Xerox WorkCentre 5022, WorkCentre 5024 Service Manual

Xerox® WorkCentre 5022/5024

Service Manual

Revised June 2014 702Pxxxxx

WC 5022/5024

Service Documentation

WC 5022/5024 Service Documentation

702P02828

Version 1.0

06/2014

Published by Xerox. 800 Phillips Road, Webster, NY 14580

© 2014 by Xerox Co. All rights reserved. Xerox® and all identifying numbers used in connection with the Xerox products mentioned in this publication are trademarks of the Xerox Corporation.

***Xerox Private Data***

All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product-trained service personnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or modules, components, or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third-party provided service.

Xerox

While Xerox has tried to make the documentation accurate, Xerox will have no liability arising out of any inaccuracies or omissions.

WARNING

This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to subpart J of part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user, at his own expense, will be required to correct the interference.

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Chapter 0 Introduction

0 Introduction

0.1	Getting to know this Service Manual........................................................................	0-3
0.2	How to use the Service Manual ...............................................................................	0-3
0.3	Description for Terminology And Symbols ...............................................................	0-4

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0.1 Getting to know this Service Manual

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

•Publication Comment Sheet

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

Solution Service & Operational Management CS Dept.

0.2 How to use the Service Manual

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

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

0.2.1 Contents of Manual

This manual is divided into 10 chapters as described below.

•Chapter 1 Service Call Procedure

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

•Chapter 2 Troubleshooting

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

•Chapter 3 Image Quality Troubleshooting

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

•Chapter 4 Disassembly/Assembly and Adjustment

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

•Chapter 5 Parts List

This chapter contains the spare parts information for this product.

•Chapter 6 General

This chapter contains the following information.

6.1Specifications

6.2Tools/Service Consumables/Consumables

6.3Service Data

6.5 Service Mode

6.8Fax-related Information

•Chapter 7 Wiring Data

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

•Chapter 8 Accessories (not yet issued)

•Chapter 9 Installation/Removal

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

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

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0.2.2 Information on Updating

This manual will be sent to each Service Center as specified below. Revisions must be incorporated correctly to keep the manual up-to-date.

Updating Procedure:

•When the manual is updated, the issue number 'Ver. 1' will be changed to Ver. 1.1, Ver. 1.2, and so on.

	06/2014	Introduction
		0.1 Getting to know this Service Manual
	0-3

0.3 Description for Terminology And Symbols

The terms and symbols used throughout this manual are explained here.

•The terms and symbols used at the beginning of a text are defined as follows:

WARNING

Indicates an imminently hazardous situation, such as death or serious injury if operators do not handle the machine correctly by disregarding the statement.

WARNING

Indicates a potentially hazardous situation, such as death or serious injury if operators do not handle the machine correctly by disregarding the statement.

CAUTION

Indicates a potentially hazardous situation, such as injury or property damage if operators do not handle the machine correctly by disregarding the statement.

Instruction: Used to alert you to a procedure which, if not strictly observed, could result in damage to the machine or equipment.

NOTE: Used when work procedures and rules are emphasized.

Used when other explanations are given.

Used to describe the purposes of Adjustment and Troubleshooting.

REP: Indicates the disassembly/assembly procedure for reference.

ADJ: Indicates the adjustment procedure for reference.

PL: Indicates the parts list for reference.

Terminology

	Table 1 Terminology
Terminology	Description
Assy	Means Assembly.
TEC Value	Abbreviation of Typical Electricity Consumption, which means the stan-
	dard power consumption. Read as 'tec'.

Installation of any part other than the ones designated by Xerox shall be strictly prohibited because it cannot be guaranteed in quality and safety.

Important Information Stored Component (ISC)

This component stores all the important customer information that is input after the installation. When performing replacement, follow the procedures in 'Chapter 4 Disassembly/Assembly and Adjustment' to replace/discard. Make absolutely sure that no customer information gets leaked outside.

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		0-4

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Chapter 1 Service Call Procedures

1 Service Call Procedures

1.1 Before Starting the Servicing ...................................................................................

1-3

1.2 Service Call Procedure

1.2.2 Service Call Procedure .........................................................................................		1-5
1.3	Detailed Contents of the Service Call ......................................................................	1-5
1.4	TRIM Check List.......................................................................................................	1-6
1.5	Periodic Replacement Parts/Consumables List .......................................................	1-6

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1.1 Before Starting the Servicing

1.1.1 Safety

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

1.Power Supply

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

2.Drive Area

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

3.Heavy Parts

Position your hip lower when removing or installing heavy parts.

