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FrameMaker Ver.5.5(PC) 8020/8031
02.08.19




CONTENTS
GENERAL
1. SPECIFICATION ............................................................................................. G-1
2. PRECAUTIONS FOR INSTALLATION ............................................................ G-4
2-1. Installation Site ........................................................................................ G-4
2-2. Power Source .......................................................................................... G-4
2-3. Grounding ................................................................................................ G-4
3. PRECAUTIONS FOR USE .............................................................................. G-5
3-1. To ensure that the copier is used in an optimum condition ..................... G-5
3-2. Operating Environment ............................................................................ G-5
3-3. Power Requirements ............................................................................... G-5
3-4. Note ......................................................................................................... G-5
4. HANDLING OF CONSUMABLES .................................................................... G-6
5. OTHER PRECAUTIONS ................................................................................. G-7
6. LED RADIATION SAFETY .............................................................................. G-7
7. SYSTEM OPTIONS ......................................................................................... G-8


MAINTENANCE
1. MAINTENANCE SCHEDULE .......................................................................... E-1
1-1. Guideline for Life Specifications Values by Unit ...................................... E-3
2. DISASSEMBLY/REASSEMBLY AND CLEANING .......................................... E-5
(1) Cleaning of the Paper Take-Up Roll ................................................ E-5
(2) Replacing of the Paper Take-Up Roll .............................................. E-5
(3) Cleaning of the Paper Separator Roll .............................................. E-5
(4) Replacing of the Separator Roll Assy .............................................. E-6
(5) Cleaning of the Synchronizing Rollers ............................................. E-7
(6) Cleaning of the Paper Dust Remover .............................................. E-7
(7) Replacing of the Paper Dust Remover ............................................ E-8
(8) Cleaning of the Transport Roller ...................................................... E-8
(9) Cleaning of the 2nd Image Transfer Entrance Upper Guide ........... E-8
(10) Cleaning of the Scanner Rails ......................................................... E-9
(11) Cleaning of the Mirrors (1st/2nd/3rd) ............................................... E-10
(12) Cleaning of the Lens ........................................................................ E-11
(13) Cleaning of the Original Glass ......................................................... E-11
(14) Cleaning of the CCD Sensor ........................................................... E-12
(15) Replacing the Waste Toner Bottle ................................................... E-13
(16) Cleaning of the Area around the Waste Toner Collecting Port ........ E-14
(17) Replacing Ozone Filter .................................................................... E-15
(18) Cleaning of the Comb Electrode ...................................................... E-15
(19) Cleaning LPH Assy .......................................................................... E-16
(20) Cleaning of the Fusing Entrance Guide Plate ................................. E-17
(21) Replacement of the Deodorant Filter ............................................... E-17
3. Replacing the Units .......................................................................................... E-18
(1) Replacing the Image Transfer Roller Unit ....................................... E-18
(2) Replacing the Image Transfer Belt Unit ........................................... E-19
(3) Replacing the Imaging Unit (C, M, Y, Bk) ........................................ E-22



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(4) Replacing the Fusing Unit ............................................................... E-26


