A description of the Top 10 Service Issues experienced by. ir ADV C2000 service techs with an explanation of the solutions

Transcription

1 Symptoms & Solutions For the imagerunner ADVANCE C2000 Series A description of the Top 10 Service Issues experienced by ir ADV C2000 service techs with an explanation of the solutions that resolve each scenario! Issued Dec 2012

2 < Analyzed Model Series / Analyzed Term > ir-adv C2030 Series / From Oct 1 st to Oct 31 st in 2012 < Analyzed Result of Field Visit > We analyzed the Field visit data one by one, and then the following chart shows the Top 10 symptom. Symptom October July Foggy Image / Ghost Image / Solid Image 1 8 Light Image / Faulty Density / Faulty Color Reproduction 2 6 Fixing Jam / Delivery Jam 3 2 Pick-up jamming 4 Out of rank Feeder Jamming 5 7 E "Waste Toner is Full" message 7 5 Noise (Fixing Assembly) 8 10 Duplex jamming 9 Out of rank Load Paper message 10 Out of rank Black Line due to dirt of Stream Reading Glass Out of rank 3 E532 Out of rank 4 < Comments on the Top 10 service calls analysis > Image related issues listed as the Top 1 and 2 symptoms that have increased. The Top 4 Pick-up jamming, the Top 9 Duplex jamming and the Top 10 Load Paper message are new symptoms to make the list of Top 10. The Top 3 Black Line due to dirt of Stream Reading Glass and the Top 4 E in the previous Top 10 analysis did not make the list this time. < Added FAQs from the previous version> - Water drop marks on 2nd side of 2-sided print occurred in 2-sided printing after continuous 1-sided printing (3 WAY UNIT-C1) - Lines on image in the sub-scanning direction due to the deformation of the contact spring on the Drum Unit - Lines occur at approximately 30mm from the leading edge of paper, in the main scanning direction due to the deformation of the pre-fixing guide sheet - Lines at 30mm from the leading edge of paper in the main scanning direction due to stained paper feed paths - Page borders are printed lightly Microsoft Word2007/ A/010B jam code displays while the 3 Way Unit-C1 is being installed - 010C Jam Code occurs after installation of the 3 Way Unit-C1-070A Jam Code due to detached first delivery sensor flag spring Jam Code due to floating Cassette 1 Separation Roller Unit Jam Code due to failure of gear engagement when the multi-purpose tray is used - 0D91/0205 Jam Code occurs on a machine with a version of system software earlier than Ver due to a wrong paper size setting for the multi-purpose tray - 010A Jam occurs in the 2nd side of thin paper due to the paper separation error - "Load Paper" is displayed: Excel file cannot be printed when the resolution of UFR II Printer Driver is set to 1200 dpi

3 Contents <Foggy Image / Ghost Image / Solid Image>...5 Ghost image occurs due to remained toner on the primary charging roller...5 Fogging occurs on the whole image...12 Foggy image in magenta/poor density on solid image Ghosting at a 94mm pitch...13 Water drop marks on 2nd side of 2-sided print occurred in 2-sided printing after continuous 1-sided printing (3 WAY UNIT-C1)...14 Lines on image in the sub-scanning direction due to the deformation of the contact spring on the Drum Unit...15 Lines occur at approximately 30mm from the leading edge of paper, in the main scanning direction due to the deformation of the pre-fixing guide sheet...16 Lines at 30mm from the leading edge of paper in the main scanning direction due to stained paper feed paths...17 <Light Image / Faulty Density / Faulty Color Reproduction >...18 Faulty image where specific color of toner does not get printed due to laser shutter lever malfunction...18 Variation of image hues occurs when continuous output is being made...21 Output image becomes dark when the resolution is set at 1200dpi...24 When printing from PS driver, output in different color if the version of the system software is earlier than Ver Gradation is not reproduced when printing from the PS3 printer driver on a machine with system software earlier than Ver PS printer driver on Windows prints color data that Illustrator creates in RGB color mode as the monochrome black data...25 Page borders are printed lightly Microsoft Word2007/ < Fixing Assembly Jam / Delivery Jam > A Jam Code occurs due to the delivery roller bushing coming off /1001/020B Jam Code/ dog-ear on delivered paper (Inner Finisher -C1) A/010B jam code displays while the 3 Way Unit-C1 is being installed C Jam Code occurs after installation of the 3 Way Unit-C A Jam Code due to detached first delivery sensor flag spring...33 <Pick-up Jamming> Jam Code occurs due to the detached registration sensor (Added FAQ) Jam Code due to floating Cassette 1 Separation Roller Unit Jam Code due to failure of gear engagement when the multi-purpose tray is used D91/0205 Jam Code occurs on a machine with a version of system software earlier than Ver due to a wrong paper size setting for the multi-purpose tray...45 <Feeder Jamming>...46 Last sheet of multiple-sheet document not picked up (DADF-AC1)...46 DADF fails to feed originals after the machine recovers with a version of System Software earlier than Ver recovers from Sleep Mode /0005/0006 jam code (Measure against double feeding jam when the document is fed by ADF)...48

4 <E020>...50 E occurs due to the dust on the dustproof glass...50 E020-0x60/E020-0x91/E020-0xb1 due to stained Toner Level Detection Area...52 E occurred due to the screw of the inner middle panel in the machine coming off or getting loose...56 E occurs due to the stuck coupling of the drum unit upon inserting the drum unit...57 E020-0x90 upon installation due to the return failure of a contact spring on the Developing bias...57 E020-0x90 /abnormal noise/toner leakage occurs at the time of installation due to the displacement of gear inside the drum unit cover...59 E displays because the Dustproof Shutter is not open...60 E occurs due to an installation error of the Bk hopper unit...61 < Waste Toner is Full message >...62 "Insert the waste toner container" does not disappear...62 Waste toner overflow/method to change setting of waste toner full detection timing...63 <Noise from Fixing Assembly & Fixing Drive Assembly>...65 Abnormal sound due to the chipped off gear inside the fixing assembly...65 Noise from the fixing drive assembly due to failure of the fixing drive gear at the time of turning OFF the main power/transition to sleep mode/occurrence of jam/error...72 <Duplex Jamming> A Jam Code upon paper being attracted to the ITB due to the influence of the Secondary Transfer Voltage in duplex mode A Jam occurs in the 2nd side of thin paper due to the paper separation error...79 < Load Paper message >...80 "Load Paper" is displayed: Excel file cannot be printed when the resolution of UFR II Printer Driver is set to 1200 dpi...80 <Appendix>...82 E when the stapler moves due to the contact with the earth spring (Inner Finisher-C1)...82

5 <Foggy Image / Ghost Image / Solid Image> Symptom Ghost image occurs due to remaining toner on the primary charging roller Two types of ghost images have occurred. Cause of each ghost image and field remedy will be explained. A) A ghost image wherein toner of different color is transferred to a band of a solid color image (called a retransfer residue ghost). The following sample image [A] shows that Magenta toner [a] is transferred to a solid yellow part or a white background. B) A ghost image wherein the same color toner has been retransferred (called a transfer residue ghost). The following sample image [B] shows that Black (Bk) toner has been retransferred. pg. 5

6 Cause A) Cause of the retransfer residue ghost The cause will be explained by referring to the sample image [A]. Yellow toner transferred to ITB [2] was retransferred when Magenta was transferred, and passed through the upstream brush [4] or the downstream brush [5], thereby staining the primary charging roller [6]. This caused a failure in appropriately controlling potential on the surface of the drums, leading to the occurrence of the ghost image. B) Cause of the transfer residue ghost The cause will be explained by referring to the sample image [B]. The remained toner [3] that was not transferred from the Black drum [1] to ITB [2] is collected by the upstream brush [4] or the downstream brush [5]. However, toner that could not be collected by the upstream and downstream brushes stained the primary charging roller [6]. This caused a failure in appropriately controlling potential on the surface of the drums, leading to the occurrence of the ghost image. pg. 6

7 Field Remedy Output a PG print by following the steps below and make Service Mode adjustment of toner color that has the ghost image problem. 1) Execute "Full Adjust" in Settings/Registration > Adjustment/Maintenance > Adjust Image Quality > Auto Adjust Gradation. 2) Select paper source and then press "OK." Then, output and read the test print according to the message on the screen, and then perform Full Adjust. 3) Change the setting value from "59" to "1000" in Service Mode > Mode List > COPIER > Adjust > BLANK > BLANK-B. 4) Select a paper cassette from "A4" or "LTR" in Service Mode > Mode List > COPIER > Test > PG >PG-PICK. 5) Change the setting value to "255" in Service Mode > Mode List > COPIER > Test > PG > DENS-Y/M/C/K. 6) Change the setting value to "0" (Full Color Mode) in Service Mode> Mode List > COPIER > Test > PG > F/M-SW, set "49" in Service Mode > Mode List > COPIER > Test > PG > TYPE, and then output a PG print. Repeat the above procedure by changing the setting value to "1" (Black and White Mode) in Service Mode> Mode List > COPIER > Test > PG > F/M-SW. The following image is a PG49 test print when the ghost did not occurred. The sample [A] is an image printed in Full Color Mode, and the sample [B] in Black and White Mode. pg. 7