4.Safety Device

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

5.Installing and Removing Parts

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

6.CAUTION:

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

7.Specified Tools

Follow the instruction when a tool is specified.

8.Cleaning the Toner and Developer

11.Harmful Laser

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

As the toner can be explosive, sweep or brush the spilled toner into a container for collecting the sweepings.

Clean away the remaining toner with a damp cloth or use a standard vacuum cleaner that is toner-tolerant. Never use the customer's vacuum cleaner.

Do the same when cleaning the Developer because it also contains some toner.

9.Organic Solvents

When using an organic solvent such as the Drum Cleaner or Machine Cleaner, pay attention to the following:

•Ensure good ventilation in the room to prevent too much inhalation of solvent fumes.

•Do not use heated solvent.

•Keep it away from fire.

•Wash your hands thoroughly after use.

10.Modifications to the Machine

Before altering the machine, submit the irregular use license application.

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1.1.2 Things to Take Note When Handling Customer Information

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

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

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

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

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

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

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

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

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

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

1.1.3 Other Precautions

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

1.Reference Materials

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

2.Disassembling

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

3.Installation/Adjustment

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

4.Handling of replaced parts/consumables

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

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

• Drum Cleaner

WARNING

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

5.General Precautions

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

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

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

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

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1.2.2 Service Call Procedure

1.2.2.1 Initial Actions

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

2.Record the billing meter readings.

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

4.Check the Service Log.

1.2.2.2 When UM is requested, perform the following:

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

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

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

4.Check the copy quality.

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

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

a.Press the <Machine Status> button.

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

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

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

6.Repair all the secondary problems.

7.Perform TRIM Service.

1.2.2.3 When SM is requested, perform the following:

1.Check the copy quality.

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

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

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

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

3.Perform TRIM Service.

1.2.2.4 Final Actions

1.Check overall operation/features.

2.Check the machine exterior and consumables.

3.Train the operator as required.

4.Complete the Service Log and Service Report.

5.Keep the copy samples with the Service Log.

1.3 Detailed Contents of the Service Call

1.3.1 Initial Actions

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

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

•How is the copy quality

2.Record the copy meter readings.

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

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

1.3.2 Checking Reproducibility of Problem

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

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

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

1.3.3 Checking Copy Quality

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

1.3.4 TRIM Servicing

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

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

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

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1.4TRIM Check List

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

O:Always perform cleaning and checking.

*: Always perform replacement service at the specified interval.

				Table 1
		Every
No.	Servicing Items	time	Service Details
1.1	Pre-servicing Check	C	•	Activate the machine and check that abnormal
	(Check the machine			noise is not heard.
	operation sound)
1.2	Pre-servicing Check	C	•	Make several sheets of copies using the Test
	(Copy and print the			Chart (499T 00247), then check the quality of the
	Test Chart)			copies.
2	Clean the interior of	C	•	Clean any paper dust and toner residue in the
	the machine			paper path and on the jam sensor.
	(Clean the paper		•	Especially, clean the operation section of the
	transport system)			operator carefully.
3	Cleaning the IIT	C	•	Clean the Platen Glass surface and the Platen
				Cushion with the optical cleaning cloth.
4	Clean the DADF	C	•	Clean the Feed Roll, Nudger Roll, and Retard Roll
				with a cloth that has been wrung dry.
			•	Clean the DADF Platen Glass with the optical
				cleaning cloth.
5	Safety Check	O	•	Make sure that the power plug is plugged in prop-
				erly.
			•	Make sure that the power cords are not cracked
				and no wires are exposed.
			•	Make sure that no extension cord with insufficient
				length or power cord outside the specification,
				such as an off-the-shelf power strip, is being used.
			•	Make sure that a single socket does not have mul-
				tiple power plugs plugged into it.
6.1	Post-servicing check	C	•	Make several sheets of copies using the Test
	(Copy Quality Check)			Chart (499T 00247), then check if the quality sat-
				isfies the specification.
6.2	Post-servicing check	C	•	Check the paper feed and abnormal noise.
	(Check the machine
	operation)
6.3	Post-servicing check	C	•	Create the Service Log and Service Report.
	(Check the meter)

