Konica Minolta bizhub 163 User manual

SERVICE MANUAL
2007.042007.04
Ver. 1.0Ver. 1.0
FIELD SERVICE
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FIELD SERVICE TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1
IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
WARNING INDICATIONS ON THE MACHINE ........................................................S-18
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-19
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub 163/211/220 Main body
General...........................................................................................................................1
Maintenance ................................................................................................................... 7
Adjustment/Setting........................................................................................................95
Troubleshooting...........................................................................................................153
Appendix.....................................................................................................................199
FK-506
General...........................................................................................................................1
Maintenance ................................................................................................................... 3
Adjustment/Setting........................................................................................................13
Troubleshooting...........................................................................................................117
DF-605/MK-501
General...........................................................................................................................1
Maintenance ................................................................................................................... 5
Adjustment/Setting........................................................................................................21
Troubleshooting.............................................................................................................31
DF-502
General...........................................................................................................................1
Maintenance ................................................................................................................... 3
Adjustment/Setting........................................................................................................17
Troubleshooting.............................................................................................................27
AD-504
General...........................................................................................................................1
Maintenance ................................................................................................................... 3
Adjustment/Setting........................................................................................................11
Troubleshooting.............................................................................................................13
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PF-502
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 11
Troubleshooting ............................................................................................................ 17
MB-501
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 19
Troubleshooting ............................................................................................................ 25
JS-503
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Troubleshooting ............................................................................................................ 11
SF-501
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Troubleshooting .............................................................................................................. 9
IC-206/NC-503
General........................................................................................................................... 1
Maintenance................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 11
Troubleshooting ............................................................................................................ 21
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SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
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bizhub 163/211/220GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Se
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bizhub 163/211/220 Main body
General
1. System configuration...............................................................................................1
2. Product specification...............................................................................................3
2.1 Fax kit (FK-506): (Option).....................................................................................6
Maintenance
3. Periodical check ...................................................................................................... 7
3.1 Service schedule..................................................................................................7
3.1.1 Main body (bizhub 163) /PF-502/MB-501.....................................................7
3.1.2 Main body (bizhub 211/220) /PF-502/MB-501..............................................7
3.1.3 DF-502..........................................................................................................7
3.1.4 DF-605..........................................................................................................7
3.2 Maintenance items................................................................................................8
3.2.1 Parts to be replaced by users (CRU) ............................................................8
3.2.2 Periodical parts replacement/cleaning 1 (per 30,000-original feed)..............8
3.2.3 Periodical parts replacement/cleaning 2 (per 40,000-original feed)..............8
3.2.4 Periodical parts replacement/cleaning 3 (per 50,000-original feed)..............9
3.2.5 Periodical parts replacement/cleaning 4 (per 80,000-print)..........................9
3.2.6 Periodical parts replacement/cleaning 5 (per 120,000-original feed)............9
3.2.7 Periodical parts replacement/cleaning 6 (per 150,000-print)......................10
3.2.8 Periodical parts replacement/cleaning 7 (per 200,000-original feed)..........10
3.3 Maintenance parts..............................................................................................11
3.3.1 Replacement parts......................................................................................11
3.3.2 Cleaning parts.............................................................................................13
3.4 Concept of parts life............................................................................................14
3.5 Maintenance procedure (periodical check parts)................................................15
3.5.1 Cleaning of the original glass and original scanning glass .........................15
3.5.2 Replacing the separation roller assy...........................................................15
3.5.3 Replacing the feed roller.............................................................................17
3.5.4 Replacing the paper dust remover assy......................................................18
3.5.5 Replacing the toner bottle...........................................................................18
3.5.6 Replacing the imaging unit..........................................................................20
3.5.7 Disassembly of the imaging unit .................................................................20
3.5.8 Replacing the PC drum...............................................................................22
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bizhub 163/211/220Ad
Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2007
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3.5.9 Replacing the ozone filter........................................................................... 23
3.5.10 Replacing the PC drum charge corona assy.............................................. 24
