CHAPTER 4

TROUBLESHOOTING IMAGE FAULTS/

MALFUNCTIONS

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

1. Making Initial Checks in the Event of an Image Fault

1.1 Site Environment
The site must meet the following requirements:
1. The main source of power must provide the rated voltage. (The power plug must remain
connected throughout the night.)
2. The site must not be subject to high temperature/humidity (near a water faucet, water
boiler, humidifier) or low temperature. It must not be near a source of fire, and must not
be subject to dust.
3. The site must not be subject to ammonium gas.
4. The site must be free of the direct rays of the sun; otherwise, curtains must be provided
to block out the rays.
5. The room must be well ventilated.
6. The floor must keep the machine level.
7. The source of power must provide power night and day.

Check the site of installation to see if it meets the requirements.

1.2 Checking the Originals for Symptoms

Try to find out where the problem is caused by the originals or the machine:
1. The copy density is optimum when it is as indicated by the index (5±1).
2. An original with a reddish background prevents good contrast; e.g., red slips.
3. Check the original for density:

A diazo copy (used as an original) or an original with transparency tends to

produce prints that are likely to be judged “foggy.”.
Memo An original prepared in pencil tends to produce prints that are likely to be
judged “light.”.

1.3 Copyboard Cover, Copyboard Glass, and Standard White

Plate
Check the copyboard cover, copyboard glass, and standard white plate for dirt and
scratches. If soiled, clean it with mild detergent or alcohol; if scratched, replace it.

1.4 Checking the Charging Assemblies

1. Check each charging assembly for soiling and each charging wire for a fault (scratch,
rust, etc.).
2. Clean the charging wire of each charging assembly and the shielding plate; if the dirt is
excessive, replace it.
3. Check the type and the height of each charging assembly.
4. Check to make sure that each charging assembly is correctly mounted.
5. Check the charging wire cleaning pad (of each charging assembly) for displacement.

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

1.5 Checking the Developing Assembly

1) Check to make sure that the rolls on both ends of the developing assembly are in contact
with the drum.
Otherwise, “light images” may occur.
2) Check to make sure that the surface of the developing cylinder is coated with an even
layer of toner.
Otherwise, “light images” or “uneven density” may occur.

1.6 Checking the Paper

1) Check to see if the paper is of a recommended type.
Advise the user that the use of paper not of a recommended type may not bring abut the
best image quality.
2) Check to find out if the paper is moist.
Try using paper fresh out of package.
Advise the user that the use of moist paper will adversely affect transfer, generating poor
images. Advise him/her on the correct method of storing paper.

1.7 Checking the Periodically Replaced Parts

Check with the Scheduled Servicing Chart and the Periodically Replaced Parts Table; if
any part has reached the end of its life, replace it.

1.8 Image Adjustment Basic Procedure

If the prints have uneven density (difference in density between front and rear), light im-
ages, or foggy background, perform the Image Adjustment Basic Procedure.

1.9 Others
Bringing in a machine from a cold to warm room in winter for installation can cause con-
densation inside the machine, leading to various problems.

1. Condensation in the scanner (glass, mirror, lens) can cause dark images.
2. Condensation in the charging system can cause electrical leakage.
Memo 3. Condensation on the pickup/feeding guide plate can cause paper feed-
ing faults.
If condensation is noted, dry wipe the parts, or leave the machine alone
while powered for 60 min or so.

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 CHAPTER 2 IMAGE ADJUSTMENT BASIC PROCEDURE

2. Samples of Image Faults

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3. Troubleshooting Image Faults

3.1 The image is too light (halftone)

AE adjustment
1) Make prints in AE mode. Is the density normal?
YES: End.
Developing assembly
2) Are the rolls of the developing assembly in firm contact with the photo-
sensitive drum?
YES: Check to see if the surface of the developing cylinder is coated
with an even layer of toner.
NO: Check to find out if the developing assembly locking unit is
mounted correctly.

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

3.2 The print is too light (including solid black area)

3.3 The print is too light (overall, appreciably)

1) Turn off the main power switch in the middle of printing. At this time, is
the toner image on the surface of the photosensitive drum (before transfer)
more or less normal?
YES: The cause is in a process that follows transfer. Go to step 3).
Developing assembly
2) Are the rolls of the developing assembly in firm contact with the photo-
sensitive drum?
NO: Check to see if the developing assembly locking unit is mounted
correctly.
YES: Check the control system of the developing bias.
Pre-transfer charging assembly
3) Is the pre-transfer charging assembly fitted securely?
NO: Fit the charging assembly securely.
Transfer faults
4) Is the transfer/separation charging assembly fitted securely?
NO: Fit the transfer/separation charging assembly securely.
5) Try changing the setting of the following in service mode between ‘1’
and ‘3’: COPIER>OPTION>BODY>FUZZY. Is the problem corrected?
YES: End. (The problem is due to the environment.)
NO: Set ‘0’ to ‘FUZZY’, and go to the next step.
6) Measure the resistance between the transfer guide and the base (metal)
with a meter. Is it 0Ω?
YES: Check to find out if the transfer guide is in contact with a metal
area (e.g., side plate of the feeding assembly).
NO: Check the high-voltage transformer (HVT) and the DC controller
PCB.

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3.4 The print has uneven density (darker at front)

3.5 The print has uneven density (lighter at front)

Pre-exposure lamp
1) Does the pre-exposure lamp turn on at an even intensity across its length
during printing?
NO:
1. Replace the pre-exposure lamp.
2. Replace the DC controller PCB.
Developing assembly
2) Are the rolls of the developing assembly in firm contact with the photo-
sensitive drum?
NO: Check to see if the developing assembly locking unit is mounted
correctly.
3) Is the surface of the developing cylinder coated with an even layer of
toner?
NO:
1. Clean the edge of the blade of the developing assembly. (dry wip-
ing)
2. Clean the surface of the developing cylinder.
3. Check to see if the toner inside the developing assembly is thicker
on one side.
YES: Check the nip of the fixing roller.

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3.6 The print is foggy (overall)

Potential control system

1) Set ‘0’ to the following in service mode to turn off potential control:
COPIER>OPTION>BODY>PC-CNT> Is the problem corrected?
YES: The cause is in the potential control mechanisms. Make checks ac-
cording to the instructions for the potential control mechanism in
Chapter 3 “Standards and Adjustments.”
Photosensitive drum cleaner unit
2) Is the cleaning blade mounted correctly?
NO: Mount the cleaning blade correctly.
Pre-exposure lamp/DC controller PCB
3) Is the pre-exposure lamp on during printing?
NO:
1. Replace the pre-exposure lamp.
2. Replace the DC controller PCB.
Developing assembly
4) Are the developing rolls worn?
YES: Replace the developing rolls.
Photosensitive drum
5) Is the photosensitive drum soiled?
YES: Clean the photosensitive drum.
NO: Replace the photosensitive drum.

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3.7 The print if foggy vertically

3.8 The print has black lines (vertical, blurred, thick)

Reader unit
1) Does the problem occur on copy images only?
YES: The cause is in the reader unit. Check the following:
1. Scanning lamp for dirt and life
2. Reflecting plate, mirrors, lens, and glass for dirt
3. Standard white plate (back of copyboard glass) for dirt
Fixing assembly
2) During printing, turn off the main power switch while paper is in the
feeding assembly; then, check the image on the paper. Is it normal?
YES: The cause is in a process after the fixing system. Check the follow-
ing:
1. Fixing assembly upper roller for dirt
2. Web for dirt
Potential control system
3) Set ‘0’ to the following in service mode to turn off potential control:
COPIER>OPTION>BODY>PC-CNT. Is the problem corrected?
YES: The problem is in the potential control system. Make checks for
the potential control system in Chapter 3 “Standards and Adjust-
ments.”
Primary charging assembly
4) Clean the primary charging wire, grid wire, and shielding plate. Is the
problem corrected?
YES: End.
Pre-exposure lamp
5) Clean the pre-exposure lamp. Is the problem corrected?
YES: End.
Developing assembly, Photosensitive drum cleaner unit
6) Is the surface of the developing cylinder coated with an even layer of
toner?
NO:
1. Check the edge of the blade of the developing assembly.
2. Check the surface of the developing cylinder.
YES:
1. Check the edge of the cleaning blade of the photosensitive drum.
2. Check the photosensitive drum cleaner unit.

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3.9 The print has black lines (vertical, fine)

Reader unit
1) Does the problem occur only in copy images?
YES:
1. Check the standard white plate and mirrors for dirt.
2. Execute the following in service mode:
COPIER>FUNCTION>CCD>CCD-ADJ.
Dust-proofing glass.
2) Clean the Dust-proofing glass. Is the problem corrected?
YES: End.
Fixing system
3) During printing, turn off the main power switch while paper is in the
feeding assembly; then, check the image. Is it normal?
YES: The cause is in a process after the fixing system. Check the follow-
ing:
1. Fixing assembly upper roller for scratches and black lines.
2. Web for dirt
3. Thermistor and separation claw for dirt, and reciprocating opera-
tion
Primary charging assembly
4) Clean the primary charging assembly. Is the problem corrected?
YES: End.
Photosensitive drum cleaner unit
5) Is there paper or foreign matter trapped in the cleaning blade assembly?
YES: Remove the foreign matter, and clean the cleaning blade and the
casing of the cleaner unit.
6) Are there scratches on the edge of the cleaning blade? (Feel the edge of
the blade with your finger to find out.)
YES: Turn it over to use the other edge. If both edges have scratches, re-
place it.
Photosensitive drum, Developing system
7) Are there scratches or black lines in the peripheral direction of the sur-
face of the photosensitive drum?
YES: Replace the photosensitive drum.
If scratches are found, be sure to find out the cause.
NO: Check the developing system.