8 The following image is a PG49 test print when the ghost occurred. The sample [C] is an image printed in Full Color Mode, and the sample [D] in Black and White Mode. When the ghost image occurs, check "toner color" of the part within a red frame. The sample [C] shows the retransfer residue ghost of Magenta [a] and the transfer residue ghost of Cyan [b] occurred, while the sample [D] shows the transfer residue ghost of Black [c] occurred. - In case the retransfer residue ghost of different color such as [a] of the sample [C] occurs, proceed with A) The step for responding to the retransfer residue ghost of different color. - In case the transfer residue ghost of the same color such as [b] of the sample [C] occurs, proceed with B) The step for responding to the transfer residue ghost of the same color. - In case the transfer residue ghost of Black such as [c] of the sample [D] occurs, proceed with C) The step for responding to the transfer residue ghost of only Black. pg. 8

9 A) The step for responding to the retransfer residue ghost of different color A-1) Change the setting values as described in red in the row "1" of the table below in accordance with the toner color of which the retransfer residue ghost was confirmed in the step 6), and open and close the front cover of the main body. This will enable the change of the setting value in Service Mode. The retransfer residue ghost of Magenta occurred in case of [a] of the sample [C], change the setting value for Magenta in Service Mode. Y/M/C/K Upstream Auxiliary Brush DC Ghost bias Adjustment Discharge current control Y/M/C/K target current adjustment Primary Transfer ATVC Y/M/C/K target current adjustment (Under Full Color Mode) Settings Image Adjust > HV-PRI > Sample Adjust > HV-PRI > Adjust > HV-TR > USUB-Y/KDC DIS-TGY/M/C/K 1TR-TGY/M/C/K4 (*1) 1 [C] [C] [C] [Caution] With regard to "Adjusting Y/M/C Upstream Auxiliary Brush DC bias" described in (*1) of the above chart, Service Mode USUB-YDC is for adjusting all of Y/M/C at the same time, and USUB-KDC is for adjusting only Black. A-2) Check if the ghost image has occurred by outputting a PG49 test print in Full Color Mode. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step A-3). A-3) Change the setting values as described in the row "2" of the table above, output a PG49 test print in Full Color Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step A-4). A-4) Change the setting values as described in the row "3" of the table above, output a PG49 test print in Full Color Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, refer to FAQ titled "Drum ghost due to advanced life of Drum Unit with high duty/high CV." pg. 9

10 B) The step for responding to the transfer residue ghost of the same color B-1) Change the setting values as described in blue in the row "1" of the table below in accordance with the toner color of which the transfer residue ghost was confirmed in the step 6), and open and close the front cover of the main body. This will enable the change of the setting value in Service Mode. The transfer residue ghost of Cyan occurs in case of [b] of the sample [C], change the setting value for Cyan in Service Mode. Discharge current Primary Transfer ATVC Y/M/C/K Upstream Setting of control Y/M/C/K Y/M/C/K target current Auxiliary Brush DC toner deposit Ghost target current adjustment (Under Full bias Adjustment amount Settings Image adjustment Color Mode) Sample Adjust > HV-PRI > Option > Adjust > HV-PRI > Adjust > HV-TR > USUB-YDC/KDC IMG-MCON > DIS-TGY/M/C/K 1TR-TGY/M/C/K4 (*1) TNR-DWN 1 [c] [c] [c] [Caution] With regard to "Adjusting Y/M/C Upstream Auxiliary Brush DC bias" described in (*1) of the above chart, Service Mode USUB-YDC is for adjusting all of Y/M/C at the same time, and USUB-KDC is for adjusting only Black. B-2) Check if the ghost image occurs by outputting a PG49 test print in Full Color Mode. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step B-3). B-3) Change the setting values as described in the row "2" of the table above, output a PG49 test print in Full Color Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step B-4). B-4) Change the setting values as described in the row "3" of the table above, output a PG49 test print in Full Color Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, refer to FAQ titled "Drum ghost due to advanced life of Drum Unit with high duty/high CV." pg. 10

11 C) The step for responding to the transfer residue ghost of only Black C-1) As the transfer residue ghost of Black [c] in the sample [D] was confirmed in the step 6), change the setting values as described in green in the row "1" of the table below, and open and close the front cover of the main body. This will enable the change of the setting value in Service Mode. Primary Transfer ATVC Bk Adjust Bk Discharge current control target current adjustment Ghost Upstream Auxiliary Y/M/C/K target current (Under Black & White Color Settings Image Brush DC bias adjustment Mode) Sample Adjust > HV-PRI > USUB-KDC Adjust > HV-PRI > DIS-TGY/M/C/K Adjust > HV-TR > 1TR-TGK1 1 [d] [d] [d] C-2) Check if the ghost image occurs by outputting a PG49 test print in Black and White Mode. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step C-3). C-3) Change the setting values as described in the row "2" of the table above, output a PG49 test print in Black and White Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, proceed with the step C-4). C-4) Change the setting values as described in the row "3" of the table above, output a PG49 test print in Black and White Mode and check if the ghost image has occurred. - If the output has improved, restore the setting values in Service Mode that were changed in the steps 1) to 4), and make 10 copies of the test sheet. If the output is normal, the operation is completed. - If the output has not improved, refer to FAQ titled "Drum ghost due to advanced life of Drum Unit with high duty/high CV." pg. 11

12 Symptom Fogging occurs on the whole image Yellow fogging occurs on the whole image. [A] is an incorrect image. [B] is a correct image. Cause The connector J832 pin of the Connector PCB in the Laser Scanner Unit is deformed. Field Remedy Replace the Laser Scanner Unit. FM LASER SCANNER UNIT Symptom Foggy image in magenta/poor density on solid image. Overall fogging in magenta/poor density on solid image occurred. Below is a sample of PG test print. [A] shows the symptom. [B] is a normal image. Cause Due to the failure of the primary charging PCB, bias was not applied to the primary charging roller. pg. 12

13 Field Remedy Replace the Primary Charging PCB. FM ST CORONA PCB ASSEMBLY Symptom Ghosting at a 94mm pitch Ghosting at a 94mm pitch (drum cycle) occurs. Cause After a certain period of using the drum unit under an environment of high duty/high print volume, the residual toner accumulated on the upstream auxiliary brush increases, the potential cannot be even on the photosensitive drum when outputting blank or solid black images, and then ghosting occurs. Field Remedy The measure differs according to the version of the system software for the machine. a. DCON Ver. earlier than Lower the setting of the appropriate color by "1" in Service Mode (level 2) > COPIER > Adjust > HV-PRI > USUB-YDC/MDC/CDC. This service mode adjusts the Y/M/C upstream auxiliary brush DC bias. The set range is "-5" to "5". The default is "0". b. DCON Ver or later Change the setting in Service Mode (level 2) > COPIER > Option > IMG-FIX > NEGA-GST to "1". This service mode is added in DCON Ver : Ghosting improvement mode OFF(Default) - 1: Ghosting improvement mode ON - 2: Not used [Note] When upgrading DCON from a version earlier than to or later, return the setting in Service Mode (level 2) > COPIER > Adjust > HV-PRI > USUB-YDC/MDC/CDC to the original value. pg. 13

14 Symptom Water drop marks on 2nd side of 2-sided print occurred in 2-sided printing after continuous 1-sided printing (3 WAY UNIT-C1) When making 2-sided prints after performing continuous 1-sided printing while the 3 WAY UNIT-C1 is installed, water drop marks may appear on the 2nd side of 2-sided prints. Cause Water drops on the Paper Feed Guide attached to the 2nd side of the paper when 1st side is fed. Continuous 1-sided printing causes moisture in the paper to evaporate in the Fixing Assembly, which leaves water drops on the Paper Feed Guide of 3 WAY UNIT-C1. If 2-sided printing is performed afterwards, water drops on the Paper Feed Guide attach to the 2nd side of the paper when 1st side is fed, and the water drops appear as an image when 2nd side is transferred. This symptom occurs on the 2nd side of the first few 2-sided prints. [Reference] This symptom is likely to occur under the following conditions. - High temperature and high humidity environment - Shelf paper (complete moist paper) - After more than 30 pages of 1-sided prints are fed Field Remedy Select "1" to "3" for the value of Service Mode (level 2) > COPIER > Option > CUSTOM > FAN-POST. This starts the 3 Way Unit Cooling Fan (FM4) to remove the water drops on the Paper Feed Guide before executing the 2-sided printing job. Setting Value Fan drive time Effect 0 OFF(default) - 1 Approx. 15 sec. Small 2 Approx. 30 sec. Medium 3 Approx. 60 sec. Large pg. 14

