

Spiral roller

<Fig1 Check Drum Rotation> Turn it below direction.

Page 81

1. C510X

Main HVT error

Check the Firmware version and version up to above FW PACK V3.07.

Please check the following a-f, when a problem is not solved. a. Remove the DRUM unit from machine.

b. Check the drum rotation (refer to Fig1) In case of no rotation, replace the drum unit c. Check rotation of the drum spiral roller (refer to Fig2) In case of no rotation, replace the drum unit.

d. Check the poor connection of cleaning lamp connector. e. Replace the HVT PCB. f. Replace the engine PCB.

<Fig2 Check Spiral Roller Rotation Check whether the spiral roller is rotating when turning the drum manually.

Spiral roller

C510X

<Fig1 Check Drum Rotation> Turn it below direction.

Page 82

C6000（Fuser heater broken）,C6030（Fuser thermistor1 broken）, C6050（Fuser thermistor1 low temp error）

C6200（Fuser edge heater broken）, C6230（Fuser thermistor2 broken）, C6250（Fuser thermistor2 low temp

error）

Check whether the contact of fuser unit connection connector is removed.

Check the harness pin at the main machine side is

not removed.

Change harness

Change of cable wiring at

main machine side.

O K

Replace the fuser unit

Change of cable wiring

Check that the contact is not removed while pulling it lightly.

Check YC26 on engine PCB

Check whether version of engine firmware is [2LF_1000.003.083]or after.

O K

Version up the firmware

N G

O K

N G

C6030

Other than C6030

302LH46120

Re-insert

O K

Replace the engine PCB.

O K

N G

Replace the harness between engine

PCB and fuser unit.

Replace the heater PCB.

302H746191

Wire from connector is smoothly aligned

Wire alignment: after

Before

Main machine side harness

Wire alignment: before

Access saddle relocated

After

For 3500i/4500i/5500i

Page 83

C6020/C6220（Abnormal high temperature detected by Fuser thermistor）

Check whether the version of engine firmware is [2LF_1000.003.083]or after.

Version up firmware

N G

O K

N G

O K

YC26

C6020

C6220

302H746191

If C6020/C6220 occurs, take the following measure.

Check the poor connection on the engine PCB YC26

Check the poor connection between the fuser unit and main unit connection part.

Replace Fuser unit

Replace the engine PCB OK

OK NG

Replace the harness between the engine PCB and Fuser unit.

OK NG

For 3500i/4500i/5500i

Page 84

C6020 (Abnormally high fuser thermistor 1 temperature)/C6030（Broken fuser

thermistor 1 wire）/The fuser press roller may melt and stick./Poor Fusing

Please be required following the below cases such as C6030/C6020/The fuser press roller may fuse and stick./The fuser failure.

１．Please upgrade the firmware to the Upgrade Pack Ver.V3.07 or later. ２．When the phenomenon is not cleared even if upgrading, please replace with the new fuser

unit as below.

FK-6305（100V）：302LH93042～ FK-6306（120V）：302LH93052～ FK-6307（220V）：302LH93062～ FK-6307（CHN）：302LH9C062～ FK-6307（KR）：302LH9K062～ FUSER 110 H UNIT（TW）：302LH93082～

For 3500i/4500i/5500i

【Service bulletin】 2LH-0011(C172)

Page 85

C6030(Fuser thermsitor 1 broken), C6050 (Abnormal l ow temperature

detected by Fuser thermistor 1)

Check whether the engine firmware Is above [Upgrade Pack Ver. V3.06]

Firm Version UP

C6030

Replace the Fuser unit

Replace the engine PCB

C6050

Replace IH PCB

Replace the IH coil

Replace the harness between the engine PCB and the fuser unit.

Check whether the voltage drop occurs (NG less 70V during operation)

Change the power code connection.

Item code for harness 6500i/8000i :302K946590

OK NG

Page 86

C6600/C6720

Check whether the fuser belt is broken.

YES

Judge the fuser belt slackness as referring to content of right fig. (Fig.1)

“Take a measure for “a.”

(refer to next page)

Error

Take a measure for “a.” ”b.” (refer to next page)

Normal

“Take a measure for “c.” (refer to next page)

FRONT

REAR

Check the slackness of belt tension at FRONT/REAR.

Normal

Error (Breakage of bearing)

about 6ｍｍ

About 3ｍｍ

■If the bearing is broken, the slackness of belt tension becomes large and above clearance is increased.

Procedure the check the fuser belt slacking condition

Fig 1

If C6600/C6720 o ccu rs, acco rd in g t o the below checking procedure, find the solution for a to c.

C6600（Fuser Belt Rotation Error）/C6720（Fuser IH Belt

Rotation Error）/Fuser Belt Failure

For 6500i/8000i

Page 87

b. Check the machine’s serial number whether its number is before taking the measure (use the jig to adjust the fuser position plate) during the production.