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3.10 The print has white spots (vertical)

3.11 The print has white lines (vertical)

Reader unit
1) Does the problem occur only in copy images?
YES: The cause is in the reader unit. Check the following:
1. Standard white plate (back of copyboard glass) for dirt
2. Execute the following in service mode:
COPIER>FUNCTION>CCD>CCD-ADJ.
3. Execute the following in service mode:
COPIER>FUNCTION>CCD>SH-PS-ST.
Fixing assembly
2) Generate test print TYPE [00]. Turn off the main power switch immedi-
ately before the paper enters the fixing assembly, and check the image. Is it
normal?
YES: The cause is in a process after the fixing system. Check the follow-
ing:
1. Fixing assembly upper roller for offset
Photosensitive drum
3) Are there scratches in the peripheral direction of the surface of the pho-
tosensitive drum that match the image?
YES: Find out the cause of the scratches, and replace the photosensitive
drum.
Developing assembly
4) Is the surface of the developing cylinder coated with an even layer of
toner?
NO: Check the edge of the blade of the developing assembly for paper
lint or the like.
Transfer/Separation charging assembly, Pre-transfer charging assembly
5) Clean the pre-transfer charging assembly and the transfer/separation
charging assembly. Is the problem corrected?
YES: End.
NO: Try changing the setting of the following in service mode:
COPIER>OPTION>BODY>FUZZY.

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3.12 The print has white spots (horizontal)

Reader unit
1) Does the problem occur only in copy images?
YES:
1. Check the scanner rail for foreign matter.
2. Check the scanner cable for tension
Charging wire
2) Does the problem occur at even intervals?
YES: Clean each charging wire.
Developing assembly, Photosensitive drum
3) Does the problem occur at intervals of about 52 mm?
YES: Check the developing assembly:
1. Clean the developing rolls.
2. Dry wipe the surface of the developing cylinder.
3. If scratches are found on the surface of the developing cylinder, re-
place the developing cylinder.
NO: Check the photosensitive drum.
1. Clean the photosensitive drum.
2. If scratches are found on the surface of the photosensitive drum,
find out the cause and replace the photosensitive drum.

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3.13 The back of the print is soiled

Transfer guide
1) Is the transfer guide soiled with toner?
YES:
1. Clean the transfer guide.
2. Check the transfer guide bias.
3. Check the developing assembly for leakage of toner.
Drum cleaner
2) Is the paper feeding assembly soiled with toner?
YES:
1. Clean the feeding assembly.
2. Check the drum cleaner assembly for leakage of waste toner.
Fixing assembly
3) Is the fixing assembly lower roller soiled?
YES:
1. Clean the fixing assembly lower roller.
2. Clean the fixing assembly inlet guide.
3. Check the fixing upper roller and the web for dirt.
NO: Check the following:
1. Registration roller for dirt.
2. Delivery roller and separation claw for dirt.

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3.14 The print has fixing faults

Copy paper
1) Is the paper of a type that has poor fixing performance (e.g., thick pa-
per)?
YES: Set ‘2’ (thick paper mode) in service mode:
COPIER>OPTION>BODY>FSPD-S.
Perform the following, and advise the user:
a. Set the source of paper (cassette, deck) to ‘Heavy’.
Additional Function>common settings>store paper type>source of
paper>‘Heavy’
b. Advise the user to always use the selected source of paper (after
depositing thick paper) whenever using thick paper.
2) Is the paper of a recommended type?
NO: Try using recommended paper. If the results are good, advise the
user to use recommended paper.
Fixing assembly
3) Does the problem occur vertically?
YES: Check the fixing roller for scratches and dirt.
NO: Check the fixing roller for nip.

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3.15 The print has a displaced leading edge

(appreciably large margin)
3.16 The print has a displaced leading edge (large margin)
3.17 The print has a displaced leading edge (no margin)

Placement of originals
1) Is the original placed correctly?
NO: Place the original correctly.
Pickup assembly
2) Make prints using the following source of paper. Is the displaced lead-
ing edge different?
1. Let/right front deck
2. Cassettes
3. Side paper deck
4. Duplex feeding assembly (double-sided print)
YES: Check the source of paper in question for the following:
1. Life of each roller
2. Paper lint on each roller
3. Dirt on the paper path
Registration clutch, Registration roller
3) Make adjustments in service mode: COPIER>ADJUST>Feed-
ADJ>REGIST. Is the problem corrected?
YES: End.
NO:
1. Check the registration roller for deformation/wear.
2. Check the registration roller drive system.

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3.18 The print has a blurred image

Reader unit
1) Does the problem occur only in copy images?
YES: Go to step 2).
NO: Go to step 5).
Scanner drive cable
2) While the scanner is moving, is the cable wound on the cable pulley in
lengths laid on top of one another?
YES:
1. Route the cable once again.
2. If the cable has a fault, replace it.
Scanner drive belt
3) Is the belt too taut or too slack?
YES:
1. Attach the belt properly.
2. If the belt has a fault, replace it.
Scanner rail
4) Move the No. 1 mirror base slowly by hand. Does it move smoothly?
YES: Check the each mirror to see if it is free of wobbling.
NO: Clean the surface of the scanner rail, and apply a small amount of
silicone oil so that the No. 1 mirror base moves smoothly.
Photosensitive drum
5) Does the problem occur at intervals of about 250 mm?
YES:
1. Check the drum gear.
2. Check the ends of the drum (in contact with the developing rolls)
for scratches and protrusions.
Drum drive gear
6) Does the problem occur at intervals of about 3 mm?
YES: Check the drum drive gear.
Developing gear
7) Does the problem occur at intervals of about 2.5 mm?
YES:
1. Check the developing assembly.
2. Check to find out if the end of the drum is coated with toner; if so,
clear it.
Drum drive system
8) Does the problem occur at intervals of about 10 mm?
YES: Check the cleaner assembly and the drum drive system.
Laser scanner unit
9) Is the problem noted at intervals of about 0.5 mm?
YES: Check the laser scanner unit. (The polygon mirror may be faulty.)

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3.19 The print is foggy (horizontally)

1) Make a copy in Direct. Does the problem occur in the same position?
YES: Go to step 3).
Reader unit
2) Does the scanning lamp flicker while the scanner is moving forward?
YES: Check the scanning lamp and the inverter PCB.
NO: Check the scanner drive system of the reader unit.
Scanner, Feeding system (wobbling)
3) Make a reduced copy, and compare it against a copy made in Direct. Is
the position of the problem different?
NO: Check the scanner.
YES: Check the feeding system.

3.20 The print has poor sharpness

Reader assembly
1) Does the problem occur only in copy mages?
YES: Go to step 2).
NO: Go to step 4).
Copyboard glass
2) Is the copyboard glass coated with oil?
YES: Clean the copyboard glass.
Mirrors
3) Is the horizontal reproduction on in copies made in Direct within stan-
dards?
NO: Adjust the distance between No. 1 mirror and No. 2 mirror.
YES: Clean the scanning lamp, reflecting plate, mirrors, and lens.
Dust-proofing glass, Photosensitive drum
4) Clean the durst-proofing glass. Is the problem corrected?
YES: End.
Sharpness
5) Try changing the level of sharpness in service mode. Is the problem cor-
rected?
COPIER>OPTION>BODY>SHARP (A lager setting increases the sharp-
ness.)
YES: End.
NO: Replace the photosensitive drum.

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3.21 The print is blank

Reader unit
1) Does the problem occur only in copy images?
YES: Check the connection of the following PCBs; if normal, replace the
PCB.
1. CCD/AP PCB
2. DC controller PCB
Primary charging assembly
2) Make the following selections in service mode:
COPIER>DISPLAY>DPOT.
(Copier) Are the readings <VDM> ± 6V of the <VDT> ?
(Printer) Are the readings <VDM-P> ± 6V of the <VDT-P> ?
NO:
1. Check the primary charging assembly.
2. Check the HVT PCB.
3. Check the potential sensor and the potential control PCB.
Developing assembly locking unit
3) During printing, is the developing assembly locked against the photo-
sensitive drum?
NO: Check the mechanism of the developing assembly locking unit.
Developing assembly drive assembly
4) During copying, is the developing assembly rotating?
NO: Check the drive system for the developing assembly.
Transfer charging assembly
5) Is the transfer charging assembly fitted fully and securely?
NO: Fit it securely.
6) Is leakage found in the transfer charging assembly?
YES: Check the transfer charging assembly.
NO:
1. Replace the DC controller PCB.
2. Replace the main controller PCB.

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3.22 The print is solid black

Reader unit/Printer unit (isolation)

1) Does the problem occur only in copy images?
YES: Got to step 2).
NO: Go to step 3).
Scanning lamp
2) Is the scanning lamp on?
NO: See “The scanning lamp fails to turn on.”
YES: Check the connection of the following PCBs; if normal, replace the
PCB.
1. CCDAP PCB
2. DC controller PCB
Laser unit
3) Make the following selections in service mode:
COPIER>DISPLAY>MISC>LPOWER. Is the laser output present during
printing?
NO: Replace the laser unit.
YES:
1. Replace the DC controller PCB.
2. Replace the main controller PCB.

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

4. Troubleshooting Malfunctions
4.1 Troubleshooting by Malfunction
4.1.1 E000

Thermistor (TH1, TH2)

1) Clear E000, and turn off and then on the main power switch. Make
the following selections in service mode:
COPIER>DISPLAY>ANALOG. Does <FIX-U> show an increase in
temperature?
YES: The thermistor is faulty. Check the following:
• thermistor for mounting condition
• thermistor for soiled surface
• connection
Fixing heater (H1, H2; open circuit)
2) Is the electrical continuity of the fixing upper heater normal?
NO: Replace the fixing heater.
DC controller PCB, AC driver PCB (faulty)
3) Turn off the main power switch, and let the fixing upper roller cool.
Then, turn on the main power switch. Clear E000, and trun off and
then on the main power switch. Make the following in service
mode: COPIER>I/O>DC-CON. Are bit 4 and bit 5 of IO-P12 ‘0’?
YES: Check the wiring; if normal, replace the DC controller PCB.
NO: Check the wiring; if normal, replace the AC driver PCB.