1.5 Periodic Replacement Parts/Consumables List

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

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

CAUTION

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

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

Table 1

		HFSI
	Parts/Consumables Name/	[Chain-	Replacement
No	PL No.	Link]	Interval	Check the counter
1	Tray 1 Feed No.	950-803	50,000PV	1 Feed = 1 Count Up.
	Tray 1 Feed Roll / Retard			Replace both at the same
	Pad			time.
	(PL 9.2)
2	Tray 2 Feed No.	950-804	300,000PV	1 Feed = 1 Count Up.
	Tray 2 Feed Roll/Nudger			Replace all 3 at the same
	Roll/Retard Roll			time.
	(PL 10.3)
3	Tray 3 Feed No.	950-808	300,000PV	1 Feed = 1 Count Up.
	Tray 3 Feed Roll/Nudger			Replace all 3 at the same
	Roll/Retard Roll			time.
	(PL 11.3)
4	Tray 4 Feed No.	950-809	300,000PV	1 Feed = 1 Count Up.
	Tray 4 Feed Roll/Nudger			Replace all 3 at the same
	Roll/Retard Roll			time.
	(PL 11.3)
5	MSI Feed Count	950-802	50,000PV	1 Feed = 1 Count Up.
	MSI Feed Roll/MSI Nudger			Replace all 3 at the same
	Roll/MSI Retard Pad			time.
	(PL 13.3)
6	Fusing Unit	950-801	175,000PV	1 pass through the Fusing
	(PL 7.1)			Unit Exit Sensor = 1 Count
				Up.
7	BTR Unit	950-800	100,000PV	1 pass through the Fusing
	(PL 6.1)			Unit Exit Sensor = 1 Count
				Up.

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Table 1

		HFSI
	Parts/Consumables Name/	[Chain-	Replacement
No	PL No.	Link]	Interval	Check the counter
8	Document Feed No.	955-806	200,000PV	Replace the Feed Roll,
	DADF Feed Roll/Nudger Roll			Nudger Roll, and Retard Pad
	(PL 56.5)			at the same time.
	DADF Retard Pad			NOTE: Clean the Platen
	(PL 56.13)
				Glass with a Platen Wax
				Cleaner 499D 00914 (194D)
				every 10K Feeds.
9	Toner Cartridge	-	9,000PV
	(PL 8.1)
10	Low Capacity Toner Car-	-	5,000PV
	tridge
	(PL 8.1)
13	Drum Cartridge *1	950-807	343k cycle
	(PL 8.1)		66,000PV
			(22PPM)
			78,000PV
			(24PPM)
15	Cartridge Guide	-	300,000PV
	(PL 8.2)

*1 As the PV may differ greatly from the target value depending on the usage conditions, it should only be regarded as a reference value.

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Chapter 2 Troubleshooting

					2 Troubleshooting
	2.1 Introduction			CHAIN 10
	2.1.1	How to Troubleshoot .............................................................................................	2-5	010-311	Fusing Unit Center Thermistor Defect..............................................................	2-27
	2.1.3	Glossary ................................................................................................................	2-5	010-312	Fusing Unit Rear Thermistor Defect.................................................................	2-27
	2.2 Product FIP			010-320	Over Heat Temperature Fail ............................................................................	2-28
				010-327	Fusing Unit On Time Fail	2-28
	2.2.1 Level 1 FIP			010-379	Fusing Unit Hot Not Ready Return Time Fail...................................................	2-29
				010-392 NOHAD Fan Defect		2-29
	2.2.1.1 Level 1 FIP		2-7
				010-602 Over Temp Cooling Mode		2-30

2.2.2 Level 2 FIP

CHAIN 3

003-500 N-Up NG Out Of Range ...................................................................................		2-9
003-754 IPS Overrun .....................................................................................................		2-9
003-795 AMS NG Out Of Range....................................................................................		2-10
003-942 Not-Supported Doc Size ..................................................................................		2-10
003-956	Not-Supported Doc Size ..................................................................................	2-11
003-963	APS NG Out Of Range ....................................................................................	2-11
003-972	1Job Max Page Over .......................................................................................	2-12
003-973	Auto Rotation NG Out Of Range......................................................................	2-12

CHAIN 4

004-345 HVPS Communication Error ............................................................................

