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Model K-C1
(Machine Code: B039/B040/B043)
SERVICE MANUAL
February 20th, 2001 Subject to change
20 February, 2001
SERVICE CALL CONDITIONS
4. TROUBLESHOOTING
4.1 SERVICE CALL CONDITIONS
4.1.1 SUMMARY
There are 2 levels of service call conditions.
Level Definition To prevent the machine from being damaged, the SC can only be reset by a service representative. The copier cannot be operated at all. The SC can be reset by turning the main power switch off and on. Reset Procedure Enter SP 5-810 (SC code reset) and select "1". Then hold down the Original type key and the OK or ! key at the same time (this does not require the main switch to be turned off and on). Turn the main power switch off and on.
A
B
NOTE: 1) If the problem concerns electrical circuit boards, first disconnect then reconnect the connectors before replacing the PCBs. 2) If the problem concerns a motor lock, first check the mechanical load before replacing motors or sensors.
4-1
Troubleshooting
SERVICE CALL CONDITIONS
20 February, 2001
4.1.2 SC CODE DESCRIPTIONS
No. Definition 101 B Symptom Exposure Lamp Error The standard white level was not detected properly when scanning the white plate. Possible Cause · Exposure lamp defective · Exposure lamp stabilizer defective · Exposure lamp connector defective · Dirty scanner mirror or scanner mirror out of position · SBU board defective · SBU connector defective · Lens block out of position · Incorrect position or width of white plate scanning ( SP4-015) · Scanner home position sensor defective · Scanner drive motor defective · Scanner home position sensor connector defective · Scanner drive motor connector defective · IOB board defective · Scanner home position sensor defective · Scanner drive motor defective · Scanner home position sensor connector defective · Scanner drive motor connector defective · IOB board defective · Scanner home position sensor defective · Scanner drive motor defective · Scanner home position sensor connector defective · Scanner drive motor connector defective · IOB board defective · Scanner home position sensor defective · Scanner drive motor defective · Scanner home position sensor connector defective · Scanner drive motor connector defective · IOB board defective
120
B
Scanner home position error 1 The scanner home position sensor does not detect the off condition during initialization or copying.
121
B
Scanner home position error 2 The scanner home position sensor does not detect the on condition during initialization or copying.
122
B
Scanner home position error 3 The scanner home position sensor detects the on condition while the scanner is returning to the home position.
123
B
Scanner home position error 4 The scanner home position sensor does not detect the on condition after the scanner returns to the home position.
4-2
20 February, 2001
No. Definition 130 B Symptom
SERVICE CALL CONDITIONS
Possible Cause
192
B
194
B
302
B
320
B
321
B
Communication Error between BiCU and SBU The BiCU board cannot detect the SBU · The flat cable between the BiCU connect signal. board and the SBU has a poor connection · The flat cable between the BiCU board and the SBU damaged · BiCU board defective · SBU defective Automatic SBU adjustment error During the automatic SBU adjustment, · Exposure lamp defective the machine detects that the white level · SBU auto adjustment was not done read from the white plate or paper is correctly ( 3.13 Copy adjustment out of range. ( SP4-908) printing/scanning Standard white density adjustment) · SBU defective · BiCU board defective · Exposure lamp stabilizer defective SBU White Level Detection Error The automatic SBU adjustment failed · Exposure lamp defective twenty times consecutively. · Dirty white plate · Incorrect position or width of white plate scanning ( SP4-015) · BiCU board defective · SBU board defective Charge roller current leak A current leak signal for the charge · Charge roller damaged roller is detected. · High voltage supply board defective · Poor connection of the PCU Polygonal mirror motor error The polygon mirror motor does not · Polygon mirror motor defective reach operating speed within 10 · Poor connection between the seconds after the motor ON signal is polygonal mirror motor driver and the sent, or does not turn on within one of BiCU board the 200 ms check intervals during · Damaged cable between BiCU/IOB operation. and polygonal mirror motor driver · BiCU board defective No laser writing signal (F-GATE) error The laser writing signal (F-GATE) fails · BiCU board defective to turn Low after the laser crosses 5 · IMB board defective mm on the drum surface from the laser · The fax controller or printer controller writing start position. has a poor connection · Fax controller or printer controller defective
4-3
Troubleshooting
SERVICE CALL CONDITIONS
No. Definition 322 B Symptom Laser synchronization error The main scan synchronization detector board cannot detect the laser synchronization signal for more than 5 consecutive 100 ms intervals.
