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TASKalfa 3500i, Troubleshooting Manual

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TASKalfa 3500i Troubleshooting Manual Download Page 60

J6100/J6110 (DF) 

 

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5. When select A4 paper size at the manual bypass tray, be careful below item.  
 
If the actual direction of A4(Letter)size paper set on the manual bypass tray is not same as setting the direction by 
the operation panel, JAM6110 may occur after feeding is started . Therefore, please instruct user about the setting 
method of manual bypass size.  
 

60 

Summary of Contents for 3500i

Page 1: ...2012 3 8 Revised 3 16Revised 3 19Revised 3 21Revised 4 6 Revised 8 30 Revised 2013 11 18 3rd Edition 3500i 4500i 5500i 6500i 8000i Troubleshooting Guide 1...

Page 2: ...f TRAY PAPER 34 J1313 J1314 35 J150X J1904 36 J1512 37 J341X PF 38 J4103 J4104 39 Abnormal Sound J42XX J40XX Add Intermediate Motor Cover 40 J42XX Fixing Separation Claw Tip Missing or Damaged 41 J421...

Page 3: ...20 Fixing Belt Damage 86 90 C6620 91 C6730 92 C6770 93 C6910 94 C7101 95 C9500 C9510 C9520 C0630 C0640 CF245 SATA Cable Failture 96 CF000 Welcome Screen Lock 97 CF040 98 CF182 186 99 Abnormal Sound Fr...

Page 4: ...ack Dots drum If one of several 126mm interval black dots appears randomly at sub scanning direction take the following measure Image sample 1 there is the case that the black dots appearance becomes...

Page 5: ...not be disappeared after wiping off replace the developing unit Image 0 1 0 3 45mm Above is to check the black dots on the paper by the Magnifying glass 1 38mm interval black dots black marks Charger...

Page 6: ...mage will not be recovered replace the developing unit Image sample 1 Leak at the solid part Void image appear at the solid part U89 Sample set Void image at Solid part Image sample 2 Leak at the half...

Page 7: ...the image will not be recovered replace the developing unit 3 4 1 2 Image sample 1 Leak at the solid part Void image appear at the solid part U89 Sample set Void image at Solid part Image sample 2 Lea...

Page 8: ...interval horizontal streaks occur at the gray image in the main scanning direction take the following measure In case of this appearance at the machine s rear side is more noticeable than at front a...

Page 9: ...direction take the following measure a Clean the cover glass on the LSU Image sample 1 Vertical white streaks Image sample 2 4 Vertical White lines void image Image sample 2 If the void image appears...

Page 10: ...nit and check whether the transfer belt is cracked 1 When the transfer belt is torn or cracked please replace the drum unit and the transfer belt unit 2 Check the firmware version U019 and upgrade it...

Page 11: ...jected paper Clean the duct at inside if machine and the developing unit Refer to 3 Cleaning Procedure for cleaning 1 Image Smudges Image sample 1 There is no periodicity and it occurs intermittently...

Page 12: ...d drum unit after detaching the inner unit Remove the toner box 2 screws Fig 1 b Clean the conveying guide Clean the paper feeding side of the conveying guide Fig 2 At the next remove the conveying gu...

Page 13: ...Exhaust Aperture Fig 4 d Check the machine s production month Check the production month from the machine s serial number on the rating label and clean it according to the production month Before 201...

Page 14: ...ONER UNIT with the vacuum cleaner Procedure 1 Clean and suction the outlet of duct with cleaner for 1 min A cleaner tip is put in and attracted from this direction If a opening is covered with a rag e...

Page 15: ...lean suction it with the vacuum cleaner Reattaching the seal after cleaning and cut the part of duct 302LF33012 DUCT FAN TONER Remove the duct with 2 screws Lift up this part if it is detached Clean t...

Page 16: ...N TONER and replace with 302LF94410 PARTS LID TONER FAN ASSY ZG SP 302LF94410 PARTS LID TONER FAN ASSY ZG SP FILM 302LF94410 is re usable After this replacement the level of unit is same as 2012 Mar a...