15 [Caution] Values "2" or higher are effective in removing water drops. However, since this causes down time, consult with the user when setting the value. Symptom Lines on image in the sub-scanning direction due to the deformation of the contact spring on the Drum Unit Lines on all over image in the sub-scanning direction occurred. Cause The contact spring on the Bk Drum Unit was deformed. Field Remedy Reset the contact spring to the normal position. Reinstall the Drum Unit to the machine and check to see if output images are normal. If the lines on images recur, replace the Bk Drum Unit. pg. 15

16 Symptom Lines occur at approximately 30mm from the leading edge of paper, in the main scanning direction due to the deformation of the pre-fixing guide sheet Lines occurred at image center, approximately 30mm from the leading edge of paper, in the main scanning direction. Cause The pre-fixing guide sheet was deformed and contacted paper. Field Remedy 1) Remove the pre-fixing guide sheet[a] from the machine. pg. 16

17 2) Replace the pre-fixing guide sheet. If there is no part for replacement at hand, remove the pre-fixing guide sheet as a temporary measure and be sure to attach a new pre-fixing guide sheet later. FC SHEET, PRE-FIXING GUIDE Symptom Lines at 30mm from the leading edge of paper in the main scanning direction due to stained paper feed paths Lines occurred at image center, approximately 30mm from the leading edge of paper, in the main scanning direction. Cause The following paper feed paths were stained. - Fixing Feed Guide area [A] - Secondary Transfer Outer Roller Guide area [B] - Pre-registration Guide area [C] pg. 17

18 Field Remedy Clean the paper feed paths [A], [B] and [C] with lint-free paper. <Light Image / Faulty Density / Faulty Color Reproduction > Symptom Faulty image where specific color of toner does not get printed due to laser shutter lever malfunction When color copying/printing, specific color of toner does not get printed. Cause The laser shutter lever was unable to operate because spattering toner is accumulated on moving parts of the laser shutter lever. As a result, specific color does not get printed because a drum is not exposed to enough laser beam. Field Remedy Follow the steps below to remove toner bottle mounts, and clean moving parts of laser shutter lever. 1) In Service mode > COPIER > Function > MISC-P > SHT-OPEN, press OK to open the laser shutter. 2) Turn OFF the power, then remove the elective Drum unit. 3) Place a flashlight where the removed drum unit was located, and make sure the laser shutter is open. If the laser shutter is open, then a cause of the problem is different from the one noted in this FAQ; look for other contributing factors. 4) Remove the all drum units. 5) Remove the ITB unit. 6) Remove the cassette 1, the front cover, the left cover and the first delivery tray. 7) Remove the toner cartridge. 8) Remove the fan holder cover [1]. pg. 18

19 9) Depending on the toner bottle mount to be removed, follow the steps below. a. When removing the toner bottle mount "M" Remove the connector [2](1 pc), screw [3](2 pcs), protrusion [a](2 places), and remove the fan duct 2 in the direction of the arrow. b. When removing the toner bottle mount "Y" Remove the connector [4](1 pc), screw [5](2 pcs), protrusion [b](2 places), and remove the fan duct 1 in the direction of the arrow. c. When removing the toner bottle mount "C" Remove the screw [6](2 pcs), protrusion [c](3 places), and remove the fan duct 3 in the direction of the arrow. pg. 19

20 10) Put the cover [7] of drum unit back and remove the spring [8]. After step 10), steps are the same for all colors. 11) Remove the screw [9] (1 pc) of the toner guide rail reinforcing member. 12) Remove protrusion [d](3 pcs), then remove the toner guide rail [10]. 13) Remove the boss [e](2 places) of the toner guide rail reinforcing member [11], and pull out the toner guide rail reinforcing member [11]. pg. 20

21 14) Clean toner build-up on moving parts of the laser shutter lever. [Caution] Check for a cause for toner leakage. 15) Attach all the removed parts in the reverse order from step 13). 16) Make copies with the test chart, and make sure the image is printed correctly. Symptom Variation of image hues occurs when continuous output is being made Variation of image hues occurs when continuous output is being made. Cause The amount of toner charge in the developing assembly drastically changed due to the installation environment change (temperature/humidity) or image density change, causing the problem. Field Remedy If variation of hues occurs on plain paper, go to "a. Steps for plain paper." If it occurs on "heavy paper" or "print" output, go to "b. Steps for heavy/print output." a. Steps for plain paper pg. 21

22 1. Execute "Full Adjust" in Settings/Registration > Adjustment/Maintenance > Adjust Image Quality > Auto Adjust Gradation. 2. Select paper source and then press "OK." Then, output and read the test print according to the message on the screen, and then perform Full Adjust. 3. Change the paper interval value of ARCDAT control to "20" from "80" in Service Mode (Level 2) > COPIER > Option > IMG-SPD > ARC-INT1. Setting range is between "10" to "500" (Default: 80). [Caution] Actual setting value is calculated by dividing the entry value by 0.9 and rounding up after the decimal points. (e.g.: If an entry value is 80, setting value will be 89. And if an entry value is 20, setting value will be 23.) First, make sure to let the customer know that the productivity will slow down slightly after making the setting. After the customer accepts this, make the setting. b. Steps for heavy/print output 1. Select the settings below from HPFL-DSP in Service Mode > COPIER > Option > DSPL-SW and then turn OFF and ON the main power. 0: Displays Auto Gradation Adjustment with plain paper only (default) 1: Displays Auto Gradation Adjustment with plain paper and heavy paper 2: Displays Auto Gradation Adjustment with plain paper and 1200dpi resolution setting. 3: Displays Auto Gradation Adjustment with plain paper, heavy paper and 1200dpi resolution setting. 2. Select an appropriate paper type (plain paper, heavy paper and 1200dpi resolution setting) [B] and then perform Full Adjust in Adjustment/Maintenance > Adjust Image Quality > Auto Adjust Gradation. You will get the following screen if you select "3" in Step 1. pg. 22

23 3. Select the paper type you perform the adjustment and then press "OK." After that, output and read the test print and then perform Full Adjustment. [Caution] When you perform Auto Adjust Gradation, make sure to perform this for each paper type. The file below shows recommended paper type for Japan, USA, and Europe. Plain Heavy USA Hammermill Photo White (105g) Hammermill Color Copy Cover (162g) 4. Change the paper interval value of ARCDAT control to "20" from "80" in Service Mode (Level 2) > COPIER > Option > IMG-SPD > ARC-INT1. Setting range is between "10" to "500" (Default: 80). [Caution] Actual setting value is calculated by dividing the entry value by 0.9 and rounding up after the decimal points. (e.g.: If an entry value is 80, setting value will be 89. And if an entry value is 20, setting value will be 23.) First, make sure to let the customer know that the productivity will slow down slightly after making the setting. After the customer accepts this, make the setting. pg. 23

24 Symptom Output image becomes dark when the resolution is set at 1200dpi When the resolution is set at 1200dpi in the printer driver, output images become darker than those output at 600dpi. This symptom is not affected by the data. [A] is the output at 1200dpi, and [B] is at 600dpi. Cause The electric charge of toner inside the developing assembly suddenly changed due to frequent output at 1200 dpi, the change of installation environment (temperature/humidity), or the change of image density. Field Remedy 1) To show "Auto Adjust Gradation" button for 1200dpi on the display, set "2" or "3" in the following step. In Service Mode > COPIER > OPTION > DSPLY-SW > HPFL-DSP > set "2" or "3" as the setting value. - 0: OFF (Default) - 1: Plain / Heavy - 2: Standard / For Printer 1200dpi - 3: Standard(Thin) / Standard(Heavy) / For Printer 1200dpi 2) In the display > "Settings/Reg.Shortcut" > "Auto Adjust Gradation" > For Printer 1200dpi > perform "Adjust" Symptom When printing from PS driver, output in different color if the version of the system software is earlier than Ver When printing from PS driver, some characters or image were printed in different color or not printed. [1] is output like [2] in different color (blue characters). pg. 24

