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SERVICE MANUAL
FIELD SERVICE
The
is available only for Inch area.
2005.08 Ver. 1.0
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-17 MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-20 Composition of the service manual ................................................................................. C-1 Notation of the service manual ....................................................................................... C-2
bizhub 200/250/350 Main Unit
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 7 Adjustment/Setting...................................................................................................... 111 Troubleshooting........................................................................................................... 221 Appendix ..................................................................................................................... 273
Duplex Unit/Switchback Unit
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting.......................................................................................................... 7 Troubleshooting............................................................................................................. 11
Standard Controller
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Troubleshooting............................................................................................................... 5
FK-503
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 5 Adjustment/Setting........................................................................................................ 11 Troubleshooting........................................................................................................... 161
DF-605
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 5 Adjustment/Setting........................................................................................................ 17 Troubleshooting............................................................................................................. 27
i
PC-102/PC-202
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting ....................................................................................................... 13 Troubleshooting ............................................................................................................ 21
PC-402
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting ....................................................................................................... 17 Troubleshooting ............................................................................................................ 25
JS-502
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting ......................................................................................................... 5
FS-508/PU-501/OT-601
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 5 Adjustment/Setting ....................................................................................................... 23 Troubleshooting ............................................................................................................ 35
MT-501
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting ......................................................................................................... 7 Troubleshooting ............................................................................................................ 11
SD-502
General ........................................................................................................................... 1 Maintenance ................................................................................................................... 3 Adjustment/Setting ....................................................................................................... 19 Troubleshooting ............................................................................................................ 27
ii
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY AND IMPORTANT WARNING ITEMS
Read carefully the Safety and Important Warning Items described below to understand them before doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians. Changes may have been made to this product to improve its performance after this Service Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that the information contained in this Service Manual is complete and accurate. The user of this Service Manual must assume all risks of personal injury and/or damage to the product while servicing the product for which this Service Manual is intended. Therefore, this Service 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 this Service Manual also for future service.
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION
In this Service Manual, each of three expressions " DANGER", " WARNING", and " CAUTION" is defined as follows together with a symbol mark to be used in a limited meaning. When servicing the product, the relevant works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with utmost care. 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 Symbols used for safety and important warning items are defined as follows:
:Precaution when servicing the product. :Prohibition when servicing the product. :Direction when servicing the product.
General precaution General prohibition General instruction
Electric hazard
High temperature
Do not touch with wet hand Unplug
Do not disassemble Ground/Earth
S-1
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such modifications are therefore strictly prohibited. the points listed below are not exhaustive, but they illustrate the reasoning behind this policy.
Prohibited Actions DANGER
· Using any cables or power cord not specified by KMBT.
· Using any fuse or thermostat not specified by KMBT. Safety will not be assured, leading to a risk of fire and injury. · Disabling fuse functions or bridging fuse terminals with 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 a risk of fire and injury. · Making any modification to the product unless instructed by KMBT · Using parts not specified by KMBT
S-2
SAFETY AND IMPORTANT WARNING ITEMS
[2] POWER PLUG SELECTION
In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation 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 meets the following criteria: - provided with a plug having configuration intended for the connection to wall outlet appropriate for the product's rated voltage and current, and - the plug has pin/terminal(s) for grounding, and - provided with three-conductor cable having enough current capacity, and - the cord set meets regulatory requirements for the area. Use of inadequate cord set leads to fire or electric shock. · Attach power plug which meets the following criteria: - having configuration intended for the connection to wall outlet appropriate for the product's rated voltage and current, and - the plug has pin/terminal(s) for grounding, and - meets regulatory requirements for the area. Use of inadequate cord set leads to the product connecting to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock. · Conductors in the power cable must be connected to terminals of the plug according to the following order: · Black or Brown: · White or Light Blue: · Green/Yellow: L (line) N (neutral) PE (earth)
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Wrong connection may cancel safeguards within the product, and results in fire or electric shock.