20 February, 2001
Possible Cause · Poor connection between the LD unit and the BICU board · Damaged cable between BiCU and LD unit · LD unit out of position · LD unit defective · BiCU board defective · TD sensor abnormal · Poor connection of the PCU · Poor connection of the PCU · High voltage supply board defective · ID sensor defective · No developer · Drum does not turn · Development roller does not turn · Poor connection of the PCU · The voltage is not applied to charge roller · High voltage supply board defective · Poor connection of the PCU · Transfer/separation unit set incorrectly · Transfer roller damaged · High voltage supply board defective · Poor connection of the PCU · Transfer/separation unit set incorrectly · Transfer roller damaged
390
B
391
B
TD sensor error The TD sensor outputs less than 0.2 V or more than 4.0 V 10 times consecutively during copying. Development bias leak A development bias leak signal is detected. TD sensor initial setting error TD sensor initial setting is not performed correctly.
392
B
401
B
Transfer roller leak error 1 A current leak signal for the transfer roller is detected. A current feedback signal for the transfer roller is not detected. Transfer roller leak error 2 A current leak signal for the transfer roller is detected. A current feedback signal for the transfer roller is not detected.
402
B
500
B
503
C
Main motor lock A main motor lock signal is not · Too much load on the drive detected for more than 7 consecutive mechanism checks (700 ms) after the main motor · Main motor defective starts to rotate, or the lock signal is not detected for more than 7 consecutive checks during rotation after the last signal. Upper paper tray lift motor malfunction (optional paper tray units) The paper lift sensor fails to activate · Paper lift sensor defective twice continuously after the tray lift · Tray lift motor defective motor has been on for 18 seconds. · Too much load on the drive mechanism · Poor tray lift motor connection
4-4
20 February, 2001
No. Definition 504 B Symptom
SERVICE CALL CONDITIONS
Possible Cause
506
B
541
A
542
A
543
A
544
A
546
A
547
B
620
B
Lower paper tray lift motor malfunction (optional two-tray paper tray unit) The paper lift sensor fails to activate · Paper lift sensor defective twice continuously after the tray lift · Tray lift motor defective motor has been on for 18 seconds. · Too much load on the drive mechanism · Poor tray lift motor connection Paper feed motor lock (optional paper tray units) A motor lock signal is not detected for · Paper feed motor defective more than 1.5 s or the lock signal is not · Too much load on the drive detected for more than 1.0 s during mechanism rotation. Fusing thermostat/thermistor open The fusing temperature detected by the · Fusing thermostat defective or out of position thermistor is below 10°C for 5 seconds after the main power switch is turned · Fusing thermistor defective or out of on. position · Power supply board defective Fusing temperature warm-up error The fusing temperature does not reach · Fusing thermistor defective or out of 80°C within 30 seconds after the main position switch is turned on. · Fusing lamp open · Fusing thermostat open · Fusing thermofuse open · Power supply board defective Fusing overheat error · Fusing thermistor defective A fusing temperature of over 230°C is detected for 1 second by the fusing · Power supply board defective thermistor. Fusing low temperature error A fusing temperature of lower than · Fusing lamp open 100°C is detected for 1 second by the · Fusing thermistor defective fusing thermistor during operation or · Power supply board defective stand-by mode. · Fusing thermistor open · Fusing thermostat open Unstable fusing temperature The fusing temperature does not rise · Thermistor defective 3 °C or more within 5 seconds after the · Power supply unit defective fusing lamp has been on over 8 seconds. Zero cross signal malfunction Zero cross signals are not detected · Power supply board defective within 5 seconds after the main power · IOB defective switch is turned on, or are not detected · BiCU defective within 1 second after operation begins. Communication error between IOB and ADF The IOB does not receive a response · Poor connection between the IOB and from the ADF main board for 4 seconds ADF main board (DF connector) or more. · ADF main board defective
· IOB defective
4-5
Troubleshooting
SERVICE CALL CONDITIONS
No. Definition 691 B Symptom
20 February, 2001
Possible Cause
692
B
695
B
760
B
900
B
901
B
921
B
922
B
924
B