4.1.2 E001

AC driver PCB (fixing heater drive circuit; short circuit)

1) While keeping the main power switch off, let the fixing upper roller
cool. While at it, check each thermistor for a soiled surface, poor
mounting, and poor connection.
Turn on the main power switch, and clear E001; then, turn off and
then on the power switch. Make the following selections in service
mode: COPIER>DISPLAY>ANALOG. Is <FIX-U> about 230°C or
higher?
YES: Replace the AC driver PCB.
Thermistor (TH1, TH2), DC controller PCB
2) Try replacing the thermistor. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

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4.1.3 E002
4.1.4 E003

General condition
1) Turn on the main power switch, and clear E002/E003. Then, turn
off and then on the main power switch. Is the fixing heater operat-
ing?
NO: See “The fixing heater fails to operate.”
General condition
2) Is the connection of the connectors on the DC controller PCB and
in the fixing assembly good? In addition, is the wiring from the
thermistor to the DC controller PCB good?
NO: Correct the connection/wiring.
Main thermistor (TH1; mounting)
3) Is the thermistor in even contact with the fixing upper roller?
NO: Mount it correctly.
Main thermistor (TH1; soiling)
4) Clean the area of contact of the thermistor. Is the problem cor-
rected?
YES: End.
Main thermistor (TH1; faulty)
5) Try replacing the thermistor. Is the problem corrected?
YES: End.
Fixing heater (H1, H2), DC controller PCB
6) Try replacing the heater. Is the problem corrected?
YES: End.
NO: Replace the DC controller PCB.

4.1.5 E004

Fixing heater (H1, H2), AC driver PCB, DC controller PCB

1) Try replacing the fixing heater. Is the problem corrected?
YES: End.
2) Try replacing the AC driver PCB. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.6 E005

Fixing web
1) Is the fixing web taken up?
YES: Replace the web with a new one.

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Service mode
2) After replacing the fixing web, has the fixing web counter been re-
set in service mode (COPIER>COUNTER>MISC>FIX-WEB) ?
NO: Reset the counter.
Fixing web length detecting lever.
3) Is the position of the web length detecting lever correct?
YES: Correct the position of the lever.
Fixing web length sensor (PS45), DC controller PCB
4) Is the fixing web length sensor normal? (See the instructions on
how to check the photointerrupters.)
NO: Replace the sensor.
YES: Replace the DC controller PCB.

4.1.7 E010

Connector
1) Is the connector of the main motor connected?
NO: Connect the connector.
Main motor (M2), DC controller PCB
2) When the Start key is pressed, does the voltage between J108-A6
(+) and J108-A8 (-) on the DC controller PCB change from 0 to
about 5 V?
YES: Replace the main motor.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.8 E012

1) Are the connectors of the drum (J601, J602) connected securely?

NO: Connect them securely.
DC power supply PCB
2) Turn on the main power switch, and measure the voltage of the
connectors of the drum motor. Is it as indicated?
J601-1:24 V (approx.)
J601-2:0 V
NO: Check the wiring; if normal, replace the DC power supply PCB.

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Drum motor (M1), DC controller PCB

3) Turn on the main power switch, and measure the voltage of the
connectors of the drum motor. Is it as follows?
J602-2:5 V
J602-3:5 V
J602-1:0 V
YES: Replace the drum motor.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.9 E013

Waste toner feedscrew (locked)

1) Is the waste toner feedscrew drive gear pushing the waste toner
feedscrew lock detecting switch (MSW2)?
YES: Connect the connector.
Waste toner feedscrew lock detecting switch (MSW2), DC controller PCB
2) Make the following selections in service mode: COPIER>I/O>DC-
CON. Is bit 15 of IO-P02 ‘0’?
YES: It is likely that the feedscrew inside the waste toner pipe is pre-
vented from rotating because of some fault. If the outlet of the
waste toner pipe is clogged with toner, remove the waste toner
drive unit, and remove the toner. If otherwise, try turning the main
motor clockwise by hand. If the screw rotates, wait and see what
happens; if the screw does not rotate, replace the waste toner feed-
ing unit.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.10 E014

Connectors
1) Are the connectors of the fixing motor connected?
NO: Connect the connectors.
Fixing motor (M19), DC controller PCB
2) When the Start key is pressed, does the voltage between J106-B16
(+) and J106-B18 (-) on the DC controller PCB change from 0 to
about 5 V?
YES: Replace the fixing motor.
NO: Check the wiring; if normal, replace the DC controller PCB.

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4.1.11 E020

General condition
1) Is the developing assembly locking plate mounted correctly?
NO: Mount the plate correctly.
General condition
2) Is the shutter releasing member of the hopper mouth mounted cor-
rectly to the developing assembly locking plate?
NO: It is likely that the inside of the hopper is clogged with toner. Re-
move and then mount back the shutter releasing member to remove
the clog, or replace the hopper unit.
General condition, Developing assembly toner sensor (TS1)
3) Is the developing assembly adequately provided with toner?
YES: Check the developing assembly toner sensor.
General condition, Hopper toner sensor (TS2)
4) Is the hopper adequately provided with toner?
NO: Check the hopper toner sensor.
Hopper connector, Hopper supply motor (M10)
5) Is the connection of the hopper connector normal?
NO: Connect the connector securely.
YES: Check the hopper supply motor.

4.1.12 E032

Connector
1) Is the remote diagnostic device connected securely?
NO: Connect it securely.
Remote diagnostic device
2) Try replacing the remote diagnostic device. Is the problem cor-
rected?
YES: End.
NO: Check the wiring; if normal; replace the main controller PCB.

4.1.13 E061

Laser shutter
1) Remove the laser scanner unit. Is the laser shutter mechanism nor-
mal?
NO: Correct the laser shutter mechanism.
Potential sensor unit
2) Is the potential sensor normal? (See “Checking the Surface Poten-
tial Control System” under “Standards and Adjustments.”)

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Laser unit, DC controller PCB

3) Try replacing the laser unit. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.14 E100

BD PCB
1) Try replacing the BD PCB. Is the problem corrected?
YES: End.
Laser output
2) Try replacing the laser unit. Is the problem corrected?
YES: End.
Laser scanner unit, DC controller PCB
3) Try replacing the laser unit. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.15 E110

Connectors
1) Is the connector (J116) on the DC controller PCB connected se-
curely?
NO: Connect the connector securely.
Connector
2) Open the manual feed cover, and remove the developing assembly
locking plate. Is the relay connector (5-pin) behind the laser scan-
ner plate connected securely? (Do NOT detach the lid of the laser
scanner unit.)
NO: Connect it securely.
Laser scanner unit, DC controller PCB
3) Try replacing the laser scanner unit. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.16 E121

Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanism of the controller cooling fan?
YES: Remove the foreign object.

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Connector
2) Is the connector (J108) on the DC controller PCB connected cor-
rectly?
NO: Connect the connector securely.
Controller cooling fan (FM4), DC controller PCB
3) Try replacing the controller cooling fan. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.17 E196

EEPROMs
1) If the EEPROMs (6 pc.) have been removed from the DC controller
PCB, have they been put back in their initial sockets?
IC Nos. and Stickers on the EEPROMs
IC104: brown, IC105: red, IC109: yellow,
IC110: green, IC127: blue, IC130: white

EEPROMs
2) Are all EEPROMs securely connected to the sockets of the DC con-
troller PCB?
NO: Connect them correctly.
Data
3) Execute the following in service mode:
COPIER>FUNCTION>CLEAR>DC-CON. Is the problem cor-
rected? Thereafter, be sure to enter the service mode data once
again.
YES: Check the operation; if normal, end the work.
EEPROM, DC controller PCB
4) Try replacing the EEPROM. Is the problem corrected?
Thereafter, be sure to enter the service mode data once again.
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.18 E202

General condition
1) Is the scanner in its home position when E202 is indicated?
NO: See “The scanner fails to move forward.”

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Scanner HP sensor (PS39), Reader controller PCB

2) Is the scanner HP sensor normal? (Check the instructions on how
to check photointerrupters.)
NO: Replace the sensor.
YES: Check the wiring; if normal, replace the reader controller PCB.

4.1.19 E204

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Sensor (sensitivity)
2) Adjust the sensitivity of the ADF read sensor. Is the problem cor-
rected?
YES: End.
Read sensor (S2)
3) Try replacing the ADF read sensor. Is the problem corrected?
YES: End.
ADF controller PCB, Reader controller PCB
4) Try replacing the ADF controller PCB. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the reader controller PCB.

4.1.20 E220

Wiring
1) Is the wiring from the xenon lamp to the reader controller PCB
normal?
NO: Disconnect and then connect the connectors; correct or replace the
wiring.
Inverter PCB, Reader controller PCB
2) Try replacing the lamp inverter PCB. Is the problem corrected?
YES: End.
NO: Replace the reader controller PCB.

4.1.21 E225

Xenon lamp (LA2)

1) Try replacing the xenon lamp. Is the problem corrected?
YES: End.

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CCD unit, Reader controller PCB

2) Try replacing the CCD unit. Is the problem corrected?
YES: End.
NO: Check the wring; if normal, replace the reader controller PCB.

4.1.22 E240

Wiring
1) Is the wiring from the main controller PCB to the DC controller
PCB normal?
YES: End.
DC controller PCB, Main controller PCB
2) Try replacing the DC controller PCB. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the main controller PCB.

4.1.23 E243

Wrong operation
1) Turn off and then on the power switch. Is the problem corrected?
YES: Check the operation once again; if normal, end the work.
Control panel CPU PCB, Main controller PCB

YES: End.
NO: Check the wiring; if normal, replace the main controller PCB.

4.1.24 E248

EEPROMs
1) Are the EEPROMs connected securely to the sockets of the reader
controller PCB?
NO: Connect them securely.
Data (faulty)
2) Execute the following in service mode:
COPIER>FUNCTION>CLEAR>R-CON. Is the problem cor-
rected?
Thereafter, be sure to enter the service mode data.
YES: Check the operation; if normal, end the work.
EEPROM, Reader controller PCB
3) Try replacing the EEPROM. Is the problem corrected?
Thereafter, be sure to enter the service mode data newly.
YES: End.
NO: Check the wiring; if normal, replace the reader controller PCB.

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4.1.25 E302

Connectors
1) Are the connectors (J6001/J6002) on the CCD/AP PCB and the
connectors (J5002/J5003) on the reader controller PCB connected
securely?
NO: Connect the connectors securely.
CCD unit
2) Try replacing the CCD unit. Is the problem corrected?
YES: End.
Reader controller PCB, Main controller PCB
3) Try replacing the reader controller PCB. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the main controller PCB.

