TASKalfa 6500i Troubleshooting Manual Download

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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

Summary of Contents for 6500i

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 J421X J460X J470X J460Xのみ 42 43 Torn Paper J430X 431X 440X 471X 60mm from bottom edge 44 45 J49XX J50XX J51XX J600X 46 54 J610X J611X DF 55 60 J631X J641X J650X DF 61 63 J6510 DF 790 Caution of Manual Sta...

Page 3: ...720 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 From Developing Unit 100 Abnormal Sound From Fixing Drive Unit 101 105 DP Motor Driven Sound 106 Others DP Size Detection Error 107 Disporsal Toner Bottle 108 Time for maintenance T 109 Damage of Casse...

Page 4: ...Black Dots drum If one of several 126mm interval black dots appears randomly at sub scanning direction take the following measure Image sample 1 there is the case that the black dots appearance becomes vertical line a Replace the DRUM ASSY DK 6305 6705 126mm ...

Page 5: ...not be disappeared after wiping off replace the developing unit Image φ0 1 0 3ｍｍ 45mm Above is to check the black dots on the paper by the Magnifying glass 1 38mm interval black dots black marks Charger roller Take the following measure if the 38mm interval black dots or marks appear at the image In the sub scanning direction a Check the 38mm interval to print out the test sample by U089 Mono4 b R...

Page 6: ...image 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 halftone part Horizontal streaks appear at Halftone image U89 Sample set Horizontal streaks at halftone image Void Line White Band Horizontal White Streaks 1 Leak Image 1 3500i 4500i Execute AC Calib Ope...

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 Leak at the halftone part Horizontal streaks appear at Halftone image U89 Sample set Horizontal streaks at halftone image Void Line White Band Horizontal White Streaks 1 Leak Image 2 5500i 6500i 8000i E...

Page 8: ...m interval horizontal streaks occur at the gray image in the main scanning direction take the following measure In case of this appearance at the machine s rear side is more noticeable than at front a Replace the LSU Image sample 1 About 1 2mm Machine Front Machine Rear 8 ...

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 by wide width in the sub scanning direction take the following measure a Replace the LSU In case of the machine is produced before 2011 Oct 9 ...

Page 10: ...unit and check whether the transfer belt is cracked 1 When the transfer belt is torn or cracked please replace the drum unit and the transfer belt unit 2 Check the firmware version U019 and upgrade it higher than Upgrade Pack Ver V4 00 Image sample 1 Void Line Black Band Vertical Black Streak Condition of tear or crack on the transfer belt 10 ...

Page 11: ...ejected 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 in the paper conveyance direction a Clean the conveying guide b Clean the paper dust cleaner at the regist roller section Image sample 1 Cleaner 11 ...

Page 12: ...nd 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 guide one each at front and rear clean the back side of conveying guide Fig 3 For cleaning use the dry and soft cloth It locates at the size indication plate slot on 1st cassette Clean the conveying gu...

Page 13: ...r 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 2012 Feb production machine Refer to the cleaning procedure e g After 2012 Mar production model Refer to the cleaning procedure f g MACHINE No N4P22 16 2011 6 17 2011 7 18 2011 8 19 2011 9 1X 2011 10 1Y...

Page 14: ...TONER 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 etc so that the open air may not be attracted from a cleaner tip toner can be attracted effectively 14 ...

Page 15: ...clean suction it with the vacuum cleaner Reattaching the seal after cleaning and cut the part of duct 302LF33012 DUCT FAN TONER Remove the duct with 2 screws Lift up this part if it is detached Clean the removed duct Clean after removing the duct too Before cleaning Toner is accumulating 15 ...

Page 16: ...AN 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 and after production model Please replace with the parts as shown in fig when 302LF94410 PARTS LID TONER FAN ASSY ZG SP is available Image Smudges 6 13 16 ...

Page 17: ...ith 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 that the open air may not be attracted from a cleaner tip toner can be attracted effectively Image Smudges 7 13 17 ...

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 position after cleaning Image Smudges 8 13 18 ...