S-3
SAFETY AND IMPORTANT WARNING ITEMS
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear 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 mains voltage is as 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 leads to the product connecting to inadequate power supply (voltage, current capacity, grounding), and may result in fire or electric shock. If proper wall outlet is not 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 flows in the wall outlet, fire may result. · If two or more power cords can be plugged into the wall outlet, the total load must not exceed the rating of the wall outlet. If excessive current flows in the wall outlet, fire may result. · Make sure the power cord is plugged in the wall outlet securely. Contact problems may lead to increased resistance, overheating, and the risk of fire. · Check whether the product is grounded properly. If current leakage occurs in an ungrounded product, you may suffer electric shock while operating the product. Connect power plug to grounded wall outlet.
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S-4
SAFETY AND IMPORTANT WARNING ITEMS
Power Plug and Cord WARNING
· When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly. If the power cord (inlet type) is not connected to the product securely, a contact problem may lead to increased resistance, overheating, and risk of fire. · Check whether the power cord is not stepped on or pinched by a table and so on. Overheating may occur there, leading to a risk of fire.
· Check whether the power cord is damaged. Check whether the sheath is damaged. If the power plug, cord, or sheath is damaged, replace with a new 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 a risk of fire.
· Check whether dust is collected 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 a wet 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 a risk of fire and electric shock.
S-5
SAFETY AND IMPORTANT WARNING ITEMS
Wiring WARNING
· Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists.
· When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire. Do not use an extension cable reel with the cable taken up. Fire may result. 2. Installation Requirements
Prohibited Installation Places WARNING
· Do not place the product near flammable materials or volatile materials that may catch fire. A risk of fire exists. · Do not place the product in a place 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 is not 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.
S-6
SAFETY AND IMPORTANT WARNING ITEMS
Ventilation CAUTION
· The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a. When the product is used in a poorly ventilated room b. When taking a lot of copies c. When using multiple products at the same time
Stability CAUTION
· Be sure to lock the caster stoppers. In the case of an earthquake and so on, the product may slide, leading to a injury.
Inspection before Servicing CAUTION
· Before conducting an inspection, read all relevant documentation (service manual, technical notices, etc.) and proceed with the inspection following the prescribed procedure, using only the prescribed tools. Do not make any adjustment not described in the documentation. If the prescribed procedure or tool is not used, the product may break and a risk of injury or fire exists. · Before conducting an inspection, be sure to disconnect the power plugs from the product and options. When the power plug is inserted in the wall outlet, some units are still powered even if the POWER switch is turned OFF. A risk of electric shock exists. · The area around the fixing unit is hot. You may get burnt.
S-7
SAFETY AND IMPORTANT WARNING ITEMS
Work Performed with the Product Powered On WARNING
· Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury. · Take every care when servicing with the external cover detached. High-voltage exists around the drum unit. A risk of electric shock exists.
Safety Checkpoints WARNING
· Check the exterior and frame for edges, burrs, and other damage. The user or CE may be injured. · Do not allow any metal parts such as clips, staples, and screws to fall into the product. They can short internal circuits and cause electric shock or fire. · Check wiring for squeezing and any other damage. Current can leak, leading to a risk of electric shock or fire. · Carefully remove all toner remnants and dust from electrical parts and electrode units such as a charging corona unit. Current can leak, leading to a risk of product trouble or fire. · Check high-voltage cables and sheaths for any damage. Current can leak, leading to a risk of electric shock or fire.
S-8
SAFETY AND IMPORTANT WARNING ITEMS
Safety Checkpoints WARNING
· Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. · Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected. The laser light can enter your eye, leading to a risk 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 mounting position. The laser light can enter your eye, leading to a risk of loss of eyesight. · When replacing a lithium battery, replace it with a new lithium battery specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority. Improper replacement can cause explosion. · After replacing a part to which AC voltage is applied (e.g., optical lamp and fixing lamp), be sure to check the installation state. A risk of fire exists. · Check the interlock switch and actuator for loosening and check whether the interlock functions properly. If the interlock does not function, you may receive an electric shock or be injured when you insert 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 a risk of electric shock or fire.