DIS/REASSEMBLY, ADJUSTMENT
1. SERVICE INSTRUCTIONS ............................................................................. D-1
1-1. IDENTIFICATION OF FUSES ................................................................. D-1
1-2. PARTS WHICH MUST NOT BE TOUCHED ........................................... D-2
(1) Red painted Screws ........................................................................ D-2
(2) Variable Resistors on Board ............................................................ D-2
2. DISASSEMBLY/REASSEMBLY ...................................................................... D-3
2-1. DOORS, COVERS, AND EXTERIOR PARTS:
IDENTIFICATION AND REMOVAL PROCEDURES ............................... D-3
2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL
COMPONENTS ....................................................................................... D-5
(1) Removal of the CCD Unit ................................................................ D-8
(2) Removal of the Image Processing Board and Image Processing
Interface Board ................................................................................ D-10
(3) Removal of the Image Control Board .............................................. D-12
(4) Removal of the High Voltage Unit (PC Drum CH.),
High Voltage Unit (Image Transfer, Neutralizing),
High Voltage Unit (Developing Bias),
and Paper Size Detecting Board ..................................................... D-13
(5) Removal of DC Power Supply 1 ...................................................... D-15
2-3. Removal of Units ..................................................................................... D-16
(1) Removal of the Toner Hopper Unit .................................................. D-16
(2) Removal of the LPH Unit ................................................................. D-17
2-4. Disassembly of the IR Unit ...................................................................... D-19
(1) Removal of the Scanner Motor ........................................................ D-19
(2) Remove of the Scanner Assy .......................................................... D-20
(3) Removal of the Scanner Drive Cables ............................................ D-21
(4) Winding of the Scanner Drive Cables .............................................. D-23
2-5. CLEANING AND DISASSEMBLY OF THE ENGINE PARTS ................. D-28
(1) Cleaning of the Transfer Belt Unit ................................................... D-28
(2) Removal of the Imaging Unit Motor C/M/Y/Bk ................................. D-29
(3) Removal of the Main Motor ............................................................. D-30
(4) Removal of the Fusing Drive Motor ................................................. D-31
(5) Removal of the Fusing Pressure/Retraction Motor .......................... D-31
(6) Removal of the 1st Image Transfer Pressure/Retraction Motor ...... D-33
(7) Removal of Toner Replenishing Motor C/Bk ................................... D-33
(8) Removal of Toner Replenishing Motor Y/M ..................................... D-34
(9) Removal of the 2nd Image Transfer Pressure/Retraction Motor ..... D-34
(10) Removal of the Transport Roller Motor ........................................... D-35
(11) Removal of AIDC/Registration Sensor 1/2 ...................................... D-37
(12) Removal of the LPH Assy ................................................................ D-38
(13) Removal of ATDC Sensor Y/M/C .................................................... D-40
(14) Removal of the LED Drive Board .................................................... D-41
3. ADJUSTMENTS .............................................................................................. D-42
3-1. ADJUSTMENT JIGS AND TOOLS USED (SPECIAL TOOLS) ............... D-42



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3-2. OTHER TOOLS USED (ACCESSORY PARTS OF MACHINE) ............. D-42
3-3. MECHANICAL ADJUSTMENT ................................................................ D-43
(1) Adjustment of the Scanner Motor Timing Belt ................................. D-43
(2) Focus Positioning of the Scanner and 2nd/3rd Mirrors Carriage ..... D-44
(3) Scanner Position Adjustment .......................................................... D-44
3-4. ELECTRICAL/IMAGE ADJUSTMENT ..................................................... D-45
(1) Accessing the Tech. Rep. Mode ...................................................... D-45
(2) Producing a Test Print ..................................................................... D-45
(3) Top Margin ...................................................................................... D-46
(4) Left Margin ....................................................................................... D-48
(5) Dup. Left Margin .............................................................................. D-49
(6) Zoom for FD .................................................................................... D-50
(7) Color Shift Correction ...................................................................... D-51
(8) Leading Edge Tilt Adjustment .......................................................... D-53
(9) LPH Chip Adjust .............................................................................. D-54
(10) Gradation Adjust .............................................................................. D-55
(11) PRT Max Density ............................................................................. D-56
(12) PRT Highlight .................................................................................. D-57
(13) Background Voltage Margin ............................................................ D-58
(14) ATDC Level Setting ......................................................................... D-59
(15) AE Adjust ......................................................................................... D-60
(16) 2nd Transfer Adjust ......................................................................... D-61
(17) Fuser Temp. .................................................................................... D-62
(18) Fuser Speed .................................................................................... D-63
(19) Touch Panel Adj. ............................................................................. D-64
(20) Left Image ........................................................................................ D-65
(21) Top Image ....................................................................................... D-66
(22) CD-Mag. .......................................................................................... D-67
(23) FD-Mag. ........................................................................................... D-68
(24) Org. Detect Sensor .......................................................................... D-69
4. OTHER ADJUSTMENTS ................................................................................. D-70
4-1. INSTALLATION OF THE MECHANICAL COUNTER (OPTION) ............ D-70
4-2. HOW TO INSTALL THE KEY COUNTER (OPTION) .............................. D-71
4-3. MOUNTING OF THE ORIGINAL SIZE DETECTING SENSORS
(OPTION) ................................................................................................. D-73
4-4. FLASH MEMORY .................................................................................... D-74
4-5. REMOUNTING RAM IC (IC202) .............................................................. D-76


