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NSSG SUPPORT SOLUTIONS

This document contains information that was exported directly from Konica's NSSG Supportknowledge base. Some solutions may contain hyperlink references which originallycontained links to graphic or text files. If you wish to view these files, you must access thesolutions via NSSG Web Support on Konica's website, www.konicabt.com.

Legal Notice

This document is designed as a diagnostic tool, primarily for Konica's support personnel, and authorized service representatives. Konicarecommends that all service be performed by an authorized service representative. Users are responsible for seeking advice of a Konicaauthorized service representative regarding the information, opinion, advice or content of this document.

USER AGREES THAT USE OF THIS DOCUMENT IS AT USER'S SOLE RISK AND THAT THIS DOCUMENT IS PROVIDED ONAN AS IS BASIS WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOTLIMITED TO, WARRANTIES OF TITLE OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE, OTHER THAN THOSE WARRANTIES THAT ARE IMPLIED BY LAW AND INCAPABLE OFEXCLUSION. IN NO EVENT WILL KONICA OR THOSE ACTING ON ITS BEHALF BE LIABLE FOR ANY DAMAGES,INCLUDING, WITHOUT LIMITATION, DIRECT, INDIRECT, INCIDENTAL, SPECIAL, CONSEQUENTIAL OR PUNITIVEDAMAGES ARISING OUT OF YOUR USE OF THIS DOCUMENT.

Copyright 2001, Konica Business Technologies, Inc.

March 20023035 - ALL ACTIVE SOLUTIONS

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How to reset an F86 code.DESCRIPTION: SOLUTION ID: 11,285

SOLUTION: F86 occurs when the waste toner collection box is full. To reset an F86 code, perform the following steps:1. Install a new (or empty the) waste toner [[collection box| IMAGE V:\BITMAPS\JRC036.BMPSCROLL]].2. Access the 47 mode (power the machine OFF, hold down the 4 and 7 keys, and power the machine ON).3. Enter 94 using the keypad.4. Press the start/print key.5. Power the machine OFF then ON to exit the 47 mode.

USAGE: 467

F43 while copying.DESCRIPTION: SOLUTION ID: 16,367

SOLUTION: PROBABLE CAUSES:1. The optics temperature fuse is open. Replace the fuse (p/n 540088412).

2. The L1 terminals are not making proper contact with the lamp. Reinstall the lamp, and ensure that there isgood contact from the terminals. Verify that the lamp pressure spring (p/n 540061690) is not broken ordetached.

3. Loose hardware has dropped into the optics area, and is causing the optics to stop short of therestart/brake sensor (PS5). Remove any loose hardware from the optics area.

4. The optics cable and spring are worn preventing the optics unit from reaching home. Replace the cable(p/n 540061111) and spring (p/n 540061480). Note: If the cable and spring were replaced recently, ensurethat the optics positioning jig is used (p/n 00M6-1-00).

5. The glass stopper plate assembly is malformed, and the exposure unit is contacting it. See 3035[[Technical Bulletin #33| IMAGE V:\BITMAPS\JRC071.BMP SCROLL]. Order the new style glass stopperplate assembly (p/n 5400-6363), and scale plate assembly (p/n 0481-1201).

6. The optics slide shaft holder has dislodged from the main reflector base assembly. This causes the lampassembly to bind on the optics shaft. Reposition the optics slide shaft holder.

7. F43 intermittently. Faulty/binding toner motor (M6). Ensure there is no binding in the toner hopper andtoner hopper drive gears. Replace toner motor. There is a new toner motor kit available (p/n 5400-K120).Order the new style toner motor cover also (p/n 540032191). See 3035 [[Technical Bulletin #88| IMAGEV:\BITMAPS\JRC054.BMP SCROLL]].

8. The optics cable, optics shaft, and optics bushings are worn. Replace the optics cable (p/n 540061111),optics shaft (p/n 540061090), and the optics bushings (p/n 540076042).

9. The machine has an old style AC driver board. Upgrade the AC driver board to the new style (p/n5400-9085). The new style is identified by the letter T on IC2. The new style boards were put intoproduction starting with s/n 542224652.

10. The optics drive motor (M2) has failed.Inspect the optics drive motor for sluggishness or binding. Replace M2 (p/n 540080020) as necessary.

USAGE: 164

ST205S, J72.DESCRIPTION: SOLUTION ID: 29,565

SOLUTION: PROBABLE CAUSES:1. The programming is incorrect. On the sorter CB, ensure that hardware dipswitch 1-1 is ON, and all otherswitches are OFF. In the 25 mode, ensure that software dipswitches P03, and P59 are set to 5.

2. The exit sensor (PS202) is out of adjustment. Perform the [[sensor adjustment.| IMAGEV:\BITMAPS\JRC013.BMP SCROLL]] a. Turn the power OFF and remove the rear cover to expose the sorter CB. b. Check PS202 for dust or dirt; clean as required. c. Turn VR1 on the sorter CB fully clockwise. d. Set hardware dipswitches 1, and 2 to the ON position. Close all covers, including the lower linkedinterlock (MS203). e. Turn the power on while pressing SW1 on the sorter CB. Press SW1 seven times; this will cause theindexer to begin to lower. When the indexer has reached the 11th, 12th, or 13th bin, press SW1 again to stopthe lowering of the indexer. f. Turn VR1 on the sorter CB fully counterclockwise; this should turn LED A OFF. If it does not, turn itOFF by blocking the LED 202 light path to PS202 with a piece of copy paper. g. Turn VR1 clockwise very slowly until LED A lights up; then, continue turning to one mark beyond thatpoint. h. Reset hardware dipswitches 1 and 2, reinstall the rear cover, and check the operation to confirm that thecopies are properly fed to all 20 bins.

3. The sorter has a level 16 EPROM installed. Install the level 18 EPROM (p/n ST20563-18.0) on the sorter

USAGE: 103

2Copyright 2001, Konica Business Technologies, Inc. March 2002

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CB.

4. The conveyance shaft holders are dry causing the shafts to bind. Clean and lube the conveyance shaftholders.

5. The indexer height is out of adjustment. Verify the [[indexer height| IMAGE V:\BITMAPS\JRC011.BMPSCROLL]] , and retime the indexer pulleys the timing belt may have jumped out of position.

6. The exit drive gear is worn and needs replacing. As a temporary countermeasure, remove the exit rollersattached to left side door. Replace the exit drive gear (p/n 048677080).

7. The home position sensor (PS204) has failed. Replace the sensor (p/n 037185010).

8. The exit detect sensor (LED202) and (PS202) have failed. Replace LED202 (p/n 037187030) and PS202(p/n 037187020).

9. The sorter conveyance belts are loose. Replace the conveyance belts (p/n 037145490).

10. The paper exit guide is malformed. This slows paper feed timing. Reform or replace the paper exitguide (p/n 037145130).

11. The sorter is not aligned properly to the main body preventing the linked interlock (MS203) from beingactuated. Ensure that the interlock switch is actuated. If the sorter is not level, adjust the rail height.

12. J72, only when feeding from the DB201. There is a timing problem between the drawer base and themain body. See 3035 [[Technical Bulletin #16| IMAGE V:\BITMAPS\JRC078.BMP SCROLL]]. AdjustVR1 on the PFU drive board as necessary.

13. The main CB has failed. Ensure that PS202 has been adjusted to specification. The sorter will work indiagnostics and the main body will function without the sorter. CN1-2 of the sorter CB is reading 5V DCwhich indicates the sorter is in a normal state. This indicates the problem is not with the sorter but with themain body CB. Replace the main CB (p/n 5402-9017).

How to add toner, 3035.DESCRIPTION: SOLUTION ID: 41,309

SOLUTION: Refer the end user to the add toner decal on the inside of the copier front door. The User's Reference Guidemaintenance, and supplies section also explains [[how to add toner.| IMAGE V:\BITMAPS\JRC055.BMPSCROLL]]

USAGE: 100

How to program ECM, 3035.DESCRIPTION: SOLUTION ID: 15,428

SOLUTION: To program the ECM, perform the following:1. In the 25 mode, enter the 8-digit master key code starting at address P72 through P79. Valid data is 0through 9 at each address, press the start print button to enter the new data.

2. Set 25 mode, P05 (ECM limit features) based on key operators request.0: ECM disabled.1: ECM enabled (no stop at limit).3: ECM enabled (natural stop at limit).5: ECM enabled (forced stop at limit).

3. In the standby mode, hold down P then press 9, then enter your Master Key Code. Then, access thefollowing setting modes to perform ECM functions:

1: Password Set. Create up to 20 5-digit individual passwords, from 01 to 20.

2: Limit Copy Count. Limit copy count for each password to a maximum of 999,999 copies.

3: Read Copy Count. Read the current copy count for each password.

4: Account Reset. Reset the copy count and copy limit for all passwords or selected passwords.

USAGE: 84

AD205, J94 or J95.DESCRIPTION: SOLUTION ID: 16,996

SOLUTION: PROBABLE CAUSES: 1. The changeover gate is not open. The spring for the gate solenoid (SD503) has fallen off. Replace thespring (p/n 048642240).

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2. The changeover gate is binding and the copies feed back into the ADU stacker. Verify the operation ofthe gate solenoid (SD503) in the 47 mode, output code 84. Ensure the changeover gate does not bind.

3. The ADU motor (M501) is running too slow. Replace M501 with the new style motor (p/n 460080031).

4. The paper feed motor (M3) is running too slow. Replace M3 (p/n 5400-4071).

5. The conveyance roller is worn. Replace the conveyance roller (p/n 048645010).

6. There is insufficient pressure against the ADU conveyance roller. Adjust the conveyance roller. SeeAD205 [[Techncial Bulletin #5| IMAGE V:\BITMAPS\JRC012.BMP SCROLL]] Note: Use this skewadjustment to increase the spring pressure equally on both sides of the roller, to provide optimum paper drive.

7. Stray light is entering from the left side where the main body meets the drawer unit. This gap allowsexcessive light to shine on the photosensors. Use some form of weather stripping to block the light, orrelocate the machine away from the direct light source.

8. The changeover gate is binding against roller (A) (p/n 048645120). Reform the gate to ensure it does nottouch roller (A) when it is in the closed position.

ST206, J72.DESCRIPTION: SOLUTION ID: 17,002

SOLUTION: PROBABLE CAUSES:1. The paper drags on the front frame side of the paper deflect plate (p/n 074045070). This is caused byeither incorrect zoning of the paper drawer, or incorrect positioning of the deflect plate. The problem usuallyaffects 8.5x11 paper only.Verify the paper drawer is zoned correctly. If so, reposition the deflect plate by placing a stopper ring (p/n396040680) between the bushing (p/n 074075540) and the C-clip on the rear frame side of the deflect plate.This will shift the plate to the rear frame of the sorter.

2. The bin timing is incorrect.See [[page 23| IMAGE V:\BITMAPS\JRC039.BMP SCROLL]] of the ST206 service manual third editiondated October 1993 for the bin timing (lead cam position) adjustment.

3. The guide bar home position sensor (PS207) has failed.Ensure that the guide bar moves freely, and flags the sensor. If no change of state from the sensor, replacethe sensor (p/n 074084030).

4. The conveyance motor encoder (PS206) has a poor connection.Reseat CN29 on PS206.

5. The stapler does not cycle to the nonstaple position. There is intermittent contact of the staplerpositioning switch (MS206).Ensure that MS206 is actuating properly.

6. The lower limit sensor flag is loose.Retighten the sensor flag.

7. The flag which actuates the cam position sensor (PS202) is not turning. The flag should turn with thecam.Repair as necessary.

8. Error only when feeding from the DB201. There is a timing problem between the drawer base and themain body. See 3035 [[Technical Bulletin #16| IMAGE V:\BITMAPS\JRC078.BMP SCROLL]].Adjust VR1 on the PFU drive board as necessary.

9. There is a poor connection on the sorter CB for the bin home position sensor (PS203). Reseat all the pinson CN14 on the sorter CB.

10. The rollers on the non-sort conveyance shaft are worn. This causes paper to hesitate when feeding intothe bin(s).Replace the non-sort conveyance shaft (p/n 074045100). As a temporary countermeasure, cover the wornrollers with electrical tape cut to the proper width.

11. The guide bar and lower guide arm are missing from the sorter, therefore the guide bar home positionsensor (PS207) is not actuated at power up.Replace the missing components related to the guide arm. See page 10 of the ST206 parts catalog.

12. The bin shift interlock (MS204) switch is actuated, this switch detects if the bin unit binds. The switchis located directly above the front helical cam.Perform the MS204 adjustment. Loosen the two adjusting screws, and adjust the switch so the distance

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between the switch (not the actuator) and the front cam holder is 2.5mm.

13. The stapler interlock switch (MS205) is faulty. The J72 may not occur until after the first copy has beensorted.Replace MS205 (p/n 074085020).

14. The sorter conveyance drive motor (M201) has failed, which can damage the sorter CB. Replace M201(p/n 074088050), and the sorter CB (p/n 074089020) at the same time.

15. The sorter DCPS has failed. There is no 24V DC output.Replace the sorter DCPS (p/n 074089030).

16. The sorter CB has failed.Replace the sorter CB (p/n 074089020).

17. CN34 located on the base of the sorter, which is the power supply and logic control interface to theguide bar swing action motor (M203), is not firmly seated.To check CN34, perform the following: a. Power the copier OFF. b. Remove the splineguide cover (p/n 074042180), on the base of the sorter to gain access to CN34. c. Disconnect the female and male ends of CN34. Ensure that all pins are firmly inserted into theconnector and that the female connector ends are properly shaped to provide firm contact with the maleconnector ends. d. Reseat CN34 together. Power the copier ON and check the guide bar swing action motor for properoperation.

F41 or F42.DESCRIPTION: SOLUTION ID: 13,532

SOLUTION: PROBABLE CAUSES:1. There are poor electrical connections on the AC driver board for the optics motor (M2).Reseat CN63 and CN35 on the AC driver board. If necessary insert a meter lead into the pins to ensure goodconnections with the pins on the board.

2. F41 at the start of print cycle. The scanner does not move from the home position. The optics drivepulley (p/n 540061130) set screw, has backed away from the drive shaft on M2.Manually move the exposure unit until the set screw is visible in the drive pulley. Tighten the set screw, andtest operation in the 47mode, output code 31.

3. The machine has an old style AC driver board.Check the AC driver board for T (modified version). This eliminates reverse motor voltage feedback. Orderthe new style board (p/n 5400-9085).

4. The optics does not actuate the reversing timing sensor (PS4). The optics cable was installed withoutusing the optics jig.Use the optics jig (p/n 00M6-1-00) when replacing the cable.

5. The AC driver board and/or the optics motor (M2) has failed.Replace the AC driver board, (p/n 5400-9085) and the optics drive motor (p/n 540080020).

6. Fuse F3 on the AC driver board is open.Check the optics motor (M2) for binding and for any shorting to ground. Replace F3 (3.15A) (p/nE64311-11).

7. The optics drive shaft is warped.Replace the optics drive shaft (p/n 540061090).

8. Failed optics drive motor (M2).Replace M2 (p/n 540080020).Note: The optics scanner will slam to one side when operated in the 47 mode (hold down the 4 and 7 keys atpower up), output code 31.

USAGE: 57

Intermittent blank copies.DESCRIPTION: SOLUTION ID: 11,848

SOLUTION: Perform the steps necessary to correct the problem:1. Order the improved toner motor kit (p/n 5400-K120). Note: A new toner hopper cover (p/n 540032191)must be installed if motor kit is installed. See 3035 [[Technical Bulletin #88| IMAGEV:\BITMAPS\JRC054.BMP SCROLL]].

2. Remove the transfer/separation corona unit and clean it thoroughly (use soap and warm water on theplunging arrestor [separation bridge]). Slightly stretch the electrode contact springs (p/n 540026040) toensure proper contact.

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3. With a multimeter, measure the resistance between each corona wire and its corresponding contact spring.The readings must not exceed 12 ohms. See 3035 [[Technical Bulletin #17A| IMAGEV:\BITMAPS\JRC072.BMP SCROLL]].

4. Verify that the transfer ground springs (p/n 540026071) located on the underside of the ground plate, areformed so that the proper contact is made with the guide plate (p/n 540045331).

5. Remove the transfer guide plate (p/n 5400-4550) and verify that the spark arrester mylar sheet (p/n540045150) is positioned correctly and shows no sign of wear. The overlap should be a consistent 0.5 to1.0mm for the entire length, which can be checked using a steel pocket ruler. If reusing the guide plate, cleanit with alcohol, then apply Brillianize*. Ensure that all the toner and debris are removed from the arrestermylar sheet and the underside of the plate.