4.1.26 E601

a. E601-0000
Wiring
1) Are the connection and the cable of the connector (J1017) on the
main controller PCB and the connector (J1551) on the hard disk
drive normal?
NO: Correct the connection/cable.
Hard disk drive (HDD), Main controller PCB
2) Try replacing the hard disk drive and downloading the system soft-
ware. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

b. E601-0001
Wiring
1) Are the connection and the cable of the connector (J122) on the DC
controller PCB and the connector (J1015) on the main controller
PCB normal?
NO: Correct the connection/cable.
DC controller PCB, Main controller PCB
2) Try replacing the DC controller PCB. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

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4.1.27 E602

Wiring
1) Are the connection and the cable of the connector (J1017) on the
main controller PCB and the connector (J1551) on the hard disk
drive normal?
NO: Correct the connection/cable.
Hard disk drive (HDD), Main controller PCB
2) Try replacing the hard disk drive and downloading the system soft-
ware. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

4.1.28 E607

Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanism of the hard disk fan?
YES: Remove the foreign object.
Connector
2) Is the connector (J124) on the DC controller PCB connected se-
curely?
NO: Connect it securely.
Hard disk fan (FM7), DC controller PCB
3) Try replacing the hard disk fan. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.29 E677

Connector
1) Is the connection of the printer board (accessory) normal?
NO: Correct the connection.
Printer board, Main controller PCB
2) Try replacing the printer board.
YES: End.
NO: Check the wiring; if normal, replace the main controller PCB.

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4.1.30 E710

a. E71-0001
Wrong operation, Reader controller PCB
1) Turn off and then on the power switch. Is the problem corrected?
YES: Check the operation once gain; if normal, end the work.
NO: Replace the reader controller PCB.

b. E710-0002
Wrong operation, DC controller PCB
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
NO: Replace the DC controller PCB.

c. E71-0003
Wrong operation, Main controller PCB
1) Turn off and then on the power switch. Is the problem corrected?
YES: Check the operation once gain; if normal, end the work.
NO: Replace the main controller PCB.

4.1.31 E711

a. E711-0001
Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Connector, ADF controller PCB
2) Is the interface cable between the ADF controller PCB and the
reader controller PCB normal?
NO: Correct the cable.
YES: Replace the ADF controller PCB.

b. E711-0002
Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once gain; if normal, end the work.
Connector, Finisher controller PCB
2) Is the interface cable between the finisher controller PCB and the
DC controller PCB normal?
NO: Correct the cable.
YES: Replace the finisher controller PCB.
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c. E711-0003
Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Connector, Remote diagnostic device PCB
2) Is the interface cable between the remote diagnostic device PCB
and the main controller PCB normal?
NO: Correct the cable.
YES: Replace the remote diagnostic device PCB.

4.1.32 E712

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Connector
2) Is the cable between the ADF controller PCB and the reader con-
troller PCB normal?
NO: Correct the cable.
ADF controller PCB, Reader controller PCB
3) Try replacing the ADF controller PCB. Is the problem corrected?
YES: End.
NO: Replace the reader controller PCB.

4.1.33 E713

Wrong operation
1) Turn off and then on the main power switch.
YES: Check the operation once again; if normal, end the work.
Connectors
2) Is the interface cable between the finisher controller PCB and the
DC controller PCB normal?
NO: Correct the cable.
Finisher controller PCB, DC controller PCB
3) Try replacing the finisher controller PCB. Is the problem cor-
rected?
YES: End.
NO: Replace the DC controller PCB.

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4.1.34 E717

Connector
1) Is the remote diagnostic device PCB connected securely?
NO: Connect it securely.
Remote diagnostic device PCB, Main controller PCB
2) Try replacing the remote diagnostic device PCB. Is the problem
corrected?
YES: End.
NO: Replace the main controller PCB.

4.1.35 E719

Connector
1) Is the coin vendor connected securely?
NO: Connect the coin vendor securely.
Coin vendor, Main controller PCB
3) Try connecting to a different coin vendor. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

4.1.36 E732

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Connectors, Reader controller PCB
2) Is the connection of the connector (J1014) on the main controller
PCB and the connector (J5004) on the reader controller PCB nor-
mal? Further, is the cable between these connectors normal?
NO: Correct the connectors/cable.
YES: Replace the reader controller PCB.

4.1.37 E733

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.

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Connectors, DC controller PCB

2) Is the connection of the connector (J1015) on the main controller
PCB and the connector (J122) on the DC controller PCB normal?
Further, is the cable between these connectors normal?
NO: Correct the connectors/cable.
YES: Replace the DC controller PCB.

4.1.38 E740

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
General condition
2) Is the detail code ‘0002’?
YES: Go to step 4.
Connectors
3) Are the connectors of the Network PCB and the connectors of the
main controller PCB normal? Further, is the cable between these
connectors normal?
NO: Correct the connectors/cable.
MAC address setting
4) Have the MAC address checked by the network administrator, and
reset it. Is the problem corrected?
YES: End.
LAN card, Main controller PCB
5) Try replacing the Network PCB. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

4.1.39 E741

Disabling each PCI slot in service mode (BOARD>PCI1-OFF through PCI3-OFF) will
limit the occurrence of errors.
Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation; if normal, end the work.
Board
2) Is the connection between the riser PCB and the main controller
PCB normal? Further, is the cable normal?
NO: Correct the connection/cable.

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Riser board, Main controller PCB

3) Try replacing the riser PCB. Is the problem corrected?
YES: End.
NO: Replace the main controller PCB.

4.1.40 E742

Disabling the PCI slot in service mode (BOARD>PCI1-OFF through PCI3-OFF) can
limit the occurrence of errors.
Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once gain; if normal, end the work.
RIP1 board
2) Execute the following in service mode: BOARD>RIP1-CHK. Does
the generated test print show 32-dot lines?
NO: Check the connection; if normal, replace the RIP1 PCB.
YES: Replace the main controller PCB.

4.1.41 E743

Wrong operation
1) Turn off and then on the main power switch. Is the problem cor-
rected?
YES: Check the operation once again; if normal, end the work.
Connector, Main controller PCB
2) Is the connection of the connector (J1014) on the main controller
PCB and the connector (J5004) on the reader controller PCB nor-
mal? Further, is the cable between these connectors normal?
NO: Correct the connection/cable.
YES: Replace the main controller PCB.

4.1.42 E804

Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanism of the DC power supply fan?
YES: Remove the foreign object.
Connector
2) Is the connector (J102) on the DC controller PCB connected se-
curely?
NO: Connect the connector securely.

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DC power supply fan (FM6), DC controller PCB

3) Try replacing the DC power supply fan. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.43 E805

a. E805-0001
Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanism of the heat discharge fan?
YES: Remove the foreign object.
Connector
2) Is the connector (J111) on the DC controller PCB connected se-
curely?
NO: Connect it securely.
Heat discharge fan (FM3), DC controller PCB
3) Try replacing the heat discharge fan. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

b. E805-0002
Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanisms of the feeding fan?
YES: Remove the foreign object.
Connector
2) Is the connector (J109) on the DC controller PCB connected se-
curely?
NO: Connect the connector securely.
Feeding fan (FM1), DC controller PCB
3) Try replacing the feeding fan. Is the problem corrected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.1.44 E824

Foreign object
1) Is there a foreign object that hinders the rotation of the fan in the
rotating mechanisms of the primary charging cooling fan?
YES: Remove the foreign object.

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Fan (direction, mounting condition)

2) Are the orientation and the mounting of the primary charging cool-
ing fan normal?
NO: Mount the cooling fan correctly.
Connector
3) Is the connector (J103) on the DC controller connected securely?
NO: Connect the connector securely.
Primary charging cooling fan (FM6), DC controller PCB
4) Try replacing the primary charging cooling fan. Is the problem cor-
rected?
YES: End.
NO: Check the wiring; if normal, replace the DC controller PCB.

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4.2.1 AC power is absent

Power plug
1) Is the power plug connected to the power outlet?
NO: Connect the power plug.
Power source
2) Is there rated AC voltage present at the power outlet?
NO: The problem is not in the machine. Advise the user.
Leakage breaker
3) Has the leakage breaker located in the left bottom of the machine
turned on (i.e., is the switch at the marking)?
NO: Remove the cause that turned on the leakage breaker, and shift the
switch of the leakage breaker to the | marking.
Power cord, Line noise filter (LF1)
4) Try replacing the power cord/line filter. Is the problem corrected?
NO: Check the wiring of the AC power supply line and the connectors
for poor contact.
Main power switch (SW1), Wiring
5) Is the resistance 0Ω Ω when the switch is turned on and ∞Ω when the
switch is turned off?
NO: Replace the power switch.
YES: Check the wring of the AC power line and the connectors for poor
contact.

4.2.2 DC power is absent

AC power supply
1) Is there rated AC voltage between connectors J4001-1 and J4001-2
on the DC power supply PCB?
NO: See “AC power is absent.”
Fuse (F4001)
2) Is the fuse on the DC power supply PCB blown?
YES: Remove the cause of the fuse, and replace the fuse.

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Wiring, DC load, DC power supply PCB

3) Turn off the main power switch. Is the voltage between the follow-
ing terminals on the DC power supply PCB as indicated when the
power is turned on in about 3 min?
Connector Output voltage Remarks
J4014-1 to 5 3VA1 ± 3%
J4017-1 to 5 3VA2 ± 3%
J4003-7 3VA3 ± 3%
J4015-1 to 3 3VB + 2%, - 2.5%
J4003-5 5V ± 3%
J4004-1 5V ± 3%
J4008-1 5V ± 3%
J4009-1 5V ± 3%
J4016-1, 2 5V ± 3%
J4003-3, 4 12VU ± 5%
J4005-1 24VU1 ± 5%
J4004-3 24VU2 ± 5%
J4009-3 24VU2 ± 5%
J4003-1 24VU3 ± 5%
J4006-1 24VU3 ± 5%
J4007-1, 3 24VU4 ± 5%
J4010-1 24VU4 ± 5%
J4011-1 24VU4 ± 5%
J4013-2 24VA + 7%, - 5%
However, the above output voltages assume tolerances of ±10% in
the AC input power.
YES: Check the wiring from the DC power supply PCB to each load.
NO: Replace the DC power supply PCB.