SWITCHES ON PWBs, TECH. REP. SETTINGS
1. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ........................ S-1
1-1. PWB Location .......................................................................................... S-1
1-2. PWB-S1 (Tech. Rep. Setting Switches Board) ........................................ S-1
(1) Initialize Procedure .......................................................................... S-2
(2) Memory Clear Procedure ................................................................ S-2
(3) Data/Conditions Cleared by Reset Switches/Pins ........................... S-3
2. UTILITY MODE ................................................................................................ S-4
2-1. Utility Mode Function Setting Procedure ................................................. S-4



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2-2. Utility Mode Function Tree ....................................................................... S-5
(1) Administrator Mode Function Tree .................................................. S-6
2-3. Setting in the Utility Mode ........................................................................ S-7
3. TECH. REP. MODE ......................................................................................... S-16
3-1. Tech. Rep. Mode Function Setting Procedure ......................................... S-16
3-2. Tech. Rep. Mode Function Tree .............................................................. S-17
3-3. Setting in the Tech. Rep. Mode ............................................................... S-20
4. SECURITY MODE ........................................................................................... S-42
4-1. Security Mode Function Setting Procedure ............................................. S-42
4-2. Security Mode Function Tree ................................................................... S-42
4-3. Settings in the Security Mode .................................................................. S-43


TROUBLESHOOTING
1. INTRODUCTION ............................................................................................. T-1
1-1. Checking the electrical components ........................................................ T-1
(1) Sensor ............................................................................................. T-1
(2) Switch ............................................................................................. T-1
(3) Solenoid ........................................................................................... T-2
(4) Clutch ............................................................................................. T-2
(5) Motor ............................................................................................. T-3
1-2. I/O CHECK .............................................................................................. T-4
(1) Check Procedure ............................................................................. T-4
(2) I/O Check List .................................................................................. T-5
1-3. System Control Block Diagram ................................................................ T-11
2. PAPER MISFEED ............................................................................................ T-12
2-1. Initial Check Items ................................................................................... T-12
2-2. Misfeed Display ....................................................................................... T-13
2-3. Misfeed Detecting Sensor Layout ............................................................ T-14
2-4. Misfeed Detection Timing/Troubleshooting Procedures .......................... T-16
(1) 1st Drawer Paper Take-Up Misfeed ................................................ T-16
(2) 2nd Drawer Paper Take-Up Misfeed ............................................... T-17
(3) 3rd Drawer Paper Take-Up Misfeed (PF-232) ................................. T-18
(4) LCT Paper Take-Up Misfeed (DB-432) ........................................... T-19
(5) 4th Drawer Paper Take-Up Misfeed (PF-232) ................................. T-20
(6) LCT Lift 2 to 1 paper transport Misfeed (DB-432) ........................... T-21
(7) Manual Bypass Take-Up Misfeed .................................................... T-22
(8) Vertical Transport Misfeed ............................................................... T-23
(9) Duplex Paper Take-Up Misfeed (AD-231) ....................................... T-26
(10) Duplex Paper Transport Misfeed (AD-231) ..................................... T-27
(11) 2nd Image Transfer Misfeed ............................................................ T-28
(12) Fusing/Exit Misfeed ......................................................................... T-29
3. MALFUNCTIONS ............................................................................................ T-30
3-1. Warning Detection Timing and Troubleshooting Procedure .................... T-31
(1) P-5: AIDC Sensor (Front) failure ..................................................... T-31
(2) P-28 AIDC Sensor (Back) failure ..................................................... T-31
(3) P-6: Cyan IU failure ......................................................................... T-32
(4) P-7: Magenta IU failure .................................................................... T-32