Page 17: ...th the vacuum cleaner Procedure 1 Clean suction the duct outlet for 1 min with the vacuum cleaner A cleaner tip is put in and attracted from this direction If a opening is covered with a rag etc so th...

Page 18: ...FAN from the machine and clean suction it with the vacuum cleaner Before cleaning Toner is accumulating LID TONER FAN Remove it after releasing 3 pcs of snap fit Return the LID TONER FAN at original p...

Page 19: ...e LID from the DISPOSAL TONER Old type 2 piles sheets New type 2 layer structure Clean the inner part of accumulating toner and filter after opening the DISPOSAL TONER UNIT When cleaning the old type...

Page 20: ...5500i At cleaning the FILTER the FILTER can be detached after removing the DF Rear Cover without releasing DF from the main body After removing clean or replace it h Clean the FILTER FILTER 302LC3337...

Page 21: ...he inside toner while fitting the nozzle of the vacuum cleaner to the toner waste aperture of the DUCT Clean the accumulating toner on the toner receiver of the developing unit At rear side of the dev...

Page 22: ...tte Image sample4 a Clean the duct at inside if machine and the developing unit Refer to 3 Cleaning Procedure for cleaning b Please use the PARTS SEAL SET ALL SP Refer to the service bulletin No 2LF 0...

Page 23: ...m position from paper bottom edge please take the following measure image sample B a Replace the DV unit DV 6305 6705 302LH93034 302LF93034 a Replace the DV unit DV 6305 6705 302LH93034 302LF93034 Ima...

Page 24: ...auto adjustment 2 1 Place the designated adjustment original Part No 7505000005 on the contact glass 2 2 Select Target on U411 Scanner Auto Adjustment 2 3 Select Auto and press the start key 2 4 Selec...

Page 25: ...et of papers but it may occur in the middle The uneven density appears periodically at background image with developing sleeve pitch 3500i 4500i 5500i 6500i 8000i 45mm How to Respond Check the Firmwar...

Page 26: ...8 4 Set to Mode 3 if the condensation can not be eliminated at mode 2 Caution Refresh frequency will be increased if increment of mode number Therefore if it is pointed out that the warm up period bec...

Page 27: ...front and rear nip pressure at scanning the original during DP conveying and stabilizing the original conveying speed 1 Change of the front nip pressure 1700g 1200g Cut two coils Item 303LL24120 SPRI...

Page 28: ...iginal scan are cut two and a half coils 1 2 3 Remove the rear cover and left side stay by 2screws then remove the screws in the bottom of it 4 Remove the lower cover while sliding front side then rem...

Page 29: ...4500i 5500i 6500i 8000i Note Check the color of Roller to find the Old and New difference at the Primary Feed Rubber color Black Rubber color Gray Feed Roller 302K906350 PULLEY FEED 2AR07230 PULLEY SA...

Page 30: ...Procedures for adjusting the pressure of the retard pulley Flow chart Refer to the service bulletin No 2LF 0015 C191 for the detail information J0501 to 7 J0523 to 7 Misfeed 30...

Page 31: ...assette is inserted into the end d After performing above b and c the problem is not solved replace with the modification parts mentioning on the service bulletin No 2LC 0023 B287 Fig 3 If the paper s...

Page 32: ...est version b After above a action if JAM is still not solved Replace the Conveying Unit Refer to the service bulletin No 2LC 0036 B402 2LC 0083 C126 for the detail information Modified from the produ...

Page 33: ...he count number of U901 Paper Feeding Counter The maintenance cycle for Primary Feed is 150K Fig 1 JAM Paper For the detail refer to the service bulletin No 3NG 004 C024 Affected machines After 2012 J...

Page 34: ...d rear NG STOPPER DECK Clearance about 5mm SHAFT LIFT STAY DECK SIDE Same flat level FEED UNIT side TRAY PAPER Feeding direction FEED UNIT side STAY DECK SIDE Opposite FEED UNIT side TRAY PAPER FRAME...

Page 35: ...2K994130 PARTS GUIDE FEED MIDDLE ASSY SP unit J1313 J1314 c Push in the wires inside of the machine through the hole on the metal plate where the wire fastener was fitted Then take care the connector...