S-9
SAFETY AND IMPORTANT WARNING ITEMS
Safety Checkpoints WARNING
· Make sure that all screws, components, wiring, connectors, etc. that were removed for safety check and maintenance 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.
Handling of Consumables WARNING
· Toner and developer are not harmful substances, but care must be taken not to breathe excessive amounts or let the substances come into contact with eyes, etc. It may be stimulative. If the substances get in the eye, rinse with plenty of water immediately. When symptoms are noticeable, consult a physician. · Never throw the used cartridge and toner into fire. You may 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 (acetone-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 remnants on the cleaned parts have fully evaporated. A risk of fire exists.
S-10
SAFETY AND IMPORTANT WARNING ITEMS
Handling of Service Materials CAUTION
· Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. · When using any solvent, ventilate the room well. Breathing large quantities of organic solvents can lead to discomfort.
S-11
SAFETY AND IMPORTANT WARNING ITEMS
[4] Used Batteries Precautions
ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer's instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers. France ATTENTION Il y a danger d'explosion s'il y a remplacement incorrect de la batterie. Remplacer uniquement avec une batterie du même type ou d'un type équivalent recommandé par le constructeur. Mettre au rebut les batteries usagées conformément aux instructions du fabricant. 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, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä käytetty paristo valmistajan ohjeiden mukaisesti. VARNING Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
SAFETY AND IMPORTANT WARNING ITEMS
[5] Laser Safety
· This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
5.1
Internal Laser Radiation
Semiconductor laser
Maximum average radiation power(*) Wavelength
28.9 µW 770-795 nm
*:Laser Aperture of the Print Head Unit · This product employs a Class 3b laser diode that emits an invisible laser beam. The laser diode and the scanning polygon mirror are incorporated in the print head unit. · The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit should not be opened under any circumstances.
Laser Aperture of the Print Head Unit
4040P0C504DA
S-13
SAFETY AND IMPORTANT WARNING ITEMS the U.S.A., Canada (CDRH Regulation) · This machine is certified as a Class I Laser product under Radiation Performance Standard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation. · The label shown to page S-16 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States. 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 Wavelength 5 mW 770-795 nm
All Areas 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 Wavelength 5 mW 770-795 nm
Denmark ADVARSEL · Usynlig Laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.
Halvlederlaser Laserdiodens højeste styrke Bølgelængden 5 mW 770-795 nm
S-14
SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden VARO! · Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! · Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.
Puolijohdelaser Laserdiodin suurin teho Aallonpituus 5 mW 770-795 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 maximala effekten för laserdioden Våglängden 5 mW 770-795 nm
VARNING! · Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen. Norway ADVERSEL · Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning, kan brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser klass 1.
Halvleder laser Maksimal effekt till laserdiode Bølgelengde 5 mW 770-795 nm
S-15
SAFETY AND IMPORTANT WARNING ITEMS
5.2
Laser Safety Label
· A laser safety labels is attached to the outside of the machine as shown below.
* Only for the U.S.A.
4040P0C506DA
5.3
Laser Caution Label
· A laser caution label is attached to the inside of the machine as shown below.
4040P0C503DA
5.4
Precautions For Handling The Laser Equipment
· When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. · When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the copier OFF. · If the job requires that the copier be left ON, take off your watch and ring and wear laser protective goggles. · A highly reflective tool can be dangerous if it is brought into the laser beam path. Use utmost care when handling tools on the user's premises.
S-16
SAFETY AND IMPORTANT WARNING ITEMS
WARNING INDICATIONS ON THE MACHINE
Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock.