6. Set the corona currents to specification. See 3035 [[Technical Bulletin #86| IMAGEV:\BITMAPS\JRC073.BMP SCROLL]].7. Replace the transfer/separation corona unit (p/n 5400-2607) if cleaning it did not resolve the problem.Replace the worn components. Front block (p/n 5400-2613) rear block (p/n 5400-2620) front spark arrestor(p/n 540026053) transfer discharge plate (p/n 540026031) separating bridge (p/n 540026111) discharge wires(p/n 540026080). Caution: Do not use these parts on machines that have been modified according to thedeveloping unit modification program introduced in Technical Operations Bulletin #A23 & D14 dated12/19/95. Use only the parts listed in those bulletins. Mod kit T/S corona unit (p/n M400-2605), Mod kitfront block (p/n M400-2610).

8. Check CN5 on the main CB. Ensure that the wiring is not pinched.

9. Check the terminal block for signs of arcing. If any arcing is evident, or an old style block is installed,replace it with the new style white block (p/n 540073231).

10. Check the drum wiring connector CN50 (p/n 5400K0190) for cracks; replace it if necessary.

11. Check for corrosion on the electrode guide plate (p/n 540045331).

12. Check for an open fuse (F2) on the main CB. Packed toner may cause this fuse to open.

13. With a multimeter, check for zener diode failure on the drum carriage. Enter the 47 mode, address 02,and press the print button. A value of -600 to -800V DC should be read across the diode.

14. Verify that all ozone filters (p/n 540073050) have been replaced during preventive maintenance.

15. Troubleshoot the high voltage (B) unit (p/n 540084022) for arcing and proper grounding by checking forloose screws along the grounding path for the HV(B). Replace the unit if necessary.

16. If no image is present on the drum, check R26 on HV(A) for cold solder joints. Repair or replace asnecessary.

17. Verify the center optics sensor (PS6) operation. Use the 47 mode, input code 35.

*[[Trademark ownership information| FILE V:\TEXT\TRADEMRK.TXT NEW]]

Light copies.DESCRIPTION: SOLUTION ID: 16,992

SOLUTION: PROBABLE CAUSES:1. The main CB has failed.Check the toner motor control signal at CN8-B9 (gray wire) on the main CB. Use the 47 mode output code01; the voltage should read 28V DC at idle, and drop to .6V DC when the start print is pressed. If there is no change of state, replace the toner motor and main CB (p/n 5402-9019) at the same time. Orderthe improved toner motor kit (p/n 5400-K120). Note: A new toner hopper cover (p/n 540032191) must beinstalled if the motor kit is installed.See 3035 [[Technical Bulletin #88| IMAGE V:\BITMAPS\JRC054.BMP SCROLL]].2. The H-cut plate is dirty.Clean the H-cut plate.

3. A high volume machine. Extensive testing has shown that when these models exceed 300,000 copies,there is a tendency for the surface of the magnet roller in the developing unit to become smooth.For dealers see Technical Operations Bulletin #D14 dated 12/19/95. For branches see Technical OperationsBulletin #A23 dated 12/19/95. See [[installation procedure.| IMAGE V:\BITMAPS\JRC014.BMPSCROLL]] Note: Please look inside the cardboard tube in kit. The tube is not just packing material, butcontains parts inside.

4. The toner hopper gears are worn.Replace the gears (p/n 540077410), (p/n 540077420), and (p/n 312077430). Ensure there is no binding inthe toner hopper.

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5. The copier is 4,000+ feet above sea level; this may contribute to poor copy quality. Order EPROM (p/n303512-21.9). Note: This EPROM must be used with (p/n 303513-20.0). Set address 7 in the 25 mode to 0.Clean the corona wires, then check the currents. See 3035 [[Technical Bulletin #89A| IMAGEV:\BITMAPS\JRC135.bmp SCROLL]].

6. A loose ground and connector in the drum carriage is causing a bias problem which is allowing thedeveloper to be pulled from the developing unit.Verify that all grounds are in place. Add a star washer if necessary. Verify that the bias connector on thedeveloping unit is making proper contact with the bias pin.

7. CN5 on the main CB, which provides the power supply to the CEL, PTL, and toner density sensor (PS1),is not firmly seated.To check CN5 on the main CB, perform the following: a. Power the copier OFF. b. Remove CN5 from the main CB. c. Ensure that all the pins for CN5 on the main CB are straight and properly aligned. Then inspect CN5on the wiring harness. Ensure that all the wires are properly attached to the connector. d. Reseat CN5 on the main CB. Power the copier ON and check that the toner motor is energized duringthe copy cycle.

No toner addition. M6 does not work in the 47 mode.DESCRIPTION: SOLUTION ID: 16,102

SOLUTION: PROBABLE CAUSES:1. CN8-B9 on main CB is not seated on both sides of connector. Ensure that CN8 is fully seated on mainCB.

2. Check the control signal for the toner motor at CN8-B9 (gray wire) on main CB. Use the 47 mode outputcode 01, voltage should read 28V DC at idle, and drop to .6V DC when start print is pressed.

If there is no change of state replace the toner motor and main CB (p/n 5402-9019) at the same time. Orderthe improved toner motor kit, (p/n 5400-K120). Note: A new toner hopper cover (p/n 540032191) must beinstalled if the motor kit is installed. See 3035 [[Technical Bulletin #88| IMAGEV:\BITMAPS\JRC054.BMP SCROLL]].

USAGE: 43

Blank LCD.DESCRIPTION: SOLUTION ID: 11,323

SOLUTION: PROBABLE CAUSES: 1. Drive pulley (A) (p/n 540076531) is slipping on the lens motor (M7) shaft, or the timing belt (p/n540077520) has fallen off and is lodged between the motor and pulley. An interim repair for a slipping drivepulley (A) is to apply a small amount of instant adhesive between the drive pulley and motor shaft. For apermanent repair, replace M7 with the new-style (p/n 25BA-7404). M7 must be used with the new-styleadjustable drive plate assembly (p/n 5400-6321). In addition, a new motor cover mylar (p/n 35AE61990) hasbeen established to prevent M7 from interfering with the cover of the door detect wiring. The mylar isplaced onto the bottom of the motor. These newer parts can not be mixed with the original parts. They mustbe used as a set. Note: For more detail, refer to Parts Information Bulletin #81.

2. The 5V DC to the LCD needs adjustment. Adjust VR1 on the operation board.

USAGE: 41

J11, J12, J13, J14, first paper feed jam, double scan by optics; or flat spotting of the reverse roller.DESCRIPTION: SOLUTION ID: 11,321

SOLUTION: PROBABLE CAUSES:1. The paper feed motor (M3) has failed causing fuse F4 on the AC driver board to open. Replace M3 (p/n5400-4071) and the AC driver board (p/n 5400-9085).

2. There is excessive grease on the spring clutch inside the torque limiter assembly. This is applicable to thetorque limiter assembly (p/n 5400-4392) which can be identified by the gray spring protect collar. Clean thespring clutch inside the torque limiter assembly with alcohol and then apply a small amount of Plas Guard*or light oil. See [[Technical Education Bulletin #7A| IMAGE v:\bitmaps\djc030.bmp SCROLL]] regardinglubricant applications.

3. The first paper feed clutch shaft is loose or the repair kit shaft is loose within the frame due to metalfatigue. Install the repair shaft kit. See 3035 [[Technical Bulletin #61| IMAGE v:\bitmaps\djc058.bmpSCROLL]]. If the repair shaft is already installed, replace the washer on the rear side of the frame with a 1inch diameter washer (obtain locally) to reduce metal fatigue of the PFU frame. To reduce the occurrance ofthis problem clean and lubricate (Plas Guard) the spring clutch every 100,000 copies.

4. The photosensor holder plate that supports the paper feed shaft of the tilt and feed assembly is worn.Install the paper feed repair cap. See [[Technical Bulletin #60| IMAGE V:\BITMAPS\DJC057.BMPSCROLL]].

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5. The actuator for the intermediate conveyance sensor (PS11) is not returning due to a weak return spring.Replace the actuator return spring (p/n 540040321).

6. The metal cap on the intermediate conveyance sensor (PS11) was just installed and the actuator isintermittently contacting the mounting plate. Ensure the metal cap is positioned correctly and the actuatormoves freely.

7. The actuator for the temporary stop sensor (PS10) is worn. Replace the actuator (p/n 540041111), orinstall a repair cap (p/n 5400K0120).

8. The paper detect and upper limit detect actuators are worn flat. This allows the paper to raise higherexerting more pressure on the first feed clutch, causing the clutch spring to break. Replace any wornactuators (p/n 540040200), and the clutch spring (p/n 540040510).


J31.DESCRIPTION: SOLUTION ID: 11,338

SOLUTION: PROBABLE CAUSES:1. The actuator (p/n 540041111) for the temporary stop sensor (PS10) does not return to the correct positionafter the first copy feeds, which creates half copies on the second and subsequent copies. Inspect thepressure spring (p/n 540041102) for proper alignment. Test the components manually by moving theactuator and verifying the return.

2. The actuators for PS10, and PS11 are worn to a point. Replace the actuators, or install the repair capsPS10 (p/n 5400K0120), PS11 (p/n 5400K0110).

3. Feeding 11x17 from tray 2, jam position 6 LED lights and J31 is displayed. Insufficient loop timing. Toadjust loop timing, perform the following: a. Enter the 36 mode (press the 3 and 6 keys simultaneously while powering the copier ON). b. Enter code 94 and then press the start print button. c. Select the paper tray to adjust by pressing the paper size button. d. Press the [P] key. When the copy quantity display flashes, enter the applicable data (valid data is -20 to99). e. Press the [P] key again when the display changes to the data just entered. f. Check the setting by making copies. If the setting needs to change, repeat steps 4 and 5 until theadjustment is satisfactory. g. Power the copier OFF/ON when adjustment is completed.

4. The second copy in the book copy mode has no lead edge deletion. This can cause J31 as the lead edgesticks to the upper roller. Adjust the lead edge timing for the second copy of book copy mode. Perform thefollowing steps: a. Enter the 36 mode, code 91 press the print switch. Note: Use 36/91 not code 80, or the adjustment willnot work. b. Select the book copy mode. c. Press the print switch. d. Press P, after the first scan. e. Enter the applicable data (-99 to +99 [start with +50]), and press the P button. f. Press the print switch to make a copy and check the adjustment. Then adjust the standard lead edgedeletion.

5. The second paper feed clutch is slipping or has failed. Replace the second paper feed clutch (p/n540082010).

6. The paper feed motor (M3) has failed. Replace the paper feed motor (p/n 5400-4071).

7. From the bypass tray only. The bypass lift plate is malformed, and is not providing proper lift pressure tofeed the paper. Reform the bypass lift plate and verify its operation.

8. The second paper feed roller is worn. Replace the second paper feed roller (p/n 540041030).

9. The copier experienced a power problem which caused the memory data to be corrupted. Reset the databy using the 47 mode, output code 92. Enter the proper data collection counts (i.e. drum and PM counts).Ensure the paper feed loop timing for all paper trays is checked.

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F45.DESCRIPTION: SOLUTION ID: 13,400

SOLUTION: PROBABLE CAUSES:1. The pulley for the lens drive motor (M7) is loose. An interim repair for a slipping drive pulley (A) is toapply a small amount of instant adhesive between the drive pulley and motor shaft. For a permanent repair,replace M7 with the new-style (p/n 25BA-7404). M7 must be used with the new-style adjustable drive plate

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assembly (p/n 5400-6321). In addition, a new motor cover mylar (p/n 35AE61990) has been established toprevent M7 from interfering with the cover of the door detect wiring. The mylar is placed onto the bottom ofthe motor. These newer parts can not be mixed with the original parts. They must be used as a set. Note: For more detail, refer to Parts Information Bulletin #81.

2. The toner motor wire is shorted to frame ground. Check the toner motor (M6), verify operation. Checkthe PFU wiring for shorts to frame. The code is caused by a loss of 24V DC. Any 24V DC load could causethe code.

ST206, F70.DESCRIPTION: SOLUTION ID: 8,155

SOLUTION: PROBABLE CAUSES:1. Adresses P3 and P59 in the 25 mode are set to 5, they should both be set to 0.

2. The circuit breaker on the sorter has opened. Reset the circuit breaker on the sorter.

3. The sorter power supply has failed. Verify the voltages on CN1-1, and CN1-3 to ground with no load.The reading should be 24V DC. If the circuit breaker is good, replace the sorter power supply (p/n074089030).

4. TR29 on the main CB has been damaged. The ground wire was not secured. Attach the ground wire andreplace the main CB (p/n 5402-9013).

USAGE: 25

How to program the paper size for the main body trays.DESCRIPTION: SOLUTION ID: 11,296

SOLUTION: Set the data for P67 in the 25 mode for the correct combination of main body paper trays.

0: Both upper, and lower trays are conventional.1: Upper tray is universal, and lower tray conventional.2: Upper tray is conventional, and lower tray universal.3: Both upper, and lower trays are universal.

USAGE: 23

F55.DESCRIPTION: SOLUTION ID: 15,029

SOLUTION: PROBABLE CAUSES:1. There is a loss of 24V DC to RL1. Isolate the failed load by disconnecting each 24V DC load one at atime. Check the 24V DC at CN69-A10 on the AC driver board after each load is disconnected. Repair orreplace the failed load (ensure RL1 has not failed as well).

2. CN61 on the main CB is loose. This connector supplies 24V DC to the main CB. Repair the connector asnecessary.

3. CN29 on the CVR board is loose. Repair the connector as necessary.

4. The cleaning web solenoid (SD5) has shorted to ground, creating a loss of 24V DC to RL1. Replace SD5(p/n 304082521).

5. CN351 is loose. This is the brown AC connector located below the power switch. It is best accessed byremoving the left side cover. The connector will be above and to the right of the fan. Ensure that theconnector is not loose and that none of the pins have backed out of the connector body.

6. The main relay (RL1) is pitted, loosing contact. With all power removed open up RL1, and try to cleanthe relay. If the code returns replace RL1 (p/n 540088460).

7. On the ACDB, CN69, which provides 24V DC to the main relay (RL1), is not firmly seated.To check CN69 on the ACDB, perform the following: a. Power the copier OFF. b. Remove the securing screw for the main CB mounting plate (p/n 540073180), which will allow themain CB to swing to the left and provide access to the ACDB. c. Ensure that all pins for CN69 on the ACDB are straight and properly aligned. Then inspect CN69 onthe wiring harness. Ensure all the wires are properly attached to the connector. d. Reseat CN69 on the ACDB. The remaining connectors on the ACDB should also be removed,inspected, and reseated. e. Power the copier ON and check for proper operation.

USAGE: 22

DF305, J62.DESCRIPTION: SOLUTION ID: 11,345

SOLUTION: PROBABLE CAUSES:1. The entrance sensor (PS302) is not adjusted to the correct voltage. Adjust VR1 two graduations past thepoint where LED 1 lights. An alternate method is to adjust VR1 to 0.3V DC using CN906-7 and TP-3(ground).

USAGE: 21


3035

2. The original feed solenoid (SD301) is not energizing due to a poor electrical connection on the RADFCB. This causes the paper feed lift plate not to move. Reseat CN903 on the RADF CB. Ensure no wireshave backed out of the connector body.

3. The infeed guide plate is malformed.Reform the guide plate.

4. The mounting posts that support M301 may become broken or cracked due to vibrations that occur duringshipment/transportation.All DF305 units within serial number range (048181365 through 048186490) must be inspected at the nextPM or service call. Refer to [[DF305 Technical Bulletin #11|IMAGE v:\bitmaps\djc156.bmp SCROLL]] fordetails regarding inspection/repair for this symptom. To repair the motor mounts, perform the following: a. Install the collars (p/n U091-9630) to repair the cracked mounting posts. The instructions for the repairkit are included in the kit. The 5 minute epoxy required to install the metal collars must be purchased locally. b. Install the rubber holder part on top of the motor. I. Clean the underside of the metal cover (cover/B) and the top of M301 with alcohol. II. Remove the small adhesive strip from the bottom of the rubber holder. III. Mount the rubber holder on the motor (adhesive strip from front to rear). IV. Position the motor so that the drive belts are perpendicular to the drive gear. V. Remove the large adhesive strip on the top of the rubber holder. VI. Carefully reinstall the metal cover (you get one chance).The metal cover and rubber holder will now support M301 and eliminate vibrations resulting in noise andmisfeeding.