Page 36: ...failure depending on the paper How to respond Replace the actuator ACTUATOR FEED LOW 302N706500 when the problem occurred Service Bulletin 2LC 0123 D148 500 sheet cassette feed section for the main ma...

Page 37: ...may be turned on while the cassette 2 paper stays at the registration for duplex feed Change Paper waiting position for the next feeding paper after feeding paper from the cassette 2 is changed About...

Page 38: ...thrust direction If the movement of unit is heavy re install the 303NJ31040 PLATE DECK JOINT located at right side while making the edge of 1 contacting with FRAME REAR shift lower direction of arrow...

Page 39: ...paper runs on set paper correctly Please adhesive the regulation sheet PARTS SHEET STOPPER A4 SP 303NF94170 as needed If paper seriously runs on C1100 1110 may occur When J4103 4104 occur at the time...

Page 40: ...rn with toner spillage Model TASAalfa8000i 6500i How to respond The cover 302N724020 COVER MOTOR MIDDLE is added to prevent the gear wear Service Bulletin 2K9 0040 D153 For 6500i 8000i PARTS GUIDE FEE...

Page 41: ...302FT20120 SEPARATOR ASSY Assembly 302LH94370 PARTS SEPARATOR ASSY SP If the claw is broken in half please change to the new claw claw that is integrated Service Bulletin 2LH 0016 D159 For 3500i 4500i...

Page 42: ...2LH4PH0 NHZ1Y00006 NJ91Z00198 NJ31Y00176 NextPdct 4500i KDJ KDA KDA AK CPY CS AK KDA GSA KDBR KDA 220V 1102LJ9JP0 1102LJ2US0 1102LJ2US2 1102LJ2CS0 1102LJ2CS1 1102LJ2US1 1102LJ2BR0 1102LJ4US0 N421Z0066...

Page 43: ...ere is a possibility of incorrect detection of the sensor please replace the sensor in the inside of the eject unit or the eject unit Sensor 7NXGP1A73LCH01 SENSOR OPT Eject unit 302LH94271 PARTS EXIT...

Page 44: ...t washer In the case of J421X occurs check the fuser guide shape of the fixing it will be required the following 1 2 2 For 6500i 8000i Shape of Fuser exit guide How to respond Added 2 cut washers to t...

Page 45: ...ase keep and perform the following restrictions when using 3 hole pre punched paper even if performing the corrective measures 1 The length of the punched hole in the paper feeding direction on 3 hole...

Page 46: ...boss of AK conveying in unit into the positioning hole of the drive unit Positioning with the drive unit Contact part of the tray If J49XX J50XX J51XX J600X occurs check the following item 1 to 7 2 Ch...

Page 47: ...side AK conveying unit J49XX J50XX J51XX J600X 2 9 8000i KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX OLIVETTI 1102LF2US0 1102LF2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 1102LF3LV0 From n...

Page 48: ...The film attached procedure J49XX J50XX J51XX J600X 3 9 48...

Page 49: ...shown in right fig replace the roller Fig 1 Old New Item Number Parts Name Q ty 1 302LF94010 2LF94010 PARTS ROLLER RELAY MIDDLE SP 3 2 302LF94030 2LF94030 PARTS ROLLER RELAY EXIT SP 1 Affected machine...

Page 50: ...unit No Old New Parts No Parts name Q ty 1 303NB94174 3NB94174 PARTS RELAY EXIT SP 1 6 Check there is any breakage at the hook hang part of the bridge relay exit unit Right fig If it is broken replac...

Page 51: ...1102LF3NL0 1102LF3UT0 N4P1600107 NHE1600041 1st production NJE1600001 NHF1700001 N4Q1500041 N4S1500001 OLIVETTI KDAUS KDCN KDKR KDTW KDSG 1102LF3LV0 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF...

Page 52: ...Replacement procedure for the bushing J49XX J50XX J51XX J600X 7 9 52...

Page 53: ...wing parts Fig 2 a install it to the front and rear stay while holding the upper cover of exit unit b Check whether the paper conveying guide does not come off and the fulcrum parts is not separated F...