CAUTION
4040P0C500DA
S-17
SAFETY AND IMPORTANT WARNING ITEMS
High voltage
4040P0C501DA
S-18
SAFETY AND IMPORTANT WARNING ITEMS
High voltage
4040P0C505DA
CAUTION: · You may be burned or injured if you touch any area that you are advised not to touch by any caution label. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, contact our Service Office.
S-19
MEASURES TO TAKE IN CASE OF AN ACCIDENT
MEASURES TO TAKE IN CASE OF AN ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage. 2. If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and KMBT must be notified. 3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site checks, in accordance with instructions issued by KMBT. 4. For reports and measures concerning serious accidents, follow the regulations specified by every distributor.
S-20
Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part. Field Service section gives, as information required by the CE at the site (or at the customer's premise), a rough outline of the service schedule and its details, maintenance steps, the object and role of each adjustment, error codes and supplementary information. The basic configuration of each section is as follows. However some options may not be applied to the following configuration. OUTLINE: Explanation of system configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Explanation of configuration of each unit, operating system, and control system
GENERAL: MAINTENANCE: Explanation of system configuration, and product specifications Explanation of service schedule, maintenance steps, service tools, removal/reinstallation methods of major parts, and firmware version up method etc. ADJUSTMENT/SETTING: TROUBLESHOOTING: APPENDIX: Explanation of utility mode, service mode, and mechanical adjustment etc. Explanation of lists of jam codes and error codes, and their countermeasures etc. Parts layout drawings, connector layout drawings, timing chart, overall layout drawing are attached.
C-1
Notation of the service manual
A. Product name In this manual, each of the products is described as follows: (1) IC board: (2) bizhub 200/250/350: (3) Microsoft Windows 95: Microsoft Windows 98: Microsoft Windows Me: Microsoft Windows NT 4.0: Microsoft Windows 2000: Microsoft Windows XP: Standard printer Main body Windows 95 Windows 98 Windows Me Windows NT 4.0 or Windows NT Windows 2000 Windows XP Windows 95/98/Me Windows NT 4.0/2000 Windows NT/2000/XP Windows 95/98/Me/ NT/2000/XP
When the description is made in combination of the OS's mentioned above:
B. Brand name The company names and product names mentioned in this manual are the brand name or the registered trademark of each company.
C-2
SERVICE MANUAL
FIELD SERVICE
Main Unit
2005.08 Ver. 1.0
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Revision mark: · To indicate clearly a section revised, show 1 to the left of the revised section. A number within 1 represents the number of times the revision has been made. · To indicate clearly a section revised, show 1 in the lower outside section of the corresponding page. A number within 1 represents the number of times the revision has been made. NOTE Revision marks shown in a page are restricted only to the latest ones with the old ones deleted. · When a page revised in Ver. 2.0 has been changed in Ver. 3.0: The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted. · When a page revised in Ver. 2.0 has not been changed in Ver. 3.0: The revision marks for Ver. 2.0 are left as they are.