P96 at power up or in standby.DESCRIPTION: SOLUTION ID: 43,008

SOLUTION: CAUSE: Paper is in the ADU stacker.

SOLUTION: Pull out the ADU, and lift the green handle located on the right side. Remove the paper in theADU stacker.

USAGE: 20

J17 when duplexing.DESCRIPTION: SOLUTION ID: 12,678

SOLUTION: PROBABLE CAUSES:1. There is a timing problem between the ADU and the main body. Order the increased diameter [[ADUtiming pulley,| IMAGE V:\BITMAPS\JRC103.BMP SCROLL]] (p/n U101-1240). It can be identified by thenew gray color.

2. The actuators for the paper temporary stop sensor (PS10) and the intermediate conveyance sensor (PS11)are worn down. Install the repair caps PS10 (p/n 5400K0120), and PS11 (p/n 5400K0110).

USAGE: 18

Latest EPROM level, 3035.DESCRIPTION: SOLUTION ID: 34,009

SOLUTION: [[EPROM history hyperlink| FILE V:\TEXT\EPROM\3035.TXT NEW]]. USAGE: 18

The toner cartridge is stuck.DESCRIPTION: SOLUTION ID: 10,584

SOLUTION: Put light pressure on the top/rear of the toner cartridge to facilitate the slide operation. USAGE: 18

After replacing the main CB the paper trays indicate special.DESCRIPTION: SOLUTION ID: 15,112

SOLUTION: CAUSE: The paper drawer configuration in the 25 mode is set incorrectly.

SOLUTION: Set the data for P67 in the 25 mode for the correct combination of main body paper trays.

0: Both upper, and lower trays are conventional.1: Upper tray is universal, and lower tray conventional.2: Upper tray is conventional, and lower tray universal.3: Both upper, and lower trays are universal.

USAGE: 17

How to program the auto reset with the sorter selected.DESCRIPTION: SOLUTION ID: 25,007

SOLUTION: Install EPROM versions 21.1 at IC2 (p/n 303512-21.1), and 20.0 at IC3 (p/n 303513-20.0).Set address 6, in the 25 mode, to 1 or 3, for the reset to occur with the sorter selected. See TechnicalOperations Bulletin A23 or D14.

Note: Auto reset occurs 1 minute after the last copy exits when address 48, in the 25 mode, is set to 1.

USAGE: 16

Overtoning, background on the copies, intermittent F86.DESCRIPTION: SOLUTION ID: 17,241


3035

SOLUTION: PROBABLE CAUSES:1. Background on copies. The CEL is faulty causing all the segments to light at the begining of the copycycle. At the start of the copy cycle the center segments of the CEL should be OFF to allow for patchdevelopment. Replace the CEL (p/n 5400-9141).

2. Background during long copy runs. The reflector plate is loose and vibrates out of position. This causespoor copy quality. Secure the reflector plate and ensure that the exposure unit is scanning smoothly. If theexposure unit is worn, replace the exposure unit (p/n 5400-6121).

3. The non-image areas in reduction copies have background. A Katun drum was installed. Replace thedrum with a Konica drum (PCUA 947513).

4. Extensive testing has shown that models which exceed 300,000 copies, there is a tendency for the surfaceof the magnet roller in the developing unit to become smooth affecting copy quality. For dealers seeTechnical Operations Bulletin #D14 dated 12/19/95. For branches see Technical Operations Bulletin #A23dated 12/19/95. See [[installation procedure.| IMAGE V:\BITMAPS\JRC014.BMP SCROLL]] Note: Thecardboard tube in the kit is not just packing material, but contains parts inside.

USAGE: 16

How to clear fuser abnormality codes (F34, F35, F36), 3035.DESCRIPTION: SOLUTION ID: 59,216

SOLUTION: To reset fuser codes, perform the following:1. Access the 25 mode (power OFF the machine, then while holding down the 2 and 5 keys, power themachine ON), address 47 (press P-4-7-P).2. A data value of 1, 4, 5, or 6 is displayed on the copy quantity indicator.3. Enter 0 as a data value by pressing the 0 key, then START/PRINT.5. Power the machine OFF/ON to exit the 25 mode.Note: If the F-code reoccurs after powering the machine ON or following warm-up, contact serviceimmediately.

USAGE: 14

All operation panel LEDs are lit (888 in the quantity display). The LCD is blank.DESCRIPTION: SOLUTION ID: 34,889

SOLUTION: CAUSE: The main relay (RL1) has failed.

SOLUTION: Replace RL1 (p/n 540088460).

USAGE: 14

F18 at power up.DESCRIPTION: SOLUTION ID: 29,292

SOLUTION: PROBABLE CAUSES:1. Lift up gears A, B, or C are damaged. Order repair kit (p/n SE95-2520). The individual gears are nolonger available. The kit provides all gears as a set. Instruct the customer on proper loading of paper toprevent future problems.

2. The ADU paper feed motor (M501) is shorted causing fuse F4 to open on the main CB. Ensure there areno binds in the ADU. Replace M501 (p/n 460080031), and the fuse (p/n 963010600).

3. F18, fuse F4 on the main CB opens after a few minutes. The ADU DB has failed causing fuse F4 on themain CB to open. Replace the ADU DB (p/n 0486-9010) and the fuse (p/n 963010600).

4. Fuse F2 (28V DC) on the main CB is open. Verify the following loads that F2 protects then replace thefuse (1.25A):M4, upper tray lift up motorM5, lower tray lift up motorM6, toner motorM9, paper conveyance fan motorHV2, transfer/separation power supply. Note: In addition to F18 codes, blank copies will also occur due tothe loss of 28V DC to HV2.

USAGE: 14

DF305, J63.DESCRIPTION: SOLUTION ID: 11,342

SOLUTION: PROBABLE CAUSES:1. The original exit sensor (PS303) is not adjusted to the correct voltage. Adjust VR2 two graduations pastthe point where LED 2 lights. An alternate method is to adjust VR2 to .3V DC using CN906-8 and TP3(GND).

2. J63 only when running 8.5x11. The white conveyance belt is slipping. Clean both sides of the belt. Ifnecessary replace the belt (p/n 048045010).

3. J63 when running 2-sided copies, the original exits instead of entering the reversal section. Thedampening pad on the gate solenoid (SD302) is causing the plunger to stick to its adhesive. This does notallow the gate to actuate and reverse the original. Remove the dampening pad and clean the adhesive fromthe stopper assembly with alcohol.

USAGE: 14


3035

Varying lead edge deletion.DESCRIPTION: SOLUTION ID: 25,453

SOLUTION: PROBABLE CAUSES:1. The memory stored in the 25 mode is corrupted. In the 47 mode enter output code 92, press the start printbutton to perform a process initial set. This will set all data in memory to the factory initial values.Note: Ensure the 25 mode settings and 36 mode adjustments are reprogrammed.

2. The optics is intermittently binding. Clean the optics shaft and lubricate the optic felts with Multi-oil (p/n00GR00170).

3. The optics cable is installed incorrectly. If the cable and spring were replaced recently, ensure the opticspositioning jig is used (p/n 00M6-1-00).

4. The main CB is faulty causing erratic CEL operation. Verify proper operation of the CEL. If necessaryreplace the main CB (p/n 5402-9013).

5. Poor drum grounding.Sparingly apply conductive grease (p/n 00GR00200) to the ends drum shaft.Notes:a. Refer to 2028/3035/4045 Technical Bulletin #45 for additional information on conductive greaseinstallation.b. It is highly recommended to readjust corona currents after installing conductive grease.

USAGE: 13

The paper feed clutch shaft is worn.DESCRIPTION: SOLUTION ID: 18,398

SOLUTION: PROBABLE CAUSES: 1. There is a repair kit available. Order repair kit (p/n U100-0070). See [[3035 Technical Bulletin #61|IMAGE v:\bitmaps\djc058.bmp SCROLL]].

2. The frame of the PFU is weak, and the procedure to remove the old clutch shaft can cause the frame to beslightly out of form. When the new shaft is installed, it will protrude at a slight angle. The clutch will thenrotate around the shaft unevenly and eventually cause the shaft to wear. The only way to prevent this is touse care not to bend the frame when removing the old shaft.

USAGE: 12

Is APS available for every original fed through the DF305?DESCRIPTION: SOLUTION ID: 18,161

SOLUTION: For APS order version 20.5 at IC2 (p/n 303512-20.5) and 20.0 at IC3 (p/n 303513-20.0) on the main CB.For the RADF order version 14.2 (p/n DF30530-14.2) at IC10 on the RADF CB.Note: Ensure that P61 in the 25 mode is set to 1 for APS for every original.

USAGE: 12

All lights come on in AES adjust mode.DESCRIPTION: SOLUTION ID: 14,235

SOLUTION: PROBABLE CAUSES:1. The main reflector is installed incorrectly. The longer portion of the curve should be on the bottom.

2. The auxiliary reflector (p/n 540061630) is installed incorrectly. Install the reflector so that the edge withthe sharpest angle is located at the bottom.

3. The main reflector plate has been malformed which causes improper light distribution during the AESscan. Replace the main exposure reflector plate (p/n 490061300).

USAGE: 12

PLEASE UNLOAD DUPLEX TRAY message when a duplex mode (1:2 or 2:2) is selected.DESCRIPTION: SOLUTION ID: 53,303

SOLUTION: Open ADU tray. Lift the green handle so the guide plate is perpendicular to the machine. Remove paper. USAGE: 11

Intermittent F34 or F35 shortly after power up.DESCRIPTION: SOLUTION ID: 34,007

SOLUTION: CAUSE: The temperature sensors (TH1 and TH2) have failed.

SOLUTION: Replace the sensors, TH1 (p/n 5400-5465), TH2 (p/n 5400-5473).

USAGE: 11

Part numbers for the improved design T/S corona assembly.DESCRIPTION: SOLUTION ID: 27,014

SOLUTION: PART # ITEM5400-2607 T/S corona unit5400-2613 Front block5400-2620 Rear block540026053 Front spark arrestor540026031 Transfer discharge plate540026111 Separating bridge

USAGE: 11


3035

CAUTION: Do not use these parts on machines that have been modified according to the developing unitmodification program introduced in Technical Operations Bulletin #A23 & D14 dated 12/19/95. Use onlythe parts listed in those bulletins. Mod kit T/S corona unit (p/n M400-2605), Mod kit front block (p/nM400-2610).

No toner addition. The toner motor (M6) will work in the 47 mode.DESCRIPTION: SOLUTION ID: 18,148

SOLUTION: PROBABLE CAUSES:1. There is a poor connection at CN5-A8 (10V DC) on the main CB. The pin has backed out. Repair CN5and ensure a good connection.

2. There are poor connections between the toner control sensor (PS1) and the main CB. Check CN19 forPS1, and intermediate connector CN27, and the drum carraige connector CN50. Verify all connections areclean, intact, and seated properly.

3. The toner control sensor (PS1) has failed. Verify that PS1 is clean. Check all connections, and verify10V DC between CN5-A8 (10V DC), and CN5-B2 (signal ground) on the main CB. If all checks are goodreplace PS1 (p/n 540088040).

USAGE: 11

DF305, F60 at power up.DESCRIPTION: SOLUTION ID: 17,766

SOLUTION: PROBABLE CAUSES:1. The wiring for the exit sensor (PS303) is pinched to the bracket shorting the 5V DC to ground. This canopen ICP1 on the RADF CB. Repair the shorted wiring, and replace the RADF CB (p/n 0480-9000).

2. The main harness from the DF203 to the main body has failed. Replace the harness (p/n 048090040).

USAGE: 11

High pitched noise, no ADD TONER indication.DESCRIPTION: SOLUTION ID: 11,331

SOLUTION: CAUSE: The toner level detect sensor is not detected by the main CB until 1000 copies after its piezoelement begins to vibrate (default setting). This is to prevent ADD TONER from being displayed due to airpockets in the toner hopper.

SOLUTION: Set 25 mode, P71 to 0 for the ADD TONER indication to occur 100 copies after TLD vibrates.

USAGE: 11

No power.DESCRIPTION: SOLUTION ID: 9,381

SOLUTION: PROBABLE CAUSES:1. The front door is open or one or both door switches (MS1 or MS2) failed.Ensure that the front door is completely closed at both ends. If the door is closed, replace the faulty frontdoor switch(es) (p/n 392085020).

2. The leakage breaker opens at power up or at the start of the copy cycle. The following is a list of probablecauses and solutions: a. The main motor (M1) and start up capacitor have failed.Replace M1, and the start up capacitor (p/n 5402-7310). b. The truarc ring has worn through the upper fuser roller and has shorted to the fuser lamp.Replace the upper fuser roller (p/n 540053010), and the heat sleeves (p/n 322054250), and the truarc ring(p/n 00Z680183). c. AC short in the fuser unit. The fuser drive gear, at the rear of the upper roller, has slipped off and istouching the fuser lamp terminal.Reinstall the fuser drive gear and ensure that the truarc ring secures it to the upper roller. d. The truarc ring, that keeps the fuser drive gear in place, has become dislodged and is contacting thefuser lamp terminal.Reinstall the truarc ring. Replace the truarc ring (p/n 00Z680183) if it is stretched and loose.

3. A loss AC power to the main body due to a failed NF (noise filter board). The NF is located on the rear ofthe machine directly above the power cord. It can be easily identified by the attached copper coil.There should be approximately 115V AC at the input and output sides of the NF at all times. To confirm: a. Ensure that the copier plugged into wall outlet. b. Measure AC voltage across the two lower (input) AC wires (black and white). c. Measure AC voltage across the two upper (output) AC wires (black and white). d. Both readings should be equal, approximately 115V AC.If the AC voltage is not present or is insufficient, replace the NF (p/n 540284530).Note: The symptom may be intermittent. The copier may cycle ON/OFF every few seconds.

USAGE: 11

Recommended transparency, 3035.DESCRIPTION: SOLUTION ID: 38,881

SOLUTION: The standard transparency is PCUA 946427 (equivalent to the 3M* type PP2500 688/503).Note: Konica recommends feeding transparencies through the bypass tray to reduce the occurrence of

USAGE: 10


3035

misfeeding. If a sorter is used, see [[Technical Operations Bulletin #A13 & D12| IMAGEV:\BITMAPS\JRC043.BMP SCROLL]] for other available types of transparencies.


ST206, the main motor runs for approximately 30 seconds after the print key is pressed. The copierreturns to ready to copy with no jam codes.

DESCRIPTION: SOLUTION ID: 20,348

SOLUTION: CAUSE: The bin home position sensor (PS203) is not operating properly, this will prevent the optics unit toreturn to the home position to start copy process.

SOLUTION: Check the operation of PS203. If necessary replace the sensor (p/n 074084030).

USAGE: 9

No lead edge deletion.DESCRIPTION: SOLUTION ID: 48,554

SOLUTION: PROBABLE CAUSES:1. The 6th mirror is not properly positioned. Reposition the 6th mirror and recheck all the opticsadjustments.

2. The main CB has failed. There is no CEL operation. Run a reduced sized copy with the cover up to see ifthe CEL is operating. If a black area appears on the copy, the CEL is not working. Replace the main CB(p/n 5402-9013).

3. Note: If a deletion is present, the lead edge erasure adjustment (36 mode, code 92) must be set too a veryhigh or very low number. The optics cable is incorrectly installed.Ensure that the cable is properly installed using the wire positioning jig (p/n 00M6-1-00) or (p/n 00M6-1-01).

USAGE: 9

Does not reset to the full auto mode.DESCRIPTION: SOLUTION ID: 11,861

SOLUTION: CAUSE: Incorrect programming in the 25 mode.

SOLUTION: In the 25 mode, set P56 to 3 and P58 to 0 for full auto mode reset.

USAGE: 9

ST205S, cannot select the sorter.DESCRIPTION: SOLUTION ID: 11,852

SOLUTION: CAUSE: Incorrect programming in the 25 mode.

SOLUTION: In the 25 mode set P03 and P59 to 5. Ensure that hardware dipswitch 1-1 on the sorter CB isON, and all other switches are OFF.

USAGE: 9

AD205, P33.DESCRIPTION: SOLUTION ID: 11,366

SOLUTION: PROBABLE CAUSES:1. The 5V DC ICP on the ADU driver board is open. Check for 5V DC at CN550-5. If 5V DC is present, read the voltage at TP5. If 0V DC is read at TP5, thenthe ICP is open. Replace the ADU driver board (p/n 0486-9010).

2. The left door interlock microswitch (MS501) failed. The symptom may occur only when trying to duplex.

Replace the switch (p/n 197085010).