Page 54: ...occurs replace the bridge conveying unit bridge relay exit unit Bush Bearing No Old New Parts No Parts name Q ty 1 303NB94241 3NB94241 PARTS GUIDE UPPER UNIT SP 1 303NB94174 3NB94174 PARTS RELAY EXIT...

Page 55: ...2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 N4N2100074 N4P2100809 NHE2100219 NLP NextPdct NextPrdct NHF2100013 N4Q2100481 N4S2100111 OLIVETTI KDAU KDCN KDKR KDTW KDSG 1102LF3LV0 1102LF...

Page 56: ...NL0 1102LF3UT0 1102LF3LV0 From next From next production production KDAU KDCN KDKR KDTW KDSG 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0 From next production 6500i KDA CPY KDA GSA KDBR KDA...

Page 57: ...The film attached procedure J6100 J6110 DF 3 6 57...

Page 58: ...t 3NB_9200 004 007 and after 3NK_9A00 003 004 and after b If the serial number of unit is before below number replace the Punch Unit PH 7A N361703776 and after PH 7B N351700282 and after PH 7C N371701...

Page 59: ...age on paper check whether the paper is caught by the STAY PUNCH a Add the PET Films on the middle part of cutout of the STAY PUNCH STAY PUNCH Old Parts Item New Parts Items Parts Name Q ty 1 303NB071...

Page 60: ...reful below item If the actual direction of A4 Letter size paper set on the manual bypass tray is not same as setting the direction by the operation panel JAM6110 may occur after feeding is started Th...

Page 61: ...EjectUnlock 30 c Place the MOUNT PI UPPER GUIDE a Replace the cursor 303NB36031 CURSOR L MIDDLE TRAY 303NB36041 CURSOR R MIDDLE TRAY Affected from 2012 Jan production Ref No 3NB 0017 C025 b Correct th...

Page 62: ...url the leading edge of paper is round at the inner part of the process tray and JAM occurs a Please affix the films Image sample3 Inside of process tray Paper tray leading side a Affix the films 303N...

Page 63: ...of A4R or Letter R it may bound and the 1st sheet of the next bundle may be caught up at the paper guide Then the J6311 jam may occur Hot to respond The tension of the spring is increased that pulls...

Page 64: ...make sure that the paper hold hand is away from the paper during staple operation When you perform the manual staple operations when they hold the paper by hand paper jam J6510 will occur Please do n...

Page 65: ...is fed to the direction2 instead of the direction1 a Check the assembling condition of the Feedshift guide1 Check the shaft of Feedshift guide 1 is firmly inserted into the lever of DF feedshift solen...

Page 66: ...ty 1 303ND02280 303ND02281 FULCRUM PLATE RELEASE 2 2 303ND02360 PIN HOOK BOOKLET 2 OLD NEW 2 DF hook pin OLD NEW 1 Fulcrum pin for BF lock lever Paper stop position BF Paper stop position If the gear...

Page 67: ...r multi feeding Check firmware version by U019 MAIN Ver 003 077 MMI Ver 003 074 Output the maintenance report from the maintenance mode U000 and if the count of J9020 skew original feed detection J903...

Page 68: ...0 J9400 J9600 DP 770 J9010 J9110 J9600 J9610 Check the DP firmware version at U019 8000i 6500i DP 771 3M4_9500 007 002 DP 770 3NV_9500 005 001 OK No count Count up 2 J9010 J9011 J9110 J9300 J9310 J940...

Page 69: ...t Fig 1 Affix the film No 1 to the designated location at fig after cleaning where to affix it on the conveying unit Fig 2 No Old New Parts No Parts name Q ty 1 302LF28820 2LF28820 SHEET RERAY LOWER 2...

Page 70: ...302LF28770 2LF28770 SHEET HINGE STOPPER 2 b Check whether the leverage of upper conveying guide on the bridge conveying unit is not detached if it is detached add the below parts as referring the pro...

Page 71: ...The film attached procedure Corner Folding 3 6 71...

Page 72: ...ARTS GUIDE RELAY EXIT SHEFT SP 1 2 302LF94173 2LF94173 PARTS RELAY EXIT SP 1 Service bulletin 2LH 0005 B445 Affected machine s serial number is below AK 730 KMKR KTST UTAX TA OLIVETTI 1703NB0UN0 1703N...