Page 19: ...he LID from the DISPOSAL TONER Old type 2 piles sheets New type 2 layer structure Clean the inner part of accumulating toner and filter after opening the DISPOSAL TONER UNIT When cleaning the old type Filter Be careful for FILTER of the thinner side not to be inhaled by the cleaner due to two sheet piles FILTER FILTER Remove 3 pcs of screws Release 8pcs of snap fit Install the thick density side o...

Page 20: ...i 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 302LC33370 FILTER LEFT SIDE Image Smudges 10 13 20 ...

Page 21: ...the 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 developing unit Clean the toner at inside of developing cooling duct Image Smudges 11 13 21 ...

Page 22: ...ette Image sample4 a Clean the duct at inside if machine and the developing unit Refer to 3 Cleaning Procedure for cleaning b Please use the PARTS SEAL SET ALL SP Refer to the service bulletin No 2LF 0014 C171 for the detail information Model Part No Description 8000i 6500i 302LF94451 PARTS SEAL SET ALL SP 5500i 4500i 3500i 302LH94341 PARTS SEAL SET ALL SP Image Smudges 12 13 22 ...

Page 23: ...mm position from paper bottom edge please take the following measure image sample B a Replace the DV unit DV 6305 6705 302LH93034 302LF93034 a Replace the DV unit DV 6305 6705 302LH93034 302LF93034 Image A Image B Feeding direction Feeding direction In case of A4 In case of A4 It occurs in three places of either It occurs in the range of about 20mm from paper bottom edge Image Smudges 13 13 23 ...

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 Select Table Chart1 2 5 Select ALL for items to be executed 2 6 Press the start key and start the auto adjustment Refer to the service bulletin No 2LC 0026 B314 Original Sample1 COPY 24 ...

Page 25: ...heet of papers but it may occur in the middle The uneven density appears periodically at background image with developing sleeve pitch 3500i 4500i 5500i 6500i 8000i 45mm How to Respond Check the Firmware and Upgrade to the Ver 5 00 or above Please run the calibration after upgrade it End Background occurs in the magnetic roller pitch Sample 1 Case of failure Monochrome Machine 25 ...

Page 26: ...48 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 becomes longer set to mode 1 However the effectiveness of this measures decreases in comparison with Mode2 in the case of set Mode1 please ask the user understand to perform refresh operation manually a...

Page 27: ...e front and rear nip pressure at scanning the original during DP conveying and stabilizing the original conveying speed 1 Change of the front nip pressure 1700g 1200g Cut two coils Item 303LL24120 SPRING PULLEY CONV LEFT 2 1 Change of the rear nip pressure 900g 500g Cut two and a half coils Item 303LL24130 SPRING PULLEY CONV R 1 Front scan spring 2 Rear scan spring For 3500i 4500i 5500i 27 ...

Page 28: ...riginal 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 remove the metal plate by 4 screws 5 Remove all of original scan front pulleys 5 pcs and springs 3303LL24120 SPRING PULLEY CONV LEFT are cut two coils 6 Return it original position and execute DP feedin...

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 SAPARATION Retard Roller 302K906360 PULLEY RETARD 302K906340 PULLEY RETARD Pickup Roller 302K906370 PULLEY PICKUP 302K906340 PULLEY RETARD Refer to the service bulletin No 2LC 0003 B105 for the detail ...

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: ...cassette 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 size is matched at above a e Check the paper is using other than specified such a coated paper inkjet paper f Please adjust the pressure of the retard pulley Decrease the adjusting plate by one level ...

Page 32: ...test version b After above a action if JAM is still not solved Replace the Conveying Unit Refer to the service bulletin No 2LC 0036 B402 2LC 0083 C126 for the detail information Modified from the production machine of May 2012 J05x8 J44xx JAM during Duplex printing Model Part No Description 5500i 4500i 302LH94042 PARTS CONVEYING H UNIT G SP 3500i 302LL94012 PARTS CONVEYING L UNIT G SP 8000i 6500i ...

Page 33: ...the 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 Jan production Image sample 1 d If the TRAY PAPER for paper loading was assembled by slanting condition there is possibility of JAM0545 occurring In case of the problem check it according to the next ...