2-13

CHAIN 5

005-122 DADF Simplex/Side 1 Pre Regi Sensor On Jam .............................................	2-15
005-123 DADF Simplex/Side 1 Regi Sensor On Jam....................................................	2-15
005-125/145 DADF Regi Sensor Off Jam/ DADF Regi Sensor Off Jam on Inverting....	2-16
005-131/132 DADF Invert Sensor On Jam on Inverting/ DADF Invert Sensor On Jam.	2-16
005-134/139 DADF Invert Sensor Off Jam on Inverting/ DADF Invert Sensor Off Jam.	2-17
005-135 DADF Side 2 Pre Regi Sensor On Jam ...........................................................	2-17
005-136 DADF Side 2 Regi Sensor On Jam..................................................................	2-18
005-147 DADF Pre Regi Sensor Off Jam on Inverting ..................................................	2-18
005-196 Size Mismatch Jam on No Mix-Size ................................................................	2-19
005-197 Prohibit Combine Size Jam..............................................................................	2-19
005-198/199 Too Short Size Jam/ Too Long Size Jam .................................................	2-20
005-210 DADF Download Fail .......................................................................................	2-20
005-275/280 DADF RAM Test Fail/ DADF EEPROM Fail .............................................	2-21
005-305 DADF Feeder Cover Interlock Open................................................................	2-21
005-500 DADF Download Flash Write Error ..................................................................	2-22
005-907/908/913 DADF Pre Regi Sensor/DADF Regi Sensor/DADF Invert Sensor Static Jam
2-22
005-940 DADF No Original Fail .....................................................................................	2-23
005-948 SS-Size Mismatch Jam on No Mix-size ...........................................................	2-23

CHAIN 7

007-270	Tray 1 Paper Size Switch Broken ....................................................................	2-25
007-272	Tray 3 Paper Size Switch Broken ....................................................................	2-25
007-273	Tray 4 Paper Size Switch Broken ....................................................................	2-26

CHAIN 16

016-346	Fax Parameter Incorrect ..................................................................................		2-31
016-372	File Access Error..............................................................................................		2-31
016-500	Controller Download Flash Write Error ............................................................		2-32
016-501	Controller Boot Flash Write Error .....................................................................		2-32
016-502	UI Panel Download Flash Write Error ..............................................................		2-33
016-504	UI panel Font Download Flash Write Error ......................................................		2-33
016-570 No Response from USB-Host for Scan Job .....................................................			2-34
016-571 No Response from USB-Host for Print Job......................................................			2-34
016-598 E-mail Message Size Over...............................................................................			2-35
016-742/744		Download File Error/ Download File Check Sum Error .............................	2-35
016-749/799		HBPL or XPJL Syntax Error/ Print Instruction Fail ....................................	2-36
016-759	Copy Counter Full ............................................................................................		2-36
016-764 SMTP Server Connection Fail..........................................................................			2-37
016-765 SMTP Server Disk Full.....................................................................................			2-37
016-766 SMTP Server Limit Over ..................................................................................			2-38
016-768 SMTP Sender Address Error ...........................................................................			2-38
016-776	Marker Code Detection Fail .............................................................................		2-39
016-781 SMTP Server Refusal ......................................................................................			2-39
016-981 EPC Memory Full.............................................................................................			2-40
016-982 SCAN Memory Full ..........................................................................................			2-40
016-985 Max Attachment Size Over ..............................................................................			2-41

CHAIN 17

017-745 SMB Size Over.................................................................................................

2-43

CHAIN 24

024-365 Image Output FIFO Error .................................................................................			2-45
024-910/911/915 Tray 1/Tray 2/MSI Paper Length Mismatch .......................................			2-45
024-912 Tray 3		Paper Length Mismatch ........................................................................	2-46
024-913 Tray 4		Paper Length Mismatch ........................................................................	2-46
024-946 Tray 1		Unknown Paper Size ............................................................................	2-47
024-947 Tray 2		Unknown Paper Size ............................................................................	2-47
024-948 Tray 3		Unknown Paper Size ............................................................................	2-48
024-949 Tray 4		Unknown Paper Size ............................................................................	2-48
024-950	Tray 1 No Paper...............................................................................................		2-49
024-951	Tray 2 No Paper...............................................................................................		2-49
024-952	Tray 3 No Paper...............................................................................................		2-50
024-953	Tray 4 No Paper...............................................................................................		2-50