Communication error between BiCU and fax controller The BiCU board cannot communicate · Poor connection between the BiCU with the fax controller. board and the fax controller · BiCU board defective · Fax controller defective Communication error between BiCU and printer controller The BiCU board cannot communicate · Poor connection between the BiCU with the printer controller. board and the printer controller. · BiCU board defective · Printer controller defective Fax firmware error The fax program cannot be started. · The fax firmware download has not ( Fax Service Manual) been completed correctly. Try again. ADF gate abnormal The ADF Gate signal line between the · ADF main board defective ADF main board and the IOB is · Input/output board defective disconnected. · Poor connection (ADF Gate line) between the ADF main board and the IOB. Electrical total counter error The electrical total counter does not · NVRAM defective work properly. Mechanical total counter The mechanical total counter does not · Mechanical total counter defective work properly. · IOB defective · Disconnected mechanical total counter IMB memory controller error A memory control job is not completed · IMB defective within a certain period. · BiCU defective · Poor connection between IMB and BiCU IMB DRAM error The machine detects a discrepancy in · IMB defective the IMB DRAM write/read data during · BiCU defective its write/read test (done at power off/on · Poor connection between BiCU and and at recovery from low power or IMB night/off mode). Optional DRAM error The machine detects a discrepancy in · Non-supported DRAM connected the Optional DRAM write/read data · Poor connection between IMB and during its write/read test (done at power optional DRAM off/on and at recovery from low power · Optional DRAM defective or night/off mode). · IMB defective · BiCU defective
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20 February, 2001
No. Definition 925 B Symptom IMB non-connected error IMB is not connected. This SC only appears with B040 and B043 version machines.
SERVICE CALL CONDITIONS
Possible Cause · IMB is not connected · Poor connection between BiCU and IMB · IMB defective · BiCU defective · Poor connection between optional DRAM and IMB · Optional DRAM defective · IMB defective · BiCU defective
926
B
Memory capacity error The machine detects a discrepancy between the memory capacity detected during the memory check at power on and the check at recovery from low power or night/off mode. NVRAM error The machine detects a discrepancy in the NVRAM write/read data when attempting to save actual data to the NVRAM (i.e. during actual use).
981
B
990
B
999
B
· NVRAM defective · Poor connection between BiCU and NVRAM · NVRAM is not connected · BiCU defective Communication error between BICU and IOB The BiCU board cannot communicate · The connection between the BiCU with the IOB. board and the IOB is poor. · BiCU board defective · IOB defective Program version error An incorrect type of main software was · The main software for another downloaded. machine was downloaded to this machine. Switch the machine off. Connect an IC card that has the correct firmware to the machine. Switch the machine on, and download the firmware (see section 5.1.9).
4-7
Troubleshooting
ELECTRICAL COMPONENT DEFECTS
20 February, 2001
4.2 ELECTRICAL COMPONENT DEFECTS
4.2.1 SENSORS
Component Registration CN 312-2 (IOB) Relay 312-5 (IOB) Upper Paper End Open 314-2 (IOB) Shorted Vertical Transport Open Shorted Condition Open Shorted Symptom The Paper Jam message will appear whenever a copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a copy is made except for 1st and by-pass tray feeding. The Paper Jam message appears even if there is no paper at the sensor. The Paper End indicator lights when the 1st paper tray is selected, even if there is paper in the tray. The Paper End indicator does not light when the 1st paper tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the 1st paper tray. The Paper Jam message will appear whenever a copy is made from an optional paper tray unit. The Paper Jam message appears even if there is no paper at the sensor. The Paper End indicator lights when the 2nd paper tray is selected, even if there is paper in the tray (B040/B043 models only). The Paper End indicator does not light when the 2nd paper tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the 2nd paper tray (B040/B043 models only). The Paper End indicator lights when the bypass tray is selected, even if there is paper in the tray. The Paper End indicator does not light when the bypass tray is selected, even if there is no paper in the tray. The Paper Jam message will appear whenever a copy is made from the bypass tray. The Paper Jam message will appear whenever a copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. SC390 is displayed. The toner density control process is changed (see the note below the table).