25 Cause The system software (earlier than MN-CONT Ver.23.02) had a problem in color table for postscript color matching. Field Remedy Upgrade the system software of the machine to Ver (MN-CONT Ver.23.02) and later. When upgrading after MN-CONT Ver.61.05, use the combination of versions shown below: MN-CONT: Ver.23.02/DC-CON: Ver.41.02//Inner Finisher-C1 SORTER: Ver.7.01 Symptom Gradation is not reproduced when printing from the PS3 printer driver on a machine with system software earlier than Ver When printing from PS3 printer driver in MacOS X, the gradation area was reproduced as solid color image. Gradation [A] was reproduced as solid color image like [B]. Cause Shading processing had a problem on a machine with system software earlier than Ver Field Remedy Upgrade the system software to Ver (MN-CONT Ver.23.02) or later. When upgrading it to MN-CONT Ver.23.02, use the combination of versions shown below: MN-CONT: Ver.23.02/DC-CON: Ver.41.02/Inner Finisher-C1 SORTER: Ver.7.01 Symptom PS printer driver on Windows prints color data that Illustrator creates in RGB color mode as the monochrome black data When printing a color data that was created by Illustrator or a color data that was printed first time in the following condition, the data was output as the black and white one. 1) Set a printer driver other than PS printer driver in Devices and Printers > "Default printer" and set its color mode to "Black and White." 2) Start Illustrator and create a new document with "RGB" set as its color mode under New Document. 3) Chose "Illustrator Determine Colors" for Color Handling in Illustrator side. 4) In Illustrator side, select File menu > Print > Printer list, select PS printer driver and print the new document. Then, the document is output as the black and white data. pg. 25

26 [Reference] - Data created with CMYK color mode is correctly printed in color. - Once such a document is printed in color by the default printer, it comes to be output as color data afterward. Cause This behavior is by design of Illustrator. Illustrator checks whether the default printer that has been set in OS is PS printer driver or not upon startup, and if it recognizes a printer driver other than PS printer driver as the default printer, it gets the color mode information of the driver via dmcolor of DEVMODE data structure. On the other hand, the printer driver sets the black and white mode in its dmcolor if "Black and White" is set on UI. In this situation, if Illustrator starts, it sets its color mode to Black and White in accordance with the dmcolor value. - DEVMODE data structure: stores information about printer environment - dmcolor: a member of DEVMODE data structure, and switches the color mode of the color printer between color and black and white. Field Remedy Select "PostScript Printer Determine Colors" in "Color Handling" in Illustrator side. [Reference] It is possible to avoid the problem by changing color mode setting of "Default printer" from "black and white" to "color". Symptom Page borders are printed lightly Microsoft Word 2007/2010 When a file in which page borders were used in Microsoft Word 2007/2010 was printed to an ir-adv series machine, the print was lighter than that from an LBP machine. Calibration with special fine line processing was ineffective. Cause ir-adv series machines draw and reproduce the page borders faithfully with the specified width, while LBP machines reproduce the page borders with a width greater than the specified width according to the specifications. Therefore, such a difference appears. Further, the reason why the calibration with special fine line processing is ineffective is that the page borders are sensed an image. In the special fine line processing, since texts/lines are the objects to be applied, it is ineffective for images. Field Remedy The symptom is improved with the workaround below: Perform printing by setting File > Print > Properties > Quality tab > Advanced Settings > Halftones > "Resolution" and also by setting Sharpness > "3[High]". pg. 26

27 < Fixing Assembly Jam / Delivery Jam > Symptom 070A Jam Code occurs due to the delivery roller bushing coming off 070A Jam occurred with a machine having a serial number earlier than the numbers listed below A: First Delivery Sensor (PS21) Wrap Jam Location Model Serial # UL imagerunner ADVANCE C2020 imagerunner ADVANCE C2030 imagerunner ADVANCE C2020 G imagerunner ADVANCE C2030 G FAH10614 EZS10942 GDV10009 GEB10010 Cause The delivery roller bushing [1] came off from the fixing delivery upper guide [2], which caused the delivery roller to fail to rotate. pg. 27

28 [Reference] The delivery roller bushing [1] is provided with claws [a] which are engaged with the fixing upper delivery guide [2] for fixation. [A] shows the correctly attached deliver roller bushing and [B] does the detached bushing. Field Remedy According to the steps below, replace the fixing upper deliver guide by the one having the delivery roller bushing with the increased engagement amount of claws. 1) Open the right lower cover. 2) Hold the right and left grips [c] and pull out the fixing assembly to the direction of the arrow [d]. [Caution] Be careful when removing the fixing assembly because it is hot immediately after the power is turned OFF. 3) Remove the 2 screws and 2 claws [e], and then replace the fixing delivery upper guide. Photo [C] shows the fixing delivery upper guide that is used when the 3 way unit-c1 is connected and Photo [D] does the guide that is used when the 3 way unit-c1 is not connected. pg. 28

29 4) Attach all the removed parts in the reverse order from Step 2). [Part replacement] FM GUIDE, FIXING DELIVERY, UPPER Symptom 1101/1001/020B Jam Code/ dog-ear on delivered paper (Inner Finisher -C1) In the combination use of the 3 way unit-c1 and the Inner Finisher-C1, the 3 way unit-c1 with the old type compensation sheet caused 1101/1001/020B Jam or dog-ear on delivered paper. For the 3 way unit-c1 with the new type compensation sheet, the 3rd digit from the right [a] is "2" or greater : Entrance Sensor Stationary Jam : Entrance Sensor Delay Jam - 020B: Second Delivery Sensor Stationary Jam Photo [A] below shows the 2nd/3rd delivery guide assembly with the old type compensation sheet [1] and Photo [B] shows the 2nd/3rd delivery guide assembly with the new type compensation sheet [2]. Cause The 2nd/3rd delivery guide assembly [1] had the old type tough compensation sheet [2], and thereby, allowed delivered paper [3] to butt against the lower entrance guide [4] of the Inner Finisher-C1, which caused 1101/1001/020B Jam or dog-gear on delivered paper. pg. 29

30 Field Remedy As the measure to prevent this symptom, the factory is using the new type compensation sheet [2] which is made by dividing the (old type) compensation sheet [1] into 2 parts to change the attaching angle. This prevents delivered paper from butting against the lower entrance guide of the Inner Finisher-C1. When the old type compensation sheet was attached, follow the steps below. [Caution] In the combination use of the Inner 2 way tray-f1 and the 3 way unit-c1, do not remove the old type compensation sheet. A jam can occur. 1) Open the lower right door [3]. pg. 30

31 2) Open the 2nd/3rd delivery guide assembly so that the compensation sheet [1] will come in sight. 3) Remove the compensation sheet [1] from back. At this time, be sure to hold the static-eliminator [4] under the compensation sheet by fingers. [Caution] - When removing the compensation sheet, be careful not to remove the static-eliminator. - Be careful not to leave the double-sided tape fixing the static-eliminator [4] which is encircled by a red frame on the compensation sheet. pg. 31

32 Symptom 010A/010B jam code displays while the 3 Way Unit-C1 is being installed 010A/010B jam occurs while the 3 Way Unit-C1 is being installed A: First Delivery Sensor Delay Jam - 010B: Second Delivery Sensor Delay Jam Cause The 3 Way Unit-C1 was installed without removing the Inner Guide [A]. So, the 2nd/3rd Delivery PCB Assembly [B] touched the Inner Guide, and the chip was no longer attached to the board securely. Field Remedy Replace the 2nd/3rd Delivery PCB Assembly. FM ND/3RD DELIVERY PCB ASSEMBLY Symptom 010C Jam Code occurs after installation of the 3 Way Unit-C1 If paper is delivered to Tray C after installation of the 3 Way Unit-C1, a jam (010C) occurs C: Third Delivery Sensor (PS30) Delay Jam Cause A harness extending from the 3 Way Unit-C1 was connected at an angle to a connector on the copier body side, which deformed pins of the connector. pg. 32

33 Field Remedy Straighten the deformed pins of connector with tweezers. Symptom 070A Jam Code due to detached first delivery sensor flag spring 070A Jam occurred upon installation A: First Delivery Sensor Wrap Jam Cause Detached first delivery sensor flag spring. pg. 33

34 Field Remedy Reattach the first delivery sensor flag spring as shown in the photo. <Pick-up Jamming> Symptom 0105 Jam Code occurs due to the detached registration sensor (Added FAQ) 0105 Jam occurred with all cassettes : Registration Sensor Delay Jam Cause When attaching and detaching the Registration Patch Sensor, since the claw of the attachment position of the Registration Sensor (PS20) attached to the Registration Patch Sensor was not securely fitted, the Registration Sensor was unable to detect the paper correctly. Field Remedy Follow the steps to reinstall the registration sensor. 1) Turn OFF the power. 2) Pull out the Cassette 1. 3) Open the Right Lower Cover [1], and then release the lock by pushing the part [a] to open the Right Cover fully. pg. 34

35 4) Move the Lock Lever [2] in the direction of the arrow. 5) Remove the Cassette 1 Separation Roller Unit [3] in the direction of the arrow. [CAUTION] When installing the Cassette 1 Separation Roller Unit [3], be sure that the Lock Lever [2] is released. 6) Remove the screw [4] of the Pickup Guide. pg. 35