USAGE: 9

The LCD is dim.DESCRIPTION: SOLUTION ID: 42,587

SOLUTION: CAUSE: The 5V DC to the LCD may need adjustment.

SOLUTION: Ensure that the LCD is not being affected by overhead lighting. Adjust VR1 on the operationboard.

USAGE: 8

Information for individual parts for the Swingline stapler unit.DESCRIPTION: SOLUTION ID: 30,754

SOLUTION: Konica does not supply any individual stapler parts.Contact Swingline at 1-800-222-6462.

USAGE: 8

Lead-to-trail registration is off from the ADU, 8.5x11 copies only.DESCRIPTION: SOLUTION ID: 11,251

SOLUTION: CAUSE: The ADU lead edge timing for small size paper needs adjustment.

SOLUTION: Adjust ADU lead edge timing for small size paper. Use the 36 mode code 91.

USAGE: 8

The copies are out of focus when using magnification below 60%.DESCRIPTION: SOLUTION ID: 47,983


3035

SOLUTION: CAUSE: The optics drive wire is worn, stretched or incorrectly installed.

SOLUTION: Replace the optics drive wire (p/n 540061111) using the wire positioning jig (p/n 00M6-1-01).

USAGE: 7

The document feeder mutifeeds originals.DESCRIPTION: SOLUTION ID: 44,860

SOLUTION: CAUSE: The DF305 is out of adjustment.

SOLUTION: Perform all related DF305 adjustments using the February 1993 or later version service manual(p/n CSM-DF305).

USAGE: 7

Power requirements, 3035.DESCRIPTION: SOLUTION ID: 41,047

SOLUTION: Voltage: 115V AC ñ10% (dedicated line)Current: 15A ACFrequency: 60HzGrounding: Isolated ground is recommended.Note: A dedicated AC line with an isolated ground is strongly recommended. A dedicated line mandates theexclusive use of an electrical branch circuit where the receptacle grounding terminal is grounded by aninsulated grounding conductor that is isolated from the receptacle mounting hardware (per National Electricalcode, article 250-74 exception no. 4).

Termination: NEMA Type 5-15R receptacle (125V AC, 2-pole, 3 wire, grounded).

USAGE: 7

ST206, clear bins before stapling is displayed.DESCRIPTION: SOLUTION ID: 26,890

SOLUTION: CAUSE: The paper sensor (PS201) needs adjustment.

SOLUTION: Perform the following steps.1. Remove the sorter CB cover.2. Set Dip switches on the sorter CB as follows: 1 ON, 2,3,4 OFF.3. Remove all paper from the bins.4. Check to see that LED 1 on the sorter CB is OFF.5. If LED 1 is not OFF then turn VR3 CCW until it is OFF.6. Insert paper into one of the sort bins to see that LED 1 turns ON.

USAGE: 7

DF305, APS only selects the first original size when copying mixed sized originals.DESCRIPTION: SOLUTION ID: 24,036

SOLUTION: CAUSE: The feature is not enabled in the 25 mode.

SOLUTION: In the 25 mode set P61 to 1 for mixed original detection.

USAGE: 7

ST205S, P71.DESCRIPTION: SOLUTION ID: 16,307

SOLUTION: PROBABLE CAUSES:1. Fuse F101 is open. Check fuse F101 for 21.6V AC on each side. Replace the sorter CB if F101 is open.

2. P71, without any sorter attached. The machine had a sorter previously. In the 25 mode ensure addressesP3 and P59 are set to 0.

USAGE: 7

F43 is displayed when the copy button is pressed in an enlargement mode.DESCRIPTION: SOLUTION ID: 53,584

SOLUTION: CAUSE: Exposure unit did not move to PS6 optics center sensor (p/n552085510 ).

SOLUTION: Manually move the exposure unit to the PS6 and make a copy. If F43 does not occur, replacePS7, optics home position sensor ( p/n 540085510).

USAGE: 6

The spring on the first clutch assembly continues to break within 10,000 copies after replacement.DESCRIPTION: SOLUTION ID: 53,393

SOLUTION: CAUSE: The first clutch shaft may be at an angle to the frame of the PFU or the frame may be weak and theprocedure to remove the old clutch shaft can cause the frame to be slightly out of form.

SOLUTION: When the new shaft (p/n U100-0070) is installed, it will protrude at a slight angle. The clutchwill then rotate around the shaft unevenly and eventually cause the shaft to wear. The only way to preventthis is to use care not to bend the frame when removing the old shaft. Verify that the shaft for the first paperfeed clutch is perpendicular to the frame of the PFU.

USAGE: 6

The copies are blurry from front to rear.DESCRIPTION: SOLUTION ID: 53,080

SOLUTION: CAUSE: The sixth mirror is out of adjustment. USAGE: 6


3035

SOLUTION: Turn the sixth mirror position adjusting thumb screw (located in the optics cavity) a quarter ofa turn and check copy quality. Depending on the copy quality of the copy, rotate the thumb screw to achieveoptimum copy quality.

The Hecon counter pulses when the key is inserted or removed, but will not count copies.DESCRIPTION: SOLUTION ID: 45,735

SOLUTION: CAUSE: An improperly inserted key or a faulty key has damaged the main CB on the copier.

SOLUTION: Replace the main CB (p/n 5762-9012). Note: For MBE accounts, a countermeasure isavailable to prevent damage caused by improperly inserted keys. See Technical Operations Bulletin #A14 &D14.

USAGE: 6

How to enable the auto reset.DESCRIPTION: SOLUTION ID: 42,817

SOLUTION: To enable the auto reset, perform the following:1. Power the copier OFF.2. While holding down the 2 and 5 keys power the copier ON.3. Enter P-4-8-P.4. Press 1 from the key pad.5. Press the start print button to enter the new data.6. Power the copier OFF/ON.

Note: If testing the copier, the 2 minute auto reset will not occur unless a copy is made to start the internaltimer.

USAGE: 6

AD205, J15 or J92 feeding from the ADU (heavy static, double feeding).DESCRIPTION: SOLUTION ID: 39,364

SOLUTION: CAUSE: The corona currents are not set to specification, and the ADU has an old style paper neutralizingbrush.

SOLUTION: Set the T/S corona current to specification. Replace the ADU neutralizing brush with the newstyle (p/n 048645461). Verify that the ADU and machine are properly grounded.

Note: The old style neutralizing brush length is 12mm. The new style brush length is 25mm.

USAGE: 6

F36 shortly after power up.DESCRIPTION: SOLUTION ID: 32,649

SOLUTION: CAUSE: The thermostat (TS1) is open.

SOLUTION: Take a continuity check across the thermostat. If open replace the thermostat (p/n540088420). This code must be cleared by entering the 25 mode address 47, press 0, then press start print.

USAGE: 6

High yield drum information.DESCRIPTION: SOLUTION ID: 30,328

SOLUTION: A new drum is available (PCUA 947542) with an increased yield of 250,000 copies.Note: For proper firmware when using this drum see 3035 [[Technical Bulletin #89A| IMAGEV:\BITMAPS\JRC135.bmp SCROLL]].

USAGE: 6

J32.DESCRIPTION: SOLUTION ID: 29,328

SOLUTION: PROBABLE CAUSES:1. The paper is caught on the upper fuser claws.The portion of the cleaning web initially contacting the upper roller is dry. Advance the web, and ensure theweb advance mechanism is working.

2. PS2 (paper exit sensor) failure.To check PS2, perform the following: a. Access the 47 mode (power the machine OFF, hold down the 4 and 7 keys while powering the machineON), input code 22 (press the 2 key twice). b. Check the magnification display, it indicates either HI (HIGH) or LO (LOW). c. Move the exit sensor actuator. d. The magnification display should indicate a change of state. e. If no change of state occurs, replace PS2 (p/n 540085510). f. Power the machine OFF/ON to exit the 47 mode.

USAGE: 6

How to perform the light intensity adjustment.DESCRIPTION: SOLUTION ID: 59,598

SOLUTION: To adjust the light intensity, perform the following:1. Power the copier OFF.2. Enter the 36 mode, (power the copier ON, while holding the 3 and 6 keys).

USAGE: 5


3035

3. Using the numeric keypad, press the 9 key, followed by the 0 key, and then press the START PRINT key.4. Press the P key, the CVR DATA will be displayed on the LCD. The adjustment range is from 01(dark) to64 (light).5. Using the numeric keypad, enter the desired CVR data, and then press the P key.6. Press the START PRINT key and inspect the copy quality.7. Repeat steps 4 through 6 until the proper copy quality is achieved.8. Using the Konica potential chart, the adjustment standard is 0.1 patch on the test chart does not reproduceand the 2nd row is legible.9. Power the copier OFF/ON, to exit the 36 mode.

Paper specifications, 3035.DESCRIPTION: SOLUTION ID: 55,767

SOLUTION: Ordinary paper: High quality (20 to 24lb)Special paper: Transparencies, offset masters, high quality paper (16 to 19lb and 25 to 32lb)Note: Special paper should be fed using the bypass tray. The feed and conveyance performance of specialpaper may sometimes be inferior to that of high grade paper. Double-sided copying should not be performedwith special paper.

USAGE: 5

DF305, F67.DESCRIPTION: SOLUTION ID: 51,944

SOLUTION: PROBABLE CAUSES: 1. Intermittent F67 displayed when using the RADF. The RADF drive motor (M301) is faulty. Verify theconnection for CN901 on the RADF CB, and the interconnect wiring harness at CN950. Ensure there is 5VDC at CN902-1, and CN900-1 on the RADF CB. Verify that CN900-2 reads 28V DC. If necessary replaceM301 (p/n 048080010).

2. F67 when the print button is pressed. The RADF drive motor (M301) has failed damaging the RADF CB.Confirm that the RADF drive system moves freely. Replace the RADF CB (p/n 0480-9001), and M301 (p/n048080010) at the same time.

USAGE: 5

DF305, P64 will not clear.DESCRIPTION: SOLUTION ID: 46,377

SOLUTION: CAUSE: The black actuator for the interlock sensor (PS305) is stuck closed.

SOLUTION: Locate the actuator on the front, underside of the RADF. Free the actuator and ensure properoperation.

USAGE: 5

Intermittent blank LCD.DESCRIPTION: SOLUTION ID: 43,893

SOLUTION: CAUSE: The operation panel is faulty.

SOLUTION: Replace the operation panel (p/n 5402-7003).

USAGE: 5

ST102, J32 or J72. Accordion jam occurs at the sorter entrance.DESCRIPTION: SOLUTION ID: 42,679

SOLUTION: PROBABLE CAUSES:1. Fuse F1 on the sorter CB and fuse F4 on the main CB (28V DC) are open. If either fuse is open check thesorter conveyance motor (M201) for binding. If necessary replace M201 (p/n 197580011).

2. The sorter entrance guide plate is malformed, interfering with the paper. Reform the guide plate.

3. The entrance sensor (PS201) is dirty, misaligned or requires adjustment. Clean PS201 (located in thebottom of the sorter frame cavity) and adjust while in idle mode. a. Turn VR3 fully clockwise (LED 1 should be OFF or dim). b. Then turn VR3 counterclockwise until LED 1 lights. c. Adjust VR3 scale two gradations past the point where the LED lights. If the adjustment cannot beperformed, replace PS201 (p/n 059085510) and LED201 (p/n 059085530).

4. The sorter bins are damaged. If the bin mounting clips break, the (paper) bracket guides (p/n 059046110)will not convey paper into the individual bins. Replace the damaged sorter bins (p/n 059046160). Note: Toremove the bins, lift them up in the front before pulling them out; this releases the clips.

5. The data in memory is corrupted. Perform the memory reinitialization (47 mode, code 92). Note: TheL-detect data, drum and PM counters, CVR, registration and lead edge deletion data will be set to initialvalues.

6. If the paper speed appears to slow down as the copy enters the bins, the conveyance system may bebinding which causes the drive motor (M201) to slow, resulting in IC13 on the sorter CB to heat up andpossibly fail. Confirm that the [[vertical conveyance belt and drive belt| IMAGE v:\bitmaps\djc138.bmpSCROLL]] are not too tight and check for binding in the sorter conveyance system. With power OFF, rotatethe conveyance motor by hand and check for binding or varying tension and repair. If necessary, replace thesorter CB (p/n 0590-9011) and M201 (p/n 197580011) as a set. Ensure that no drive system binds exist prior

USAGE: 5


3035

to replacement.

7. The drive motor speed is too slow. To adjust M201 (ST102 only) speed, use the 47 mode output code 70.To increase the motor speed turn VR2 on the sorter drive board clockwise.

Light area at the trail edge of the copies.DESCRIPTION: SOLUTION ID: 42,324

SOLUTION: PROBABLE CAUSES:1. The transfer corona wire is contaminated or oscillates due to lack of tension. Replace the corona wire (p/n540026080) and tension spring (p/n 006078070) as necessary. Readjust the corona currents.

2. The HV(B) unit has failed. Replace HV(B) (p/n 540084022).

USAGE: 5

Paper will not feed from any tray.DESCRIPTION: SOLUTION ID: 41,482

SOLUTION: CAUSE: The paper feed motor (M3) has failed, causing F4 on the AC driver board to open.

SOLUTION: Check the wiring at CN33 for shorting to frame ground. Repair the wiring as necessary.Check the resistance of M3 for a shorted condition. Replace M3 if necessary (p/n 5400-4070). Once allshorts are corrected, replace F4 with the properly rated fuse.

USAGE: 5

Cannot feed from the bypass feed tray.DESCRIPTION: SOLUTION ID: 38,542

SOLUTION: PROBABLE CAUSES:1. The loop data for the bypass tray is too low. Use the 36 mode code 94. Set the paper feed loop data forthe bypass tray to 99.

2. The bypass feed spring clutch is worn. Replace the bypass spring clutch (p/n 3960-4180), and lubricate*the feed clutch.

* Prior to lubrication, thoroughly clean the area to be lubricated.See [[Technical Education Bulletin #7A| IMAGE v:\bitmaps\djc030.bmp SCROLL]] regarding lubricantapplications.

3. The guide plates are malformed interfering with the paper path. Reform the bypass guide plate to allowproper paper passage.

USAGE: 5

Corona currents cannot be set to specification.DESCRIPTION: SOLUTION ID: 36,783

SOLUTION: PROBABLE CAUSES:1. A faulty meter lead is not providing a path to ground for the drum unit. Repair or replace the meter lead.

2. The plastic insulator tip of the drum shaft jig (p/n 00M6-4-00) is too large, causing incorrect readings.Sand the outer diameter of the plastic tip slightly, and make sure that it seats properly within the drum drivebearing.

USAGE: 5

Paper is Z-folded at the second feed roller.DESCRIPTION: SOLUTION ID: 35,979

SOLUTION: PROBABLE CAUSES:1. The paper feed loop data is too high. Adjust the paper feed loop using the 36 mode. Enter code 94, andpress the Print button. Press the paper size button to select the desired cassette. Press the P button to displaythe current data. The adjustment range is -20 to +99.

2. The actuator for the intermediate conveyance sensor (PS11) is worn. Install a repair cap (p/n 5400K0110)or replace the actuator (p/n 540041112) for PS11.

USAGE: 5

Paper intermittently jams under the drum.DESCRIPTION: SOLUTION ID: 32,601

SOLUTION: CAUSE: The actuator for the paper temporary stop sensor (PS10) is worn.

SOLUTION: Replace the actuator (p/n 540041111) or install a repair cap (p/n 5400K0120).

USAGE: 5

Cannot access the diagnostic modes.DESCRIPTION: SOLUTION ID: 15,131

SOLUTION: CAUSE: There is a poor connection between the socket and the Dallas chip on the main CB.

SOLUTION: Power the copier OFF. Remove the Dallas chip, clean the legs of the chip with a pencil eraserand reseat the chip. If necessary replace the Dallas chip (E46DS1220).

USAGE: 5


3035

Copies gradually get darker from lead-to-trail.DESCRIPTION: SOLUTION ID: 11,290

SOLUTION: CAUSE: The mirror holders B (p/n 392061420) located on the first V-mirror assembly are out of position.This affects the angle of the optics mirror.

SOLUTION: Reposition the mirror holders.

USAGE: 5

Part number for the fuser drive unit.DESCRIPTION: SOLUTION ID: 40,065

SOLUTION: The part number for the new style fuser drive unit is (p/n 5400-1514). There are two different style fixingdrive units. See [[Parts Information Bulletin #43.| IMAGE V:\BITMAPS\JRC053.BMP SCROLL]] Thisbulletin provides information on the old verses new style drive units, and addresses compatibility issues.