Page 34: ...nd rear NG STOPPER DECK Clearance about 5mm SHAFT LIFT STAY DECK SIDE Same flat level FEED UNIT side TRAY PAPER Feeding direction FEED UNIT side STAY DECK SIDE Opposite FEED UNIT side TRAY PAPER FRAME F L FRAME DECK REAR TRAY PAPER Same height at front rear OK About 5mm About 5mm difference between front and rear height NG Recovery Procedure If above item 2 and 3 is NG the following re assembling ...

Page 35: ...02K994130 PARTS GUIDE FEED MIDDLE ASSY SP unit J1313 J1314 c Push in the wires inside of the machine through the hole on the metal plate where the wire fastener was fitted Then take care the connector at the feed drive unit side not to be loose b Cut the snap fit part not to refit after the measures a Remove the snap fit wire fastener from the side plate that is fitted to the machine frame in the ...

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 machine Paper conveying sensor PCS PFPCS2 Paper conveying actuator Changed the shape of the paper detection parts Before After 36 ...

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 50mm before the current position Upgrade to the latest F W Upgrade Pack Ver V5 00 or above Service Bulletin 2LC 0116 D089 37 ...

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 2 Shape of modified spring Shift it smoothly this thrust direction ROLLER CONVEYING VF １２ 303NJ31040 PLATE DECK JOINT Refer to service bulletin No 3NJ 0001 B354 for the detail Affected machines After...

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 １ When J4103 4104 occur at the time of A4 size paper feed from the large capacity deck 3 or 4 please take the following measure 39 ...

Page 40: ...orn with toner spillage Model TASAalfa8000i 6500i How to respond The cover 302N724020 COVER MOTOR MIDDLE is added to prevent the gear wear Service Bulletin 2K9 0040 D153 For 6500i 8000i PARTS GUIDE FEED REGIST ASSY SP X Viewed from X Groove width of the shaft 1 3 1mm 0 8 0 1mm Cut washer t 1 0 t 0 5 Added Cover Fixed together with the metal plate Y with the screw Metal plate Y 40 ...

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 5500i Before After The claw and holder are joined Unifying the claw and hold prevents the crack at the joint part The claw may crack or come off from the joint part 41 ...

Page 42: ...02LH4PH0 NHZ1Y00006 NJ91Z00198 NJ31Y00176 NextPdct 4500i KDJ KDA KDA AK CPY CS AK KDA GSA KDBR KDA 220V 1102LJ9JP0 1102LJ2US0 1102LJ2US2 1102LJ2CS0 1102LJ2CS1 1102LJ2US1 1102LJ2BR0 1102LJ4US0 N421Z00668 N431Y02336 NWQ1Y00001 NHK1Z00485 NWP1Y00001 NextPdct NJB1Z00040 NHR1Z00017 KDE UTAX OLIVETTI KDAU KDCN KDKR KDTW KDHK 1102LJ3NL0 1102LJ3UT0 1102LJ3LV0 1102LJ3AS0 1102LJ3KS0 1102LJ3KR0 1102LJTTW0 11...

Page 43: ...here is a possibility of incorrect detection of the sensor please replace the sensor in the inside of the eject unit or the eject unit Sensor 7NXGP1A73LCH01 SENSOR OPT Eject unit 302LH94271 PARTS EXIT UNIT B SP Measurement time April 2012 after March 2012 production lot the sensor selection is executed J421X J460X J470X 2 2 43 ...

Page 44: ...the fuser guide shape of the fixing it will be required the following 排出ｶﾞｲﾄﾞ形状対応方法ｶｯﾄﾜｯｼｬｰを以下支点部に追加して下さい機械前側支点部 1枚機械後側支点部 2枚ｶｯﾄﾜｯｼｬｰを以下支点部に追加して下さい機械後側支点部 2枚 For 6500i 8000i Shape of Fuser exit guide How to respond Added 2 cut washers to the fulcrum of the fuser exit guide Machine front fulcrum 1pc Machine back fulcrum 2pcs Please add to the fulcrum below the cut washer Machine back fulcrum ...

Page 45: ...ease 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 pre punched paper must be 8mm or less If the punching hole is longer than 8mm in lengthwise the leading edge of the actuator switching the switchback sensor falls down the center hole of the paper w...