36 7) Remove 2 claws [b], then remove the Pickup Guide [5] in the direction of the arrow with releasing the boss [c]. 8) Remove the Cable Cover [6] with releasing the claw [d]. 9) Disconnect the 3 connectors [7]. 10) Remove the 2 screws [8]. pg. 36

37 11) While lifting up the Sensor Lever [9], pull out the Cassette 1 Pickup Unit toward the front. 12) Remove the Connector Cover with pushing the claw [e] by slotted screwdriver. 13) Disconnect the 2 connectors. 14) Remove the 2 springs (right and left) of Registration Patch Sensor. pg. 37

38 15) Remove the Left Shaft in the direction of the arrow to remove the Registration Patch Sensor. 16) Correctly fit the claw of the Registration Sensor with the Registration Sensor [10] upward at an angle [f] as in the photo. [Reference] [A] Shows the Registration Sensor as seen from [f] angle. pg. 38

39 17) Attach the part to the main body in reverse order from Step 15). 18) Feed 10 sheets each from the Cassette 1 and the Cassette 2 and make sure that there is no error such as Jam. Symptom 0105 Jam Code due to floating Cassette 1 Separation Roller Unit 0105 Jam occurred Jam: Registration Sensor (PS20) Delay Jam Cause The Cassette 1 Separation Roller Unit [A] was not fixed to the proper setting location. [B] indicates the wrong status whereas [C] indicates the correct status. Field Remedy Properly set the Cassette 1 Separation Roller Unit. pg. 39

40 Symptom 0105 Jam Code due to failure of gear engagement when the multi-purpose tray is used During paper feeding from the multi-purpose tray, 0105 jam and abnormal sound occurred : Registration Delay Jam Cause To feed paper from the multi-purpose tray, paper is picked up in such a way that the gear [2] attached to the gear holder [1] of the cassette 1 pickup unit causes rotation of the gear [4] of the M.P. paper pick-up gear ass'y [3] attached to the right door assembly. When the failure occurs, in the M.P. paper pick-up gear ass'y on the right door assembly, the front portion [a] of the gear holder assembly is displaced in the direction indicated by [b]. This causes the gear holder [1] and the gear [2] of the cassette 1 pickup unit to be displaced toward the M.P. paper pick-up gear ass'y [3] (in the direction of the arrow). Accordingly, play cannot be provided properly between the gear [2] and the gear [4], resulting in pickup failure and abnormal sound. The following Figure [A] shows the normal state and Figure [B] shows the state when the symptom occurs. pg. 40

41 Field Remedy Prepare the new type gear holder (FM1-B ), and replace the part according to the steps below. The following Figure [A] shows the old type and Figure [B] shows the new type. 1) Turn OFF the main power switch of the machine. 2) Pull out the cassette 1. 3) Open the right upper cover. Release the lock by pushing the part [a] to open the right lower cover [1] fully. 4) Move the lock lever [2] in the direction of the arrow. pg. 41

42 5) Remove the cassette 1 separation roller unit [3] in the direction of the arrow. [Caution] When installing the cassette 1 separation roller unit [3], make sure that the lock lever [2] is released. 6) Remove the screw [4] of the pickup guide. 7) Remove the two claws [b] of the pickup guide, and remove the pickup guide [5] in the direction of the arrow by releasing it from the boss [c]. pg. 42

43 8) Remove the cable cover [6] by releasing the claw [d]. 9) Disconnect the three connectors [7]. 10) Remove the two screws [8]. pg. 43

44 11) While lifting up the sensor lever [9], pull out the cassette 1 pickup unit. 12) Remove the E-ring [10], and remove the gear holder assembly [11]. 13) From the gear holder assembly, remove the output gear [12], the idler gear [13], and the torsion spring [14], and install them to the new type gear holder. 14) Install the parts by reversing the steps from step 12). 15) Test paper feeding from the multi-purpose tray and check that there is no problem. [Replacement Part] FM1-B HOLDER, GEAR pg. 44

45 Symptom 0D91/0205 Jam Code occurs on a machine with a version of system software earlier than Ver due to a wrong paper size setting for the multi-purpose tray When paper was fed from the multi-purpose tray, 0D91/0205 jam occurred due to a wrong setting of paper size. - 0D91: Registration Sensor Size Error Jam : Registration Sensor Stationary Jam Cause For versions of system software earlier than Ver.24.03, the default paper size setting for the multi-purpose tray was A4/LTR. When the multi-purpose tray was used, the paper size setting was not changed from the default setting. Therefore, A4/LTR-size paper was used, and consequently causing the jams. If the paper size to be fed was smaller than A4/LTR, 0D91 jam occurred. If the paper size to be fed was larger than A4/LTR, 0205 occurred. Field Remedy Upgrade the machine's system software (MN-CONT) to Ver or later. For system software Ver and later, the default setting of paper size for the multi-purpose tray has been cancelled. Make the following combination upon upgrading it to MN-CONT Ver MN-CONT:Ver.24.03/DC-CON:Ver pg. 45

46 <Feeder Jamming> Symptom Last sheet of multiple-sheet document not picked up (DADF-AC1) When picking up the document of multiple-sheet, the last sheet was not picked up and left in the Document Tray. Cause The symptom was caused by either of the following. 1) When the ADF rear side plate deforms at either [A] or [B], the Last Document Detection Sensor moves downward. This causes the dislocated sensor flag detection position for the Last Document Detection Sensor resulting in improper detection of document presence. [a] indicates a normal status whereas [b] drawn in a yellow line indicates the deformation at the attachment position. 2) When there is only one sheet of document left, the document paper bends on the concave portion of the Separation Reverse Guide Ass'y [1]. Then the Last Document Detection Sensor Lever [2] lowers to no-paper detection position from paper presence detection position. pg. 46

47 Field Remedy 1) Open the paper pick-up cover of the DADF to remove the Rear Cover. 2) Check for the rear plate deformation from the right side [A] and back side [B] of the machine. If the plate is deformed, modify the deformation as shown in the photo below. If the plate is not deformed, attach the Rear Cover and go to Step 5). 3) Attach the Rear Cover. 4) Set 3 sheet of test document on the feeder to scan (copy.) If the symptom improves, then the work is completed. If the symptom does not improve, go to Step 5). 5) Replace with the countermeasure Last Document Detection Sensor Lever (Empty Sensor Lever) (FC ) and the countermeasure Separation Reverse Guide Ass'y (FM ) In this measure, the [C] part of the Last Document Detection Sensor Lever is extended approximately 0.5mm and the [D] part of the Separation Reverse Guide is heightened approximately 0.5mm. These measures prevent the Last Document Detection Sensor from wrongly detecting no-paper even though the last sheet of the document bends. 6) Set 3 sheet of test document on the feeder to scan (copy.) If the symptom improves, then the work is completed. FC LEVER, EMPTY SENSOR FM SEPARATION REVERSE GUIDE ASS'Y pg. 47

48 Symptom DADF fails to feed originals after the machine recovers with a version of System Software earlier than Ver recovers from Sleep Mode Even though the Start button was pressed after the following steps, the DADF did not feed originals and the copyboard glass was scanned (copied). 1) Let the machine go into Sleep Mode with its feeder being opened. 2) Close the feeder while the machine stays in Sleep Mode, and then let the machine go out of the mode. 3) Place originals on the feeder and press the Start button; then the symptom occurs. Cause Although the feeder was opened and closed while the machine was in Sleep Mode, the feeder open/close detection signal was not sent to the main controller PCB 1. Field remedy Upgrade the machine's system to Ver or later. Make the following combination upon upgrading. MN-CONT: Ver.21.01/DC-CON: Ver.40.03/G3 FAX: Ver.2.05/Inner Finisher-C1 SORTER: Ver.6.03 Symptom 0004/0005/0006 jam code (Measure against double feeding jam when the document is fed by ADF) Machines having serial numbers earlier than below had multiple feed jam (0004/0005/0006 Jam Code) when documents were fed : Registration stationary jam : Read sensor delay jam : Read sensor stationary jam Models Serial Number IR-ADV C2020 UL 120V IR-ADV C2030 UL 120V FAH1059 EZS10919 IR-ADV C2020 UL 120V G GDV10009 IR-ADV C2030 UL 120V G GEB10010 Cause Depending on paper types, separation capability of separation pad may be decreased. pg. 48

49 Field Remedy Following the steps below, implement replacement with the separation pad unit holder (FL )[1] of which the separation capability has been improved. 1. Open the feeder cover. 2. Remove 2 hooks [2] of the separation pad unit holder to remove the separation pad unit holder. 3. Attach the separation pad unit holder (FL ). Due the measure, the color of the separation pad unit holder has been changed from black to white. FL HOLDER, SEPARATION PAD UNIT pg. 49