USAGE: 4

Spots on the drum.DESCRIPTION: SOLUTION ID: 31,669

SOLUTION: PROBABLE CAUSES:1. The toner is contaminated, or the developing unit is faulty. Flush out all supplies and replace with thecorrect supplies. If necessary, install the developer performance kit (p/n SE95-3050). Replace the drum,cleaning blade, and toner guide roller.

2. The ozone filters are dirty causing excessive heat to build up in the drum cavity. Replace the ozone filters(A) (p/n 540080520) and (B) (p/n 540073060) at the recommended interval (every 100,000 copies).

USAGE: 4

F43 only in the morning during the first copy.DESCRIPTION: SOLUTION ID: 58,599

SOLUTION: CAUSE: The ACDB has failed.

SOLUTION: Replace the ACDB (p/n 5400-9085).

USAGE: 4

DF305, originals feed past the scale plate and become damaged.DESCRIPTION: SOLUTION ID: 52,740

SOLUTION: CAUSE: The RADF height requires adjustment.

SOLUTION: Adjust the RADF height by performing the following:1. Close the RADF unit.2. Loosen the 4 RADF height adjusting screws.3. Press down on the top of the RADF unit and tighten the height adjusting screws. a. Insert 2 strips of 20lb paper (approximately 1x8) between the RADF and the platen glass. Ensure thatpaper is under the shaft supports (black protruding pieces) located in each corner of the RADF. b. Hook a gram gauge to the exposed end of the paper. Pull the paper, and the gram gauge shouldindicate at least 200 grams of pull tension for the feed side of the RADF (front and rear); at least 50 grams ofpull tension for the exit side of the RADF (front and rear). Note: When adjusting the right side of theRADF, insert a 0.5mm spacer below the 2 strips of paper. If available, use a 6-inch metal ruler. It isapproximately 0.5mm thick.Refer to the DF305 Service Manual height adjustment procedure for more detail.

USAGE: 4

The RADF drive motor mounting screw inserts are breaking away from the mounting posts duringshipment.


SOLUTION: CAUSE: The mounting posts that support M301 may become cracked due to vibrations that occur intransportation.

SOLUTION: Install the [[countermeasure kit (p/n DF204-301)| IMAGE v:\bitmaps\djc136.bmp SCROLL]]to repair the cracked mounting posts. The instructions for the repair kit are included in the kit. The 5 minuteepoxy must be purchased locally.

Note: All DF204's in stock have been modified to prevent additional cracking. The modified ADF's can beidentified by a red dot on the side of the box, next to the serial number.

USAGE: 4

How to program the power saver mode.DESCRIPTION: SOLUTION ID: 49,374

SOLUTION: To program the power saver mode, perform the following:1. Power the machine OFF.2. While holding down the 2 and 5 keys, power the machine ON.3. Press P-6-2-P. 4. Enter the desired data: 0 for OFF, 1 for 2 minutes, 2 for 6 minutes, and 3 for 10 minutes. 5. Press the Print button to enter the new data.6. Power the machine OFF/ON.

USAGE: 4

DF305, unable to select the RADF.DESCRIPTION: SOLUTION ID: 49,208


3035

SOLUTION: CAUSE: The interlock sensor (PS305) is not actuated. This is caused by the RADF height being out ofadjustment.

SOLUTION: Adjust the RADF height to ensure that it sits level on the main body and actuates the interlock.

USAGE: 4

Cannot select the 1:2 or 2:2 copy modes.DESCRIPTION: SOLUTION ID: 49,199

SOLUTION: There is no ADU installed in the machine. These modes require the use of a duplexer. USAGE: 4

J16 while copying.DESCRIPTION: SOLUTION ID: 46,880

SOLUTION: CAUSE: The second paper feed clutch (MC1) has failed, and has damaged the main CB.

SOLUTION: Replace MC1 (p/n 540084022) and the main CB (p/n 5402-9017).

USAGE: 4

Toner cartridge yield.DESCRIPTION: SOLUTION ID: 40,666

SOLUTION: The specified toner yield is 12,500 copies (PCUA# 947376) based on the industry standard [[6% coveroriginal| IMAGE v:\bitmaps\djc117.bmp SCROLL]]. The actual yield will vary depending on the types oforiginals used.

USAGE: 4

The paper is tearing when the cassette is pulled out.DESCRIPTION: SOLUTION ID: 40,548

SOLUTION: CAUSE: The upper limit detect actuators are worn.

SOLUTION: Replace the upper limit detect actuators (p/n 540040200).

USAGE: 4

Erratic display when the machine is first turned on.DESCRIPTION: SOLUTION ID: 30,200

SOLUTION: CAUSE: The DC power supply is failing under load. The problem occurs when the copier is first turned on.The voltages will be present with no loads applied.

SOLUTION: Replace the DC power supply (p/n 540084510).

USAGE: 4

The original is not reaching the scale plate.DESCRIPTION: SOLUTION ID: 29,765

SOLUTION: CAUSE: The original feed belt is on backwards, and the tension for the RADF belt is set incorrectly.

SOLUTION: Reinstall the feed belt. Note: Ensure the [[directional grooves| IMAGEV:\BITMAPS\JRC101.BMP SCROLL]] are positioned correctly in reference to paper flow. Ensure theconveyance belt tension plates are set correctly.

USAGE: 4

Spots on copies which do not appear on the drum. This is an enhancement-modified copier.DESCRIPTION: SOLUTION ID: 27,990

SOLUTION: CAUSE: The drum carriage mylars from the developing unit modification kit, are installed incorrectly.

SOLUTION: Ensure that the mylar strips are installed correctly. For dealers see Technical OperationsBulletin #D14 dated 12/19/95. For branches see Technical Operations Bulletin #A23 dated 12/19/95. See[[installation procedure.| IMAGE V:\BITMAPS\JRC014.BMP SCROLL]]

USAGE: 4

Skew approximately 2mm, which is more evident with 11x17.DESCRIPTION: SOLUTION ID: 22,364

SOLUTION: PROBABLE CAUSES:1. The lower second paper feed roller is worn. Replace the lower roller (p/n 540041030).

2. The second paper feed pressure springs are reversed. Place the springs in the correct locations. The rearspring is silver, and the front spring is black.

USAGE: 4

The lower PF201 does not indicate the correct paper size.DESCRIPTION: SOLUTION ID: 20,481

SOLUTION: CAUSE: Address P69 in the 25 mode is set to a value other than 0.

SOLUTION: In the 25 mode set address P69 to 0. Note: P69 is the LT151 paper size setting. This shouldbe set to 0 if there is no LCT.

USAGE: 4

Blur areas or jitter from front-to-rear.DESCRIPTION: SOLUTION ID: 14,262

SOLUTION: PROABLE CAUSES:1. The optics drive shaft, and slide shaft holder is worn. Replace the worn parts: optics drive shaft, (p/n540061090) and slide shaft holder, (p/n 540061240).

USAGE: 4


3035

2. The grip ring on the 1st mirror assembly is too tight on the optics shaft, causing the optics to bind.Loosen the grip ring on the 1st mirror assembly.

3. The optics scanner is contacting the top of the lens cover. Reposition the lens cover to ensure that thescanner does not contact it.

4. The second feed drive roller is worn. To verify, check the image created on the drum using the 36 mode.The image will appear normal.

What is the part number for the new separation drum claw?DESCRIPTION: SOLUTION ID: 36,293

SOLUTION: For the new separation claws order (p/n SE95-3200). USAGE: 3

ST102, F77.DESCRIPTION: SOLUTION ID: 33,958

SOLUTION: PROBABLE CAUSES:1. The 5V DC protector (ICP1) on the sorter CB is open. With power applied, check each side of ICP1 for5V DC. If 5V is not present on both pins, ICP1 is open. Replace the sorter drive board (p/n 0590-9011).

2. Fuse F4 on the main CB is open. Replace the fuse (p/n 963010600).

3. The sorter drive board (STDB) has failed. Confirm that all DC voltages are present to the STDB. Ifnecessary replace the STDB (p/n 0590-9011).

USAGE: 3

How to change the developing unit agitators.DESCRIPTION: SOLUTION ID: 31,705

SOLUTION: See 3035 [[Technical Bulletin #72| IMAGE V:\BITMAPS\JRC077.BMP SCROLL]], which can be accessedthrough the Konica Fax on Demand system, using document #202872.

USAGE: 3

ST205S, the sorter sorts when the group mode is selected.DESCRIPTION: SOLUTION ID: 30,276

SOLUTION: CAUSE: The sorter harness is faulty.

SOLTION: Replace the sorter wiring harness (p/n 037190080).

USAGE: 3

What is the part number for the metal caps for PS10/PS11?DESCRIPTION: SOLUTION ID: 23,090

SOLUTION: The part number for PS11 is (p/n 5400K0110). For PS10 order (p/n 5400K0120). USAGE: 3

No drive from the ADU.DESCRIPTION: SOLUTION ID: 48,852

SOLUTION: CAUSE: An incorrect spring was installed onto the first paper feed clutch on the ADU. This caused a bindin the ADU drive system causing fuse F1 on the ADU DB and fuse F4 on the main CB to open.

SOLUTION: Install the correct spring (p/n 190040730) onto the first paper feed clutch. Replace the openfuses on the ADU DB and the main CB.

USAGE: 3

The platen glass is very hot.DESCRIPTION: SOLUTION ID: 45,439

SOLUTION: CAUSE: The cooling fan (M11) located at the rear of the machine behind the black ozone filter has failed.This causes no air flow.

SOLUTION: Replace M11 (p/n 25AA80540) and the ozone filter (p/n 540073050).

USAGE: 3

Blank copies with no image on the drum.DESCRIPTION: SOLUTION ID: 59,846

SOLUTION: CAUSE: The drum is not rotating. Drive is not being transmitted from the main motor (M1) to the druminput gear.

SOLUTION: Inspect all gears within the drive assembly which transmit drive from the main motor to thedrum input gear. Replace any damaged gear.

USAGE: 3

The 8.5x11 tray is not recognized.DESCRIPTION: SOLUTION ID: 58,713

SOLUTION: CAUSE: The paper size detection actuators on the rear of the paper tray are incorrectly set.

SOLUTION: There are two green buttons on the back of the universal tray. One is marked S, and the otheris marked L. For 8.5x11 paper the one marked S should be in the down position.

USAGE: 3


3035

The document feeder conveyance belt sticks to the glass.DESCRIPTION: SOLUTION ID: 49,126

SOLUTION: CAUSE: The conveyance belt has been cleaned with solvents that have damaged the belt.

SOLUTION: Replace the conveyance belt (p/n 048045010). The conveyance belts should only be cleanedwith alcohol.

USAGE: 3

The document feeder is multifeeding.DESCRIPTION: SOLUTION ID: 46,711

SOLUTION: CAUSE: Laser printed originals are being used.

SOLUTION: Reducing the original pressure plate tension slightly below specification may resolve theproblem. Note: See the DF305 service manual page 7 for the adjustment procedure. The specification is220±10g.

USAGE: 3

ST205S, as the indexer goes from bin two to bin one, two copies exit into bin two and none into binone. No jam code is displayed.


SOLUTION: CAUSE: The gate solenoid (SD201) is not operating properly due to a dirty or misaligned plunger.

SOLUTION: Clean the plunger and internal body of SD201 with alcohol. Reinstall and verify proper sorteroperation.

USAGE: 3

When the upper or lower paper drawers are pulled out, the top sheet of paper catches, causing acrumpled sheet which has to be removed.


SOLUTION: CAUSE: The PFU spring clutches have failed allowing the top sheet of paper to prefeed off the paper stack.

SOLUTION: Clean or replace the paper feed spring clutch assemblies as necessary (p/n 5400-4080).

USAGE: 3

How is the service control data collection mode accessed?DESCRIPTION: SOLUTION ID: 44,160

SOLUTION: The service control data collection mode is not available for the 3035, only the 2028 or 4045 offer thisfeature.

USAGE: 3

How to change the horizontal magnification.DESCRIPTION: SOLUTION ID: 43,767

SOLUTION: To change the horizontal magnification, perform the following: 1. Enter the 36 mode.2. Enter code 95.3. Press the start print button and check the horizontal magnification.4. Select 1.00 magnification with the magnification buttons. Press buttons P and 2. The copy quantitydisplay will flash.5. Enter the applicable data: -40 to 40.6. Press the button again when the display changes to the data just entered.7. Repeat steps 3 to 6 until the adjustment is within standards.8. Turn the main switch OFF.

USAGE: 3

The platen glass is very hot.DESCRIPTION: SOLUTION ID: 43,446

SOLUTION: CAUSE: The ozone filter on the cooling fan located at the rear of the copier is plugged with dirt.

SOLUTION: Clean or replace the ozone filter (p/n 540073050). It is recommended that the ozone filters bereplaced every 100,000 copies.

USAGE: 3

Dark copies.DESCRIPTION: SOLUTION ID: 43,136

SOLUTION: CAUSE: The drum and charge corona are past the recommended replacement interval.

SOLUTION: Install a new drum (PCUA 947542) and reset the drum counter. Replace the charge coronaand set the currents to specification. Adjust the CVR to obtain proper copy density. Note: Therecommended replacement interval of the new style drum is 250,000 copies.

USAGE: 3

How to program the ATS.DESCRIPTION: SOLUTION ID: 42,284

SOLUTION: ATS is not programmable unless the developing unit modification EPROM, version 21.9, is installed at IC2(p/n 303512-21.9). Note: This EPROM must be used with (p/n 303513-20.0). See Technical OperationsBulletins A23 & D14. If the modification is not installed, version 21.13 (p/n 202812-21.13) should beinstalled at IC2. See 3035 [[Technical Bulletin #89A| IMAGE V:\BITMAPS\JRC135.bmp SCROLL]],which can be accessed through the Konica Fax on Demand system, using document #202889.

USAGE: 3


3035

Copying in progress is indicated when feeding from the RADF. Copying from the platen glass isnormal.


SOLUTION: CAUSE: The optics cable is walking to the front of the capstan; binding the optics and causing the opticscable to fray.

SOLUTION: Clean and lubricate the optics. Remove the cable from where it attaches to the first mirrorframe, turn it 3 times counterclockwise and reattach. If the cable appears damaged (frayed) replace the cable(p/n 540061111).

USAGE: 3

J72 even though no sorter is attached.DESCRIPTION: SOLUTION ID: 41,848

SOLUTION: CAUSE: The programming in the 25 mode is incorrect.

SOLUTION: In the 25 mode set P03 to 0 if no sorter is attached.

USAGE: 3

Erratic operation of the optics.DESCRIPTION: SOLUTION ID: 36,599

SOLUTION: CAUSE: The copier has an old style AC driver board.

SOLUTION: Replace the AC driver board with the new style (p/n 5400-9085).

USAGE: 3

DF305, the originals are creasing from front to rear.DESCRIPTION: SOLUTION ID: 31,131

SOLUTION: CAUSE: The swing back roller ends have burrs which are binding the movement from left to right.

SOLUTION: Lightly sand the ends with emory cloth to remove the burrs.

USAGE: 3

Can the LCT be programmed as the priority tray?DESCRIPTION: SOLUTION ID: 25,911

SOLUTION: This function is not available for the 3035. USAGE: 3

How to disable the APS.DESCRIPTION: SOLUTION ID: 23,133

SOLUTION: To disable the APS for a machine with an RADF, perform the following:1. Power the machine OFF.2. While holding down the 2 and 5 keys power the machine ON.3. Press P-5-6-P.4. Press 3 from the key pad.5. Press the start print button to enter the new data.6. Press P-5-8-P.7. Press 2 from the key pad.8. Press the start print button to enter the new data.9. Power the machine OFF/ON.

USAGE: 3

Can a DF203 ADF be installed on the model 3035?DESCRIPTION: SOLUTION ID: 22,055

SOLUTION: The DF203 can be used, providing the correct EPROMs are installed. See 3035 [[Technical Bulletin #31|IMAGE V:\BITMAPS\JRC074.BMP SCROLL]], which can be accessed through the Konica Fax on Demandsystem, using document #202831.

USAGE: 3

Can the paper tray be removed by the end user?DESCRIPTION: SOLUTION ID: 21,353

SOLUTION: The paper tray cannot be removed by the customer on this model. USAGE: 3

ST206, no staple selection.DESCRIPTION: SOLUTION ID: 21,311

SOLUTION: CAUSE: The end user was trying to auto staple in the non auto mode.

SOLUTION: The machine must be in the fully auto mode to select sort/staple.

USAGE: 3

Blurr, one inch from the lead edge.DESCRIPTION: SOLUTION ID: 20,505

SOLUTION: CAUSE: The optics drive shaft, and slide shaft holder are worn.