Page 46: ...g boss of AK conveying in unit into the positioning hole of the drive unit Positioning with the drive unit Contact part of the tray If J49XX J50XX J51XX J600X occurs check the following item 1 to 7 2 Check whether the positioning hole of the bridge drive unit is damaged If it is damaged replace the AK drive unit following item number Broken Normal No Old New item number Parts name Q ty 1 303NB9420...

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 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 220VI KDE UTAX OLIVETTI 1102LG2...

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 s serial number is below Service bulletin 3NB 0001 B235 J49XX J50XX J51XX J600X 4 9 49 ...

Page 50: ...t unit No Old New Parts No Parts name Q ty 1 303NB94174 3NB94174 PARTS RELAY EXIT SP 1 6 Check there is any breakage at the hook hang part of the bridge relay exit unit Right fig If it is broken replace the relay exit unit No Old New Parts No Parts name Q ty 1 303NB94174 3NB94174 PARTS RELAY EXIT SP 1 Service bulletin 2LC 0034 B395 J49XX J50XX J51XX J600X 5 9 50 ...

Page 51: ...0 1102LF3NL0 1102LF3UT0 N4P1600107 NHE1600041 1st production NJE1600001 NHF1700001 N4Q1500041 N4S1500001 OLIVETTI KDAUS KDCN KDKR KDTW KDSG 1102LF3LV0 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0 NK11600001 N4R1600012 NKP1800001 NMQ1700001 NJQ1900001 NJK1500001 6500i KDA CPY KDA GSA KDBR KDA 220VI KDE UTAX 1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 N4U15...

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

Page 53: ...owing parts Fig 2 a install it to the front and rear stay while holding the upper cover of exit unit b Check whether the paper conveying guide does not come off and the fulcrum parts is not separated Fig 1 Old New Parts Items Parts Name Q ty 1 302LF28240 2LF28240 GUIDE RELAY EXIT RIGHT 1 Service Bulletin 2LC 0015 B221 Fig 2 J49XX J50XX J51XX J600X 8 9 53 ...

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 ２ 303NB94174 3NB94174 PARTS RELAY EXIT SP 1 No Old New Parts No Parts name Q ty 1 303NB94174 3NB94174 PARTS RELAY EXIT SP 1 2 302LF28621 2LF28621 PLATE REINFORCEMENT EXIT 1 3 302LF28840 2LF28840 SPRING COMPRESSION RELAY EXIT 4 Service b...

Page 55: ...F2CS0 1102LF2US1 1102LF2BR0 1102LF4US0 1102LF3NL0 1102LF3UT0 N4N2100074 N4P2100809 NHE2100219 NLP NextPdct NextPrdct NHF2100013 N4Q2100481 N4S2100111 OLIVETTI KDAU KDCN KDKR KDTW KDSG 1102LF3LV0 1102LF3AS0 1102LF3KS0 1102LF3KR0 1102LFTTW0 1102LF3SG0 NK12100036 NextPrdct NextPrdct NMQ2100022 NJQ2100002 NextPrdct 6500i 2LG KDJ KDA CPY KDA GSA KDBR KDA 220V KDE UTAX 1102LG9JP0 1102LG2US0 1102LG2CS0 1...

Page 56: ...3NL0 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 220VI KDE UTAX OLIVETTI 1102LG2US0 1102LG2CS0 1102LG2US1 1102LG2BR0 1102LG4US0 1102LG3NL0 1102LG3UT0 1102LG3LV0 From next From next production production KDAU KDCN KDKR KDTW KDSG 1102LG3AS0 1102LG3KS...

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

Page 58: ...et 3NB_9200 004 007 and after 3NK_9A00 003 004 and after b If the serial number of unit is before below number replace the Punch Unit PH 7A N361703776 and after PH 7B N351700282 and after PH 7C N371701264 and after PH 7D NMY1700042 and after Paper is caught by the convex of welding part at the Punch unit upper guide conveying surface Scratch mark Corner Folding small fold Sample 2 Sample 1 The lea...

Page 59: ...mage on paper check whether the paper is caught by the STAY PUNCH a Add the PET Films on the middle part of cutout of the STAY PUNCH STAY PUNCH Old Parts Item New Parts Items Parts Name Q ty 1 303NB07140 SHEET ROLLER FEED 2 0 1 1 1 Adhesive position for Both sided Tape Adhesive position 59 ...