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(5) P-8: Yellow IU failure ....................................................................... T-32
(6) P-9: Black IU failure ......................................................................... T-32
(7) P-21: Color Shift Test Pattern failure ............................................... T-33
(8) P-22: Color Shift Adjust failure ........................................................ T-33
(9) P-23: ATVC(C) failure ...................................................................... T-34
(10) P-24: ATVC(M) failure ..................................................................... T-34
(11) P-25: ATVC(Y) failure ...................................................................... T-34
(12) P-26: ATVC(Bk) failure .................................................................... T-34
(13) P-27: ATVC(2nd) failure .................................................................. T-34
3-2. Malfunction Detection Timing and Troubleshooting Procedure ............... T-35
(1) C0000: Main Motor's failure to turn ................................................. T-35
(2) C0001: Main Motor Turning at abnormal timing .............................. T-35
(3) C0010: Imaging Unit Motor C's failure to turn ................................. T-36
(4) C0011: Imaging Unit C turning at abnormal timing .......................... T-36
(5) C0012: Imaging Unit Motor M's failure to turn ................................. T-36
(6) C0013: Imaging Unit M turning at abnormal timing ......................... T-36
(7) C0014: Imaging Unit Motor Y's failure to turn .................................. T-36
(8) C0015: Imaging Unit Y turning at abnormal timing .......................... T-36
(9) C0016: Imaging Unit Motor Bk's failure to turn ................................ T-36
(10) C0017: Imaging Unit Bk turning at abnormal timing ........................ T-36
(11) C0040: Suction Fan Motor's failure to turn ...................................... T-38
(12) C0043: Cooling Fan Motor 1's failure to turn ................................... T-38
(13) C0044: Cooling Fan Motor 3's failure to turn ................................... T-38
(14) C0045: Cooling Fan Motor 4/5's failure to turn ................................ T-38
(15) C0046: Fusing Cooling Fan Motor's failure to turn .......................... T-38
(16) C004C: Ozone Ventilation Fan Motor's failure to turn ..................... T-38
(17) C004E: Power Supply Cooling Fan Motor's failure to turn .............. T-38
(18) C004F: Cooling Fan Motor 2's failure to turn ................................... T-38
(19) C0060: Fusing Drive Motor's failure to turn ..................................... T-42
(20) C0061: Fusing Drive Motor turning at abnormal timing ................... T-42
(21) C0094: 2nd Image Transfer Roller pressure/retraction failure ........ T-43
(22) C0096: Image Transfer Belt pressure/retraction failure ................... T-44
(23) C0098: Fusing Pressure Roller pressure/retraction failure .............. T-45
(24) C0200: Cyan PC Drum Charge Corona malfunction ....................... T-46
(25) C0202: Magenta PC Drum Charge Corona malfunction ................. T-46
(26) C0204: Yellow PC Drum Charge Corona malfunction ..................... T-46
(27) C0206: Black PC Drum Charge Corona malfunction ...................... T-46
(28) C0208: PC Drum Charge Corona malfunction ................................ T-46
(29) C0400: Exposure Lamp's failure to turn ON .................................... T-47
(30) C0410: Exposure Lamp turning ON at abnormal timing .................. T-47
(31) C0500: Heating Roller warm-up failure ........................................... T-48
(32) C0501: Fusing Pressure Roller warm-up failure .............................. T-48
(33) C0510: Heating Roller abnormally low temperature ........................ T-48
(34) C0511: Fusing Pressure Roller abnormally low temperature .......... T-48
(35) C0520: Heating Roller abnormally high temperature ...................... T-48
(36) C0521: Fusing Pressure Roller abnormally high temperature ......... T-48
(37) C0650: Scanner Home Sensor malfunction .................................... T-50