2005/08 Date
1.0 Service manual Ver.
-- Revision mark
Issue of the first edition Descriptions of revision
Field Service Ver. 1.0 Aug. 2005
bizhub 200/250/350
CONTENTS bizhub 200/250/350 Main Unit General
1. 2. 3. System configuration............................................................................................... 1 Product specifications ............................................................................................. 3 Built-in Controllers ................................................................................................... 5
Maintenance
4. 4.1 Periodical check ...................................................................................................... 7 Service schedule .................................................................................................. 7 bizhub 350 .................................................................................................... 7 bizhub 250 .................................................................................................... 7 bizhub 200 .................................................................................................... 7 Option ........................................................................................................... 8 bizhub 350 .................................................................................................... 8 bizhub 250 .................................................................................................. 10 4.1.1 4.1.2 4.1.3 4.1.4 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.5
Maintenance items................................................................................................ 8
Maintenance parts .............................................................................................. 15 Replacement parts...................................................................................... 15 Cleaning parts............................................................................................. 16
Concept of parts life............................................................................................ 17 Maintenance procedure (Periodical check parts) ............................................... 18 Replacing the Bypass Tray Feed Roller ...................................................... 18 Replacing the Bypass Tray Separation Roller Assy .................................... 19 Replacing the Tray 1 Feed Roller ................................................................ 20 Replacing the Tray 1 Pick-up Roller ............................................................ 21 Replacing the Tray 1 Separation Roller Assy .............................................. 23 Replacing the Tray 2 Feed Roller ................................................................ 25 Replacing the Tray 2 Pick-up Roller ............................................................ 26 Replacing the Tray 2 Separation Roller....................................................... 28
4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8 4.5.9 4.5.10 4.5.11 4.5.12
Cleaning of the Paper Dust Remover.......................................................... 31 Replacing of the Toner Filter (Developing Unit)........................................... 32 Replacing of the Toner Filter (Main Unit)..................................................... 33
i
Appendix
Replacing of the Registration Roller Bearings and Registration Roller Gears 1, 2..................................................................... 30
Troubleshooting
Adjustment / Setting
bizhub 200 .................................................................................................. 13
Maintenance
General
Field Service Ver. 1.0 Aug. 2005
bizhub 200/250/350
4.5.13 4.5.14 4.6 4.6.1 4.6.2 4.6.3 4.6.4 5.
Replacement of the Ozone Filter ................................................................ 33 Replacement of the Developer ................................................................... 34 Replacement of the Fusing Unit ................................................................. 37 Replacement of the Transfer Roller Unit ..................................................... 38 Replacement of the Photo Conductor Unit ................................................. 39 Replacement of the Developing Unit .......................................................... 40
Replacing the unit............................................................................................... 37
Service tool ........................................................................................................... 41 CE Tool list ......................................................................................................... 41 Copy materials ................................................................................................... 41 Developer.................................................................................................... 41 Photo Conductor Unit ................................................................................. 41 Toner Bottle................................................................................................. 41
General
5.1 5.2
5.2.1 5.2.2 5.2.3 6.
Maintenance
Firmware upgrade................................................................................................. 42 Preparations for Firmware rewriting ................................................................... 42 Service environment ................................................................................... 42 Writing into the Compact flash.................................................................... 42 Checking ROM version ............................................................................... 42 MSC............................................................................................................ 42 Engine......................................................................................................... 44 6.1.1 6.1.2 6.1.3
6.1
6.2
Adjustment / Setting
Firmware rewriting.............................................................................................. 42
6.2.1 6.2.2 7. 7.1 7.2
Other ..................................................................................................................... 46 Disassembly/Adjustment prohibited items.......................................................... 46 Disassembly/Assembly/Cleaning list (Other parts) ............................................ 47 Disassembly/Assembly parts list ................................................................ 47 Cleaning parts list ....................................................................................... 48 IR Upper Left Cover/Original Scanning Glass/Front Holding Bracket/ Original Glass ............................................................................................. 49 Lower Rear Cover/Lower Right Rear Cover/Tray Rear Cover..................... 49 Upper Rear Cover....................................................................................... 50 Rear Right Cover/Front Right Cover ........................................................... 50 IR Right Cover/Rear Cover ......................................................................... 51 Front Door................................................................................................... 51 Paper Output Cover/Lower Front Cover...................................................... 52 Upper Front Cover/Front Cover................................................................... 53 IR Left Cover/Rear Left Cover/Left Cover ................................................... 54 Rear Manual Bypass Cover/Front Manual Bypass Cover/ Lower Right Cover ...................................................................................... 55
7.2.1 7.2.2 7.3
Disassembly/Assembly procedure ..................................................................... 49
Troubleshooting
7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6
Appendix
7.3.7 7.3.8 7.3.9 7.3.10
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7.3.11 7.3.12 7.3.13 7.3.14 7.3.15 7.3.16 7.3.17 7.3.18 7.3.19 7.3.20 7.3.21 7.3.22 7.3.23 7.3.24 7.3.25 7.3.26 7.3.27 7.3.28 7.3.29 7.3.30 7.3.31 7.3.32 7.3.33 7.3.34 7.3.35 7.3.36 7.3.37 7.3.38 7.3.39 7.3.40 7.3.41 7.3.42 7.3.43 7.4 7.4.1 7.4.2 7.4.3