SOLUTION: Replace the optics drive shaft (p/n 540061090) and slide shaft holder (p/n 540061240).

USAGE: 3

The mounting bosses for the original feed solenoid (SD301), and the pressure feed assembly arebreaking on older document feeders.



3035

SOLUTION: There are repair brackets available. See DF305 [[Technical Bulletin #8| IMAGEV:\BITMAPS\JRC075.BMP SCROLL]] and, DF305 [[Technical Bulletin #9| IMAGEV:\BITMAPS\JRC076.BMP SCROLL]], which can be accessed through the Konica Fax on Demand system,using document #3330508, and #3330509.

USAGE: 3

Intermittent misfeeding from the PFU.DESCRIPTION: SOLUTION ID: 18,444

SOLUTION: CAUSE: The machine has an old style double feed prevention plate.

SOLUTION: Install the newer style DFP plate assembly (p/n 5400-4043), and the spring (p/n 540040742).

USAGE: 3

How to enable mixed original mode (APS) through the RADF.DESCRIPTION: SOLUTION ID: 69,189

SOLUTION: To enable the mixed original mode, perform the following:1. Access the 25 mode (power the copier ON while simultaneously pressing the 2 and 5 keys), P61 to 1.2. Press the Start Print key to enter the data.3. Power the copier OFF/ON to exit the 25 mode.Note: The following minimum EPROM levels must be installed:DF203 level 11.0Copier main CB IC2 level 18.1Copier main CB IC3 level 14.0

DF305 level 13.1Copier main CB IC2 level 17.8Copier main CB IC3 level 11.0

USAGE: 3

Intermittent F35.DESCRIPTION: SOLUTION ID: 93,065

SOLUTION: CAUSE: The main relay (RL1) has contaminated/pitted electrical contacts.

SOLUTION: With main switch OFF and machine unplugged, open RL1 and clean the relay electricalcontacts. Replace RL1 (p/n 540088460) if the problem persists.

USAGE: 2

Part number request for the optics wire tension gauge or jig.DESCRIPTION: SOLUTION ID: 36,693

SOLUTION: The part number for the wire tension jig is (p/n 00M6-1-01). USAGE: 2

11x17 enlarged, produces half copies that are dark.DESCRIPTION: SOLUTION ID: 21,991

SOLUTION: CAUSE: The mirror holders (B) (p/n 392061420) located on the first V-mirror assembly are out of position.This affects the angle of the mirror.

SOLUTION: Reposition the mirror holders.

USAGE: 2

AD205, J92 when selecting 1:2. There is no problem when selecting 2:2.DESCRIPTION: SOLUTION ID: 69,287

SOLUTION: CAUSE: The ADU DB failed.

SOLUTION: Replace the ADU DB (p/n 0486-9010).

USAGE: 2

Special release Spanish EPROM version 20.7 does not allow recognition of 8.5x14 paper.DESCRIPTION: SOLUTION ID: 81,503

SOLUTION: This is a product limitation. USAGE: 2

Enhancement kit (p/n SE95-3050) includes incorrect instructions.DESCRIPTION: SOLUTION ID: 69,714

SOLUTION: The enhancement kit (p/n SE95-3050) introduced in Technical Operations Bulletin #D14 dated 12/19/95 hasbeen replaced with kit p/n SE95-3180 or SE95-3180RF. The new kit includes directions to change themagnet angle. Since the magnet angle has already been adjusted, do not follow the instructions with the kit.

USAGE: 2

J61 when using ADF.DESCRIPTION: SOLUTION ID: 52,806

SOLUTION: CAUSE: The conveyance belt is slipping.

SOLUTION: Clean both sides of the conveyance belt. If necessary replace the belt (p/n 048045010).

USAGE: 2

Part number for the waste toner collection bottle.DESCRIPTION: SOLUTION ID: 51,970

SOLUTION: The part number for the toner collecting box is (p/n 540022010). USAGE: 2


3035

The RADF multifeeds when running laser printed originals.DESCRIPTION: SOLUTION ID: 51,648

SOLUTION: CAUSE: Some laser printed originals may cause multifeeding.

SOLUTION: Adjust the RADF lift up pressure plate to approximately 170 grams. Note: This adjustment isnot within specifications, and should only be performed based on the frequency of running laser printedoriginals. Increase the lift up pressure 10 grams at a time until a good medium is found. Check the feedingperformance of standard 20lb paper when done.

USAGE: 2

How to reset the PM counter.DESCRIPTION: SOLUTION ID: 49,156

SOLUTION: To reset the PM counter, perform the following:1. Access the 47 mode (power the copier ON while pressing the 4 and 7 keys simultaneously), output code90.2. Enter the Start date, (month/day/year) using the numeric keys. a. This is the date of the PM.3. Press the START/PRINT button again.4. Power the copier OFF/ON to return to normal copy mode.

USAGE: 2

The lower two drawers are not being recognized.DESCRIPTION: SOLUTION ID: 48,621

SOLUTION: CAUSE: The wiring harness (PFU power source wiring) between the drawer base and the main body hasfailed.

SOLUTION: Replace the wiring harness (p/n 049295010).

USAGE: 2

ST206, unable to make copies when the sorter is attached.DESCRIPTION: SOLUTION ID: 47,916

SOLUTION: CAUSE: The sorter CB is not providing the correct acknowledgement signal to the main body which shutsdown operation.

SOLUTION: Inspect and reseat the wiring harness from the sorter CB and the main CB. If there is nochange, check for 5V DC at CN101-3 and CN101-7. If the voltage is not present; replace the sorter CB (p/n074089020).

USAGE: 2

Intermittent multiple feeding out of the ADU.DESCRIPTION: SOLUTION ID: 47,314

SOLUTION: CAUSE: The torque limiter is worn causing multiple sheet feeding.

SOLUTION: Replace the torque limiter (p/n 048640270).

USAGE: 2

AD205, skewing when feeding out of the ADU.DESCRIPTION: SOLUTION ID: 44,912

SOLUTION: CAUSE: The loop timing for the ADU is set too low.

SOLUTION: Enter the 36 mode, code 94. Select the two sided copy mode. Make one copy so that one is inthe ADU. Press the [P] button, adjust the data, press [P] again and run the copy out of the ADU. Repeatuntil the skew is corrected.

USAGE: 2

The toner rubs off the copies.DESCRIPTION: SOLUTION ID: 43,342

SOLUTION: CAUSE: The fuser release lever (lever 2) is in the released position.

SOLUTION: Pressure the fuser rollers together by moving lever 2 to the right until it latches.

USAGE: 2

AD205, J15 when duplexing.DESCRIPTION: SOLUTION ID: 43,314

SOLUTION: CAUSE: The rear home position sensor (PS504) is out of adjustment. This will cause a misalignment of thepaper and the first feed rollers when duplexing.

SOLUTION: Adjust PS504 and inspect the paper in the duplex tray after copying the first side.

USAGE: 2

The copies in the 1:1 mode are out of focus.DESCRIPTION: SOLUTION ID: 42,727

SOLUTION: CAUSE: The main reflector assembly and first V-mirror assembly have been damaged causing poor copyquality.

SOLUTION: Ensure that all the optics adjustments have been made correctly, and that the optics movefreely. Inspect the main reflector assembly (p/n 5402-6121) and the first V-mirror assembly (p/n 5400-6133)for any damage. Replace any damaged assemblies as necessary.

USAGE: 2


3035

ST206, the stapler swings in, but intermittently it does not staple.DESCRIPTION: SOLUTION ID: 42,582

SOLUTION: CAUSE: The wiring harness from the stapler to the sorter CB is damaged.

SOLUTION: Replace the stapler harness (p/n 074087050).

USAGE: 2

When feeding mixed originals (8.5x11R and 8.5x14) from the RADF, the second copy (if 8.5x14) willhave a deletion on the trail edge.


SOLUTION: CAUSE: The method of CEL timing, address 70 in the 25 mode is set to 0 for APS detect.

SOLUTION: Set address 70 to 2 for copy paper detect.

USAGE: 2

The optics unit is noisy during the scan operation.DESCRIPTION: SOLUTION ID: 42,162

SOLUTION: CAUSE: There is excessive play in the first mirror unit.

SOLUTION: Replace the optics sleeve (p/n 540061240) and inspect the optics shaft (p/n 540061090).

USAGE: 2

ST206, when the last copy exits the main body; power to the copier is lost for a brief moment.DESCRIPTION: SOLUTION ID: 42,075

SOLUTION: CAUSE: The relay signal wiring (adaptor harness) between the sorter and main body is damaged.

SOLUTION: Replace the relay signal wiring (p/n 074087060).

USAGE: 2

Part numbers for the main body internal heater (dew prevention) and associated components.DESCRIPTION: SOLUTION ID: 41,207

SOLUTION: The heater is offered as a kit. Order (p/n SE95-2560). USAGE: 2

P91 code.DESCRIPTION: SOLUTION ID: 40,836

SOLUTION: CAUSE: The sorter (ST205S) CN17 was plugged into CN150 on the main CB which is an ADU connector.

SOLUTION: Install the sorter connector, CN17 on CN142 on the main CB.

USAGE: 2

Intermittent loss of display and operation.DESCRIPTION: SOLUTION ID: 39,148

SOLUTION: CAUSE: The door interlock switches are faulty.

SOLUTION: Replace the door interlock switches (p/n 392085020).

USAGE: 2

High static buildup on the RADF conveyance belt.DESCRIPTION: SOLUTION ID: 37,376

SOLUTION: CAUSE: The drive roller bearings are dirty and causing a loss of ground to the RADF.

SOLUTION: Check the end of the drive roller to frame ground for continuity. Ensure that the bearings areclean.

USAGE: 2

ST205S, groups when the sort mode is selected.DESCRIPTION: SOLUTION ID: 34,762

SOLUTION: CAUSE: There is a damaged wire on CN17-10.

SOLUTION: Repair the wire or replace the wiring harness (p/n 037190080).

USAGE: 2

Cannot select the RADF.DESCRIPTION: SOLUTION ID: 31,351

SOLUTION: CAUSE: The swingback roller is out of its holder, not allowing the interlock sensor (PS305) to be flagged.

SOLUTION: Ensure that the holders are not worn, and that the swingback roller is not bent. Replace asnecessary.

USAGE: 2

Streaks lead-to-trail on the edges appears at 77% and below.DESCRIPTION: SOLUTION ID: 30,462

SOLUTION: CAUSE: The CEL is not completely discharging the non-image area.

SOLUTION: Replace the CEL (p/n 5400-9141).

USAGE: 2

ST206, the staples within the cartridge will not advance.DESCRIPTION: SOLUTION ID: 28,977


3035

SOLUTION: CAUSE: The stapler unit has an old style feeder.

SOLUTION: Replace the stapler feeder with the new style (p/n 50200-808). See ST206 [[Technical Bulletin#2| IMAGE V:\BITMAPS\JRC081.BMP SCROLL]], which can be accessed through the Konica Fax onDemand system, using document #7820602.

USAGE: 2

Separation jam only with 8.5x11 paper.DESCRIPTION: SOLUTION ID: 24,063

SOLUTION: CAUSE: The data stored in memory is corrupted.

SOLUTION: In the 47 mode enter output code 92. Press the start print button to perform a process initialset. This will set all data in memory to the factory initial values. Note: Ensure the 25 mode settings and 36mode adjustments are reprogrammed.

USAGE: 2

ST205S, only 8.5x11R jams in the indexer.DESCRIPTION: SOLUTION ID: 22,913

SOLUTION: CAUSE: The indexer height is out of adjustment.

SOLUTION: Verify the [[indexer height| IMAGE V:\BITMAPS\JRC011.BMP SCROLL]] , and retime theindexer pulleys the timing belt may have jumped out of position.

USAGE: 2

After removing the document feeder and installing a platen cover, the APS selects 11x17.DESCRIPTION: SOLUTION ID: 21,720

SOLUTION: CAUSE: The APS adjustment was not performed.

SOLUTION: Perform the APS. Use the 47 mode, output code 99. Note: Ensure the platen top is in thedown position when the adjustment is done.

USAGE: 2

How to disable APS and AMS on a platen top machine.DESCRIPTION: SOLUTION ID: 18,038

SOLUTION: Order Eprom 21.2 at IC2 and 20.0 at IC3 to cancel AMS. Note: In the 25 mode set P58 and P56 to 3 todisable APS.

USAGE: 2

Can the ST205 sorter be installed on a 3035?DESCRIPTION: SOLUTION ID: 17,905

SOLUTION: The ST205 can be installed on a 3035. Use the 10 pin wire harness (p/n 037190080). USAGE: 2

The main relay (RL1) is chattering at power up.DESCRIPTION: SOLUTION ID: 14,720

SOLUTION: CAUSE: RL1 was installed upside down. The AC voltage is going to the coil.

SOLUTION: Reposition the relay and properly connect the AC and DC connections.

USAGE: 2

Drum drive gear damage.DESCRIPTION: SOLUTION ID: 13,237

SOLUTION: See 3035 [[Technical Bulletin #66| IMAGE V:\BITMAPS\JRC079.BMP SCROLL]], which can be accessedthrough the Konica Fax on Demand system, using document #202866. Also, see [[ Parts InformationBulletin #54| IMAGE V:\BITMAPS\JRC080.BMP SCROLL]] for rebuild kit, and part change information.

USAGE: 2

AD205, noise while duplexingDESCRIPTION: SOLUTION ID: 113,962

SOLUTION: CAUSE: Dirty or worn feed roller bushings found on the first feed roller shaft A (p/n 048640010) and firstfeed roller shaft B (p/n 048640020).

SOLUTION: Clean or replace the feed roller bushings (p/n 396076050).Note: For further explanation of parts layout refer to the AD205 Service Manual including parts catalog(September1992) page 10.

USAGE: 1

P81 at power up.DESCRIPTION: SOLUTION ID: 40,224

SOLUTION: CAUSE: There is a loose pin in the key counter connector CN55.

SOLUTION: Repair any loose pins in CN55.

USAGE: 1

The copies begin to fade after about 75 copies in a row. Copy quality will come back if machine sits fora while.


SOLUTION: CAUSE: The drum is worn.

SOLUTION: Replace the drum (PCUA 947513).

USAGE: 1


3035

ST102, in group mode, the sorter does not cycle back up after reaching the tenth bin and will continueto feed copies into that bin.


SOLUTION: In the group mode the maximum number of originals to be copied is 10. The maximum print quantity is 30.If the maximum number of originals is exceeded they will exit to the bottom bin.

USAGE: 1

Can AMS be disabled when selecting paper size? Customer runs originals smaller than 8.5x11 anddoes not have a tray configured for 8.5x11.


SOLUTION: AMS cannot be disabled. The RADF only detects a minimum length of 8.5 inches. It therefore defaults to8.5x11 paper size.

USAGE: 1

Cannot access the ECM mode.DESCRIPTION: SOLUTION ID: 10,398

SOLUTION: CAUSE: The customer is inputting the wrong master key code code.

SOLUTION: Obtain the master key code using the 25 mode addresses P72-P79.

USAGE: 1

DF305, original skew.DESCRIPTION: SOLUTION ID: 47,658

SOLUTION: CAUSE: The scale plate is warped.

SOLUTION: Replace the scale plate assembly (p/n 0481-1200).

USAGE: 1

Only the center of the copy is out of focus.DESCRIPTION: SOLUTION ID: 47,447

SOLUTION: CAUSE: The sixth mirror is out of position.

SOLUTION: Reposition the sixth mirror, and reverify the position of any other mirrors that were moved.

USAGE: 1

The copies are distorted after replacing the optics cable.DESCRIPTION: SOLUTION ID: 41,720

SOLUTION: CAUSE: The lens unit was knocked out of position when the optics drive cable was replaced.

SOLUTION: Reposition the lens unit.

USAGE: 1

Part number for the LCT heater kit.DESCRIPTION: SOLUTION ID: 41,208

SOLUTION: The part number for the heater kit is (p/n SE95-2830). USAGE: 1

Interchangeability of 4145 and 3035 developing units.DESCRIPTION: SOLUTION ID: 81,913

SOLUTION: When ordering the 3035 developing unit (p/n 5440-3003) from the Parts Department, the assembly will besubstituted with a 4145 developing unit (p/n 25LA-3001).

USAGE: 1

ST206, P71 with the message(s) PLEASE CLOSE SORTER ENTRANCE COVER and PLEASECONNECT SORTER TO THE COPIER.


SOLUTION: CAUSE: The front door to the stapler unit is not fully closed.