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(38) C0660: Scanner overrun failure ....................................................... T-50
(39) C0F30: Abnormally low toner density detected Cyan
ATDC Sensor .................................................................................. T-51
(40) C0F31: Abnormally high toner density detected Cyan
ATDC Sensor .................................................................................. T-51
(41) C0F32: Abnormally low toner density detected Magenta
ATDC Sensor .................................................................................. T-51
(42) C0F33: Abnormally high toner density detected Magenta
ATDC Sensor .................................................................................. T-51
(43) C0F34: Abnormally low toner density detected Yellow
ATDC Sensor .................................................................................. T-51
(44) C0F35: Abnormally high toner density detected Yellow
ATDC Sensor .................................................................................. T-51
(45) C0F36: Abnormally low toner density detected Cyan
ATDC Sensor .................................................................................. T-53
(46) C0F37: Abnormally high toner density detected Cyan
ATDC Sensor .................................................................................. T-53
(47) C0F3A: Cyan ATDC Sensor adjustment failure .............................. T-54
(48) C0F3B: Magenta ATDC Sensor adjustment failure ......................... T-54
(49) C0F3C: Yellow ATDC Sensor adjustment failure ............................ T-54
(50) C0F3D: Black ATDC Sensor adjustment failure .............................. T-54
(51) C1200: Memory mounting failure .................................................... T-56
(52) C1203: Memory mounting failure .................................................... T-57
(53) C1204: Memory mounting failure .................................................... T-57
(54) C1220: Image Input Time Out ......................................................... T-58
(55) C1229: Image Output Time Out ...................................................... T-59
(56) C1240: JBIG Error ........................................................................... T-60
(57) C1241: JBIG Error ........................................................................... T-60
(58) C1242: JBIG Error ........................................................................... T-60
(59) C1243: JBIG Error ........................................................................... T-60
(60) C1261: Memory Board Time Out ..................................................... T-61
(61) C1265: Memory Board Time Out ..................................................... T-61
(62) C1279: Memory Board Time Out ..................................................... T-61
(63) C1290: Compress/Expand Time Out ............................................... T-61
(64) C12C0: Hard Disk Error ................................................................... T-62
(65) C12CB: Hard Disk Error .................................................................. T-62
(66) C12CC: Hard Disk Error .................................................................. T-62
(67) C12C1: Hard Disk Error ................................................................... T-63
(68) C12C2: Hard Disk Error ................................................................... T-63
(69) C12C3: Hard Disk Error ................................................................... T-63
(70) C12C4: Hard Disk Error ................................................................... T-63
(71) C12C5: Hard Disk Error ................................................................... T-63
(72) C12C6: Hard Disk Error ................................................................... T-63
(73) C12C7: Hard Disk Error ................................................................... T-63
(74) C12C8: Hard Disk Error ................................................................... T-63
(75) C12C9: Hard Disk Error ................................................................... T-63
(76) C12CA: Hard Disk Error .................................................................. T-63