3.5.11 Replacing the cleaning blade...................................................................... 24
3.5.12 Cleaning of the PC drum paper separator fingers...................................... 25
3.5.13 Cleaning of the Ds collars........................................................................... 25
3.5.14 Cleaning of the developer scattering prevention plate................................ 26
3.5.15 Replacing the developer / toner agitating seal............................................ 27
3.5.16 Cleaning of the pre-image transfer guide plate........................................... 29
3.5.17 Replacing the image transfer roller assy..................................................... 30
3.5.18 Replacing the fusing unit ............................................................................ 30
4. Service tool........................................................................................................... 32
4.1 Service material list............................................................................................ 32
4.2 CE tool list.......................................................................................................... 32
5. Firmware upgrade................................................................................................. 33
5.1 Preparations for firmware rewriting..................................................................... 33
5.1.1 Installing the driver...................................................................................... 33
5.2 Firmware rewriting.............................................................................................. 35
5.2.1 Updating method ........................................................................................ 35
5.2.2 Procedure when upgrading the firmware has failed.................................... 37
6. Other..................................................................................................................... 39
6.1 Disassembly/adjustment prohibited items.......................................................... 39
6.2 Disassembly/assembly/cleaning list (other parts) .............................................. 40
6.2.1 Disassembly/assembly parts list................................................................. 40
6.2.2 Cleaning parts list....................................................................................... 41
6.3 Disassembly/assembly procedure...................................................................... 42
6.3.1 Original glass/Original scanning glass........................................................ 42
6.3.2 Control panel .............................................................................................. 42
6.3.3 Front cover.................................................................................................. 43
6.3.4 Paper exit cover.......................................................................................... 44
6.3.5 Front door ................................................................................................... 44
6.3.6 Tray 1.......................................................................................................... 44
6.3.7 Left cover.................................................................................................... 45
6.3.8 Paper exit tray............................................................................................. 45
6.3.9 Rear inside cover........................................................................................ 46
6.3.10 Upper rear cover......................................................................................... 46
6.3.11 Left rear cover............................................................................................. 47
6.3.12 Rear cover .................................................................................................. 47
6.3.13 Right rear cover .......................................................................................... 47
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Troubleshooting
Appendix
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6.3.14 Rear right cover...........................................................................................48
6.3.15 Right cover..................................................................................................48
6.3.16 Printer control board (PRCB)......................................................................48
6.3.17 MFP board (MFPB).....................................................................................49
6.3.18 High voltage unit (HV1)...............................................................................50
6.3.19 Power supply unit (DCPU) ..........................................................................51
6.3.20 Paper size detect board (PSDTB)...............................................................53
6.3.21 Heater relay board (RYB): 200 V areas only...............................................54
6.3.22 Pre-image transfer register board (PITRB) .................................................54
6.3.23 Manual bypass tray.....................................................................................55
6.3.24 Toner hopper unit/Toner replenishing motor (M2).......................................55
6.3.25 PH unit ........................................................................................................57
6.3.26 Disassembly of the fusing unit ....................................................................58
6.3.27 CCD unit .....................................................................................................61
6.3.28 Scanner, exposure lamp, and inverter board (PU2)....................................63
6.3.29 Scanner motor (M4)....................................................................................65
6.3.30 Scanner drive cables...................................................................................66
6.3.31 Main motor (M1)..........................................................................................76
6.3.32 Power unit cooling fan motor (FM2)............................................................77
6.3.33 Fusing cooling fan motor (FM1)..................................................................78
6.3.34 Paper size sensor (S5) assy.......................................................................79
6.3.35 Fusing unit interlock switch (S2) .................................................................80
6.3.36 Inch/metric sensor/1 (PS7) assy (3rd area only).........................................83
6.3.37 Flickerless resistor (R1) (Only for 200 V areas of bizhub 163) ...................83
6.3.38 Replacing the TCR sensor (TCRS).............................................................84
6.3.39 Application of toner .....................................................................................85
6.4 Cleaning procedure ............................................................................................ 86
6.4.1 Separation roller..........................................................................................86
6.4.2 Feed roller...................................................................................................87
6.4.3 Upper/Lower Synchronizing Rollers............................................................87
6.4.4 Paper dust remover.....................................................................................88
6.4.5 Bypass transport roller/roll..........................................................................88
6.4.6 Mirrors.........................................................................................................89
6.4.7 Lens ............................................................................................................89
6.4.8 CCD Sensor................................................................................................90
6.4.9 Scanner rails/bearings ................................................................................91
6.4.10 PH window..................................................................................................91
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Troubleshooting
Appendix
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6.4.11 Pre-Image
6.4.12 Charge neutralizing plate............................................................................ 92