4.2.3 Pickup fails

General condition
1) Slide out and then in the cassette. Is the sound of the lifter falling
and the lifter motor rotating heard?
NO: See “The lifter fails to move up.”
Sensor
2) In service mode (COPIER>DISPLAY>JAM), find out which sensor
has detected the jam. Is the sensor normal?
NO: Check the wiring and the sensor lever; if normal, replace the sen-
sor.
Drive motor
3) Is each drive motor mounted correctly?
NO: Mount the motor correctly.

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Right upper cover, Right lower cover

4) Are the right upper cover and the right lower cover closed fully?
NO: Close the covers. If there is a gap, correct it.
Pressure spring
5) Are the springs of the right upper cover and the right lower cover
exerting pressure on the vertical path rollers 1, 2, 3, and 4?
NO: Check the pressure springs.
Pre-registration motor (M17), vertical path duplex/feeding motor (M25), Vertical path upper
motor (M26), Vertical path lower motor (M27)
6) Open the right upper cover and the right lower cover, and put pa-
per over the cover open/closed sensor assembly; then, turn on
(MTR-ON) the motor in question in service mode
(COPIER>FUNCTION>PART-CHK>MTR). Does the vertical path
rollers 1, 2, 3, and 4 or the pre-registration roller rotate?
Motor Code
Pre-registration motor 22
Vertical duplex/ feeding motor 15
Vertical path upper motor 17
Vertical path lower motor 16
NO: Check the wiring and the motor driver PCB; if normal, replace the
motor.
Registration roller clutch
7) Is the leading edge of paper as far as the registration roller assem-
bly?
YES: See “The registration roller fails to rotate.”
Pickup assembly
8) Open the right upper cover and the right lower cover, and put pa-
per over the door switch. When the Start key is pressed, does the
feeding/separation roller rotate to move paper normally?
NO: Check the pickup assembly by referring to 5. “Troubleshooting
Feeding Faults.”
Right deck pickup motor (M11), Left deck pickup motor (M24), Cassette 3/4 pickup motor
(M12), DC controller PCB
9) Set the meter range to 30 VDC, and connect the meter probes to the
connectors on the DC controller PCB of the motor in question as
indicated. Does the voltage change from 24 to 0 V when the Start
key is pressed?
Motor + -
Right deck pickup motor J104-A5, A6 GND
Left deck pickup motor J104-B4, B3 GND
Cassette 3/4 pickup motor J104-A11, A12 GND
YES: Check the wiring and the motor driver PCB; if normal, replace the
motor.
NO: Replace the DC controller PCB.

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4.2.4 The lifter fails to move up (pickup from front deck)

Gear, Lever
1) Remove the deck, and move up the lifter by hand. Does it move
smoothly?
NO: Check the gear and the lever.
Spring, Lever
2) Push up the pickup roller releasing lever with a finger. Does the
pickup roller move down?
NO: Remove the pickup assembly, and check the springs and the lever.
Right deck open/closed sensor (PS5), Left deck open/closed sensor (PS9)
3) When the deck is inserted, is the voltage of the following connectors
on the DC controller PCB about 5 V?
Sensor + -
Right deck open/closed sensor J112-B2 J112-B1
Left deck open/closed sensor J115-A14 J115-A13
NO: Check the sensor flag and the wiring; if normal, replace the sensor.
Right deck limit sensor (PS8), Left deck limit sensor (PS12)
4) Is the voltage of the following connectors on the DC controller PCB
about 0 V?
Sensor + -
Right deck limit sensor J112-B8 J112-B7
Left deck limit sensor J115-A2 J115-A1
NO: Check the sensor flag and the wiring; if normal, replace the sensor.
Right deck lifter motor (M5), Left deck lifter motor (M4), DC controller PCB
5) Turn on the main power switch, and set the meter range to 30 VDC;
then, connect the - probe of the meter to GND and the + probe to
the following connectors of the DC controller PCB. Does the voltage
change from about 0 V to 24 V when the deck is inserted?
Motor + -
Right deck lifter motor J105-13 GND
Left deck lifter motor J105-12 GND
YES: Check the wiring and the motor drive PCB; if normal, replace the
motor.
NO: Replace the controller PCB.

4.2.5 The lifter fails to move up (pickup from cassette)

Cassette size detecting switch, Service mode

1) Is the size of the cassette indicated on the control panel?
NO: Check the cassette size detecting switch. Or, check the cassette pa-
per size setting in service mode.

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Cassette latch
2) Is the movement of the cassette open button assembly normal?
NO: Mount it correctly.
Spring, Lever
3) Move up the pickup roller releasing lever with your finger. Does the
pickup roller move down?
NO: Remove the pickup assembly, and check the spring and the lever.
Cassette 3 open/closed sensor (PS15), Cassette 4 open/closed sensor (PS16)
4) When the deck is inserted, is the voltage of the following connectors
on the DC controller PCB about 5 V?
Sensor + -
Cassette 3 open/closed sensor J110-A11 J110-A10
Cassette 4 open/closed sensor J110-B11 J110-B10
NO: Check the sensor flag and the wiring; if normal, replace the sensor.
Cassette 3 lifter motor (M20), Cassette 4 lifter motor (M21), DC controller PCB
5) Turn on the main power switch, and set the meter range to 30 VDC;
then, connect the - probe of the meter to GND and the + probe to
the following connectors from the DC controller PCB. When the
cassette is inserted, does the voltage change from about 0 to 24 V?
Motor + -
Cassette 3 lifter motor J105-11 GND
Cassette 4 lifter motor J105-10 GND
YES: Check the wiring and the motor drive PCB; if normal, replace the
motor.
NO: Replace the DC controller PCB.

4.2.6 Pickup fails (manual feed)

Wiring
1) Is the connector (to the machine) of the manual pickup tray assem-
bly connected correctly?
NO: Connect the connector correctly.
General condition
2) Is the leading edge of paper as far as the registration roller?
YES: See “The registration roller fails to rotate.”
Feeding roller, Separation roller
3) Is the orientation of the feeding roller and the separation roller cor-
rect?
NO: Mount the roller correctly.
Manual feed paper sensor (PS23)
4) When paper is placed on the manual feed pickup tray, does bit 0 of
COPIER>I/O>DC-CON>IO-P01 change from ‘1’ to ‘0’?
NO: Check the wiring and the sensor flag; if normal, replace the sensor.

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Manual feed pickup clutch (CL3)

5) Execute ‘code: 1’ by making the following selections in service
mode: COPIER>FUNCTION>PART-CHK>CL. Is the sound of the
clutch operating heard?
NO: Check the wiring; if normal, replace the clutch.
Manual feed releasing solenoid (SL2)
6) Execute ‘code : 5’ by making the following selections in service
mode: COPIER>FUNCTION>PART-CHK>SL. Does the solenoid
turn on?
NO: Check the wiring and the link; if normal, replace the solenoid.
DC controller PCB
7) Try replacing the DC controller PCB. Is the problem corrected?
YES: End.
NO: Check the wiring to the solenoid and the connection of the connec-
tors.

4.2.7 The vertical path roller fails to rotate

Belt, Gear, Coupling

1) It the drive from the vertical path duplex/feeding motor (M25)
transmitted to each vertical path roller through the belt, gear, and
coupling?
NO: Mount the belt, gear, and coupling correctly.
Vertical path duplex/feeding motor (M25)
2) Execute ‘code: 15’ by making the following selections in service
mode: COPIER>FUNCTION>PART-CHK>MTR. Does the motor
operate?
NO: Check the wiring and the motor driver PCB; if normal, replace the
motor.
Vertical path upper motor (M26)
3) Execute ‘code: 17’ by making the following selections in service
mode : COPIER>FUNCTION>PART-CHK>MTR. Does the motor
operate?
NO: Check the wiring and the motor driver PCB; if normal, replace the
motor.
Vertical path lower motor (M27)
4) Execute ‘code: 16’ by making the following selections in service
mode: COPIER>FUNCTION>PART>CHK>MTR. Does the motor
operate?
NO: Check the wiring and the motor driver PCB; if normal, replace the
motor.

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Pre-registration motor (M17)

5) Execute ‘code: 22’ by making the following selections in service
mode: COPIER>FUNCTION>PART-CHK>MTR. Does the motor
operate?
NO: Check the wiring and the motor driver PCB; if normal, replace the
motor.
DC controller PCB
6) Try replacing the DC controller PCB. Is the problem corrected?
YES: End.

4.2.8 The registration roller fails to operate

Gear, Coupling
1) Is the drive from the main motor (M2) transmitted to the registra-
tion roller through the gear and coupling?
NO: Mount the gear and coupling correctly.
Registration paper sensor (PS29)
2) Place paper over the sensor. Does bit 1 of COPIER>I/O>DC-
CON>IO-P01 in service mode change from ‘0’ to ‘1’?
NO: Check the wiring and the sensor flag; if normal, replace the sensor.
Registration roller clutch (CL2)
3) Execute ‘code: 5’ by making the following selections in service
mode: COPIER>FUNCTION>PART-CHK>CL. Does the clutch
operate?
NO: Check the wiring and fixing/feeding relay PCB; if normal, replace
the clutch.
DC controller PCB
4) Try replacing the DC controller PCB. Is the problem corrected?
YES: End.

4.2.9 The No. 1 mirror mount fails to operate

Cable (broken, displaced)

1) Is the scanner drive cable routed correctly?
NO: Route the scanner drive cable correctly.
Foreign obstacle (in scanner path)
2) Is the scanner rail free of dirt? Further, does the scanner move
smoothly when pushed by hand?
NO: Check the scanner rail for surface dirt and foreign matter or object;
as necessary, clean, lubricate, or correct.
If the surface of the rail is soiled, clean it with alcohol, and apply a
small amount of silicone oil (FY9-6010).

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Wiring, Connector
3) Are the connection and the wiring of the connectors from J5004 on
the reader controller PCB to J1014 on the main controller PCB
normal?
NO: Correct the wiring, and connect the connectors securely.
Scanner motor (M3), Reader controller PCB

YES: End.
NO: Replace the reader controller PCB.

4.2.10 The pre-exposure LED fails to turn on

Pre-exposure LED (LA1)

1) Press the Start key. Does the state of bit 4 in service mode
(COPIER>I/O>DC-CON>IO-P15) change from ‘0’ to ‘1’?
YES: Check the wiring from the DC controller PCB to the pre-exposure
LED; if normal, replace the pre-exposure LED.
Pre-exposure LED (LA1), DC controller PCB
2) Set the meter range to 30 VDC. Does the voltage between J103-A3
(+) and J103-A4 (GND) on the DC controller PCB change from 0 to
24 V?
YES: Check the wiring from the DC controller PCB to the pre-exposure
LED; if normal, replace the pre-exposure LED.
NO: Replace the DC controller PCB.