SOLUTION: Fully close the front door, covering the stapler unit. The stapler unit assembly should cyclein/out every time the door is opened/closed.

USAGE: 1

A dark band running lead-to-trail approximately 1-inch wide.DESCRIPTION: SOLUTION ID: 66,417

SOLUTION: CAUSE: The 6th mirror in the optics is dirty. The mirrors in the optics section may accumulate a filmcoating that affects copy quality.

SOLUTION: Clean the 6th mirror (located to the right of the lens unit) with glass cleaner and a soft cloth orcotton pad.Notes:1. There is a black cover running front-to-rear that shields the 6th mirror.2. The rear lens rail must be removed to allow removal of the 6th mirror cover.

Caution: Areas of the optics cavity may have sharp edges.

USAGE: 1

AD205, J92 as paper enters the ADU.DESCRIPTION: SOLUTION ID: 64,845

SOLUTION: CAUSE: The one-way gear assemblies in the ADU inversion unit are slipping. USAGE: 1


3035

SOLUTION: Replace the two (2) one-way gear assemblies in the inversion unit. Each of the assembliesconsists of the following parts:PART NUMBER ITEM048676520 pulley (B) 540077010 clutch lock gear 540077010 clutch base gear 540040380 cover

Operation panel display is in Japanese.DESCRIPTION: SOLUTION ID: 61,393

SOLUTION: PROBABLE CAUSES:1. Arcing from the T/S corona or the charge corona; static discharge; or power line problems.Replace T/S blocks, wires, and plunging prevention plate. The charge corona blocks and wires should becleaned or replaced. Verify a good ground at the wall outlet.To reset the language in the message display: a. Enter the 25 mode (hold the 2 and 5 keys while powering ON the copier. b. Select address P14; press the P button, and type 1, 4, and press P again. c. Enter the required data: 0= English 1= French 2= British (has metric sizes) 3= Japanese d. Press the start print button to enter the new data. e. Power OFF/ON the copier to exit the 25 mode.

2. The main CB has failed.Replace the main CB (p/n 5402-9017).

USAGE: 1

ST206, J32 shortly after pressing the START/PRINT key.DESCRIPTION: SOLUTION ID: 60,623

SOLUTION: CAUSE: The sorter selection in the 25 mode, P03, is not properly programmed.

SOLUTION: To program the proper sorter selection, perform the following:1. Power the copier OFF.2. Enter the 25 mode, (power the copier ON, while pressing the 2 and 5 keys).3. Using the numeric keypad press P-03-P, followed by the 0 key.4. Press the START PRINT key.5. Power the copier OFF/ON, to exit the 25 mode.

USAGE: 1

J17 when feeding from any paper source.DESCRIPTION: SOLUTION ID: 60,273

SOLUTION: CAUSE: The temporary stop sensor (PS10) has a poor connection, or the sensor has failed.

SOLUTION: To check the operation of the temporary stop sensor (PS10), perform the following:1. Power the machine OFF.2. Enter the 47 mode, (power the machine ON, while holding the 4 and 7 keys).3. Using the numeric keypad press the 2 and 0 keys (input code 20).4. With the temporary stop sensor (PS10) in its normal non-actuated state, the magnification display windowon the operation panel should display HI.5. Manually actuate the temporary stop sensor (PS10), the display indication on the operation panel shouldchange to LO.6. If the temporary stop sensor (PS10) fails to change state, reseat CN46 at the sensor itself, along with CN6on the main CB. If replacement of the temporary stop sensor is required, order p/n 540085510.

USAGE: 1

AD205, J15 when duplexing.DESCRIPTION: SOLUTION ID: 58,561

SOLUTION: CAUSE: A worn or excessively lubricated rotation plate spring clutch.

SOLUTION: Thoroughly clean clutch spring (B) (p/n 190040730), the hub of gear (M) (p/n 300077270),and the hub of the stop collar (p/n 190040540) with a dry, clean cloth. Apply a drop of light oil onto thespring. If the problem persists, replace the three parts. Note: If the rotary plate (p/n 190040520) does notrotate smoothly because of resistance on its metal shaft, install a roller (p/n 300040530) and an E-clip (p/n00Z670406) on the rotary plate shaft.

USAGE: 1

Deletion on the front side of 8.5x11 copies.DESCRIPTION: SOLUTION ID: 58,323

SOLUTION: CAUSE: The CEL assembly is not positioned correctly.

SOLUTION: Adjust the position of the CEL assembly (p/n 5400-9141). Perform the following:1. Remove the drum carriage.2. Loosen the screw on the front side of the CEL

USAGE: 1


3035

3. Slide the CEL to the front of the drum carriage and hold in position.4. Secure the screw to the CEL.5. Reinstall the drum carriage and verify proper operation.

PF201, intermittent paper jam when feeding from the drawer base.DESCRIPTION: SOLUTION ID: 55,363

SOLUTION: CAUSE: The main CB has failed.

SOLUTION: Check for 5V DC at CN120-A9 and CN120-A10 on the main CB. If not present, or is lessthan 4.5V DC, check for 5V at CN4-3 and CN4-4 on the main CB. If present, replace the main CB (p/n5402--9013).

USAGE: 1

Are the drive unit belts the same for the 2028, 3035, and 4045?DESCRIPTION: SOLUTION ID: 55,309

SOLUTION: The 2028 and 3035 use the same drive unit belts (p/n 540077510). The 4045 uses a different belt (p/n544077510) which is shorter due to smaller diameter pulleys on the drive unit.

USAGE: 1

The LCD is dim, and unable to program some memory functions.DESCRIPTION: SOLUTION ID: 53,751

SOLUTION: CAUSE: Poor connection at CN3, or CN67 on the main CB.

SOLUTION: Inspect and reseat CN3, and CN67 on the main CB.

USAGE: 1

Erratic operation. Memory addresses settings are not retained in 25 mode.DESCRIPTION: SOLUTION ID: 53,715

SOLUTION: CAUSE: The memory IC (Dallas chip) battery has failed.

SOLUTION: Ensure that arcing is not occurring in the corona units which will rewrite memory. Replace thememory IC (p/n E46DS1220).

USAGE: 1

Paper tray lift drives up after the tray is withdrawn resulting in broken lift up gears.DESCRIPTION: SOLUTION ID: 53,534

SOLUTION: CAUSE: One or more of the paper size detect switches are stuck on, causing the machine to think the papertray is inserted.

SOLUTION: Remove the paper size switch assembly and correct any binding or replace any defective parts.

USAGE: 1

DF305, second side intermittent skew.DESCRIPTION: SOLUTION ID: 53,260

SOLUTION: CAUSE: Burr on reversal guide cover (casing, conveyance - p/n 048012050).

SOLUTION: Remove burr using emory cloth, or scotch brite pad.

USAGE: 1

ST206, the green manual staple light flashes, and the stapler will not function.DESCRIPTION: SOLUTION ID: 52,495

SOLUTION: CAUSE: The bin paper present sensor (PS201) needs adjustment.

SOLUTION: Adjust PS201. To adjust PS201, perform the following:1. Turn the copier OFF.2. Set hardware dipswitch 1 located on the sorter CB to the ON position .3. Remove all paper from the bins. Check to see that LED1 on the sorter CB is OFF. 4. If LED1 does not turn OFF, adjust VR3 so that it does, (turn VR3 counterclockwise to turn LED1 OFF,and clockwise to turn LED1 ON). 5. Insert a sheet of paper into the bins and ensure that LED1 turns ON as paper is inserted, and OFF when itis removed. 6. When the adjustment is completed, turn the copier OFF, reposition hardware dipswitch 1 to the OFFposition, and turn the copier back ON.

USAGE: 1

The operation panel is locked up. The LCD appears normal.DESCRIPTION: SOLUTION ID: 51,812

SOLUTION: PROBABLE CAUSES:1. One or more of the operation panel buttons are stuck in the down position. Inspect all operation panelbuttons and ensure that none are stuck down. Repair as necessary.

2. The operation panel locks up at power up. The lens and exposure unit do not initialize. The main relay(RL1) has failed. Replace RL1 (p/n 540088460).

USAGE: 1

The ADU side guides are in the wrong position.DESCRIPTION: SOLUTION ID: 51,801

SOLUTION: CAUSE: The ADU driver board has failed. USAGE: 1


3035

SOLUTION: Replace the ADU DB (p/n 0486-9010).

How to clear an account in the ECM mode.DESCRIPTION: SOLUTION ID: 51,285

SOLUTION: To clear an account in the ECM mode, perform the following: 1. In the standby mode hold down P then press 9. Enter the master key code.2. Press 4 for account reset.3. Press start print button. The message center should indicate CLEAR ALL ACCOUNTS YES/NO? Pressthe start print button for yes, and the stop/clear button for no. 4. Use the magnification arrows to reach the desired account, then press the start print button to clear theaccount.5. Press the stop/clear button to return to the ECM operation mode.

USAGE: 1

Can the bypass tray run 4x6 paper?DESCRIPTION: SOLUTION ID: 51,187

SOLUTION: The smallest size substrate that the bypass tray can run is 5.5x8.5. USAGE: 1

Part number for the ST205S conveyance motor (M201).DESCRIPTION: SOLUTION ID: 50,934

SOLUTION: For the conveyance motor (M201) order (p/n 12FL80011). USAGE: 1

The front to rear zoning varies when duplexing.DESCRIPTION: SOLUTION ID: 50,464

SOLUTION: CAUSE: The main CB is faulty causing the side guides not to move to the proper position against the copiesin the ADU.

SOLUTION: Replace main CB (p/n 5402-9013), which controls the movement of the side guides via theADU driver board.

USAGE: 1

Varying lead edge registration.DESCRIPTION: SOLUTION ID: 50,445

SOLUTION: CAUSE: The shaft holders for the second feed rollers are dirty causing the rollers to bind.

SOLUTION: Clean and lightly lubricate the shaft holders and shafts.

USAGE: 1

Small black lines on the copies. The lines are also on the drum surface and can be wiped off with somedifficulty.


SOLUTION: CAUSE: Insufficient internal air flow.

SOLUTION: Ensure that filters have recently been replaced. If necessary replace the cooling fan M11 (p/n544280511). Note: The copies and drum may exhibit this problem within 20-30,000 copies; the symptomusually occurs during long copy runs.

USAGE: 1

Jamming from the base unit.DESCRIPTION: SOLUTION ID: 48,944

SOLUTION: CAUSE: The actuators for the paper temporary stop sensor (PS10) and the intermediate conveyance sensor(PS11) are worn.

SOLUTION: Replace the actuators, or install the repair caps PS10 (p/n 5400K0120), PS11 (p/n5400K0110).

USAGE: 1

High-pitched squeal from the ADU paper feed motor (M501).DESCRIPTION: SOLUTION ID: 48,932

SOLUTION: CAUSE: The ADU paper feed motor (M501) is binding internally. The motor heats up on long copy runs.

SOLUTION: Replace M501 (p/n 460080030).

USAGE: 1

ST206, the staple indicator is flashing after installing a new sorter CB.DESCRIPTION: SOLUTION ID: 48,894

SOLUTION: CAUSE: The staple supply sensor (PS209) needs adjustment.

SOLUTION: Adjust the level of PS209. Turn ON hardware dipswitches 1 and 2 on the sorter CB. Withstaples loaded, adjust VR1 until LED1 goes OFF. When the staples are removed LED1 should turn ON.Turn the dipswitches back OFF.

USAGE: 1

Can an ST102A sorter be installed on a 3035?DESCRIPTION: SOLUTION ID: 48,065

SOLUTION: If a 10 bin sorter is required, the product configuration sheet shows the ST102 sorter is recommended for the3035. The ST102A is for the 1015.

USAGE: 1


3035

Unable to acheive proper charge current specification.DESCRIPTION: SOLUTION ID: 47,297

SOLUTION: CAUSE: The high voltage power supply HV(A) has failed.

SOLUTION: Replace HV(A) (p/n 540084012).

USAGE: 1

Can the ST103 sorter be converted to an ST102 sorter?DESCRIPTION: SOLUTION ID: 44,905

SOLUTION: It is not recommended to convert an ST103 to an ST102 due to the differences in the wiring and electronics. USAGE: 1

When the 8.5x11 cassette runs out of paper, ATS is selecting the 11x17 cassette which leads tojamming.


SOLUTION: CAUSE: The paper size detect switches for the 11x17 cassette are set incorrectly, and are indicating 8.5x11sized paper.

SOLUTION: Set the detect switches to the correct position as indicated by the legend on the bottom of thecassette.

USAGE: 1

As paper enters the ADU, the paper folds over in the stacker unit.DESCRIPTION: SOLUTION ID: 44,565

SOLUTION: CAUSE: The guide mylar on the change over plate has a nick in it which the paper catches on flipping thepaper over.

SOLUTION: Temporarily smooth out the nick in the mylar until a new one can be installed (p/n12EF42160).

USAGE: 1

The copies are wavy looking.DESCRIPTION: SOLUTION ID: 43,945

SOLUTION: CAUSE: A dirty front optics rail can cause hesitation with the movement of the first and second mirrorframes.

SOLUTION: Clean both the front optics rail and the rollers on the first and second mirror frames withalcohol. Note: Do not use any lubricant in this area of the optics.

USAGE: 1

ST206, cannot attach the data connector to the main CB.DESCRIPTION: SOLUTION ID: 43,333

SOLUTION: CAUSE: The jumper wire from the sorter data harness to the main CB is missing.

SOLUTION: Order the jumper wire (p/n 074087060).

USAGE: 1

LT151, the LCT is multifeeding.DESCRIPTION: SOLUTION ID: 42,687

SOLUTION: CAUSE: The paper detect actuator is worn.

SOLUTION: Replace the paper detect actuator (p/n 564040100).

USAGE: 1

AD205, part number for the complete inversion unit.DESCRIPTION: SOLUTION ID: 42,453

SOLUTION: Inversion unit assembly (p/n 0487-4803). USAGE: 1

J94 when the duplexer is selected.DESCRIPTION: SOLUTION ID: 42,422

SOLUTION: CAUSE: The wire to the gate solenoid (SD503) has shorted to ground.

SOLUTION: Repair the wire or replace the wiring harness (p/n 048695010).

USAGE: 1

The copies will not separate from the drum.DESCRIPTION: SOLUTION ID: 42,254

SOLUTION: CAUSE: The separation corona wire is broken.

SOLUTION: Replace the separation corona wire (p/n 540026080), and check the corona currents.

USAGE: 1

What is the recommended monthly copy volume?DESCRIPTION: SOLUTION ID: 42,116

SOLUTION: The recommended monthly volume is 40,000 copies. USAGE: 1

The toner cartridge is a different shape.DESCRIPTION: SOLUTION ID: 41,997


3035

SOLUTION: To comply with environmental regulations for hard plastic containers, the [[shape of the cartridge| IMAGEV:\BITMAPS\JRC100.BMP SCROLL]] has been changed. There is no change in relation to the cartridge interms of the toner supply method. Changes started with lot #601151Y8 for the models 2028/3035/4045.

USAGE: 1

The optics cooling fan does not come on.DESCRIPTION: SOLUTION ID: 41,815

SOLUTION: CAUSE: The female pins on the motor connector are loose.

SOLUTION: Ensure that the pins are making a good connection.

USAGE: 1

Can the ECM passcodes be expanded from 20 to 40?DESCRIPTION: SOLUTION ID: 41,484

SOLUTION: The maximum number of passcodes available is 20. They cannot be expanded. USAGE: 1

Multiple sheet feeding through the RADF.DESCRIPTION: SOLUTION ID: 41,212

SOLUTION: CAUSE: The bosses which hold the mounting bracket for the original feed solenoid (SD301) are damaged.This causes more than one original to feed.

SOLUTION: Install the SD301 mounting repair bracket. See DF305 [[Technical Bulletin #8| IMAGEV:\BITMAPS\JRC075.BMP SCROLL]], which can be accessed through the Konica Fax on Demand system,using document #3330508.

USAGE: 1

The copies are skewed on the second side when copying 2:2 through the RADF.DESCRIPTION: SOLUTION ID: 40,946

SOLUTION: CAUSE: The platen glass height is incorrect.

SOLUTION: Install the platen glass pads (p/n 540098060). See 3035 [[Technical Bulletin #12A| IMAGEV:\BITMAPS\JRC102.BMP SCROLL]], which can be accessed through the Konica Fax on Demand system,using document #202812.