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(77)
C12CF: Hard Disk Error .................................................................. T-63
(78)
C13C8: New Transfer Cleaner Unit resetting failure ....................... T-64
(79)
C13CA: New Fusing Unit resetting failure ....................................... T-64
(80)
C13D1: Cyan IU EEPROM access error ......................................... T-65
(81)
C13D2: Magenta IU EEPROM access error ................................... T-65
(82)
C13D3: Yellow IU EEPROM access error ....................................... T-65
(83)
C13D4: Black IU EEPROM access error ......................................... T-65
(84)
C13D5: Cyan LPH correction data download failure ....................... T-66
(85)
C13D6: Magenta LPH correction data download failure ................. T-66
(86)
C13D7: Yellow LPH correction data download failure ..................... T-66
(87)
C13D8: Black LPH correction data download failure ....................... T-66
(88)
C3310: CCD clamp/gain adjustment failure .................................... T-67
(89)
C3700: IR Power Supply Cooling Fan Motor turning at
abnormal timing ............................................................................... T-68
(90) C3710: IR Drive Board Cooling Fan Motor turning at
abnormal timing ............................................................................... T-68
(91) C3FFF: ROM contents fault detected upon start ............................. T-68
3-3. Power Supply-Related Malfunctions ........................................................ T-69
(1) Copier is not energized at all. .......................................................... T-69
(2) Only the Power Supply Cooling Fan rotates. ................................... T-70
(3) Control panel indicators do not light. ............................................... T-70
4. IMAGE QUALITY PROBLEMS ........................................................................ T-71
4-1. Descriptions of the "State Confirm" Function of
Tech. Rep. Mode Concerning Image Quality Problems .......................... T-71
(1) Table # ............................................................................................. T-71
(2) Level History 1 ................................................................................. T-72
(3) Level History 2 ................................................................................. T-72
4-2. Troubleshooting Image Quality Problems ................................................ T-73
4-3. Initial Check Items ................................................................................... T-73
4-4. Troubleshooting Procedure by a Particular Image Quality Problem ........ T-75
(1) IR System: white lines in FD, white bands in FD, colored lines
in FD, and colored bands in FD ....................................................... T-75
(2) IR System: white lines in CD, white bands in CD, colored lines
in CD, and colored bands in CD ...................................................... T-76
(3) IR System: color spots ..................................................................... T-77
(4) IR System: fog ................................................................................. T-78
(5) IR System: blurred image, blotchy image ........................................ T-79
(6) IR System: incorrect color image registration, sync shift
(lines in CD) ..................................................................................... T-80
(7) IR System: moire ............................................................................. T-81
(8) IR System: skewed image ............................................................... T-82
(9) IR System: distorted image ............................................................. T-83
(10) IR System: low image density, rough image ................................... T-84
(11) IR System: defective ACS ............................................................... T-85
(12) IR System: blank copy, black copy .................................................. T-86
(13) IR System: abnormal image ............................................................ T-87




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(14) Printer Monocolor: white lines in FD, white bands in FD,
colored lines in FD, colored bands in FD, white lines in CD,
white bands in CD, colored lines in CD, colored bands in CD ......... T-88
(15) Printer Monocolor: uneven density in FD ........................................ T-89
(16) Printer Monocolor: uneven density in CD ........................................ T-90
(17) Printer Monocolor: low image density .............................................. T-91
(18) Printer Monocolor: gradation reproduction failure ........................... T-93
(19) Printer Monocolor: foggy background .............................................. T-95
(20) Printer Monocolor: void areas, white spots ...................................... T-97
(21) Printer Monocolor: colored spots ..................................................... T-98
(22) Printer Monocolor: blurred image .................................................... T-99
(23) Printer Monocolor: blank copy, black copy ...................................... T-100
(24) Printer Monocolor: 0.5-mm-pitch uneven image .............................. T-101
(25) Printer Monocolor: 2-mm-pitch uneven image ................................. T-102
(26) Printer Monocolor: 94-mm-pitch uneven image ............................... T-103
(27) Printer 4-Color: white lines in FD, white bands in FD,
colored lines in FD, and colored bands in FD .................................. T-104
(28) Printer 4-Color: white lines in CD, white bands in CD,
colored lines in CD, and colored bands in CD ................................. T-105
(29) Printer 4-Color: uneven density in FD ............................................. T-106
(30) Printer 4-Color: uneven density in CD ............................................. T-107
(31) Printer 4-Color: low image density ................................................... T-108
(32) Printer 4-Color: poor color reproduction .......................................... T-110
(33) Printer 4-Color: incorrect color image registration ........................... T-112
(34) Printer 4-Color: void areas, white spots ........................................... T-114
(35) Printer 4-Color: colored spots .......................................................... T-115
(36) Printer 4-Color: poor fusing performance, offset ............................. T-116
(37) Printer 4-Color: brush effect, blurred image .................................... T-117
(38) Printer 4-Color: back marking .......................................................... T-118
(39) Printer 4-Color: 204-mm-pitch uneven image .................................. T-119
(40) Printer 4-Color: 94-mm-pitch uneven image .................................... T-120




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