4.2.11 The scanning lamp fails to turn on

Lamp (mounting)
1) Is the scanning lamp mounted correctly?
NO: Disconnect the power plug from the power outlet, and mount the
lamp correctly.
Reader controller PCB
2) Press the Start key. Does bit 7 in service mode (COPIER>I/O>R-
CON>IO-P1) change from ‘1’ to ‘0’?
NO: Replace the reader controller PCB.
Inverter PCB
3) Try replacing the inverter PCB. Is the problem corrected?
YES: End.
Scanning lamp (LA2), Reader controller PCB
4) Try replacing the scanning lamp. Is the problem corrected?
YES: End.
NO: Replace the reader controller PCB.

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4.2.12 The hopper stirring motor (M9) fails to operate

General condition
1) Execute ‘code: 5’ (MTR-ON) in service mode
(COPIER>FUNCTION>PART-CHK>MTR). Does the motor oper-
ate?

Hopper toner sensor (TS2)

2) Is bit 10 in service mode (COPIER>I/O>DC-CON>IO-P02) ‘0’, in-
dicating the absence of toner?
YES: If the hopper is adequately supplied with toner, replace the sensor.
DC controller PCB
3) Execute ‘code: 5’ (MTR-ON) in service mode
(COPIER>FUNCTION>PART-CHK>MTR) to turn on the motor.
Does the voltage between J103-B7 (+) and J103-B8 (GND) on the
controller PCB change to about 24 V?
NO: Replace the DC controller PCB.
Relay connector (J153, J158)
4) Is the connection of the relay connector secure?
NO: Connect it securely.

4.2.13 The hopper supply motor (M10) fails to operate

General condition
1) Execute ‘code: 6’ (MTR-ON) in service mode
(COPIER>FUNCTION>PART-CHK>MTR). Doe the motor oper-
ate? Be sure to turn off the motor within about 10 sec to prevent
clogging with toner.
NO: Go to step 3).
Hopper toner sensor (TS2)
2) Is bit 10 in service mode (COPIER>I/O>DC-CON>IO-02) ‘0’, indi-
cating the absence of toner?
YES: If the hopper is adequately supplied with toner, replace the sensor.
DC controller PCB
3) Execute ‘code: 6’ in service mode (MTR-ON)
(COPIER>FUNCTION>PART-CHK>MTR) to operate the motor.
Does the voltage between J103-B5 (+) and J103-B6 (GND) on the
DC controller PCB change to about 24 V?
NO: Replace the DC controller PCB.
Relay connector (J153, J155)
4) Is the connection of the relay connector secure?
NO: Connect it securely.

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4.2.14 The drum heater fails to operate

General condition
1) Open the front cover, and release the fixing/feeding unit. Is the end
of the photosensitive drum warm? (Do not touch the surface of the
photosensitive drum.)
YES: The drum heater is normal.
Environment switch
2) Is the setting of the environment switch located at the left bottom of
the machine ‘ON” (powered at all times)?
NO: Set it to ‘ON’. If set to ‘OFF’, it is linked to the main power
switch.
DC controller PCB, AC driver PCB
3) Set the meter range to 12 VDC. Connect the probes of the meter to
J102-B8 (+) and J102-B7 (-) on the DC controller PCB. Is the volt-
age between terminals about 2 V during copying and 0 V during
standby?
NO: Replace the DC controller PCB.
Drum heater (H3)
4) Remove the drum, and set the meter range to Ωx1. Does the index
of the meter swing when the probes of the meter are connected to
both ends of the heater?
NO: Replace the drum heater.
YES: Replace the heater control PCB.

4.2.15 The Add Toner message fails to turn on

General condition
1) Is there toner in the hopper?
YES: Go to step 2).
Hopper toner sensor (TS2), DC controller PCB
2) Replace the hopper toner sensor. Is the problem corrected?

NO: Check the wiring; if normal, replace the DC controller PCB.

4.2.16 The Add Toner message fails to turn off

Toner (amount)
1) Is there toner in the hopper?
NO: Supply toner. (Find out how the user is supplying toner.)

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Hopper toner sensor (TS2), DC controller PCB

2) Is bit 10 in service mode (COPIER>I/O>DC-CON>IO-P02) ‘0’, in-
dicating the absence of toner?
YES: Replace the hopper toner sensor.
NO: Check the wiring; if normal, replace the DC controller PCB.

4.2.17 The Set Control Card message fails to turn on

CC-IV
1) Can a print be made without inserting a control card?
YES: Check to find out if the connector of the CC-IV has a short circuit.
Control panel, Main controller PCB
2) Try replacing the control panel. Is the message indicated?
YES: End.
NO: Check the wiring from the control panel to the main controller
PCB; if normal, replace the main controller PCB.

4.2.18 The Set Control Card message fails to turn off

Control card
1) Is the control card inserted correctly?
NO: Insert the control card correctly.
CC-IV, Main controller PCB
2) Can a print be made by pressing the Start key?
YES: Replace the CC-IV.
NO: Replace the main controller PCB.

4.2.19 The Add Paper message fails to turn on (front deck)

Right deck paper sensor (PS7), Left deck paper sensor (PS11)
1) Is the deck paper sensor mounted correctly? Further, is the move-
ment of the sensor flag normal?
NO: Mount the sensor correctly.

4.2.20 The Add Paper message fails to turn off (cassette 3/4)

Cassette 3 paper sensor (PS13), Cassette 4 paper sensor (PS14)

1) Is the cassette paper sensor mounted correctly? Further, is the
movement of the sensor flag normal?
NO: Mount the sensor correctly.

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Cassette pickup assembly

2) Is the lifter mechanism of the cassette normal?
NO: Replace the lifter unit or the cassette pickup assembly.

4.2.21 The fixing heater fails turn on

Fixing/feeding lock sensor (MSW3)

1) Is the fixing/feeding lock sensor mounted correctly?
NO: Mount the fixing/feeding lock sensor correctly.
YES: Replace the sensor.
Thermal switch (TP1)
2) Connect the probes of the meter to both terminals of the thermal
switch. Is there electrical continuity?
NO: Replace the thermal switch.
Main relay (RL1)
3) Try replacing the main relay. Is the problem corrected?
YES: End.
Fixing heater (H1, H2)
4) Connect the probes of the meter to both terminals of the fixing
heater. Is there electrical continuity?
NO: Replace the fixing heater.
AC driver PCB, DC controller PCB
5) Is the voltage between the following connectors on the DC control-
ler PCB about 5 V?
Heater + -
Main heater (H1) J102-B11 J102-B7
Sub heater (H2) J102-B9 J102-B7
YES: Replace the AC driver PCB.
NO: Replace the DC controller PCB.

4.2.22 Pickup fails (paper deck)

Right upper cover, Right lower cover

1) Are the right upper cover and the right lower cover closed prop-
erly?
NO: Close the covers.
Lifter
2) Slide out the compartment from the deck. Does the lifter move
down? Further, does the lifter move up when the compartment is
slid inside the deck?
NO: See “The deck lifter fails to move up.”

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Deck pickup roller

3) Does the deck pickup roller rotate?
YES: If the roller is soiled, clean it with alcohol. If it is deformed be-
cause of wear, replace it.
Belt (displacement)
4) Is the belt used to transmit drive to the deck pickup roller attached
correctly?
NO: Attach the belt correctly.
Gear
5) Is the drive from the deck main motor transmitted through the
gear?
NO: Check the gear.
Deck pickup clutch (CL102), Deck driver PCB
6) Measure the voltage of the connector on the deck driver PCB. Does
the voltage change from 24 to 0 V when the Start key is pressed?
Clutch + -
Deck pickup clutch J05-11 J05-12
YES: Check the wiring; if normal, replace the clutch.
NO: Replace the deck driver PCB.

4.2.23 The deck lifter fails to move up (side paper deck)

Deck
1) Is the deck mounted correctly?
NO: Mount the deck correctly.
Lifter cable
2) Is the lifter cable routed correctly?
NO: Route the lifter cable correctly.
Spring, Lever
3) Push up the deck pickup roller releasing lever with your finger.
Does the roller move down?
NO: Remove the pickup assembly, and check the spring and the lever.
Deck lifter motor (M102)
4) Does the deck lifter motor rotate?
YES: Go to step 6).
Deck open detecting switch (SW101), Deck driver PCB
5) Does the voltage between J10-1 (+) and J10-3 (GND) on the deck
driver PCB change from about 0 to 5 V when the deck is closed?
YES: Check the wiring to the switch; if normal, replace the switch.
NO: Replace the deck driver PCB.

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Deck lifter lower limit detecting switch (SW102), Deck driver PCB
6) Is the voltage between J08-8 (+) and J08-7 (GND) on the deck
driver PCB as follows when the deck is opened/closed?
opened: 0V
closed: 5V
YES: Check the lever and the wiring; if normal, replace the switch.
NO: Replace the deck driver PCB.

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5. Troubleshooting Feeding Faults

5.1 Paper Jams
Jams occurring in the machine may be grouped into the following by location:

1. Pickup assembly
2. Separation/feeding assembly
3. Fixing/delivery assembly
4. Drum cleaning assembly
5. Duplex reversing assembly
6. Feeding assembly

The troubleshooting procedures that follow are organized according to location; to find
out the location and the nature of a jam, use service mode (COPIER>DISPLAY>JAM).

[3] [4]

[2] [1]

[5] [6]

F04-501-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

5.1.1 Pickup assembly

Pickup assembly
1) Is the print paper curled or wavy?
YES: Replace the paper. Advise the user on the correct method of storing
paper.
2) Try paper of a recommended type. Is the problem corrected?
YES: Advise the user to use recommended paper.
DC controller PCB, Pickup clutch
DC controller PCB, Pickup clutch
3) Are the pickup roller of the selected cassette or the deck and the
feeding roller of the manual feed tray rotating during printing?
NO: See "Pickup fails" for each source of paper.
Pickup roller
4) Is the pickup roller deformed or worn?
YES: Replace the pickup roller.
Guide plate
NO: Check the guide plate for deformation.