Page 60: ...areful 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 ...

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 the Gear mesh View from main tray side Inside of process tray Paper trail end side Corner folding c Replace the PI mount plate 303NB36321 MOUNT PI UPPER GUIDE Affected from 2011 Oct production MOUNT PI...

Page 62: ...curl the leading edge of paper is round at the inner part of the process tray and JAM occurs a Please affix the films Image sample3 Inside of process tray Paper tray leading side a Affix the films 303NC24050 SHEET CONVEYING 2pcs Ref No 3NC 0002 C179 J631X J641X J650X 2 3 62 ...

Page 63: ...e of A4R or Letter R it may bound and the 1st sheet of the next bundle may be caught up at the paper guide Then the J6311 jam may occur Hot to respond The tension of the spring is increased that pulls up the paper holder guide Eject guide 303NB3652 Eject roller Eject pulley Spring Paper holder guide 303NB3622 63 ...

Page 64: ...e make sure that the paper hold hand is away from the paper during staple operation When you perform the manual staple operations when they hold the paper by hand paper jam J6510 will occur Please do not perform the manual staple operating with that held the paper by hand 64 ...

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 solenoid 1 In case of out of location insert the shaft into level as shown in below photo DF feedshift solenoid 1 NG OK Feedshift guide 1 2 1 65 ...

Page 66: ... Q 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 gears are not engaged replace the fulcrum pin 1 of BF lock lever DF hook pin 2 b Check whether the mesh of gears is not engaged or not after setting the BF into the DF 66 ...

Page 67: ...or multi feeding Check firmware version by U019 MAIN Ver 003 077 MMI Ver 003 074 Output the maintenance report from the maintenance mode U000 and if the count of J9020 skew original feed detection J9030 muti feeding detection 1 is frequent perform below either treatment 1 or 2 1 DP 771 has no J9030 detection function Before Higher Detect Stop the function Stop feeding by error Ignore User can be s...

Page 68: ...10 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 J9400 J9600 J9610 occurs take the following measure Download the DP firmware Before After OK J9010 J9011 J9110 J9300 J9310 J9400 J9600 J9610 68 ...

Page 69: ...it 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 Sample1 Fig 1 Fig 2 Service bulletin 2LC 0034 B395 Take the measure at the production machines after 2011 Nov If Corner Folding occurs at paper check below item Corner Folding 1 6 69 ...

Page 70: ...1 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 procedure mentioning next page Corner Folding 2 6 Service bulletin 2LF 0004 B355 70 ...

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

Page 72: ...TS 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 右仕様以外 KMKR KTST UTAX TA OLIVETTI 1703NB0UN0 1703NB0KR0 1703NB0KS0 1703NB0UT0 1703NB0LV0 N341Y17217 NEM1Y00012 NLL2100056 NKM1Y02982 NKH1Y00215 KDA CPY KDA CPY 1102LJ2US2 1102LJ2CS1 1102LH2US2 1102LH2CS1 NWQ1Y00001 NWP1Y00001 NWN1Y00001 NWM1Y0000...

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

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

Page 75: ...ge sample of creased paper spread out the creased part and check if toner is not transferred to the creased If the paper is above creasing condition check whether modified guide below photo is equipped or not YES Add the modification guide refer to next age for installation PARTS REGIST GUIDE SET SP No1 components parts A to D No Old Part No New Part No Description Q ty Old New 1 302LC94690 2LC946...

Page 76: ...ffix the film Fold the leading edge of the film A and affix it toward inner side using a flat blade screwdriver etc Note Take care of the tool not to touch the paper sensor Securely fold the film or mis sensing may occur Note Check if the film is not warped toward Z before fitting the guide C No 2 If warped so correct the warpage 6 Fit the middle feed plate B 7 Put the guide C No 2 on the middle f...

Page 77: ...aper size ２ Turn the papers in the paper cassette over and reinstall it The grade of the paper s bending may be slightly improved ３ Replace the CF blade 303J124142 BLADE MID PRESSING with the new one Service Bulletin 3ND 0008 C296 Cross section view of the center folding unit CF rollers CF blade No 1 CF blade lifts up to fold the paper indicated with the blue line in the above figure when center f...