50 <E020> Symptom E occurs due to the dust on the dustproof glass E occurred. - E : Abnormal detected patch reading value Cause Laser exposure quantity decreased due to dust on the dustproof glass [2] of the laser scanner unit [1], causing low toner density of patch. Field Remedy Clean the dustproof glass of the laser scanner glass following the steps below. 1) In Service Mode > Copier > Function > MISC-P > SHT-OPEN, press OK and open the shutter of the laser scanner unit. 2) Turn OFF the power. 3) Open the front cover and the drum unit retaining cover [1]. 4) Open the handle [2] and pull out the drum unit [3] with both hands, and pull it out horizontally. pg. 50

51 [Caution] Do not touch the surface of the photosensitive drum. 5) Block light with paper etc. to the removed Drum Unit. [Caution] Be sure to insert the drum unit until it stops before closing the retaining cover. If the drum unit is not pushed all the way when closing the retaining cover, error code E021-xx20 may occur. 6) Remove the dustproof glass cleaning tool [4] from the front cover. 7) Insert the dustproof glass cleaning tool [4] into the groove [a], and clean the Dustproof Glass. [Caution] When pulling the dustproof glass cleaning tool out, be sure to pull it out while pushing the lever toward right direction. If it is pulled out abruptly, it may come in contact with the ITB. pg. 51

52 8) Attach all the removed parts in the reverse order from step 6) to Step 3). Symptom E020-0x60/E020-0x91/E020-0xb1 due to stained Toner Level Detection Area On the machines with serial number earlier than the following, E , E , E020-03b1 occurred approximately from several days to 2 months after installation. - E : Low density for the Bk target at patch detection. - E : The average Bk value of detected ATR sampling value is equal to or higher than the specified value. - E020-03b1: The Bk T/D ratio detected by the ATR Sensor is equal to or lower than the specified value (light density) Location Model Serial # US, CA, LTN IR-ADV C2020 UL 120V FAH10547 US, CA, LTN IR-ADV C2030 UL 120V EZS10829 US IR-ADV C2030G UL 120V GDV10009 US IR-ADV C2020G UL 120V GEB10010 [Reference] Output may become available by turning the main power switch off/on when E020-03b1 occurs. Cause The Toner Level LED (light emitting section) and the Toner Level PT PCB (light receiving section) on the Toner Level Detection Area took charge resulting in toner adhering to the light emitting section and the light receiving section. Therefore, the presence of toner was detected despite the hopper being out of toner. Then toner was not supplied resulting in this symptom. [1] Toner Feed Assembly, Black [2] Toner Level Detection Area (light receiving section) pg. 52

53 Field Remedy 1) In Service Mode > COPIER > Counter > MISC > T-SPLY-K, write down the numerical value. Let this numerical value as "a". 2) Add up all the numerical values in Service Mode > COPIER > Counter > PICKUP > C1/ C2/ C3/ C4/ MF/ 2-SIDE and write down the obtained numerical value. Let this numerical value as "b". 3) In Service Mode > COPIER > Counter > MISC > SUC-A-K, write down the numerical value. Let this numerical value as "c". 4) Calculate the numerical values "b" and "c" as shown below and obtain the numerical value "d". d= (b x c)/100 5) If the numerical value "a" is bigger than "d", go to step 6). It is possible that the light emitting/receiving sections on the Toner Level Detection Area are stained. If the numerical value "a" is smaller than "d", check for the toner supply assembly and the Drum Unit. 6) Turn off the main power SW. 7) Remove all Drum Units and the ITB. 8) Remove Cassette 1, the Front Cover, the Left Cover and the First Delivery Tray. 9) Remove the Bk Toner Bottle Mount. 10) Check for the toner in the Toner Feed Assembly. If there is no toner [A] and you can see the feed screw [3], replace the Toner Feed Assembly after performing step 11) and onward. If there is toner [4] [B], do not perform step 11) and onward, but try to find another cause. pg. 53

54 11) Remove the stopper and remove the Link Stick in the direction of the arrow. 12) Remove the 2 screws [5]. 13) Push the rib [6] that Black Toner Feed Assembly catches the rear end plate back to free the plate catching hook. pg. 54

55 14) Insert fingers into the space [7] and hold the toner feed assembly. [Caution] When installing the Bk Toner Feed Assembly, be sure to make sure that the claw under the Bk Toner Feed Assembly fits into the hole on the bottom metal plate of the Bk Toner Feed Assembly. (If this claw does not fit, the toner supply operation fails, consequently leading to E ) 15) Lift up above the toner feed assembly. 16) Turn the Bk Toner Feed Assembly right down while pulling it toward the front a little. 17) If the Bk Toner Feed Assembly is turned, the claw [9] may hit against the PCB behind the assembly. To prevent this, pull the assembly toward the front a little while turning it right down. pg. 55

56 18) Replace the Toner Feed Assembly with the countermeasure part (FM ). This measure has a mechanism added to drop toner adhered to the toner level detection sensor window in the Toner Feed Assembly by vibration. 19) Put together all the removed parts in the reverse order of removal. [Caution] When you install Bk Toner Feed Assembly, please confirm the caution in Step ) Turn on the main power SW. 21) If the machine's software has a combination of less than MN-CONT Ver.20.70/DCON Ver.40.03, update to MN-CONT Ver.20.70/DCON Ver or later. [Caution] If the versions are less than the above, Service Mode in step 23) cannot be performed. 22) Check the numerical value of the affected color in Service Mode > COPIER > Display > DENS > DENS-K. You will see a numerical value close to -4.00% to -6.00% displayed, then if E020-03b1 occurs, the a numerical value will be over the -5.00%. 23) In Service Mode > COPIER > Function > INSTALL > SPLY-H-K and press "OK". "START" will be displayed for a moment in Service Mode display and then "OK!" will be displayed. This allows the initial filling of toner from the toner bottle to the hopper unit. 24) Open the front door of the machine and insert the door key switch into the door open/close sensor switch. Then the operation of toner supply to the buffer unit starts and lasts for approximately 40 seconds. Make sure that the toner bottle rotates intermittently. If the toner bottle does not rotate, check for the Toner Feed Assembly Attachment. 25) Place A3 blank sheet on the copyboard glass and make 21 copies. This allows toner to be supplied in the developing assembly. 26) Check the numerical value of Service Mode > COPIER > Display > DENS > DENS-K. You will see a numerical value close to -1.00% to -2.00% displayed as toner was supplied in the developing assembly. 27) Make a copy in CA-1 test chart. If no problem is found on the image, then the work is completed. If there is a problem with image density, go back to step 25). FM Toner Feed Assembly, Black When upgrading to MN-CONT Ver.20.70/DC-CON Ver or later, follow the combination below. MN-CONT: Ver.20.70/DC-CON:Ver.40.03/G3 FAX:Ver.2.05/Inner Finisher-C1 SORTER: Ver.6.03 Symptom E occurred due to the screw of the inner middle panel in the machine coming off or getting loose E occurred due to the screw of the inner middle panel in the machine coming off or getting loose. - E : Abnormal detected Bk patch reading value Cause If the screw [A] of the inner middle panel gets extremely loose or comes off, the inner middle panel becomes unable to retain the [B] on the drum unit to where it should be set resulting in it moving forward. Because of this, drive was not transmitted to the drum and the Bk patch could not be formed. pg. 56

57 Field Remedy Tighten the screw of the inner middle panel. Symptom E occurs due to the stuck coupling of the drum unit upon inserting the drum unit E occurred due to the stuck drum unit coupling. -E020-0x20: ATR sensor error or toner supply error (x=0: Y, 1: M, 2: C, 3: Bk) Cause When inserting the drum unit into the main unit, the coupling [A] gets stuck with the guide rail [B], causing E020-0x20.Picture [C] shows the stuck coupling. Field Remedy Release the stuck coupling. Make sure to check that the error does not recur after inserting the drum unit into the main unit. If it recurs, there may be other factors to cause the error. [Caution] If the drum unit coupling hits against something, it may get stuck with the guide rail. Handle the drum unit coupling with care. Symptom E020-0x90 upon installation due to the return failure of a contact spring on the Developing bias E020-0x90 occurred upon installation. - E020-0x90: ATR Sensor error or toner supply error (x=0:y, 1:M, 2:C, 3:Bk) pg. 57

58 Cause The leading edge of a contact spring on the Developing bias consists of a double ring. The return failure of a spring occurred due to this ring being crossed resulting in a contact failure and a subsequent error. Field Remedy 1) Detach the cap by removing the claw of the contact spring cap [A]. [Caution] Be careful not to break the claw when detaching the cap. If the cap gets broken, replace the High Voltage Holder Assembly. 2) Correct the crossed ring [B] of the contact spring. Attach the cap by getting the spring through the slit of the cap [A]. FM HIGH VOLTAGE HOLDER ASS'Y pg. 58