USAGE: 1

Where does the drawer base heater connect?DESCRIPTION: SOLUTION ID: 40,619

SOLUTION: An additional harness (p/n 049295061) is needed. This connects to CN387 on the main body. USAGE: 1

ST206, cannot select the sorter.DESCRIPTION: SOLUTION ID: 40,419

SOLUTION: CAUSE: The short adapter harness which connects the main sorter harness to the main CB has an open.

SOLUTION: Replace the short adapter harness (p/n 074087060).

USAGE: 1

The upper tray paper size detect does not work.DESCRIPTION: SOLUTION ID: 38,480

SOLUTION: CAUSE: The no paper remaining sensor actuator is stuck.

SOLUTION: Reseat the actuator, and ensure that it moves freely.

USAGE: 1

Only 8.5x14 copies are light front-to-rear at about the 11-inch area.DESCRIPTION: SOLUTION ID: 38,184

SOLUTION: CAUSE: The optics cable is frayed, causing the optics to bounce at a certain area of the scan.

SOLUTION: Replace the optics cable (p/n 540061111).

USAGE: 1

Narrow lines running front to rear. Looks like scuff marks, no specific pattern.DESCRIPTION: SOLUTION ID: 37,548

SOLUTION: CAUSE: A nonstandard substrate that has a sticky substance on it is being fed through the copier. Thissubstance is sticking to the drum and damaging it.

SOLUTION: Do not to use this type of substrate.

USAGE: 1

ST206, intermittent operation of the paper conveyance motor (M201).DESCRIPTION: SOLUTION ID: 34,414

SOLUTION: CAUSE: There is a poor electrical connection to the sorter CB.

SOLUTION: Reseat all connectors on the sorter CB.

USAGE: 1

How is the zener diode installed? Is it directional?DESCRIPTION: SOLUTION ID: 33,618

SOLUTION: Polarity must be observed. The zener should have two different sized eyelets; one larger than the other. The USAGE: 1


3035

larger eyelet attaches to the ground strap at the front of the drum carriage. If the eyelets are the same size,attach the leg of the zener marked with the dot (on the zener body) to the ground strap.

ST205S, intermittent stapling.DESCRIPTION: SOLUTION ID: 33,343

SOLUTION: CAUSE: The staple cartridge is faulty.

SOLUTION: Replace the cartridge.

USAGE: 1

Originals do not exit completely from the RADF.DESCRIPTION: SOLUTION ID: 32,369

SOLUTION: CAUSE: The mounting plate for the gate solenoid (SD302) is malformed causing poor operation of the exitplate.

SOLUTION: Reform the mounting plate for SD302. Verify the gate solenoid adjustment.

USAGE: 1

What is the part number for the 6th mirror assembly?DESCRIPTION: SOLUTION ID: 31,911

SOLUTION: The 6th mirror assembly part number is (p/n 5400-6153). USAGE: 1

The paper is rippled after going through the fuser.DESCRIPTION: SOLUTION ID: 31,610

SOLUTION: CAUSE: The lower roller fuser bearings are not turning.

SOLUTION: Replace the bearings (p/n 460075060).

USAGE: 1

Intermittent lens drive.DESCRIPTION: SOLUTION ID: 31,263

SOLUTION: CAUSE: Dirty lens drive rails.

SOLUTION: Clean the rear lens slide rail, and clean and lubricate the front rail.

USAGE: 1

Is the 2028 upper fuser roller compatible with the model 3035?DESCRIPTION: SOLUTION ID: 31,174

SOLUTION: The 2028 upper fuser roller (p/n 576053010) is not compatible with the 3035 upper fuser roller (p/n540053010).

USAGE: 1

Part number for the exposure lamp.DESCRIPTION: SOLUTION ID: 30,774

SOLUTION: The part number is (25BA83010). USAGE: 1

Will not copy 11x15 computer paper out of RADF correctly.DESCRIPTION: SOLUTION ID: 24,565

SOLUTION: CAUSE: The method of CEL timing in the 25 mode needs to be changed.

SOLUTION: In the 25 mode set P70 to 2 for copy paper size CEL operation.

USAGE: 1

When the registration is set for one cassette, the others change.DESCRIPTION: SOLUTION ID: 22,477

SOLUTION: CAUSE: The data stored in memory is corrupted.

SOLUTION: In the 47 mode enter output code 92, press the start print button to perform a process initial set.This will set all data in memory to the factory initial values. Note: Ensure to reprogram the 25 mode settingsand 36 mode adjustments.

USAGE: 1

Will not select the correct paper size after performing a memory reset. This is a platen top copier.DESCRIPTION: SOLUTION ID: 22,339

SOLUTION: CAUSE: The APS adjustment needs to be performed.

SOLUTION: Perform the APS adjustment. With the platen top in the down position, use the 47 modeoutput code 99.

USAGE: 1

The memory is scrambled.DESCRIPTION: SOLUTION ID: 21,081

SOLUTION: CAUSE: The RADF to main CB harness has failed.

SOLUTION: Replace the harness (p/n 048090040).

USAGE: 1

Dark copies.DESCRIPTION: SOLUTION ID: 19,197


3035

SOLUTION: CAUSE: The fourth mirror came loose.

SOLUTION: Repair as necessary.

USAGE: 1

Streaks on drum.DESCRIPTION: SOLUTION ID: 18,537

SOLUTION: CAUSE: The CEL is dirty.

SOLUTION: Clean the CEL.

USAGE: 1

Dark copies. Can get good copies while in 36 mode only.DESCRIPTION: SOLUTION ID: 17,635

SOLUTION: CAUSE: The density selector was at the darkest setting.

SOLUTION: Ensure the density selector is at the normal setting.

USAGE: 1

The wall circuit breaker is tripping. The copier breaker does not trip.DESCRIPTION: SOLUTION ID: 16,825

SOLUTION: CAUSE: Other loads on the line are affecting the circuit.

SOLUTION: A dedicated 15Amp 115V AC circuit is recommended.

USAGE: 1

Can metric paper be duplexed?DESCRIPTION: SOLUTION ID: 16,724

SOLUTION: Metric paper can be duplexed. Order main CB EPROMs, (p/n 303512-20.6), and (p/n 303513-20.6). Note:These will convert the machine to metric only, inch size paper will not work.

USAGE: 1

What is the upper fuser roller life expectancy?DESCRIPTION: SOLUTION ID: 15,830

SOLUTION: The 3035 service manual states 200,000 copies. USAGE: 1

ST205S, cannot select the group mode.DESCRIPTION: SOLUTION ID: 13,877

SOLUTION: CAUSE: Poor connections on the sorter CB.

SOLUTION: Reseat all connectors on the sorter CB.

USAGE: 1

ST206, copying in progress only with the sorter connected.DESCRIPTION: SOLUTION ID: 13,832

SOLUTION: CAUSE: One of the sorter CB hardware dipswitches are ON.

SOLUTION: All hardware dipswitches on the sorter CB should be OFF for normal operation.

USAGE: 1

Cleaning web compatibity.DESCRIPTION: SOLUTION ID: 13,722

SOLUTION: 2028 thru 4145 are the same (PCUA 947378).4155 and 4255 (PCUA 947512).

USAGE: 1

ST206, J75 which changes to P71 with sorter removed.DESCRIPTION: SOLUTION ID: 9,939

SOLUTION: CAUSE: Staple position sensor is flagged or dirty.

SOLUTION: Clear paper at paper staple position sensor PS208, verify change of state at connector 8 pin 8for 5V DC when flagged, should be 0V DC when not flagged.

Note: To clear P71 when no sorter is attached change the 25 mode P03 to a 0 from a 5 with sorter.

USAGE: 1

DF305, incorrect registration only when copying mixed sized originals (8.5x11R and 8.5x14).DESCRIPTION: SOLUTION ID: 112,287

SOLUTION: CAUSE: DF305 EPROM requires an update. Mixed sized originals fed through the RADF may not alwaysalign to the scale plate, causing incorrect copy registration.

SOLUTION: Install DF305 EPROM level 14.2 (p/n DF30530-14.2). This new EPROM will increase theDF305 reverse speed to ensure that the lead edge of each original properly contacts the scale plate.Note: This DF305 firmware update is detailed in DF305 Technical bulletin #10 dated 4/1/94.

USAGE: 0

How to enable two counts on the total counter for 11x17 paper.DESCRIPTION: SOLUTION ID: 94,012

SOLUTION: To enable two counts on the total counter for 11x17 paper, perform the following:1. Enter the 25 mode, (turn the machine ON, while pressing the 2 and 5 keys).

USAGE: 0


3035

2. Using the magnification arrows, scroll to address 50, or press P-50-P.3. Press 1, then Start Print.4. Turn the copier OFF, then ON to exit the 25 mode.Note: The bypass tray may not count twice for 11x17 paper (due to APS settings).

DF203, noise and intermittent J62.DESCRIPTION: SOLUTION ID: 51,861

SOLUTION: CAUSE: The mounting posts that support M301 may become broken or cracked due to vibrations that occurduring shipment/transportation.

SOLUTION: All DF203 units within serial number range (567230101 to 567231783) must be inspected atthe next PM or service call. Refer to [[DF203 Technical Bulletin #6|IMAGE v:\bitmaps\djc156.bmpSCROLL]] for details regarding inspection/repair for this symptom. To repair the motor mounts, perform the following:1. Install the collars (p/n U091-9630) to repair the cracked mounting posts. The instructions for the repairkit are included in the kit. The 5 minute epoxy required to install the metal collars must be purchased locally.2. Install the rubber holder part on top of the motor. a. Clean the underside of the metal cover (cover/B) and the top of M301 with alcohol. b. Remove the small adhesive strip from the bottom of the rubber holder. c. Mount the rubber holder on the motor (adhesive strip from front to rear). d. Position the motor so that the drive belts are perpendicular to the drive gear. e. Remove the large adhesive strip on the top of the rubber holder. f. Carefully reinstall the metal cover (you get one chance).The metal cover and rubber holder will now support M301 and eliminate vibrations resulting in noise andmisfeeding.Note: If the motor to vibrates following the procedure outlined above, adjust the screw to the left in back ofthe motor on the pulley assembly (p/n 0480-1510). This screw may be paint-locked. This adjustment will tiltthe motor in or out. The pulley assembly or the pulley (p/n 048076510) may be worn causing the pulley tobe loose on the shaft.

USAGE: 0

How to check the bias voltage.DESCRIPTION: SOLUTION ID: 39,937

SOLUTION: To check the bias voltage, perform the following:1. Enter the 47 mode.2. Enter output code 10.3. Place the red meter lead on CN65 of main CB and black lead to frame ground. 4. The reading should be -150V DC. Adjust VR1 on the main CB as necessary.

USAGE: 0

F34 at power up. Unable to access 25, 36, 47 modes.DESCRIPTION: SOLUTION ID: 78,077

SOLUTION: CAUSE: A wire from the toner motor is pinched to ground.

SOLUTION: Repair or replace the wiring (p/n 540090260 or p/n 25BA90262 based on serial number cut-in540201787 or serial number cut-in 542224102) or toner motor (p/n 396080042 or p/n 197080011 based onserial number cut-in 540201787 or serial number cut-in 542224102). To reset fuser codes, perform thefollowing:1. Access the 25 mode (power OFF the machine, then while holding down the 2 and 5 keys, power themachine ON), P47 to 0 (a data value of 1, 4, 5, or 6 is usually displayed on the copy quantity indicator).2. Power the machine OFF/ON to exit the 25 mode.

USAGE: 0

Part number for the DALLAS chip or NOVRAM.DESCRIPTION: SOLUTION ID: 71,890

SOLUTION: NOVRAM (p/n DALLAS). USAGE: 0

DF305, photosensor adjustment procedure.DESCRIPTION: SOLUTION ID: 71,743

SOLUTION: To adjust PS302 and PS303, perform the following:1. Entrance sensor (PS302) adjustment procedure: a. Clean the sensor and reflector. b. Reinstall RADF covers. c. Remove the cover to the RADF CB. d. Rotate VR1, on the RADF CB, fully counterclockwise. e. Rotate VR1 clockwise until LED 1 lights. f. Rotate VR1 clockwise 1 graduations past the point where LED 1 lights.Note: An alternate method is to adjust VR1 to 0.3V DC using CN906-7 and TP3 (ground).

2. Exit sensor (PS303) adjustment procedure: a. Clean the sensor and reflector. b. Reinstall RADF covers. c. Remove the cover to the RADF CB. d. Rotate VR2, on the RADF CB, fully counterclockwise.

USAGE: 0


3035

e. Rotate VR2 clockwise until LED 2 lights. f. Rotate VR2 clockwise 2 graduations past the point where LED 2 lights.Note: An alternate method is to adjust VR2 to 0.3V DC using CN906-8 and TP3 (ground).

DF305, J62 when copying originals from the platen glass. Both the RADF conveyance belt and thefeed tires activate when START/PRINT is pressed.


SOLUTION: CAUSE: The remainder detect actuator (p/n 048040110) is installed in the reversed direction.

SOLUTION: To check the actuator (PS301) for proper installation, perform the following:1. Power the copier OFF.2. Enter the 47 mode (power the copier ON, while holding the 4 and 7 keys), input code 62.3. The magnification indicator, on the operation panel should display HI (HIGH) with no paper loaded in theoriginal tray, and LO (LOW) with paper loaded.4. If the magnification indicator displays LO with no paper loaded in the original tray and HI with paper,the PS301 actuator is installed incorrectly.5. Remove the PS310 actuator, rotating its orientation 180 degrees and reinstall it. When properly installed,PS301 should not be flagged when the original tray is empty. 6. The illustration on page 6 of the DF305 Parts Catalog, Third Edition, contained in the DF305 ServiceManual (2/93), has the actuator shown in reversed orientation.7. Repeat steps 1 through 4 to ensure that the magnification indicator displays HI with no paper loaded in theoriginal tray and LO with paper loaded.

USAGE: 0

Lead edge skew.DESCRIPTION: SOLUTION ID: 60,950

SOLUTION: CAUSE: Distortion.

SOLUTION: Adjustment to remove distortion:1. Remove the platen cover, scale plate, platen holder, and platen glass.2. Remove the magnification light shade cover.3. Turn the screw for adjusting distortion on the 2nd V-mirror (clockwise rotation - raises the V-mirror;counterclockwise rotation - lowers the V-mirror). Repeat until the distortion measurement is withinstandards.4. Make a copy and measure the amount of distortion (difference between opposite diagonal lines).5. After performing the adjustment, tighten the screw and paint lock it in place.Note: Follow-up instructions in 2028/3035/4045 Service Manual (9/95, Fourth Edition), page 6-9.

USAGE: 0

The second copy of a copy run stops just before the 2nd paper feed rollers. No jam code is indicated.DESCRIPTION: SOLUTION ID: 60,277

SOLUTION: CAUSE: The center optics photosensor (PS6) has failed.

SOLUTION: To check PS6, perform the following:1. Remove the platen glass.2. Place the exposure unit to the PS6 position.3. Access the 47 mode (power the machine OFF, hold down the 4 and 7 keys, power the machine ON).4. Press the 3 and 5 keys (input code 35).5. Check the magnification display, it displays a HI or LO.6. Move the exposure unit.7. The magnification display should change state.8. If no change of state occurs, replace PS6 (p/n 552085510).9. Power the machine OFF/ON to exit the 47 mode.

USAGE: 0

ECM is ON, ENTER PASSWORD is not displayed.DESCRIPTION: SOLUTION ID: 54,218

SOLUTION: CAUSE: The auto reset timer did not trigger because:1. The ADU or sorter was left ON by the previous user.2. The last user did not make a copy after entering their passcode.3. The auto reset is set for 10 minutes.

SOLUTION: In the 25 mode, verify that P48 is set to 1 (2 minute reset), then make a copy and wait 2minutes.

Note: Hold down the P button, then press the STOP/CLEAR button after copying. This will cause theENTER PASSWORD message to display immediately.

USAGE: 0

The fuser cleaning web is rolled backwards.DESCRIPTION: SOLUTION ID: 34,082

SOLUTION: The new webs are rolled this way which provides more contact to the upper roller for improved cleaning. USAGE: 0

Konica recommended copy control vendors.DESCRIPTION: SOLUTION ID: 29,267


3035

SOLUTION: Contact the manufacturer of the coin-op device in question.

Konica has approved devices from the following manufacturers:1. Schlumberger Danyl* 1509 Glen Avenue Moorestown, NJ 08057 (800) 327-0183 or (609) 234-8000

2. Equitrac* 836 Ponce de Leon Boulevard Coral Gables, FL 33134 (305) 442-2060


USAGE: 0


3035

Documents

factory initial

konica business

ac driver

long copy

trademark

approximately

intermediate

laser printed