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 3500i 302LH93070 PARTS STORAGE DEVICE SP OK HDD related cable item code 5500i 4500i 3500i 302K946A10 WIRE HDD POWER 302K946A20 WIRE HDD DATA1 OK HDD initialize Stored data in HDD will be erased after thi...

Page 79: ...Fig 1 When pushing in the CASS LOCK release LEVER at the INNER UNIT there is a case not to push in smoothly In that case without pushing in by force re install the INNER UNIT while shifting it by right hand side and fix If it pushes into INNER UNIT forcefully the lock release cannot be done normally C2101 C7101 and unusual sound occur again and DLP UNIT may damage The measure against below conditi...

Page 80: ...nit 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 above Upgrade Pack Ver V3 03 Fig2 Check Spiral Roller Rotation Check whether the spiral roller is rotating when turning the drum manually Spiral roller Fig1 Check Drum Rotation Turn it below direction 8...

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 Replace the HVT PCB f Replace the engine PCB Fig2 Check Spiral Roller Rotation Check whether the spiral roller is rotating when turning the drum manually Spiral roller C510X Fig1 Check Drum Rotation...

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 after O K Version up the firmware N G O K OK N G C6030 Other than C6030 OK NG 302LH46120 Re insert NG O K OK Replace the engine PCB O K OK N G Replace the harness between engine PCB and fuser unit Replac...

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 connection part NG OK Replace Fuser unit Replace the engine PCB OK OK NG OK NG OK Replace the harness between the engine PCB and Fuser unit OK NG OK OK For 3500i 4500i 5500i 83 ...

Page 84: ...ess roller may fuse and stick The fuser failure １ Please upgrade the firmware to the Upgrade Pack Ver V3 07 or later ２ When the phenomenon is not cleared even if upgrading please replace with the new fuser unit as below FK 6305 100V 302LH93042 FK 6306 120V 302LH93052 FK 6307 220V 302LH93062 FK 6307 CHN 302LH9C062 FK 6307 KR 302LH9K062 FUSER 110 H UNIT TW 302LH93082 For 3500i 4500i 5500i Service bu...

Page 85: ...UP 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 OK OK Check whether the voltage drop occurs NG less 70V during operation OK Change the power code connection NG OK OK NG Item code for harness 6500i 8000i 302K946590 OK NG 85 ...

Page 86: ...ONT REAR Check the slackness of belt tension at FRONT REAR Normal Error Breakage of bearing about 6ｍｍ About 3ｍｍ If the bearing is broken the slackness of belt tension becomes large and above clearance is increased Procedure the check the fuser belt slacking condition Fig 1 If C6600 C6720 occurs according to the below checking procedure find the solution for a to c C6600 Fuser Belt Rotation Error C...

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 fuser unit applicable to the end of the right figure Model spec Part No Description Model spec Part No Description 100V 302K993115 FK 8705 100V 302LF93045 FK 6705 120V 302K993125 FK 8706 120V 302LF9...

Page 88: ...lange 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 of the last digit parts number Replace the fuser unit with 5 or later of the last digit parts number Replace the fuser unit with 5 or later of the last digit parts number Check the amount of the fus...

Page 89: ...en checking whether the flange keys do not get under the inside heat roller Please refer to Step 5 and 6 in Sheet 5 for details of the way to shift the fuser belt Attention If the heat roller is hot please cover it with cloth instead of directly touching it by hand Machine rear side Normal Flange key Heat roller State that the flange key is raised due to being pressed by the heat roller Rotating d...

Page 90: ...4 006 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 IH PCB NG OK OK NG Replace the engine PCB OK OK NG Replace the harness between the engine PCB and fuser unit OK OK C6600 C6720 Check firmware Ver OK NG NG Check YC26 of Engine PCB OK NG Check the fus...

Page 91: ...CB 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 302LF46940 302K946080 Replace IH unit Refer to Fig 1 Check the firmware version engine 6500i 8000i 2LF_1000 003 006 No problem if it is after above version C6620 No Item number Parts name Qt y Remark 1...