6.5 Option counter.................................................................................................... 93
6.5.1 Installation of the key counter..................................................................... 93
Adjustment/Setting
7. How to use the adjustment section....................................................................... 95
8. Utility Mode ........................................................................................................... 96
8.1 Utility Mode function tree.................................................................................... 96
8.2 Utility Mode function setting procedure .............................................................. 99
8.2.1 Procedure................................................................................................... 99
8.2.2 Exiting......................................................................................................... 99
8.2.3 Changing the setting value in Utility Mode functions.................................. 99
8.3 Setting in the Utility Mode................................................................................... 99
8.3.1 MACHINE SETTING................................................................................... 99
8.3.2 PAPER SOURCE SETUP......................................................................... 102
8.3.3 CUSTOM SIZE MEMORY ........................................................................ 103
8.3.4 USER MANAGEMENT............................................................................. 103
8.3.5 ADMIN. MANAGEMENT........................................................................... 104
8.3.6 COPY SETTING 1.................................................................................... 106
8.3.7 COPY SETTING 2.................................................................................... 108
8.3.8 DIAL REGISTRATION.............................................................................. 109
8.3.9 FAX REGISTRATION................................................................................ 109
8.3.10 FAX TX OPERATION................................................................................ 109
8.3.11 FAX RX OPERATION ............................................................................... 109
8.3.12 REPORTING............................................................................................. 109
8.3.13 SCAN SETTING....................................................................................... 109
9. Adjustment item list............................................................................................. 110
10. Service Mode...................................................................................................... 113
10.1 Service Mode function setting procedure......................................................... 113
10.1.1 Procedure................................................................................................. 113
10.1.2 Exiting....................................................................................................... 113
10.1.3 Changing the setting value in Service Mode functions............................. 113
10.2 Service Mode function tree............................................................................... 114
10.3 Setting in the Service Mode ............................................................................. 117
10.3.1 SERVICE’S CHOICE................................................................................ 117
10.3.2 ADJUST.................................................................................................... 126
10.3.3 COUNTER................................................................................................ 132
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Troubleshooting
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..................136
10.3.5 FUNCTION ...............................................................................................137
10.3.6 SOFT SWITCH .........................................................................................139
10.3.7 REPORT...................................................................................................139
10.3.8 ADMIN. REGISTRATION..........................................................................140
10.3.9 FIXED ZOOM CHANGE ........................................................................... 140
10.3.10 FACTORY TEST .......................................................................................141
10.3.11 CLEAR DATA ............................................................................................142
11. Security...............................................................................................................144
11.1 Security function setting procedure ..................................................................144
11.1.1 Procedure .................................................................................................144
11.1.2 Exiting .......................................................................................................144
11.1.3 Changing the setting value in Security functions ......................................144
11.2 Security function tree........................................................................................144
11.3 Setting in the Security.......................................................................................144
11.3.1 TOTAL COUNTER COUNT.......................................................................144
11.3.2 SIZE COUNTER COUNT .........................................................................144
11.3.3 PLUG-IN COUNTER COPY .....................................................................145
11.3.4 MACHINE COUNTER...............................................................................145
12. Mechanical adjustment .......................................................................................146
12.1 Adjustment of the position of the scanner and 2nd/3rd mirrors carriage..........146
12.2 CCD unit position adjustment...........................................................................147
12.3 Adjustment of the gap between the doctor blade and sleeve roller
(Db adjustment)................................................................................................148
12.4 Manual bypass (for the optional AD-504) CD registration adjustment
*bizhub 211/220 only........................................................................................151
Troubleshooting
13. Jam display .........................................................................................................153
13.1 Misfeed display.................................................................................................153
13.1.1 Display resetting procedure ......................................................................153
13.2 Sensor layout....................................................................................................154
13.2.1 System mounted with PF-502 and MB-501. .............................................154
13.3 Solution.............................................................................................................155
13.3.1 Initial check items......................................................................................155
13.3.2 Misfeed at tray1 paper feed section ..........................................................156
13.3.3 Misfeed at the manual bypass tray paper feed section.............................157
13.3.4 Misfeed at the paper separating section...................................................158
13.3.5 Misfeed at the fusing/exit section..............................................................159
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Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2007
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14. Malfunction code................................................................................................. 160
14.1 Trouble code..................................................................................................... 160
14.1.1 Trouble code list........................................................................................ 160