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024-954 MSI No Paper ..................................................................................................		2-51
024-958/959/960 MSI/Tray 1/Tray 2 Paper Size Mismatch ...........................................		2-51
024-961	Tray 3 Paper Size Mismatch............................................................................	2-52
024-962	Tray 4 Paper Size Mismatch............................................................................	2-52
024-965	APS NG Unselected ........................................................................................	2-53
024-966	APS NG Permission Denied ............................................................................	2-53

CHAIN 26

026-718	D-Fax Instruction Fail.......................................................................................	2-55
026-737	Network Error...................................................................................................	2-55

CHAIN 27

027-518	Forwarding Login Error ....................................................................................	2-57
027-520 SMB Forwarding Bad Volume..........................................................................		2-57
027-522	Forwarding Access Error .................................................................................	2-58
027-528	SMB Disk full....................................................................................................	2-58
027-543 SMB Forwarding Bad Address.........................................................................		2-59
027-779	SMTP Server Login Error.................................................................................	2-59

CHAIN 33

033-313 Fax Board Communication Fail........................................................................		2-61
033-316 Fax Box NVM Data Defect...............................................................................		2-61
033-325 Modem No Response ......................................................................................		2-62
033-326	Fax Controller File Broken ...............................................................................	2-62
033-503 Receive T1 Time Out .......................................................................................		2-63
033-504 T2 Time Out .....................................................................................................		2-63
033-505 T5 Time Out .....................................................................................................		2-64
033-506 DCN Receive ...................................................................................................		2-64
033-507	Unable to receive by remote ............................................................................	2-65
033-509 DIS DCS Illegal Command Receive ................................................................		2-65
033-510	Fallback Error...................................................................................................	2-66
033-517 Timeout ECM Between Frame.........................................................................		2-66
033-526 ECM Send EOR-Q Send .................................................................................		2-67
033-529 RTN Receive....................................................................................................		2-67
033-531 DM Prevention Function Receive Refuse ........................................................		2-68
033-532 Illegal Command Received ..............................................................................		2-68
033-541	No Destination Specified..................................................................................	2-69
033-547 Cancel..............................................................................................................		2-69
033-548 No Manual Send Line Job Cancel ...................................................................		2-70
033-549	Fax Service Disabled .......................................................................................	2-70
033-550 Phone Book Disabled ......................................................................................		2-71
033-567 Fax AddressInfo Sum Check Fail ....................................................................		2-71
033-572 Fax Communication Management Report Full ................................................		2-72
033-577	Control Channel Synchronization Error ...........................................................	2-72
033-578 Primary Channel Off Time Out.........................................................................		2-73
033-711	Fax File System Error ......................................................................................	2-73
033-712	Fax Flash Full ..................................................................................................	2-74
033-725 In receive, memory full (under THRESH_MEMRX) .........................................		2-74
033-753 Fax Scan Page Full..........................................................................................		2-75

CHAIN 34

034-522	No manual send Line .......................................................................................	2-77
034-550	Fax Board Loader Download Fail ....................................................................	2-77

034-711 Fax Send Count Limit.......................................................................................		2-78
034-726	Fax Calling Table Full ......................................................................................	2-78
034-746	Line Connection Fail ........................................................................................	2-79
034-752	Dial Busy ..........................................................................................................	2-79
034-757 Fax Document Does Not Delete ......................................................................		2-80
034-761	Fax Invalid Address book Data are Registered................................................	2-80
034-765	Fax Report Disabled ........................................................................................	2-81

CHAIN 35

035-550 FAX Board Download Flash Write Error ..........................................................		2-83
035-703 DCN Received at Phase B...............................................................................		2-83
035-704	Not Send Ability................................................................................................	2-84
035-708 Post Message Resend Over ............................................................................		2-84
035-728 G3 EOL Not Receive........................................................................................		2-85
035-741 ECM Phase Timeout........................................................................................		2-85
035-748 Fax Card Stopped ............................................................................................		2-86
035-758	Fax Document does not exist...........................................................................	2-86
035-759	Fax Unable to Cancel Operation......................................................................	2-87
035-761	Fax File Open Error..........................................................................................	2-87