Page 73: ...Corner Folding 5 6 73...

Page 74: ...Corner Folding 6 6 74...

Page 75: ...e sample of creased paper spread out the creased part and check if toner is not transferred to the creased If the paper is above creasing condition check whether modified guide below photo is equipped...

Page 76: ...fix the film Fold the leading edge of the film A and affix it toward inner side using a flat blade screwdriver etc Note Take care of the tool not to touch the paper sensor Securely fold the film or mi...

Page 77: ...aper size Turn the papers in the paper cassette over and reinstall it The grade of the paper s bending may be slightly improved Replace the CF blade 303J124142 BLADE MID PRESSING with the new one Serv...

Page 78: ...YC1 YC27 Replace the cable Check abnormal sound rattling sound during driving HDD Initialize HDD 1 Execute U024 2 Select FULL and start format 3 Power OFF ON Replace HDD HDD Item code 5500i 4500i 3500...

Page 79: ...ig 1 When pushing in the CASS LOCK release LEVER at the INNER UNIT there is a case not to push in smoothly In that case without pushing in by force re install the INNER UNIT while shifting it by right...

Page 80: ...it skip to e c Check rotation of the drum spiral roller refer to Fig2 In case of no rotation replace the drum unit skip to e d Replace the engine PCB e Check the Firmware version and version up to abo...

Page 81: ...case of no rotation replace the drum unit c Check rotation of the drum spiral roller refer to Fig2 In case of no rotation replace the drum unit d Check the poor connection of cleaning lamp connector e...

Page 82: ...of cable wiring Check the removal of pin Check that the contact is not removed while pulling it lightly NG Check YC26 on engine PCB Check whether version of engine firmware is 2LF_1000 003 083 or afte...

Page 83: ...O K YC26 C6020 C6220 302H746191 If C6020 C6220 occurs take the following measure Check the poor connection on the engine PCB YC26 OK OK Check the poor connection between the fuser unit and main unit c...

Page 84: ...ress roller may fuse and stick The fuser failure Please upgrade the firmware to the Upgrade Pack Ver V3 07 or later When the phenomenon is not cleared even if upgrading please replace with the new fus...

Page 85: ...P NG C6030 Replace the Fuser unit Replace the engine PCB C6050 OK Replace IH PCB OK OK Replace the IH coil OK Replace the harness between the engine PCB and the fuser unit OK OK NG OK NG OK NG OK NG O...

Page 86: ...RONT REAR Check the slackness of belt tension at FRONT REAR Normal Error Breakage of bearing about 6 About 3 If the bearing is broken the slackness of belt tension becomes large and above clearance is...

Page 87: ...the film to the fuser position adjustment plate and adjust the height Affected machine s serial number for taking the measure during the production a When replacing the fuser unit it exchanges for the...

Page 88: ...ange key gets under the U shape groove of the heat roller or is raised Yes No The fuser belt edge is torn Is the fuser belt edge repeatedly torn after adjustment Replace the fuser unit with 5 or later...

Page 89: ...n checking whether the flange keys do not get under the inside heat roller Please refer to Step 5 and 6 in Sheet 5 for details of the way to shift the fuser belt Attention If the heat roller is hot pl...

Page 90: ...006 6500i 8000i 2LF_1000 003 006 Whether it is after above version For C6600 IH PCB is not necessary checked Check as referring to the contents at left OK OK Check YC4 of IH PCB NG OK OK Replace the...

Page 91: ...B and Exit PCB 302LF46140 only 6500i 8000i OK Replace Engine PCB Replace the harness between the Core Motor and Exit PCB 302LF46100 302K946140 Replace the harness between the Front PCB and Exit PCB 30...

Page 92: ...IHPWB is clogged by dust cooling efficiency is reduced C6730 Fuser IH substrate temperature error 1 is generated How to Respond Clean the cooling fan with a vacuum cleaner After Before With clogging...

Page 93: ...or right fig OK OK NG Check the firmware version engine 6500i 8000i 2LF_1000 003 006 Increase withstanding of power noise If Fuser unit connector is disconnected C6770 occurs When C6770 occurs after c...

