Konica Minolta bizhub C360 Series User manual

SERVICE MANUAL
2012.022012.02
Ver. 2.1Ver. 2.1
FIELD SERVICE
This service manual is designed for machine with
firmware card ver. 88 and onward.
This service manual is designed for machine with
firmware card ver. 88 and onward.

i
FIELD SERVICE TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS..............................................................S-1
IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMSFOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS.................................................................................................S-2
WARNING INDICATIONSON THE MACHINE ........................................................S-18
MEASURESTO TAKE IN CASE OF AN ACCIDENT ....................................................S-20
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub C360/C280/C220 Main body
OUTLINE ........................................................................................................................ 1
MAINTENANCE............................................................................................................ 15
ADJUSTMENT/SETTING ........................................................................................... 167
TROUBLESHOOTING ................................................................................................ 537
APPENDIX.................................................................................................................. 761
i-Option LK-101 v2/102/103 v2/105
OUTLINE ........................................................................................................................ 1
ADJUSTMENT/SETTING ............................................................................................... 3
DF-617/SP-501
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 5
ADJUSTMENT/SETTING ............................................................................................. 37
PC-107/PC-207
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 19
PC-408
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3
ADJUSTMENT/SETTING ............................................................................................. 29
JS-505
OUTLINE ........................................................................................................................ 1
MAINTENANCE.............................................................................................................. 3

ii
FS-527
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 5
PK-517
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT/SETTING............................................................................................... 7
SD-509
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
ADJUSTMENT/SETTING............................................................................................. 21
JS-603
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3
FS-529
OUTLINE ........................................................................................................................ 1
MAINTENANCE ............................................................................................................. 3

SAFETY AND IMPORTANT WARNING ITEMS
S-1
Read carefully the safety and important warning itemsdescribed below to understand them
before doing service work.
Because of possible hazardsto an inexperienced person servicing thisproduct as well as
the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
(hereafter called the KMBT) strongly recommendsthat all servicing be performed only by
KMBT-trained service technicians.
Changesmay have been made to thisproduct to improve itsperformance after thisService
Manual was printed. Accordingly, KMBT doesnot warrant, either explicitly or implicitly, that
the information contained in thisservice manual iscomplete and accurate.
The user of thisservice manual must assume all risksof personal injury and/or damage to
the product while servicing the product for which thisservice manual isintended.
Therefore, thisservice manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep thisservice manual also for future service.
In thisService Manual, each of three expressions“ DANGER”, “ WARNING”, and
“CAUTION”isdefined as followstogether with asymbol mark to be used in alimited
meaning.
When servicing the product, the relevant works(disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
Symbolsused for safety and important warning itemsare defined as follows:
SAFETY AND IMPORTANT WARNING ITEMS
IMPORTANT NOTICE
DESCRIPTION ITEMSFOR DANGER,
WARNING AND CAUTION
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium
trouble, and property damage
:Precaution when servicing the
product. General
precaution
Electric hazard High temperature
:Prohibition when servicing the
product. General
prohibition
Do not touch
with wet hand
Do not
disassemble
:Direction when servicing the
product. General
instruction
UnplugGround/Earth

SAFETY AND IMPORTANT WARNING ITEMS
S-2
[1] MODIFICATIONSNOT AUTHORIZED BY KONICA MINOLTA
BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand productsare renowned for their high reliability. Thisreliability is
achieved through high-quality design and asolid service network.
Product design isahighly complicated and delicate process where numerous mechanical,
physical, and electrical aspectshave to be taken into consideration, with the aim of arriving
at proper tolerancesand safety factors. For thisreason, unauthorized modificationsinvolve
ahigh risk of degradation in performance and safety. Such modificationsare therefore
strictly prohibited. the pointslisted below are not exhaustive, but they illustrate the reason-
ing behind thispolicy.
SAFETY WARNINGS
Prohibited Actions
DANGER
•Using any cablesor power cord not specified by KMBT.
•Using any fuse or thermostat not specified by KMBT.
Safety will not be assured, leading to arisk of fire and
injury.
•Disabling fuse functionsor bridging fuse terminalswith
wire, metal clips, solder or similar object.
•Disabling relay functions(such as wedging paper between
relay contacts).
•Disabling safety functions(interlocks, safety circuits, etc.).
Safety will not be assured, leading to arisk of fire and
injury.
•Making any modification to the product unless instructed
by KMBT.
•Using partsnot specified by KMBT.