CHAIN 36

036-506	V8 Error............................................................................................................	2-89
036-550 FAX Board Loader Download Flash Write Error ..............................................		2-89
036-700 Fax Board Unable Communication ..................................................................		2-90
036-740	Fax Board Busy................................................................................................	2-90
036-777	Control Channel Off Time Out..........................................................................	2-91
036-796	Fax Document Mix Fail ....................................................................................	2-91

CHAIN 41

041-210/211 STM NVM Out-Of-Order/ STM NVM R/W Error........................................

2-93

CHAIN 42

042-325/614 Main Motor Rotation Error/ Main Motor Rotation Warning ........................		2-95
042-400	Smell Life Over.................................................................................................	2-95
042-608	Voc Life Over ...................................................................................................	2-96

CHAIN 45

045-310	Image Ready Error...........................................................................................	2-97
045-313	IOT Logic Fail...................................................................................................	2-97

CHAIN 47

047-218 MCU-2TM Communication Error......................................................................

2-99

CHAIN 61

061-321	ROS Motor Fail ................................................................................................	2-101
061-325	No SOS Fail .....................................................................................................	2-101

CHAIN 62

062-277 DADF Communication Fail...............................................................................		2-103
062-300	Platen I/L Open ................................................................................................	2-103
062-311	IIT Software Logic Fail .....................................................................................	2-104
062-360	Carriage Position Fail.......................................................................................	2-104
062-371/380 Lamp Illumination Fail/ AGC Fail...............................................................		2-105
062-386	AOC Fail...........................................................................................................	2-106

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062-389	Carriage Over Run Fail (Scan End Side).........................................................	2-106
062-396	CCD Cable Connection Fail.............................................................................	2-107

CHAIN 71

071-105 Regi Sensor On Jam (Tray 1) ..........................................................................

2-109

CHAIN 72

072-102 Feed Out Sensor 2 On Jam .............................................................................			2-111
072-105 Regi Sensor On Jam (Tray 2) ..........................................................................			2-111
072-210	Tray 2	Lift Up Fail.............................................................................................	2-112
072-212 Tray 2		Size Sensor Broken ..............................................................................	2-112
072-215	MCU-STM Communication Fail .......................................................................		2-113
072-461	STM NVM Out-Of-Order ..................................................................................		2-113
072-470	STM NVM R/W Error .......................................................................................		2-114

CHAIN 73

073-102	Feed Out Sensor 3 On Jam (Tray 3) ...............................................................	2-115
073-104	Feed Out Sensor 2 On Jam (Tray 3) ...............................................................	2-115
073-105	Regi Sensor On Jam (Tray 3) ..........................................................................	2-116
073-210	Tray 3 Lift Up Fail.............................................................................................	2-116

CHAIN 74

074-101 Feed Out Sensor 4		On Jam (Tray 4) ...............................................................	2-117
074-102	Feed Out Sensor 3	On Jam (Tray 4) ...............................................................	2-117
074-104	Feed Out Sensor 2	On Jam (Tray 4) ...............................................................	2-118
074-105	Regi. Sensor On Jam (Tray 4) .........................................................................		2-118
074-210	Tray 4 Lift Up Fail.............................................................................................		2-119

CHAIN 75

075-135 Regi Sensor On Jam (MSI)..............................................................................

2-121

CHAIN 77

077-101 Regi Sensor Off Jam........................................................................................		2-123
077-103	Fusing Unit Exit Sensor Off Jam (Long) ..........................................................	2-123
077-104	Fusing Unit Exit Sensor Off Jam (Short)..........................................................	2-124
077-106 Fusing Unit Exit Sensor On Jam......................................................................		2-124
077-129 Regi Sensor On Jam (Duplex Wait).................................................................		2-125
077-211 2TM Type Error.................................................................................................		2-125
077-212	Tray Module Reset Fail....................................................................................	2-126
077-300 Front Cover Open ............................................................................................		2-126
077-301 Left Hand Cover Open .....................................................................................		2-127
077-305 2TM Cover Open .............................................................................................		2-127
077-309 STM Cover Open .............................................................................................		2-128
077-900/901/904 Regi Sensor/Fusing Unit Exit Sensor/Feed Out Sensor 2 Static Jam		2-128
077-905 Feed Out Sensor 3 Static Jam.........................................................................		2-129
077-906	Feed Out Sensor 4 Static Jam.........................................................................	2-129