If the machine’s serial number is before affected number, perform the correctiv e measure as referring to the serv ic e bulletin No. 2LF-0003 (B345).

1) Check the fuser belt shift amount according to the content of the bulletin and judge whether i t is necessar y to affix the film or not.

2) If affixing the film is necessary , af fix ing t he film to the fuser position adjust ment plate and adjust the height. <Affected machine’ s serial number for taking the measure during the production>

a. When replacing the fuser unit, it exchanges for the fuser unit applicable to the end of the right figure.

Mo del spec Par t No . Description Mode l spec Part No. Description

100V

302K993115 FK-8705

100V

302LF93045 FK-6705

120V

302K993125 FK-8706

120V

302LF93055 FK-6706

200V

302K993135 FK-8707

200V

302LF93065 FK-6707

KDKR

302K99K135 FK-8707(KR)

KDKR

302LF9K065 FK-6707(KR)

Mercury

(TASKalfa 7550ci/6550ci)

Zeus

(TASKalfa 8000i/6500i)

C6600（Fuser Belt Rotation Error）/C6720（Fuser IH Belt Rotation Error）

/Fuser Belt Failure

For 6500i/8000i

Page 88

【How to check the unexecuted machine in the production line of the belt edge at failure】

C6600（Fuser Belt Rotation Error）/C6720（Fuser IH Belt

Rotation Error）/Fuser Belt Failure

No (A or later)

Yes

Whether the machine serial

number is less than A?

Yes (Less than A)

Whether the fuser belt

edge was torn?

Adjust MOUNT FUSER JOINT using the tool.

Check Serial Number A of the main machine. (Refer to the next page.)

Finish

Adjust MOUNT FUSER JOINT using the tool.

Finish

Flange key gets under the U-shape groov e of the heat roller or is raised.

Yes

The fuser belt edge is torn.

Is the fuser belt edge

repeatedly torn after

adjustment?

Replace the fuser unit with “5” or later of the last digit parts number.

Check the amount of the fuser belt stepping aside.

Finish

Yes

Does the fuser belt shift

0.3mm or less?

Check the amount of the fuser belt stepping aside.

Yes

Does the fuser belt shift

0.3mm or less?

Is the fuser belt edge repeatedly

torn after adjustment?

Finish

(-->)

Yes

(-->) No

For 6500i/8000i

Page 89

C6600（Fuser Belt Rotation Error）/C6720（Fuser IH Belt

Rotation Error）/Fuser Belt Failure

Step Checking contents

Detach the fuser unit and then check whether the flange keys of the machine front and rear side do not get under the inside heat roller and whether the flange key is not raised due to being pressed by the heat roller. (-->) (Note) Please shift the fuser belt aside when checking whether the flange keys do not get under the inside heat roller. Please refer to Step 5 and 6 in Sheet 5) for details of the way to shift the fuser belt.

(Attention) If the heat roller is hot, please cover it with cloth instead of directly touching it by hand.

Machine rear side

Normal

Flangekey

Heat roller

State that the flange key is r aised due to being pressed by the heat roller.

Rotating direction

of the heat roller

State that the flange key gets under the inside heat roller.

Machine

front side

Heat roller

Flangekey

Heat roller

For 6500i/8000i

Page 90

YC26（Engine PCB）

C6720 occurs due to poor connection

Identify the measured fuser unit (PI poor contact )

Method 1: Change “2” for part of serial no. Method2：Even above number is 1, if the connector color

of PI is white on fuser unit, it has been modified.

White: Modified, black: Not modified

KX8021X02529

Method1

Method2

Item code of harness 6550ci/7550ci :302LF46590 6500i/8000i :302K946590

Check firmware Ver (engine) 6550ci/7550ci : 2K9_1000.004.006 6500i/8000i : 2LF_1000.003.006 Whether it is after above version.

For C6600, IH PCB is not necessary checked. Check as referring to the contents at left.

Check YC4 of IH PCB

Replace the IH PCB

Replace the engine PCB

Replace the harness between the

engine PCB and fuser unit.

C6600/C6720

Check firmware Ver.

Check YC26 of Engine PCB

OK NG

Check the fuser unit (left lower fig.) Re-connect

Replace the fuser unit

NG OK

Firmware Version Up

C. Perform below checking.

C6600（Fuser Belt Rotation Error）/C6720（Fuser IH Belt

Rotation Error）/Fuser Belt Failure

For 6500i/8000i

Page 91

C6620(IH Core Motor rotation Error)

IH core motor

Check whether updated with measured engine firmware. (refer to right Colum)

Install updated firmware

OK NG

Replace Exit PCB (only 6500i/8000i)

Replace the Front PCB

Replace the harness between the Front PCB and

Exit PCB（302LF46140）only 6500i/8000i

Replace Engine PCB

Replace the harness between the Core Motor

and Exit PCB (302LF46100, 302K946140)

Replace the harness between the Front PCB and

Exit PCB（302LF46940,302K946080）

Replace IH unit.