Page 92: ...f IHPWB is clogged by dust cooling efficiency is reduced C6730 Fuser IH substrate temperature error 1 is generated How to Respond Clean the cooling fan with a vacuum cleaner After Before With clogging Fan Position For 6500i 8000i 92 ...

Page 93: ...tor 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 cable of Fuser unit is shorted and broken while the fuser unit is kept installing without replacing and replacing with new IH PCB first IH PCB will be damaged So replace the IH PCB after replacing the...

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 2LF_1000 004 0XX Check the Engine firmware version by U019 94 ...

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 case without pushing in by force re install the INNER UNIT while shifting it by right hand side and fix If it pushes into INNER UNIT forcefully the lock release cannot be done normally C2101 C7101 and...

Page 96: ...he applicable cable Image block dropout example Feed direction Service bulletin 2LC 077 C103 SATA cable to replace Content of failure No Parts No Parts name Affected model C9500 error C9510 error C9520 error C0630 error Scanned image block dropout Refer to below for the image sample 1 302K946700 WIRE CCD DATA 5550ci 4550ci 3550ci 30 50ci 5500i 4500i 3500i 7550ci 6550ci 8000i 6500i 2 303M446020 WIR...

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 by Boot mode OK Product Item Name Item Number Item Name Item Number MAIN PCB PARTS PWB MAIN ASSY SP 302LH9414 PARTS PWB MAIN ASSY SP 302LF9417 PARTS PWB MAIN ASSY SP EU 302LH9415 PARTS PWB MAIN ASSY...

Page 98: ...B 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 Number Item Name Item Number MAIN PCB PARTS PWB MAIN ASSY SP 302LH9414 PARTS PWB MAIN ASSY SP 302LF9417 PARTS PWB MAIN ASSY SP EU 302LH9415 PARTS PWB MAIN ASSY SP EU 302LF9418 ENGINE PCB PARTS PWB ENGI...

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 belt unit If the right cover isn t closed sufficiently the contact failure leakage may occur due to the wide gap between the high voltage terminals at the right cover and the transfer belt As the res...

Page 100: ...ile shifting it by right hand side and fix If it pushes into INNER UNIT forcefully the lock release cannot be done normally C2101 C7101 and unusual sound occur again and DLP UNIT may damage The measure against below condition was taken after 2011 Oct production Therefore below action is not necessary if the production month is Oct and after attention 1 There is a possibility that DLP is LOCKing by...

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 the service bulletin 2LH 0006 B454 Take the measure after checking the following contents and phenomenon Replace the fuser unit Still sounding 1 Add the following 2 screws as referring to next page Sc...

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: ...rame 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 after removing the screw No 6 that is added this time Abnormal sound from the fuser section 5 5 For 3500i 4500i 5500i 105 ...

Page 106: ...et 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 No2 to 4 O 1 PARTS MOTOR GEAR SET SP 303M494210 1 TASKalfa 7550ci 6550ci TASKlafa 8000i 6500i DP Remarks New Old New Old Description New Part No No Compatible Q ty Old Part No No A Exit idle gear No 4 ...

Page 107: ...of 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 6pcs is not detached or not Fig 1 Check the Scanner firmware version by U019 2LC_1200 004 003 Lower Above OK OK NG Insert the Claws OK NG Fig 1 Fig 2 Fig 3 Terminal 3HL06110 PCB 303M801030 Download ...

Page 108: ...rs 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 is 25 refer to fig A and before check it as referring to the fig B b When there are any faults such as peeling and poor adhesion replace with another waste toner bottle In case of the top 2digits is ...

Page 109: ...intenance 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 menu c When can not canceled above please exchange Main PCB 109 ...

Page 110: ...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 Where to fit direction Reinforcing parts large No2 Reinforcing parts small No3 Cassette rear side Corner cut Flange Note The reinforcing parts can not be installed depending on the cassette rail damage In 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 Where to fit direction Reinforcing parts large No2 Reinforcing parts small No3 Cassette rear side Corner cut Flange Note The reinforcing parts can not be installed depending on the cassette rail dam...

Page 112: ...02K909690 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 Reinforcing parts small No 3 Cassette rear side Cassette left side Flange Cassette upper side Apply to 1 7 in the figure left Fit this with the flange facing the id 112 ...

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