Control Panel .............................................................................................. 56 Tray 1 .......................................................................................................... 56 Tray 2 .......................................................................................................... 57 Mechanical Control Board Cover ................................................................ 57 FD Paper Size Board 1 ............................................................................... 58 FD Paper Size Board 2 ............................................................................... 59 Power Supply Unit....................................................................................... 60 High Voltage Unit ........................................................................................ 61 MFBS Board ............................................................................................... 62 Inverter Board ............................................................................................. 63 BCRS Board ............................................................................................... 64 CCD Unit..................................................................................................... 65 Operation Board.......................................................................................... 69 Manual Bypass Unit .................................................................................... 71 PH Unit........................................................................................................ 71 Toner Hopper Unit ....................................................................................... 74 Toner Replenishing Drive Unit..................................................................... 74 Duplex Unit.................................................................................................. 76 Switch Back Unit ......................................................................................... 76 Scanner Motor ............................................................................................ 77 Exposure Unit ............................................................................................. 78 Exposure Lamp ........................................................................................... 79 Scanner Drive Cables ................................................................................. 80 Main Motor .................................................................................................. 85 IU Motor ...................................................................................................... 85 Fusing Unit Cooling Fan Motor ................................................................... 86 Toner Suction Fan Motor ............................................................................. 86 Temperature/humidity Sensor ..................................................................... 87 ATDC Sensor .............................................................................................. 87 Thermistor................................................................................................... 89 Paper Exit Roll 1 ......................................................................................... 91 Paper Exit Roll 2 ......................................................................................... 91 Separation Claw.......................................................................................... 92 Manual Bypass Feed Roller ........................................................................ 94 Manual Bypass Separation Roller............................................................... 94 Tray 1 Feed Roller ....................................................................................... 95
Cleaning procedure ............................................................................................ 94
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7.4.4 7.4.5 7.4.6 7.4.7 7.4.8 7.4.9 7.4.10 7.4.11
Tray 1 Pick-up Roller................................................................................... 96 Tray 1 Separation Roller ............................................................................. 97 Tray 2 Feed Roller....................................................................................... 98 Tray 2 Pick-up Roller................................................................................... 98 Tray 2 Separation Roller ............................................................................. 99 Registration Roller .................................................................................... 100 Paper Dust Remover ................................................................................ 100 Transport Roller ........................................................................................ 100 Scanner Rails ........................................................................................... 101 Bushings ................................................................................................... 101 Mirrors....................................................................................................... 101 Lens .......................................................................................................... 102 Original Scanning Glass ........................................................................... 102 Original Glass ........................................................................................... 102 Charge Neutralizing Plate......................................................................... 103 Ds Collar ................................................................................................... 103
General
7.4.12 7.4.13 7.4.14 7.4.15 7.4.16 7.4.17
Maintenance
7.4.18 7.4.19 7.5 7.6 7.7
Mount Kit MK-709............................................................................................. 105 Option counter.................................................................................................. 106 Installation method for the Key Counter.................................................... 106 Original Size Detecting Sensor Layout ..................................................... 108 Mounting of the Original Size Detecting Sensors (Option) ....................... 109 Remounting of the EEPROM.................................................................... 110 Original Size Detecting Sensors....................................................................... 108
7.6.1
Adjustment / Setting
7.7.1 7.7.2 7.8 7.8.1
EEPROM .......................................................................................................... 110
Adjustment/Setting
Troubleshooting
8. 9. 9.1 9.2
How to use the adjustment section ..................................................................... 111 Utility/Counter Mode ........................................................................................... 112 Utility/Counter Mode function tree .................................................................... 112 Utility/Counter Mode function setting procedure .............................................. 116 Procedure ................................................................................................. 116 Exiting ....................................................................................................... 116 Changing the setting value in Utility Mode functions ................................ 116 User's Choice 1/6...................................................................................... 117 User's Choice 2/6...................................................................................... 118 User's Choice 3/6...................................................................................... 119 User's Choice 4/6...................................................................................... 120
9.2.1 9.2.2 9.2.3
Appendix
9.3
Settings in the User Setting.............................................................................. 117
9.3.1 9.3.2 9.3.3 9.3.4
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9.3.5 9.3.6 9.3.7 9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 9.5 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5 9.5.6 9.5.7 9.5.8 9.5.9 9.5.10 9.5.11 9.5.12 9.5.13 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.8 10. 11.