Refer to Fig.1

Check the firmware version (engine) 6500i/8000i : 2LF_1000.003.006

No problem if it is after above version.

C6620

No. Item number Parts name Qt’y Remark 1 302K993150 FK-8709 IH 1 200Vspec 2 302K99C150 FK-8709 IH 1 China spec 3 302K99K150 FK-8709 IH 1 Korea spec

Fig.1

Page 92

C6730

【Phenomenon】 Cooling fan of IHPWB is clogged by dust, cooling efficiency is reduced, C6730 (Fuser IH

substrate temperature error 1) is generated.

【How to Respond】 Clean the cooling fan with a vacuum cleaner.

After

Before (With clogging)

Fan Position

For 6500i/8000i

Page 93

C6770（ IH Fuser Low Power Error）

Check whether Engine firmware version is after the right Colum.

Replace Fuser unit.

Replace IH PCB

Firmware Ver UP

C6770

Replace IH Coil Unit

Check connection of Fuser unit connector (right fig.)

Check the firmware version (engine) 6500i/8000i : 2LF_1000.003.006

Increase withstanding of power noise.

If Fuser unit connector is disconnected, C6770 occurs.

When C6770 occurs after cable of Fuser unit is shorted and broken, while the fuser unit is kept installing without replacing and replacing with new IH PCB first, IH PCB will be damaged. So, replace the IH PCB after replacing the Fuser unit.

Check the connector of Fuser Unit

Page 94

C6910(Engine Firmware Ready Error)

U019 firmware Version

C6910 Check the version of the firmware on the machine.

If the version is older than the following, upgrade the firmware to the latest version.

ENGINE Venus ：2LC_1000.007.0XX Mercury ：2K9_1000.005.0XX Zeus/Gaia：2LF_1000.004.0XX

Check the Engine firmware

version by U019

Page 95

1.In case of abnormal sound occurs

a. Replace the DLP UNIT . b. Re-assemble it as referring to below attention 1.

2. In case of no abnormal sound (developing driv e possible) a. Check the firmware Ver.and version up with most updated one and

replace the DLP UNIT . b. Re-assemble it as referring to below attention 1.

3. In case of no abnormal sound and firmware vers ion is most updated one a. Remove the INNER UNIT. b. Check the CASS SHUTTER of the DLP U NI T. c. If the parts is broken, replace the DLP UNIT.（Fig.1) d. Re-assemble it as referring to below attention 1.

4. In case of not applicable above 1,2.3 a. It is possible of error at the DLP motor. Check the D LP motor.

C7101（Toner Control Sensor Error)

Normal Break (bend)

CASS SHUTTER

Fig.1

The measure against below condition was taken after 2011 Oct. production. Therefore, below action is not necessary if the production month is O ct. and after.

attention 1

If the T/C control is not capable at the DLP or there is a possibility that DLP is LOCKing by jam in the developing powder outlet etc. (It may be accompanied by the unusual rattling sound like no engagement of gears and C7101)

Page 96

C9500/C9510/C9520/C0630/C0640/CF245

SATA cable contact failure

The SATA cable (No.1 to 4) may have contact failure or may be broken if the service call error below appears.

Perform the correctiv e ac ti on bel ow when it arises. <Corrective acti on>

1) Check and perform t he cor r ect ive action for each checkpoint as described in the ser vice manual.

2) If the service call error still appears after the above action, the SATA cable may be broken and replace the applicable cable.

[Image block dropout] (example)

Feed direction

【Service bulletin】2LC-077(C103)

SATA cable to replace

Content of failure No Parts No. Parts name Affected model

- C9500 error

- C9510 error

- C9520 error

- C0630 error

- Scanned image block dropout (Refer to below for the image sample)

1 302K946700* WIRE CCD DATA

5550ci/4550ci/3550ci/30 50ci 5500i/4500i/3500i 7550ci/6550ci 8000i/6500i

2 303M446020

WIRE INTERFACE VIDEO

7550ci/6550ci, 8000i/6500i DP-771

- C0640 error

- F245 error

3 302K946A20* WIRE HDD DATA1

5550ci/4550ci/3550ci/30 50ci 5500i/4500i/3500i 7550ci/6550ci 8000i/6500i

4 302K946A30* WIRE HDD DATA2

5550ci/4550ci 7550ci/6550ci 8000i/6500i

Page 97

“Welcome” Screen Lock

Checking Method

Solution

Welcome Screen Lock ( The screen is not changed more than 3 and half min.)

Check the connection condition of harness and connector Betw een the Panel and Main PCB, between Main PCB and HDD.