Page 94: ...Check the version of the firmware on the machine If the version is older than the following upgrade the firmware to the latest version ENGINE Venus 2LC_1000 007 0XX Mercury 2K9_1000 005 0XX Zeus Gaia...

Page 95: ...motor C7101 Toner Control Sensor Error Normal Break bend CASS SHUTTER CASS SHUTTER Fig 1 When pushing in the CASS LOCK release LEVER at the INNER UNIT there is a case not to push in smoothly In that c...

Page 96: ...e applicable cable Image block dropout example Feed direction Service bulletin 2LC 077 C103 SATA cable to replace Content of failure No Parts No Parts name Affected model C9500 error C9510 error C9520...

Page 97: ...DDR memory Memory LED Light Up Attention LED Light Up Welcome Screen Lock CF000 appears after 3 and half min Replace Main PCB Replace Panel PCB OK NG NG NG NG Check whether Panel Main PCB is recovered...

Page 98: ...Replace Engine PCB Replace HDD OK OK OK OK OK OK FFC item code 5500i 4500i 3500i 302K946A00 WIRE FFC MAIN ENGINE NG NG NG NG NG NG If CF040 occurs take the following measure Product Item Name Item Nu...

Page 99: ...function 6 Retrieve the USBLOG and contact the Service Administrative Division 2 When CF182 CF186 occur from time to time Add the film to the contact part of the high voltage terminal of the transfer...

Page 100: ...le shifting it by right hand side and fix If it pushes into INNER UNIT forcefully the lock release cannot be done normally C2101 C7101 and unusual sound occur again and DLP UNIT may damage The measure...

Page 101: ...cycle Refer to sound FILE Not match with cycle According to the content of 1 take an action Replace the fuser unit No Old New Parts Item Q ty 1 7BB700308H BB105600 BIND T T S SCREW 3X8 SR 2 Refer to t...

Page 102: ...Procedure Affected machine s serial number Abnormal sound from the fuser section 2 5 For 3500i 4500i 5500i 102...

Page 103: ...Abnormal sound from the fuser section 3 5 For 3500i 4500i 5500i 103...

Page 104: ...Abnormal sound from the fuser section 4 5 For 3500i 4500i 5500i 104...

Page 105: ...ame may still not be released in case any abnormal sound is heard Perform the procedures No 1 and after again Move the frame in the procedures No 6 10 cycles Note Move the frame to the left and right...

Page 106: ...t item No6 to 8 O 1 PARTS MOTOR GEAR SET SP 303NW94070 5 DP 771 O 1 GEAR EXIT Z43 Z20 303M431440 4 X 1 GEAR Z43 Z22 303M431101 3 X X 1 1 PARTS MOTOR REGISTRATION SP 303M494181 303M494180 2 Set item No...

Page 107: ...f claws at Fig1 if finding the problem clean or replace the parts Fig 2 3 a Deformation of terminal b Dust on the terminal PCB c Peel off the PCB pattern disconnection of connector Check whether Claws...

Page 108: ...s due to the above cause Be careful of handling 2 When the waste toner bottle near end detection rubber is peeling off check the following and take the measure a When Lot No of the waste toner bottle...

Page 109: ...ntenance T was displayed on a status bar refer to attachment picture please take the following measure a Performs resetting partial operation control in Sim 906 b Set up the present time from a system...

Page 110: ...osition 1 and 5 are mostly damaged in the figure below 302K909680 PARTS A RAIL CASSETTE SP 302K909690 PARTS B RAIL CASSETTE SP For repairing the broken rail apply to damaged rail 1 2 3 4 5 6 7 Where t...

Page 111: ...damage position 1 and 5 are mostly damaged in the figure below 302K909680 PARTS A RAIL CASSETTE SP 302K909690 PARTS B RAIL CASSETTE SP For repairing the broken rail apply to damaged rail 1 2 3 4 5 6 7...

Page 112: ...2K909690 PARTS B RAIL CASSETTE SP For strengthening the rail install before broken and where is deformed or whitened at the rail resin 1 and 5 are mostly damaged 1 2 3 4 5 6 7 Where to fit direction R...

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