316-2 (IOB)
Open Shorted Open
Lower Paper End
317-6 (IOB)
Shorted Shorted
By-pass Paper End 311-7 (IOB)
Open
Shorted Exit 331-2 (IOB) Toner Density Image Density 325-3 (IOB) 326-2 (IOB) Open Shorted Open Shorted Open Shorted
4-8
20 February, 2001
Component Scanner H.P. Platen Cover 304-5 (IOB) Original Width Original Length Duplex Entrance 222-2 (DCB) Duplex Exit 222-5 (DCB) Duplex Inverter 220-6 (DCB) Open Shorted Open Shorted Open Shorted CN 304-2 (IOB) Condition Open Shorted Open Shorted Open Shorted Open Shorted
ELECTRICAL COMPONENT DEFECTS
Symptom SC120 is displayed. APS and Auto Reduce/Enlarge do not function correctly. If the Start button is pressed with the platen cover or A(R)DF closed, "Cannot detect original size" is displayed. The CPU cannot detect the original size properly. APS and Auto Reduce/Enlarge do not function correctly. The CPU cannot detect the original size properly. APS and Auto Reduce/Enlarge do not function correctly. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor. The Paper Jam message will appear whenever a duplex copy is made (paper hasn't reached the sensor). The Paper Jam message appears even if there is no paper at the sensor.
305-3,4 (IOB) 305-8,9 (IOB)
NOTE: SC392 is activated when the CPU detects an ID sensor error during developer initialization (SP2-214). However, SC392 is not displayed on the LCD but simply logged in the SC log (SMC printout), unless the technician exits SP Mode as soon as the "Error!!!" message is displayed.
4.2.2 SWITCHES
Component Upper Paper Size Vertical Transport Door CN 315 1,2,4 (IOB) 316-5 (IOB) 3171,2,4 (IOB) 3111,2,4,5 (IOB) Condition Open Shorted Open Shorted Open Shorted Open Symptom The CPU cannot detect the proper paper size, and misfeeds may occur when a copy is made from the 1st paper tray. The Cover Open indicator is lit even if the vertical transport door is closed. The Cover Open indicator is not lit even if the vertical transport door is opened. The CPU cannot detect the proper paper size, and misfeeds may occur when a copy is made from the 2nd paper tray. The CPU misdetects or is not able to detect the size of the paper set in the bypass tray, causing possible misfeeds when feeding from this tray.
Lower Paper Size By-pass Paper Size
4-9
Troubleshooting
BLOWN FUSE CONDITIONS
Component Right Door CN 331-5 (IOB) Front/Right Cover Condition Open Shorted Open Shorted Open Shorted
20 February, 2001
Symptom The Cover Open indicator is lit even if the right door is closed. The Cover Open indicator is not lit even if the right door is open. The Cover Open indicator is lit even if doors are closed. The Cover Open indicator is not lit even if doors are open. The machine does not turn on. The machine does not turn off.
328-1 (IOB) 281-3,4 (PSU)
Main
4.3 BLOWN FUSE CONDITIONS
Rating 120 V 220 240 V Power Supply Board FU1 15 A/125 V -- FU2 6.3 A/250 V 3.15 A/250 V Fuse FU3 FU4 FU5 FU6 2 A/125 V 4 A/125 V 4 A/125 V 3.15 A/125 V 2 A/250 V 4 A/250 V 4 A/250 V 3.15 A/250 V Symptom when turning on the main switch No response. No response. Anti-condensation/Tray Heater does not turn on. Optional peripheral(s) are detected but do not function. The Cover Open indicator is lit then SC901 is displayed. LEDs are not lit and the LCD display does not function (backlight only).
4.4 LED DISPLAY
4.4.1 BiCU
Number LED 1 LED 2 Function Monitors the +5 V line for the CPU and the surrounding circuit. Usually, this LED is blinking. Monitors the +5 V line. Usually, this LED is lit.
4.4.2 IOB
Number LED301 Function Monitors the connection between the IOB and the BiCU. Usually, this LED is blinking.
4-10