59 Symptom E020-0x90 /abnormal noise/toner leakage occurs at the time of installation due to the displacement of gear inside the drum unit cover At the time of installation or replacement of the drum unit, a machine having a serial number earlier than below or a drum unit having a lot number earlier than below causes abnormal noise around the drum unit or E020-0x90. In the worst cases, toner leaks from the drum unit. - E020-0x90 : ATR Sensor error or toner supply error (x=0:y, 1:M, 2:C, 3:Bk) [Reference] As for the machine having the serial number below or later, and the drum units having the serial number below or later, the positions of the take-up gear and the worm gear are checked. Location Model Serial # UL imagerunner ADVANCE C2020 imagerunner ADVANCE C2030 FAH02681 EZS02392 Drum Unit Yellow Lot No Y Magenta M Cyan Black C K The picture below shows the drum unit [A] and the ITB [B] when the magenta toner leaked. Cause At the time of installation or replacement of a drum unit, gears inside the drum cover unit roll up the toner seal sheet automatically. In the cases described above, however, the take-up gear [C] and the worm gear [D] behind the drum unit cover displaced to the left, and as the result, the toner seal sheet was not rolled up completely, and consequently leading to the symptoms. pg. 59

60 Field Remedy 1) Remove the drum unit and the ITB. Check toner leakage. 2) If the toner is leaked on the ITB, remove the toner on the ITB and put the ITB back into the machine. 3) Measure the length of the gap between the drum unit and the drum unit cover. When the length is 2.8mm or more, replace the drum unit. When the length is less than 2.8mm, there may be other factors. [Caution] When the claw receiver [E] of the drum unit cover or the claw [F] is broken, replace the drum unit. Symptom E displays because the Dustproof Shutter is not open E displays while the machine is being installed. - E : Abnormal detected patch reading value Cause Foreign substance [B] is mixed into the Dustproof Shutter [A] of cyan Laser Scanner Unit, and this prevents the shutter from opening fully. [C] indicates the range of open/close shutter. pg. 60

61 Field Remedy Check the Dustproof Shutter. Remove the foreign substances if you find any. Symptom E occurs due to an installation error of the Bk hopper unit E occurred a few days after the replacement of the Bk hopper unit. - E : Low density for the target at patch detection Cause When the Bk hopper unit was replaced, the claw [A] fixing the unit in place failed to fit into the groove firmly. As a result, no toner was supplied. pg. 61

62 [B] shows the claw that does not fit into the groove, and [C] shows the claw that fits the groove firmly. Field remedy Re-install the Bk hopper unit. < Waste Toner is Full message > Symptom "Insert the waste toner container" does not disappear. The message "Insert the waste toner container" did not disappear. Cause The cap of the waste toner container came off and dropped behind the waste toner container. This prevented the waste toner container switch from detecting the waste toner container. pg. 62

63 Field Remedy Attach the cap of the waste toner container to the correct position [A]. Symptom Waste toner overflow/method to change setting of waste toner full detection timing The waste toner may overflow according to the installation environment of the host machine and the output image. Cause a) Service mode > COPIER > Option > CUSTOM > EXT-TBOX is set other than 0. b) A high temperature and humidity environment. c) When the user prints large volume of solid images in color. The problem occurs when condition b) or c) is added while condition a) is fulfilled. Field Remedy 1) Clean the overflow waste toner. 2) Estimating the accumulation speed on the basis of the level of the waste toner remaining in the Container at the last replacement of the container, change the setting value of EXT-TBOX in service mode > COPIER > Option > CUSTOM to adjust the full level detection timing. Increasing the setting value by "1" increases the number of sheets by 1000, whereas decreasing the setting value by "1" reduces the number of sheets by [Caution] - For DCON with the version earlier than 62.02/with the version or later, detection timing is changed so as to increase the amount of toner to be collected in the waste toner box. Accordingly, the capacity corresponding to a value set in the service mode and the default setting value are changed as well. -The setting value "9" for DCON with the version earlier than is equivalent to the setting value "4" for DCON with the version or later, as shown in the table below. Setting values in Service Mode (EXT-TBOX) Earlier than Ver (default) 5 9 Ver62.02 or later 0 4 (default) 9 - Note: If DCON with the version earlier than is upgraded to the version or later, the default value "4" serves as the setting value for EXT-TBOX as shown above. pg. 63

64 The Level of the Waste Toner Remaining in the Waste Toner Container at the Last Replacement Waste Toner Accumulation Speed Reference Value for Changing the Setting Value Lower than A Slow +5 (+5,000 sheets) From A to lower than B Slightly slow +1 (+1,000 sheets) From B to lower than C Moderate No change [Note] Significantly changing the setting value at a time is not recommended because the accumulation speed changes due to change in the usage environment of the user. When changing the setting value, check the machine installation environment and the conditions of use by the user. a) Machine installation environment When the setting value is set to "0", waste toner will not overflow, but waste toner full level may be detected when the waste toner level is still 60% in a low temperature and low humidity environment. The volume of the waste toner tends to increase in a high temperature and high humidity season, so be careful not to increase the setting value too much during that season. b) Conditions of use by the user Even if the waste toner full level detection timing is adjusted, waste toner may overflow if a large amount of color solid images are printed. If the user prints a large amount of color solid images, adjust the setting to a lower value. pg. 64

65 <Noise from Fixing Assembly & Fixing Drive Assembly> Symptom Abnormal sound due to the chipped off gear inside the fixing assembly Noise was heard from the fixing assembly prior to the following Lot # or in a machine prior to the following serial number. Model Serial # Model Serial # IR-ADV C2020 UL 120V FAH14732 IR-ADV C2020 CN 220V GDW11581 IR-ADV C2030 UL 120V EZS15826 IR-ADV C2030 CN 220V GDS10304 IR-ADV C2030 UL 120V G GDV10024 IR-ADV C2025 CN 220V GDQ10628 IR-ADV C2020 UL 120V G GEB10013 IR-ADV C2020 TW 120V GDY10355 Service Parts Lot # Fixing Assemble (FM ) 120V Cause In the fixing assembly that has long been used, the 21T/15T gear [1] and the 35T gear [2] get worn out, causing gear disengagement, and resulting in noise from the fixing assembly. Field Remedy Prepare the following 3 parts: the new types of the 21T/15T gear (RU ) and 35T gear (RU ) which were made less likely to be chipped off by increasing the number of meshing teeth of the old type, and the lower fixing cover (RC ) that was changed in shape. A) 21T/15T gear [A] is the old type, and [B] is the new type. pg. 65

66 b) 35T gear [A] is the old type, and [B] is the new type. c) Lower fixing cover [A] is the old type, and [B] is the new type. Replace the above 3 parts at the same time by following the steps below. 1) Open the lower right cover, and then hold the right and left grips [1] and pull out the fixing assembly to the direction of arrow [2]. [Caution] Be careful when removing the fixing assembly because it is hot immediately after the power is turned OFF. pg. 66

67 2) Remove 2 screws and 2 claws [a], and then remove the fixing delivery guide. A) When the delivery expansion kit C1 is not attached B) When the delivery expansion kit C1 is attached pg. 67

68 3) Remove 2 screws [1] and 4 claws [a], and then remove the fixing front cover. [Caution] As the claws [a] can be broken if a flat head screwdriver is used directly onto the claws, remove the cover from the part [b] near the claw [a]. 4) Remove 2 screws [1] and 1 claw[a], and then remove the fixing right cover. [Caution] When removing the fixing right cover, the dowel pin [4] can drop off due to detachment of the cam gear [3]. Be careful not to lose the dowel pin [4] and/or the cam gear [3]. pg. 68

69 5) Remove the 21T/15T gear [1], then remove the 35T gear [2] while letting the 1 claw [a] escape, and replace them with the new type of the 21T/15T gear [1] and 35T gear [2]. 6) Hold the fixing right cover [1] and the cam gear [2] as shown in the photo, and attach them to the fixing assembly. Be sure to check the following caution when performing the above. [Caution] - Attach the cam gear [1] and the white cam [2] so that they engage with each other. pg. 69

70 - Place the harness [1] so that it can be housed within the guide [2]. - Attach the fixing right cover so that the shaft [1] of the fixing assembly can be fit into the hole position [a] of the cover. 7) Fix the fixing right cover with the 2 screws [1]. pg. 70

71 8) Attach the fixing front cover with 2 screws [1] and 4 claws [a]. 9) Remove 2 claws [a] and 2 bosses [b], and then remove the lower fixing cover. [Caution] Remove the 2 claws [a] at first. 10) Attach the new type of the lower fixing cover. [Caution] When attaching the lower fixing cover, attach the claws [a] at first and then fit the cover into the boss [b] on the fixing assembly side. pg. 71