5.1.2 Separation/Feeding assembly

Print paper
1) Is the leading edge of print paper past the registration roller?
YES: Go to step 5.
NO: Check the distance between the upper and lower guides in front of
the registration roller; then, make adjustments as needed.
Registration roller
2) Is the coupling of the registration roller engaged correctly?
NO: Mount the fixing/feeding unit correctly.
3) Is the registration roller deformed (worn) or soiled?
YES: If dirt is found, clean it with alcohol; if deformation (e.g., wear) is
found, replace it.
4) Are the retaining springs on both ends of the registration roller
mounted correctly?
NO: Mount them correctly.
YES: Check the transfer guide for foreign matte and deformation.
Registration clutch
5) Is the operation of the registration clutch normal?
NO: Check the registration clutch.

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Transfer/Separation charging assembly

6) Is the transfer/separation charging assembly mounted securely?
YES: Check the transfer/separation charging assembly.
7) Are there burrs on the paper guide of the transfer/separation
charging assembly?
YES: Remove the burrs.
8) Is there foreign matter on the transfer/separation charging assem-
bly?
YES: Remove the foreign matter.
Print paper
9) Try paper of a recommended type. Is the problem corrected?
YES: Advise the user to use recommended paper.
Separation claws (cleaning assembly)
10) Are the separation claws under the cleaning assembly damaged?
YES: Replace the separation claws.
11) Is the spring of the separation claw displaced?
YES: Mount the spring correctly.
Feeding belt
12) Are the three feeding belts rotating correctly?
YES: Check to see if the feeding fan is operating.
Feeding fan
YES: Check to make sure that the feeding fan is operating.

5.1.3 Fixing/Delivery assembly

Separation claws (delivery assembly)

1) Are the separation claws worn/deformed?
YES:
1. Replace the separation claws.
2. If dirt is found, clean them with solvent.
Upper/lower roller (fixing assembly)
2) Is the upper/lower roller of the fixing assembly worn or scratched?
YES: Replace the roller.
Paper guide (fixing assembly)
3) Is the paper guide soiled with toner?
YES: Clean it with solvent.
4) Is the height of the paper guide normal?
NO: Adjust it.
5) Is the inlet guide switched over to suit the passage of small-size pa-
per and large-size paper?
NO: Check the fixing assembly inlet guide drive solenoid (SL1).

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Nip
6) Is the lower roller pressure (nip) as indicated?
NO: Adjust it.
Web
7) Is the web taken up correctly?
NO: Check the fixing cleaning assembly.
8) Move the plunger of the fixing web solenoid (SL9) by hand. Is the
web taken up?
NO: Check the fixing web drive assembly.
Delivery assembly sensor lever
9) Does each sensor lever of the delivery assembly move smoothly?
NO: Adjust it so that it moves smoothly.
Delivery sensor
10) Are the external delivery sensor (PS36) and the fixing assembly out-
let sensor (PS4) normal?
NO: Replace the sensor.
Delivery paper deflecting plate
11) Move the delivery paper deflecting plate with your finger. Dos it re-
turn to its initial position by the work of the spring?
NO: Correct how the delivery paper deflecting plate is mounted.
12) Us the paper path of the delivery paper deflecting plate deformed
or scratched?
YES: Replace the delivery paper deflecting plate.
Delivery roller drive assembly
13) Does the delivery roller move smoothly?
NO: Check the delivery roller drive assembly.
Leading edge margin
14) Is the leading edge margin of print paper 0.3 mm or more and 5.5
mm or less?
NO: Make adjustments in service mode so that the margin is as indi-
cated.

5.1.4 Fixing/Delivery assembly (face-down delivery assembly)

Delivery sensor
1) Is the internal delivery sensor (PS35) normal?
NO: Replace the sensor.
Reversal sensor
2) Is the reversal sensor 2 (PS3) normal?
NO: Replace the sensor.
Delivery flapper solenoid (SL5)
3) Does the delivery flapper move correctly?
NO: Correct the potion of the delivery flapper solenoid, or replace it.

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

Reversal flapper solenoid (SL8)

4) Does feeding reversal flapper move correctly?
NO: Correct the position of the reversal flapper solenoid, or replace it.
Reversal motor (M14)
5) Does the reversal motor (M14) rotate at the correct timing?
NO: Replace the reversal motor (M14).

5.1.5 Cleaning Assembly

Transfer/Separation charging assembly, Pre-transfer charging assembly

1) Are feeding transfer/separation charging assembly and the pre-
transfer charging assembly fitted correctly?
NO: Fit the transfer/separation charging assembly correctly.
2) Is the height of the charging wire as indicated?
NO: Adjust the height of the charging wire.
Separation claws (cleaning assembly)
3) Are the separation claws under the cleaning assembly damaged?
YES: Replace the separation claws.
4) Is the spring of the separation claws displaced?
YES: Mount the spring correctly.
Print paper, High-voltage transformer, DC controller PCB
5) Try paper of a type recommended by Canon. Is the problem cor-
rected?
YES: Advise the user to use recommended paper.
NO:
1. Check the high-voltage transformer.
2. Check the DC controller PCB.

5.1.6 Feeding Assembly

1) Is the duplex feeding assembly mounted correctly?

NO: Mount it correctly.
Sensor lever
2) Do the sensor levers of the reversal sensor 1 (PS37), duplex paper
sensor (PS34), and the duplex pre-registration paper sensor (PS30)
move smoothly?
NO: Adjust them so that they move smoothly.
Sensor
3) Are the reversal sensor 1 (PS37), duplex paper sensor (PS34), and
duplex pre-registration paper sensor (PS30) normal?
NO: Replace any faulty sensor.

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Motor
4) Do the reversal motor (M14), duplex feeding left motor (M29), du-
plex feeding right motor (M18), and vertical path duplex motor
(M25) rotate at the correct timing?
NO: Replace the motor.

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5.2 Feeding Faults

5.2.1 Double Feeding

Separation roller
1) Is the separation roller deformed or worn?
YES: Replace the separation roller.
Spring
NO: Replace the spring used to pull the separation roller.

5.2.2 Wrinkles

Pickup assembly
1) Turn off the power while print paper is moving through the feeding
assembly. At this time, is the print paper wrinkled? Or, is the paper
askew?
YES: Check the pickup assembly.
Check the guide in front of the registration roller.
Check the registration roller.
Check the operation for the feeding fan.
Check the separation charging assembly.
Print paper
2) Try paper fresh out of package. Is the problem corrected?
YES: The paper may be moist. Advise the user on the correct method of
storing paper.
3) Try paper recommended by Canon. Is the problem corrected?
YES: Advise the user to use recommended paper.
Paper guide, Fixing assembly inlet drive solenoid (SL1)
4) Is the paper guide coated with toner or foreign matter?
YES: Clean it with solvent.
5) Are the height of the paper guide and the movement of the solenoid
correct?
NO: Correct the height of the paper guide and the operation of the sole-
noid.
Lower roller pressure
6) Is the lower roller pressure (nip) as indicated?
NO: Adjust it.
Upper/lower roller
YES: Try replacing the upper and lower roller one after the other.

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6. Arrangement and Functions of Electrical Parts

6.1 Clutches

CL1

CL3
CL2

CL4

F04-601-01

6.1.1 Reader Unit

The reader unit does not have a clutch.

6.1.2 Printer Unit

Symbol Name Notation Function

Clutch CL1 Drives the developing cylinder.
CL2 Drives the registration roller.
CL CL3 Drives the manual feed pickup roller.
CL4 Drives the left deck pull-off roller.

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-59 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.2 Solenoids and Switches

SL2

SL5 MSW2
SL9 SL1
SL8 SW2
MSW3

SL3

SL4

MSW1
SW1

SL6

SL7

SW4
SW3

F04-602-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.2.1 Reader Unit

The reader unit does not have a solenoid or a switch.

6.2.2 Printer Unit

Symbol Name Notation Function

Solenoid SL1 Drives the fixing assembly inlet guide.
SL2 Drives the manual feed pickup mechanism.
SL
SL3 Drives the cassette 3 pickup mechanism.
SL4 Drives the cassette 4 pickup mechanism.
SL5 Drives the delivery flapper.
SL6 Drives the right deck pickup mechanism.
SL7 Drives the left deck pickup mechanism.
SL8 Drives the reversing flapper.
SL9 Drives the fixing web.

Switch SW1 Main power switch

SW2 Front cover switch
SW3 Environment switch
SW4 Cassette heater switch

MSW1 Detects the state (locked) of the waste toner screw.

MSW2 Detects the state (open/closed) of the manual feed tray
cover detection
MSW3 Detects the attachment/detachment of the fixing/feed-
ing unit.

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-61 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.3 Motors

M3

M15

M10 M9

M13
M6
M16 M7
M4 M8

M19 M18
M5

M29
M14
M20

M21

M17 M1

M25 M2

M26
M11

M24

M27
M12

F04-603-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.3.1 Reader Unit

Symbol Name Notation Function

Motor M3 Scanner motor
M

6.3.2 Printer Unit

Symbol Name Notation Function

Motor M1 Drum motor
M2 Main motor
M
M4 Left deck lifter motor
M5 Right deck lifter motor
M6 Primary charging wire cleaning motor
M7 Pre-transfer charging wire cleaning motor
M8 Transfer/separation charging wire cleaning motor
M9 Hopper stirring motor
M10 Hopper supply motor
M11 Right deck pickup motor
M12 Cassette 3/4 pickup motor
M13 Delivery motor
M14 Reversal motor
M15 Laser scanner motor
M16 Duplex horizontal registration motor
M17 Pre-registration motor
M18 Duplex feeding right motor
M19 Fixing motor
M20 Cassette 3 lifter motor
M21 Cassette 4 lifter motor
M24 Left deck pickup motor
M25 Vertical path duplex feeding motor
M26 Vertical path upper motor
M27 Vertical path lower motor
M29 Duplex feeding left motor

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-63 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.4 Fans

FM7

FM2

FM5
FM8

FM6

FM4

FM1

FM3

F04-604-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.4.1 Reader Unit

The reader unit does not have a fan.

