MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

[Nighthawk]

The initial problem was ghost jams before the timing rollers. When checking jam history and sensors with sim 30-2. It showed the problem was sensor CPFD1 (Paper feed unit exit sensor) I replaced that sensor, put paper feed unit back in, then showed side door open (another sensor in paper feed unit). Replaced that sensor which tested NG and reinstalled PF unit. Machine then booted up and went ready as normal. Hit the print button and jammed and showed F2-40 code (overtoned developer). Installed new developer and recalibrated. F2-40 returned again. Installed new Developer unit and developer, recalibrated. Still no good! Next replaced PCU board, same result. Today I replaced the Drum, Maintenance kit (main charger, drum blade etc.) thoroughly cleaned everything and once again replaced and calibrated developer. Machine boots up and goes ready. Go to make a copy and paper jam! Sensor CPFD1 again!! It tests bad again. I replace it and it tests good. Boot up machine go to make a copy and works fine for 20 copies then F2-40 is back again. I can run sim7-1(Disable DV), run about 50 skyshots and bring the toner back in range. I can then run another 20 or so, then it's F2-40. This machine has 125K on it. This problem is costing me a lot of money since my customer has a full serve contract with me. It's been years since I've been stumped like this. Any help appreciated. Im tired of dissappointing my customer and losing sleep over this machine (I have a back up in place at this time but that's not what they're paying for).

[Akitu]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

The initial problem was ghost jams before the timing rollers. When checking jam history and sensors with sim 30-2. It showed the problem was sensor CPFD1 (Paper feed unit exit sensor) I replaced that sensor, put paper feed unit back in, then showed side door open (another sensor in paper feed unit). Replaced that sensor which tested NG and reinstalled PF unit. Machine then booted up and went ready as normal. Hit the print button and jammed and showed F2-40 code (overtoned developer). Installed new developer and recalibrated. F2-40 returned again. Installed new Developer unit and developer, recalibrated. Still no good! Next replaced PCU board, same result. Today I replaced the Drum, Maintenance kit (main charger, drum blade etc.) thoroughly cleaned everything and once again replaced and calibrated developer. Machine boots up and goes ready. Go to make a copy and paper jam! Sensor CPFD1 again!! It tests bad again. I replace it and it tests good. Boot up machine go to make a copy and works fine for 20 copies then F2-40 is back again. I can run sim7-1(Disable DV), run about 50 skyshots and bring the toner back in range. I can then run another 20 or so, then it's F2-40. This machine has 125K on it. This problem is costing me a lot of money since my customer has a full serve contract with me. It's been years since I've been stumped like this. Any help appreciated. Im tired of dissappointing my customer and losing sleep over this machine (I have a back up in place at this time but that's not what they're paying for).

I would haphazard a guess and say your DV unit may be shorting out something. I would have sooner replaced the dev unit than a board in any scenario. Check your voltages and make sure there's no problems with power to the machine.

[Nighthawk]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

Developer unit was replaced before board and stated in original post. But thanks for the input. Any help or suggestions are appreciated.

[Akitu]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

Developer unit was replaced before board and stated in original post. But thanks for the input. Any help or suggestions are appreciated.

My apologies, overlooked that section of the post evidently. I still stand by my statement of checking your voltages to the copier though.

[Nighthawk]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

Will check and see

[mojorolla]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

Remove the toner and run SIM 25-1. If value TCD_K is less than 26, the F2-40 code will appear. As suggested above, ADJ 8 to check the HV outputs. There is also a new DV cover for machines made after July 2010.

[Nighthawk]

Re: MX-M453N with F2-40 and blown PF unit sensors. Sharp Genius needed!!

Well it seems the problem was a bound up toner feed clutch. Whenever drive unit 2 was in operationit was continuously feeding toner. After freeing up bound clutch machine seems to be working properly. Ran hundreds of copies with no issues. Thanks for the help and suggestions. Hopefully this issue is resolved or if it acts up I'll replace that clutch.