72 11) Reassemble the parts in the reverse order from the step 2). [Replacement parts] RU T/15T GEAR RU T GEAR RC COVER, FIXING, LOWER Symptom Noise from the fixing drive assembly due to failure of the fixing drive gear at the time of turning OFF the main power/transition to sleep mode/occurrence of jam/error Noise (clattering sound) was heard from the fixing drive unit at the following timings. - At the time of turning OFF the main power - At the time of transition to sleep mode - At the time of occurrence of a jam - At the time of detection of a jam when turning ON the main power - At the time of occurrence of a jam Cause At the above timings, the drive gear [3] and the driven gear [4] in the ratchet unit [2] of the fixing drive unit [1] rotate while being engaged with each other, so that the fixing film unit and the pressure roller become separated. When the seal [5] attached to the drive gear deteriorates and becomes thinner, the engagement portion [a] of the drive gear and the driven gear becomes unstable, and then the drive gear rotates idly on the surface of the driven gear, thereby causing a noise. pg. 72

73 Field Remedy Prepare the new type of the fixing drive unit and replace the fixing drive unit with the new type by following the steps below. [Reference] Component formation for the new type fixing drive unit is changed in that the seal is not used to reduce slippery at the engagement portion. [A] is the new type and [B] is the old type. [1], [2], [3] and [a] are the seal, the drive gear, the driven gear, and the engagement portion, respectively. 1) Remove the rear upper cover, the connector cover and the rear cover. 2) Open the right lower cover, and then remove the fixing assembly. 3) Remove the waste toner container. 4) Remove 1 connector [1] and 2 screws [2], and then remove the waste toner storage box [3]. If Super G3 FAX Board-AH1 is attached, perform the following steps. If not, proceed to the step 5. pg. 73

74 4-1) Remove 2 connectors [1], and then remove the controller cover [2]. 4-2) Remove 2 connectors [1] of the main controller and 1 connector [2] of the FAX board. 4-3) Remove 3 screws [1], and then remove the FAX board [2]. pg. 74

75 5) Remove 1 screw and 4 claws, and then remove the primary transfer high-voltage power supply PCB. 6) Disconnect 1 connector [1] from the primary transfer high-voltage power supply PCB. 7) Remove the 1 claw [a], and then remove the harness cover. pg. 75

76 8) Disconnect 7 connectors [1]. 9) Remove 1 screw, and then remove the right rear sub cover. 10) Remove 1 screw, and then remove the inner guide 1 [1]. pg. 76

77 11) Remove 1 screw, and then remove the inner guide 2 [1]. 12) Remove 4 screws [1], and then remove the fixing drive unit [2]. [Caution] When installing the fixing drive unit, be sure that the plate [3] on the fixing drive unit side is positioned beneath the plate [4] on the main body side. pg. 77

78 13) Remove 4 screws and the fixing motor, and then assemble these parts on the new type fixing drive unit. [Caution] When installing a new fixing drive unit, remove the positioning member. [Replaced Parts] FM FIXING DRIVE ASS'Y pg. 78

79 <Duplex Jamming> Symptom 010A Jam Code upon paper being attracted to the ITB due to the influence of the Secondary Transfer Voltage in duplex mode In double-sided copying/printing, the leading edge of the second side of the paper was attracted to the ITB and accordingly the paper was not fed to the fixing assembly side, resulting in 010A jam. In addition, this jam tends to occur with thin paper, paper that easily becomes charged (paper that is electrostatically charged immediately after being copied and delivered), paper that contains a lot of moisture, and paper that is easily curled A: First Delivery Sensor Delay Jam (PS21) Cause The paper exhibiting the symptom was attracted to the ITB, since the paper separation failure occurred due to the influence of the Secondary Transfer Voltage of the leading edge on the second side. Field Remedy 1) Reduce the Secondary Transfer Voltage of the leading edge on the second side by changing the setting value in Service Mode > Mode List > COPIER > Option > IMG-TR > T2TOPDIV from the default "0" to "1". 2) Make ten sheets of double-sided copies. If no jam occurs, the work is completed. If the jam occurs, change the setting value in T2TOPDIV to "2", and make the double-sided copies in the similar manner. If the jam occurs with this setting, confirm other factors. [Caution] - When the setting value in T2TOPDIV is set to "1" or "2", blank area may appear at the leading edge of about 5 mm due to poor transfer. - When the setting value in T2TOPDIV is changed to "3", the separation performance is improved. However, this prevents the high Secondary Transfer Voltage from being output to the area other than the leading edge, affecting the image portion following the leading edge of 5 mm. For this reason, do not use "3". Symptom 010A Jam occurs in the 2nd side of thin paper due to the paper separation error When thin paper was used for a duplex copy/print job, 010A jam occurred in the second side. - First Delivery Sensor Delay Jam (PS21) Cause As some types of thin paper are easy to be charged, the transfer voltage in the 2nd side becomes too high, consequently leading to the jam code. pg. 79

80 Field remedy In Service Mode > COPIER > Option > IMG-TR > T2TOPDIV, increase the setting value of the voltage of the leading edge on the second side of the thin paper in increments of "1." If the setting value is increased, the transfer voltage drops, which makes the paper separate easily. This adjustment comes to the end if the jam is solved. 0: OFF(Default) 1: Weak separation 2: Medium separation 3: Strong separation [Caution] When the setting value is increased in Service Mode, poor transfer may occur at 5 mm to 10 mm away from the leading edge as a negative effect. < Load Paper message > Symptom "Load Paper" is displayed: Excel file cannot be printed when the resolution of UFR II Printer Driver is set to 1200 dpi If the cassette has only A4R (LTR) size paper and if you print Excel data using UFR II Printer Driver under the following settings, the Status Line of the main unit displays "Load Paper" message, and the printing fails. - Excel file Page Layout > Size > A4 (LTR), Orientation > Landscape - UFR II Driver Properties > Quality > Advanced Settings... > Resolution > 1200 dpi Cause If the resolution of UFR II Printer Driver is set to 1200dpi, the main unit cannot process 90 degrees/270 degrees rotation as per specification (For example, A4 (LTR) data cannot be output from A4R (LTRR) cassette. A4 (LTR) data can be output only from A4 (LTR) cassette). Excel Settings Printer Settings Cassette Setting Condition Page Layout Page Setup Quality A4/LTR cassette only A4R/LTRR cassette only Size Orientation Page Layout Resolution Result Result A4/LTR Landscape 1 in 1 600dpi Available Available 1200dpi Available Unavailable 2 in 1 600dpi Available Available pg. 80

81 Excel Settings Printer Settings Cassette Setting Condition 1200dpi Available Unavailable Portrait 1 in 1 2 in 1 600dpi Available Available 1200dpi Available Unavailable 600dpi Available Available 1200dpi Available Unavailable Field Remedy Make one of the following settings: a) If you want to set the resolution to "1200 dpi" for printing, change A4R (LTRR) paper in the cassette to A4 (LTR). b) Change the resolution of UFR II Printer Driver to "600 dpi" and then perform printing. pg. 81

82 <Appendix> Symptom E when the stapler moves due to the contact with the earth spring (Inner Finisher-C1) E occurred on the finishers with the serial number below and earlier when the stapler moved. -Inner Finisher-C1: FBZ E : Staple Move Motor Timeout Error Cause The symptom occurred because the Earth Roller [2] located at the lower part of the stapler got caught in either [a] or [b] of the Earth Plate [3] when the stapler [1] moved to its home position. The causes of the stapler being caught include the following. a) Vibration upon shipment without fixing member for the stapler such as a pre-installation. b) Moving the stapler overriding the Earth Plate with the inner cover being removed. Field Remedy Refit the Earth Plate and add 1 piece of the Washer (XD ) according to the following steps. [Caution] Prepare 1 piece of the Washer (XD ) before starting the work. 1) Remove 3 screws [1] to detach the front cover [2]. 2) Remove 2 screws [3] to detach the right cover [4]. pg. 82

83 3) Remove 4 screws [5], and the fixed plate [6]. 4) Remove 2 connectors [7] to remove the cable [8] from groove. 5) Pull out the Finisher approximately 10 to 15cm as shown below. [Caution] Finisher falls down if it is pulled out too much. pg. 83

84 6) Make sure the earth plate position from underneath, [A] is at the right position, and [B] is out of position. 7) Remove the screw [9] to detach the earth plate, and add the washer [10] as shown below and fix it with the screw. 8) When attaching the Earth Plate and washer, fit the torsion coil spring [11] to the notch [a]. The photo [C] indicates the washer properly attached whereas [D] indicates an improperly attached one. 9) Reattach the parts in reverse order from step 7). XD WASHER, PLAIN pg. 84