6.4.2 Printer unit

Symbol Name Notation Function

Fan FM1 Feeding fan
FM2 Primary charging cooling fan
FM3 Heat discharging fan
FM4 Controller cooling fan
FM5 De-curling fan
FM6 DC power supply fan
FM7 HDD fan
FM8 Duplex feeding fan

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-65 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.5 Sensors

PS23

PS25
PS48
PS47
PS26
PS50 SV1 PS13
PS49 PS21
SVR4 PS17 PS15
SV2
PS27 SVR2
SVR5 PS14
PS22
PS18 SVR3
PS16

PS43

PS39
PS40 PS24

PS28

PS7
PS32

PS8
PS19
PS6
PS12 PS11 PS5
PS20
PS10
PS9

F04-605-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

SVR1

PS3

PS30
PS31 PS34

PS38
PS33
PS37

PS2

PS29

PS4
PS35
PS45
PS36

PS46

F04-605-02

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-67 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.5.1 Reader Unit

Symbol Name Notation Function

Photointerrupter PS39 Scanner HP sensor
PS40 Copyboard cover sensor

SIZE Photosensor PS43 Original sensor

6.5.2 Printer Unit

Symbol Name Notation Function

Photointerrupter PS2 Right lower cover open/closed sensor
PS3 Manual feed tray open/closed sensor
PS4 Claw jam sensor
PS5 Right deck open/closed sensor
PS6 Right deck lifter sensor
PS7 Right deck paper sensor
PS8 Right deck limit sensor
PS9 Left deck open/closed sensor
PS10 Left deck lifter sensor
PS11 Left deck paper sensor
PS12 Left deck limit sensor
PS13 Cassette 3 paper sensor
PS14 Cassette 4 paper sensor
PS15 Cassette 3 open/closed sensor
PS16 Cassette 4 open/closed sensor
PS17 Cassette 3 lifter sensor
PS18 Cassette 4 lifter sensor
PS19 Right deck re-try sensor
PS20 Left deck re-try sensor
PS21 Cassette 3 re-try sensor
PS22 Cassette 4 re-try sensor
PS23 Manual feed paper sensor
PS24 Vertical path 1 paper sensor
PS25 Vertical path 2 paper sensor
PS26 Vertical path 3 paper sensor
PS27 Vertical path 4 paper sensor
PS28 Laser write start sensor
PS29 Registration paper sensor
PS30 Duplex pre-registration sensor

4-68 T COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

Symbol Name Notation Function

Photointerrupter PS31 Duplex horizontal registration sensor
PS32 Right deck feed paper sensor
PS33 Left deck feed paper sensor
PS34 Duplexing paper sensor
PS35 Internal delivery sensor
PS36 External delivery sensor
PS37 Reversal sensor 1
PS38 Reversal sensor 2
PS45 Fixing web length sensor
PS46 Delivery jam sensor
PS47 Right deck level sensor (upper)
PS48 Right deck level sensor (lower)
PS49 Left deck level sensor (upper)
PS50 Left deck level sensor (lower)

Photointerrupter SV1 Detects the length of paper in the cassette 4.

SV (100-V model only)
SV2 Detects the length of paper in the cassette 3.

Slide resistor SVR1 Detects the width of paper on the manual feed
tray.
SVR2 Detects the level of paper in the cassette 3.
SVR3 Detects the level of paper in the cassette 4.
SVR4 Detects the width of paper in the cassette 3.
SVR5 Detects the width of paper in the cassette 4.
(100-V model only)

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-69 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.6 Lamps, Heaters, and Others

LA2
H5
LA1
H6
H3 TS1
THM2 TS2
THM1
TP1

H1
H2

HU1

ELCB H4

F04-606-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.6.1 Reader Unit

Name Notation Function

Lamp LA2 Scanning lamp

Heater H5 Lens heater (standard in 100-V model)

H6 Mirror heater (standard in 100-V model)

6.6.2 Printer Unit

Name Notation Function

Lamp LA1 Pre-exposure lamp (LED)

Heater H1 Fixing main heater

H2 Fixing sub heater
H3 Drum heater
H4 Cassette heater (standard in 100-V model)

Thermistor TH1 Fixing heater main thermistor

TH2 Fixing heater sub thermistor (ends)

Thermal switch TP1 Fixing heater thermal switch

Leakage breaker ELCB Leakage breaker

Toner sensor TS1 Developing assembly toner sensor

TS2 Hopper toner sensor

Environment sensor HUM1 Temperature/humidity sensor (machine internal temperature

sensor)

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-71 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.7 PCBs

11

10
14

17
6
18 7

23 9

15

13
12

25

24 20
21
1

5
4 3

22

F04-607-01

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.7.1 Reader Unit

Ref. Name Function

12 Reader controller PCB Controls the reader unit/ADF.
13 CCD/AP PCB Drives the CCD/processes analog images.
15 Inverter PCB Controls the scanning lamp.
25 Fuse PCB Controls the mirror/lens heater. (standard in 100-V
model)

6.7.2 Printer unit

Ref. Name Function

1 DC controller PCB Controls the power supply of the printer unit/fin-
isher.
2 DC power supply PCB Supplies DC power.
3 AC driver PCB Controls the AC circuit.
4 Motor driver PCB Controls the motor.
5 HVT PCB Generates high-voltage.
6 Potential control PCB Controls the surface potential of the photosensitive
drum.
7 Drum heater control PCB Controls the drum heater.
8 Accessories power supply PCB Supplies power to the finisher.
9 Duplex driver PCB Controls the sensor, motor, and solenoid of the du-
plex unit.
10 Control panel PCB Controls the keys and LEDs.
11 Laser driver PCB Controls the laser drive.
14 BD PCB Detects the laser beam.
17 Control panel CPU PCB Controls the control panel.
18 LCD contrast adjustment PCB Adjusts the contrast of the control panel.
20 Serial number PCB Controls the serial number.
21 Anti-rush current PCB Prevents rush current in the fixing/feeding assem-
bly and the duplex unit.
22 Capacitor PCB Removes noise.
23 Fixing/feeding relay PCB Relays signals of sensors and motors of the fixing/
feeding unit.
24 Main controller PCB Processes digital images/controls the system.

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-73 T
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.8 Variable Resistors (VR), Light-Emitting Diodes (LED), and

Check Pins by PCB
Of the VRs, LEDs, and switches found on the machine, those used in the field are dis-
cussed:

1. Some LEDs have leakage current and emit dim light when off; this is a
normal condition and must be kept in mind:
2. VRs that may be used in the field:
VRs that must not be used in the field:

Any VR and check pin not found in the lists is for use at the factory, requir-
ing special tools and high accuracy. Do not touch them in the field.

6.8.1 Main Controller PCB

B1 B40 B40 B1
A1
J1015 A40 J1005
10 1 A40 A1
11
J1023 2
J1037
J1038
B40

A40

1 9 15 1 4 1
J1006
J1020 J1056
72 J1010 1

12
J1007
J1014

72 J1009 1

72 J1008 1
1
2
3
4

1
85

85
1

72 J1007 1 OFF 1
J1002 SW1002
B1

A1
J1061

Factory setting
132

66
5
J1060
4
10 1

1
7
J1022
40

J1024

J1003

J1004
1

LED1001
J1013
1

A22 A1
J1017

J1011 LED1002
B22 B1
J1031
A18
B1
6 1

J1028
J1044

J1030
J1018

67

1
B1 1

A15
J1012

167

167
84

84
B18

A1

J1057
B15

A1

J1029

F06-608-01

The DIP switch (SW1002 ) is for the factory. Do not use it in the field. (It is used when
making settings before shipment of the machine.)

4-74 T COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.8.2 DC Controller PCB

20 1 4 1 4 1 1 4
J121 J117 J116 J120 1 J302 4 1 J123 10

B12
A1
J114

J108
5 1

A12

B1
1
J124
8

B20
A1

J103
5
J203

A20

B1
12

1
VR103

J118
1
A17
B1

J303

2
J110

B20
A1
1
B17

A1

J106
A15
B1

6
J113

J126
A13

A20

B1
B1

4
B1 B15

J100

4 J201 1
A14 A1

J119
8 1
B13
J111

A1
A9 B14

A1

J101
J125

A15 A1 A16 A1
A18 A1 A9 A1 A20 A1
3

1
A1

13 1
J107 J112 J104 J115 J102
J109

J105
B1 A18 B1 B9 B1 B20 B1 B15 B1 B16
1

F04-608-02

The shorting connectors of J303 are set as follows; be sure to transfer the shorting con-
nectors to the new PCB upon replacement:

J303- 100V 120V 230V

1
2
3
4
5
6
7
...

12

:shorted by a jumper wire.

F04-608-03

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 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.8.3 Reader Controller PCB

1 4

6
J5021 J5009

J5011
GND
J5015

1
2
1

J5013

1
J5010

J5014 SW5001
7

J5005
J5006 J5012 J5007 1 3
4 J5002 1 1 4 1 6
A40 A1 J5008 1 5 J5001 2 1
J5004 3 1
B40 B1

F04-608-04

SW5001-1 SW5001-2
ON: Inch series. Not used.
OFF: AB series Not used.

6.8.4 Power Supply PCB

1 10 1 10 1 10
PN4004 PN4003 PN4002

J4010 J4013
PN4006
1

J4011 J4002
PN4001
1

2 12 1 3 15 1
2

1 4 1 4
1 5
J4015 J4009 J4004
1 8 1 5
1 4 J4003 J4007
J4008 1 11 J4006
1 4 J4014 1 3
J4016 1 2
J4017
1 10
J4005

1 15
PN4005
2

J4001
1

F04-608-05

4-76 T COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
 CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/MALFUNCTIONS

6.8.5 HVT PCB

J4504 J4506 J4507 J4508

3
J4505
1
VR4501

1 13 1 2
5 1
J4502 J4503
J4501

F04-608-06

6.8.6 Drum Heater Control PCB

SW2001
J2001 ON 1 2

F04-608-07

SW2001-1 SW2001-2
ON: controlled to 47°C Not used.
OFF: controlled to 43°C (default) Not used.

For details of drum heater control, see 6. “Controlling the Drum Heater” in Chapter 4.

COPYRIGHT © 2000 CANON INC. 2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000 4-77 T