CHAIN 92

092-660/668 ATC Amplitude Fail/ ATC Average Fail.....................................................		2-135
092-661	Temperature Sensor Fail .................................................................................	2-135
092-910	ATC Sensor Fail...............................................................................................	2-136

CHAIN 93

093-312	Toner Dispense Motor Rotation Fail ................................................................	2-137
093-400 Toner Near Empty............................................................................................		2-137
093-406	Toner Pre Near Empty .....................................................................................	2-138
093-912	Toner Empty.....................................................................................................	2-138
093-956	Drum New CRU Installation Fail ......................................................................	2-139
093-959	Drum New CRU Installation Fail Exceeds Thresholding Times .......................	2-139

CHAIN 116

116-317	Configuration NG .............................................................................................	2-141
116-321	Controller Logic Fail .........................................................................................	2-141
116-323	Controller NVM Data Defect.............................................................................	2-142
116-324	Exception Fail...................................................................................................	2-142
116-334 NVM Data Mismatch ........................................................................................		2-143
116-377	IIT Interrupt Timeout.........................................................................................	2-143
116-386 USB Host Terminal Unknown Device Connection Fail ....................................		2-144
116-747	Invalid Page Margin .........................................................................................	2-144

CHAIN 117

117-327 Controller Extension Card NVM Data Defect...................................................

2-145

CHAIN 123

123-314 UI Panel Communication Fail...........................................................................

2-147

CHAIN 124

124-311 Serial Number Fail ............................................................................................

2-149

CHAIN 127

127-396 E-mail Generate Fail ........................................................................................

2-151

CHAIN 133

133-226 Fax Country or Clock Not Set ..........................................................................

2-153

CHAIN 134

134-210	Fax Data Parameter Error................................................................................	2-155
134-211	Fax Board Failure.............................................................................................	2-155

2.2.3 Other Failure FIP

2.2.3.1 AC Power FIP.....................................................................................................		2-157
2.2.3.2	+5VDC Power FIP..............................................................................................	2-157
2.2.3.3	+24VDC Power FIP............................................................................................	2-158

2.2.4 Generic FIP

CHAIN 91				2.2.4.1	Reflective Sensor Failure FIP.............................................................................	2-159
091-401/402		Drum Cartridge Quality Life Over/ Drum Cartridge Life Over ...................	2-131	2.2.4.2	Permeable Sensor Failure FIP ...........................................................................	2-159
091-406/424		Drum Cartridge Normal Life Over/ Drum Cartridge Abnormal Life Over...	2-131	2.2.4.3	Switch (Normal/Open) Failure FIP .....................................................................	2-160
091-430	Drum Cartridge Life End ..................................................................................		2-132	2.2.4.4	Solenoid/Clutch Not Energized Failure FIP........................................................	2-160
091-440	Drum Cartridge Pre Near End..........................................................................		2-132	2.2.4.5	Solenoid/Clutch Left Energized Failure FIP .......................................................	2-161
091-441	Drum Cartridge Near End ................................................................................		2-133	2.2.4.6	Motor Does Not Rotate Failure FIP ....................................................................	2-161
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2.2.4.7	Motor Left Running Failure FIP ..........................................................................	2-162
2.2.4.8	NIP/RELEASE SOLENOID Not Energized Failure FIP......................................	2-162

2.3 NET System Fault Check

2.3.1	Interface (Physical/Logical) ...................................................................................	2-165
2.3.2	'Cannot connect to the network' or 'Print is not found from the PC' ......................	2-165
2.3.3	No output is available, no data is printed ..............................................................	2-166
2.3.4	Printing can be performed but abnormally ............................................................	2-167
2.3.5	Network-Related Details Check Flow....................................................................	2-167

2.4 Software Download

2.4.1 Software Download ...............................................................................................

2-169

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2.1.1 How to Troubleshoot

Level 1 Troubleshooting:

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

Level 2 Troubleshooting:

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

How to proceed with troubleshooting and Cautions:

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

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

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

2.1.3 Glossary

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

Common terms:

•Fault Code

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

•Actuate (Deactuate)

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

•Block

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

•Check

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

•Enter the CE Mode

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

•Check the connection for short circuit

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

•Check the connection for open circuit

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

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

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

•Analog Monitor [xxx-xxx]

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

•Check the voltage level

		Table 1
Voltage	Level	Range
+3.3VDC	(H)	+3.2 to +3.6VDC
	(L)	0.0 to +1.0VDC
+5VDC	(H)	+4.8 to +5.4VDC
	(L)	0.0 to +1.0VDC
+24VDC	(H)	+23.3 to +25.7VDC
	(L)	0.0 to +3.0VDC

•PL 4.2

Refer to PL 4.2 in Chapter 5 Parts List.

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•CH 6.2 Zone J4

Refer to Chain 6.2 Zone J4 in Chapter 7 BSD.

•REP 4.1.3

Refer to REP 4.1.3 in Chapter 4.

•ADJ 4.1.3

Refer to ADJ 4.1.3 in Chapter 4.

•Replace the parts in sequence

When it is impossible to analyze causes of a problem further, replace the parts in sequence. The part with a higher replacement frequency or higher possibility of causing a problem is listed first for replacement.

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2.2.1.1 Level 1 FIP

Procedure

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

YN

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

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

YN

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

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

YN

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

•Problems With Hardware

•Problems With Image Quality

•Problems With Copy

•Problems With Printer

•Problems With Scanner

•Problems With Network

•In Case of Paper Jam

•In Case of Document Jam

Proceed to Level 2 Troubleshooting and perform the applicable FIP.

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2.2.1.1 Level 1 FIP

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003-500 N-Up NG Out Of Range

BSD-ON:-

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

Cause/Action

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

003-754 IPS Overrun

BSD-ON:-

The IPS processing has overtook the Scan processing.

Cause/Action

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

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003-795 AMS NG Out Of Range

BSD-ON:-

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

003-942 Not-Supported Doc Size

BSD-ON:-

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

Cause/Action

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

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

Cause/Action

1.Press [Stop] on the UI Panel.

2.Check the setting of the document size group.

3.Check whether the document size is a supported size.

4.If the document size is a supported size, the DADF might have malfunctioned. Refer to following FIP to check the DADF.

•005-196 (Size Mismatch Jam on No Mix-size)

•005-948 (SS-Size Mismatch Jam on No Mix-size)

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003-956 Not-Supported Doc Size

BSD-ON:-

During Platen Scan, an unsupported document size was detected.

Cause/Action

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

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

003-963 APS NG Out Of Range

BSD-ON:-

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

Cause/Action

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

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003-972 1Job Max Page Over

BSD-ON:-

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

Cause/Action

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

003-973 Auto Rotation NG Out Of Range

BSD-ON:-

During Copy Job, the following conditions were met.

•Rotation is required.

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

Cause/Action

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

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004-345 HVPS Communication Error

BSD-ON: CH9.1

Communication failure between the ESS/MCU PWB and the HVPS was detected.

Cause/Action

1.Turn the power OFF and ON.

2.Turn OFF the power and check the connection between the HVPS J500 and the ESS/ MCU PWB J402 for open circuit, short circuit, and poor contact.

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

•HVPS (PL 18.3)

•ESS/MCU PWB (PL 18.3)

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

BSD-ON: CH5.4

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

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

Cause/Action

Check the following:

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

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

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

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

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

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

•The Drive Gear for wear and damage.

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

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

BSD-ON: CH5.5, CH5.4

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

Cause/Action

Check the following:

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

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

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

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

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

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

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

•The Drive Gear for wear and damage.

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

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

BSD-ON: CH5.5, CH5.4

[DADF Regi Sensor Off Jam]

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

[DADF Regi Sensor Off Jam on Inverting]

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

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

BSD-ON: CH5.5, CH5.4

[DADF Invert Sensor On Jam on Inverting]

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

[DADF Invert Sensor On Jam]

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

Cause/Action

Check the following:

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

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

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

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

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

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

•The Drive Gear for wear and damage.

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

Cause/Action

Check the following:

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

•The surface of the Out Roll for foreign substances.

•The surface of the Out Roll for wear

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

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

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

•The Drive Gear for wear and damage.

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

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