SAFETY AND IMPORTANT WARNING ITEMS
S-3
[2] POWER PLUG SELECTION
In some countriesor areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it isobligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
•Use power supply cord set which meetsthe following
criteria:
- provided with aplug having configuration intended for
the connection to wall outlet appropriate for the prod-
uct’srated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
- the cord set meetsregulatory requirementsfor the area.
Use of inadequate cord set leadsto fire or electric shock.
•Attach power plug which meetsthe following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product’srated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meetsregulatory requirementsfor the area.
Use of inadequate cord set leadsto the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
• Conductorsin the power cable must be connected to ter-
minalsof the plug according to the following order:
•Black or Brown:L (line)
•White or Light Blue:N (neutral)
•Green/Yellow:PE (earth)
Wrong connection may cancel safeguardswithin the
product, and resultsin fire or electric shock.
kw

SAFETY AND IMPORTANT WARNING ITEMS
S-4
[3] CHECKPOINTSWHEN PERFORMING ON-SITE SERVICE
KONICA MINOLTA brand productsare extensively tested before shipping, to ensure that all
applicable safety standardsare met, in order to protect the customer and customer engi-
neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to partswear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.
1. Power Supply
Connection to Power Supply
WARNING
• Check that mainsvoltage isas specified.
Connection to wrong voltage supply may result in fire or
electric shock.
• Connect power plug directly into wall outlet having same
configuration as the plug.
Use of an adapter leadsto the product connecting to
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet isnot available, advice the customer
to contact qualified electrician for the installation.
•Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flowsin the wall outlet, fire may
result.
• If two or more power cordscan be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flowsin the wall outlet, fire may
result.
•M
ake sure the power cord isplugged in the wall outlet
securely.
Contact problemsmay lead to increased resistance,
overheating, and the risk of fire.
• Check whether the product isgrounded properly.
If current leakage occursin an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
kw

SAFETY AND IMPORTANT WARNING ITEMS
S-5
Power Plug and Cord
WARNING
• When using the power cord set (inlet type) that came with
thisproduct, make sure the connector issecurely inserted
in the inlet of the product.
When securing measure isprovided, secure the cord with
the fixture properly.
If the power cord (inlet type) isnot connected to the prod-
uct securely, acontact problem may lead to increased
resistance, overheating, and risk of fire.
• Check whether the power cord isnot stepped on or
pinched by atable and so on.
Overheating may occur there, leading to arisk of fire.
• Check whether the power cord isdamaged. Check
whether the sheath isdamaged.
If the power plug, cord, or sheath isdamaged, replace
with anew power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.
• Do not bundle or tie the power cord.
Overheating may occur there, leading to arisk of fire.
• Check whether dust iscollected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with awet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to arisk of fire and
electric shock.

SAFETY AND IMPORTANT WARNING ITEMS
S-6
2. Installation Requirements
Wiring
WARNING
•Neveruse multi-plug adaptersto plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord isrequired, use aspecified one.
Current that can flow in the extension cord islimited, so
using atoo long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
Prohibited Installation Places
WARNING
• Do not place the product near flammable materialsor vola-
tile materialsthat may catch fire.
A risk of fire exists.
• Do not place the product in aplace exposed to water such
as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time
WARNING
• When the product isnot used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.

SAFETY AND IMPORTANT WARNING ITEMS
S-7
Ventilation
CAUTION
• The product generatesozone gas during operation, but it
will not be harmful to the human body.
If abad smell of ozone ispresent in the following cases,
ventilate the room.
a. When the product isused in apoorly ventilated room
b. When taking alot of copies
c. When using multiple productsat the same time
Stability
CAUTION
•Besure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to ainjury.
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool isnot used, the prod-
uct may break and arisk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect
the power plugsfrom the product and options.
When the power plug isinserted in the wall outlet, some
unitsare still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The areaaround the fixing unit ishot.
Yo umay get burnt.

SAFETY AND IMPORTANT WARNING ITEMS
S-8
Work Performed with the Product Powered On
WARNING
•Take every care when making adjustmentsor performing
an operation check with the product powered.
If youmake adjustmentsor perform an operation check
with the external cover detached, youmay touch live or
high-voltage partsor youmay be caught in moving gears
or the timing belt, leading to arisk of injury.
•Take every care when servicing with the external cover
detached.
High-voltage existsaround the drum unit. A risk of elec-
tric shock exists.
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.
•Donotallow any metal partssuch as clips, staples, and
screwsto fall into the product.
They can short internal circuitsand cause electric shock
or fire.
• Check wiring for squeezing and any other damage.
Current can leak, leading to arisk of electric shock or
fire.
•Carefully remove all toner remnantsand dust from electri-
cal partsand electrode unitssuch as acharging corona
unit.
Current can leak, leading to arisk of product trouble or
fire.
• Check high-voltage cablesand sheathsfor any damage.
Current can leak, leading to arisk of electric shock or
fire.

SAFETY AND IMPORTANT WARNING ITEMS
S-9
• Check electrode unitssuch as acharging coronaunit for
deterioration and sign of leakage.
Current can leak, leading to arisk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating alaser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to arisk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to arisk of
loss of eyesight.
• When replacing alithium battery, replace it with anew lith-
ium battery specified in the PartsGuide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing apart to which AC voltage isapplied (e.g.,
optical lamp and fixing lamp), be sure to check the installa-
tion state.
A risk of fire exists.
• Check the interlock switch and actuator for loosening and
check whether the interlock functionsproperly.
If the interlock doesnot function, youmay receive an
electric shock or be injured when youinsert your hand in
the product (e.g., for clearing paper jam).
•Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to arisk of electric shock or
fire.
Safety Checkpoints
WARNING

SAFETY AND IMPORTANT WARNING ITEMS
S-10
•Make sure that all screws, components, wiring, connec-
tors, etc. that were removed for safety check and mainte-
nance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Safety Checkpoints
WARNING
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amountsor let the
substancescome into contact with eyes, etc. It may be
stimulative.
If the substancesget in the eye, rinse with plenty of water
immediately. When symptomsare noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.
Yo umay be burned due to dust explosion.
Handling of Service Materials
CAUTION
•Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before
any solvent remnantson the cleaned partshave fully
evaporated.
A risk of fire exists.