14.2 How to reset ..................................................................................................... 164
14.3 Solution ............................................................................................................ 165
14.3.1 C0000: Main motor malfunction................................................................ 165
14.3.2 C0045: Fusing cooling fan motor malfunction........................................... 165
14.3.3 C004E: Power unit cooling fan motor malfunction.................................... 166
14.3.4 C0070: Toner replenishing motor malfunction .......................................... 166
14.3.5 C0210: Abnormal image transfer voltage ................................................. 167
14.3.6 C0500: Warm-up failure............................................................................ 167
14.3.7 C0501: Warm-up failure 2 (bizhub 211/220 Only) .................................... 167
14.3.8 C0510: Fusing failure (Abnormally low fusing temperature)..................... 167
14.3.9 C0511: Fusing failure (Abnormally low fusing temperature 2)
(bizhub 211/220 Only) .............................................................................. 167
14.3.10 C0520: Fusing failure (Abnormally high fusing temperature) ................... 167
14.3.11 C0521: Fusing failure (Abnormally high fusing temperature 2)
(bizhub 211/220 Only) .............................................................................. 167
14.3.12 C0650: Faulty scanner home position sensor........................................... 169
14.3.13 C0F32: Faulty TCR sensor....................................................................... 169
14.3.14 C0F33: Improperly adjusted TCR sensor................................................. 169
14.3.15 C1038: Engine connection failure............................................................. 170
14.3.16 C1200: Faulty ASIC/Memory.................................................................... 170
14.3.17 C1300: Polygon motor malfunction........................................................... 171
14.3.18 C13F0: Faulty HSYNC.............................................................................. 171
14.3.19 C14A3: IR fluorescent lamp fault.............................................................. 171
14.3.20 C3FFF: Flash ROM error.......................................................................... 172
15. Power supply trouble........................................................................................... 173
15.1 The copier does not turn ON............................................................................ 173
16. Image quality problem......................................................................................... 174
16.1 How to identify problematic part....................................................................... 174
16.1.1 Initial check items ..................................................................................... 174
16.1.2 Identification of the faulty system.............................................................. 175
16.2 Solution ............................................................................................................ 176
16.2.1 Image reading section: Blank copy........................................................... 176
16.2.2 Image reading section: Black copy........................................................... 177
16.2.3 Image reading section: Low image density............................................... 178
16.2.4 Image reading section: Foggy background or rough image...................... 179
16.2.5 Image reading section: Black streaks or bands 180
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Troubleshooting
Appendix
Field Service Ver. 1.0 Apr. 2007
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16.2.6 Image reading section: Black spots ..........................................................181
16.2.7 Image reading section: White streaks or bands........................................182
16.2.8 Image reading section: Uneven image density .........................................183
16.2.9 Image reading section: Gradation reproduction failure.............................184
16.2.10 Image reading section: Periodically uneven image...................................185
16.2.11 Image reading section: Moire....................................................................186
16.2.12 Printer section: Blank copy........................................................................187
16.2.13 Printer section: Black copy........................................................................188
16.2.14 Printer section: Low image density ...........................................................189
16.2.15 Printer section: Foggy background or rough image ..................................190
16.2.16 Printer section: black streaks or bands.....................................................191
16.2.17 Printer section: Black spots.......................................................................192
16.2.18 Printer section: Blank streaks or bands ....................................................193
16.2.19 Printer section: Void areas........................................................................194
16.2.20 Printer section: Smear on back.................................................................195
16.2.21 Printer section: Uneven image density......................................................196
16.2.22 Printer section: Gradation reproduction failure..........................................197
16.2.23 Printer section: Periodically uneven image...............................................198
Appendix
17. Parts layout drawing............................................................................................199
17.1 Main body.........................................................................................................199
17.2 DF-502 (option).................................................................................................202
17.3 DF-605 (option).................................................................................................203
17.4 PF-502 (option).................................................................................................204
17.5 MB-501 (option)................................................................................................205
17.6 AD-504 (option) ................................................................................................ 206
17.7 JS-503 (option).................................................................................................207
17.8 SF-501 (option).................................................................................................208
18. Connector layout drawing....................................................................................209
19. Timing chart ........................................................................................................210
19.1 Main body.........................................................................................................210
19.2 DF-605..............................................................................................................211
19.2.1 1-Sided Mode (A4 two sheets feeding).....................................................211
19.2.2 2-Sided Mode (A4 two sheets feeding).....................................................212
19.2.3 Fax Fine mode (A4 two sheets feeding)....................................................214
19.2.4 Fax real-time transmission mode (A4 two sheets feeding) .......................215
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SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
fineline6

SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
fineline6

SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
fineline6

SERVICE MANUAL
2007 04
FIELD SERV
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SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
fineline6

SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
fineline6

SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERV
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SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
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SERVICE MANUAL
2007.04
Ver. 1.0
FIELD SERVICE
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