1.Check the contact of DDR memory (detach and attac h). (If possible, replac e it.)

1.Check the contact of CODE DIMM (detach and attach). (If possible, r eplace it.)

Replace Panel PCB

Replace Main PCB

<Connector Check Points> (Between Main and Panel I/F)

Main PCB ：YC12、YC17、YC30 Panel PCB：YC1、YC2、YC3 (Between Main and HDD) Main PCB：YC1、YC2、YC27、YC32

<Note> At appearance of CF000, if Panel LED is “light up” as stating right, DDR2 failure might be the cause. Check the contact between YS1 or YS2 and this DDR memory.

Memory LED  Light Up Attention LED  Light Up

Welcome Screen Lock ( CF000 appears after 3 and half min.)

Replace Main PCB

Replace Panel PCB

Check whether Panel Main PCB is

recovered by Boot mode.

Product

Item Name Item Number Item Name Item Number

MAIN PCB PARTS PWB MAIN ASSY SP 302LH9414* PARTS PWB MAIN ASSY SP 302LF9417*

PARTS PWB MAIN ASSY SP EU 302LH9415* PARTS PWB MAIN ASSY SP EU 302LF9418*

PANEL PCB PARTS PWB PANEL MAIN ASSSY SP 302LC9425* PARTS PWB PANEL MAIN ASSSY SP 302K99484*

PARTS PWB PANEL MAIN ASSSY J SP 302LC9426* PARTS PWB PANEL MAIN ASSSY J SP 302K99485* PARTS PWB PANEL MAIN ASSSY TW SP 302LC9456* PARTS PWB PANEL MAIN ASSSY TW SP 302K994B2* PARTS PWB PANEL MAIN ASSSY CN SP 302LC9457* PARTS PWB PANEL MAIN ASSSY KR SP 302K994B4* PARTS PWB PANEL MAIN ASSSY KR SP 302LC9458* PARTS PWB PANEL MAIN ASSSY KS SP 302K994B3* PARTS PWB PANEL MAIN ASSSY KS SP 302LC9463*

3500i/4500i/5500i

6500i/8000i

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CF040（Communication Error between the Main

PCB and Engine PCB）

Whether aging dr i ve is starts or not after closing the cover.

Check the short cir cui t of harness for 5V or 3.3V

connected to the Engi ne PCB and recover the

fault wire.

Replace Engine PCB

Main PCB YC3

Re-insert the FFC

connector

Re-insert the Engine PCB FFC connector （YC46）

Replace FFC

Replace Main PCB

Replace Engine PCB

Replace HDD

OK OK

FFC item code： 5500i/4500i/3500i ： 302K946A00 WIRE FFC MAIN-ENGINE

If CF040 occurs, take the following measure.

Product

Item Name Item Number Item Name Item Number

MAIN PCB PARTS PWB MAIN ASSY SP 302LH9414* PARTS PWB MAIN ASSY SP 302LF9417*

PARTS PWB MAIN ASSY SP EU 302LH9415* PARTS PWB MAIN ASSY SP EU 302LF9418*

ENGINE PCB PARTS PWB ENGINE ASSY SP 302LH9417* PARTS PWB ENGINE ASSY SP 302LF9420* HDD PARTS STO RAGE DEVICE SP 302LH9307* PARTS STORAGE DEVICE SP 302LC9316*

3500i/4500i/5500i

6500i/8000i

Page 99

1. When CF182/CF186 occur after every printing.

1) Check connection of the harness (Engine - Main board) and connectors and check function. *[Main⇔ENGINE Interface] Main board:YC3 Engine board:YC46 or YC50

2) Format the HDD and check function. (U024 FULL formatting)

3) Execute the U021 Memory initializing to initialize the controller backup memory and check function.

4) Replace the engine board and check function.

5) Replace the main board and check function.

6) Retrieve the USBLOG and contact the Service Administrative Division.

2.When CF182/CF186 occur from time to time Add the film to the contact part of the high voltage terminal of the transfer belt unit.

*If the right cover isn’t closed sufficiently, the contact failure (leakage) may occur due to the wide gap between the high voltage

terminals at the right cover and the transfer belt. As the result, the F186 error may appear due to the misdetection of the inter-lock switch caused by the noise that is generated by unstable transfer voltage.

Item ：302LF22670 SHEET CONTACT TRANSFER 1set

CF182/CF186

【Service bulletin】2LH-0010（C128）

Page 100

a. Replace the DLP UNIT . b. Re-assemble it as referring to below attention 1.

Abnormal Sound from Developing Section

The measure against below condition was taken after 2011 Oct. production. Therefore, below action is not necessary if the production month is O ct. and after.

attention 1

There is a possibility that DLP is LOCKing by jam in the developing powder outlet etc. (It may be accompanied by C2101 and C7101)

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