SAFETY AND IMPORTANT WARNING ITEMS
S-11
•Use only asmall amount of cleaner at atime and take
care not to spill any liquid. If thishappens, immediately
wipe it off.
A risk of fire exists.
• When using any solvent, ventilate the room well.
Breathing large quantitiesof organic solventscan lead to
discomfort.
Handling of Service Materials
CAUTION

SAFETY AND IMPORTANT WARNING ITEMS
S-12
[4] Used BatteriesPrecautions
ALL Areas
CAUTION
Danger of explosion if battery isincorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteriesaccording to the manufacturer’sinstructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben desHerstellers.
France
AT T E N T I O N
Il y adanger d’explosion s’il y aremplacement incorrect de labatterie.
Remplacer uniquement avec une batterie dumême type oud’un type équivalent recom-
mandé par le constructeur.
Mettre au rebut lesbatteriesusagéesconformément aux instructionsdufabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
Finland, Sweden
VAROlTUS
Paristo voi räjähtää, josse on virheellisesti asennettu.
Vaihdaparisto ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfaravid felaktigt batteribyte.
Använd sammabatterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kasseraanvänt batteri enligt fabrikantensinstruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseresi henhold til fabrikantensinstruksjoner.

SAFETY AND IMPORTANT WARNING ITEMS
S-13
[5] Laser Safety
•Thisisadigital machine certified as aClass 1 laser product. There isno possibility of
danger from alaser, provided the machine isserviced according to the instruction in this
manual.
5.1 Internal Laser Radiation
*at laser aperture of the Print Head Unit
•Thisproduct employsaClass 3B laser diode that emitsan invisible laser beam. The
laser diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit isNOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
semiconductor laser
Maximum power of the laser diode 15 mW
Maximum average radiation power (*) bizhub C360/C2808.0 µW
bizhub C220 5.3 µW
Wavelength 770-800 nm
A0EDP0C501DA
Laser Aperture
of the Print Head
Unit
Print Head Unit

SAFETY AND IMPORTANT WARNING ITEMS
S-14
U.S.A., Canada
(CDRH Regulation)
•Thismachine iscertified as aClass 1 Laser product under Radiation Performance Stan-
dard according to the Food, Drug and Cosmetic Act of 1990. Compliance ismandatory
for Laser productsmarketed in the United Statesand isreported to the Center for
Devicesand Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services(DHHS). Thismeansthat the device
doesnot produce hazardous laser radiation.
• The label shown on page S-16 indicatescompliance with the CDRH regulationsand
must be attached to laser productsmarketed in the United States.
.
All Areas
Denmark
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode 15 mW
Wavelength 770-800 nm
CAUTION
• Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode 15 mW
Wavelength 770-800 nm
ADVARSEL
• Usynlig laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.
halvlederlaser
Laserdiodenshøjeste styrke 15 mW
bølgelængden 770-800 nm

SAFETY AND IMPORTANT WARNING ITEMS
S-15
Finland, Sweden
Norway
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
• Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat-
taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser-
säteilylle.
puolijohdelaser
Laserdiodin suurin teho 15 mW
aallonpituus 770-800 nm
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats,
kan användaren utsättas för osynlig laserstrålning, som överskrider gränsen för
laserklass 1.
halvledarlaser
Den maximalaeffekten för laserdioden 15 mW
våglängden 770-800 nm
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser-
säteilylle. Älä katso säteeseen.
VARNING!
• Osynlig laserstråining när denna del är öppnad och spärren är urkopplad.
Betrakta ej stråien.
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen
for laser klass 1.
halvleder laser
Maksimal effekt till laserdiode 15 mW
bølgelengde 770-800 nm

SAFETY AND IMPORTANT WARNING ITEMS
S-16
5.2 Laser Safety Label
•Alaser safety label isattached to the inside of the machine as shown below.
5.3 Laser Caution Label
•Alaser caution label isattached to the outside of the machine as shown below.
A0EDP0E505DA
* Only for the U.S.A.
A0EDP0C503DA

SAFETY AND IMPORTANT WARNING ITEMS
S-17
5.4 PRECAUTIONSFOR HANDLING THE LASER EQUIPMENT
• When laser protective gogglesare to be used, select oneswith alensconforming to the
above specifications.
• When adisassembly job needsto be performed in the laser beam path, such as when
working around the printerhead and PC drum, be sure first to turn the printer OFF.
• If the job requiresthat the printer be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it isbrought into the laser beam path. Use
utmost care when handling toolson the user’spremises.