User's Choice 5/6...................................................................................... 121 User's Choice 6/6...................................................................................... 123 Store Overlay ............................................................................................ 124 Confirmation Beep .................................................................................... 125 Alarm Volume............................................................................................ 125 Job Complete Beep .................................................................................. 125 Panel Cleaning.......................................................................................... 125 Dehumidify ................................................................................................ 125 Toner Supply ............................................................................................. 126 Initial Setting ............................................................................................. 127 Admin. Set ................................................................................................ 127 Account/User Auth. ................................................................................... 128 Call Remote Center .................................................................................. 130 Network Setting......................................................................................... 130 LDAP Setting............................................................................................. 135 Frame Type Set ......................................................................................... 137 Prefix/Suffix Settings ................................................................................. 138 Printer Setting ........................................................................................... 139 Software SW ............................................................................................. 139 Ping........................................................................................................... 139 Delete Job................................................................................................. 139 SSL/TLS.................................................................................................... 139 TX Report.................................................................................................. 140 RX Report ................................................................................................. 140 One-Touch List .......................................................................................... 140 Mail Program List ...................................................................................... 140 MFP Set .................................................................................................... 141 Default Set ................................................................................................ 141 PDL Set..................................................................................................... 143 Test Print ................................................................................................... 144
Settings in the User Management .................................................................... 125
Settings in the Admin. Management................................................................. 127
Reports ............................................................................................................. 140
Settings in the Printer Setting ........................................................................... 141
Check Detail ..................................................................................................... 144 Adjustment item list ............................................................................................. 146 Tech. Rep. Mode ................................................................................................. 148
11.1 Tech. Rep. Mode function setting procedure .................................................... 148
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11.2 Tech. Rep. Mode function tree.......................................................................... 149 11.3 Settings in the Tech. Rep. Choice .................................................................... 151 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 System Set ............................................................................................... 151 Printer ....................................................................................................... 153 Sheet-through-ADF................................................................................... 155 The amount of Center Erase .................................................................... 156 Orientation Change................................................................................... 156 Finisher ..................................................................................................... 156 Trail Erase (Dup) ....................................................................................... 156 Standard paper ......................................................................................... 157 Special Paper............................................................................................ 158 OHP .......................................................................................................... 158 Thin Paper ................................................................................................ 158 LCT Paper Size......................................................................................... 159 Change Fixed Zoom ................................................................................. 159 Machine Configuration.............................................................................. 159 Technical Memo........................................................................................ 159 Hard Disk .................................................................................................. 159 Original Size Detecting Option.................................................................. 160
General
11.3.7 11.4.1 11.4.2 11.4.3 11.4.4
11.4 Table of Temperatures for Adjusting the Fusing Temperature .......................... 157
Maintenance
11.5 Settings in the System Input............................................................................. 159 11.5.1 11.5.2 11.5.3 11.5.4
Adjustment / Setting
11.5.5 11.5.6
11.6 Settings in the Administrator # Initialize............................................................ 160 11.7 Settings in the Counter..................................................................................... 160 11.7.1 11.7.2 11.7.3 Checking the counter reading................................................................... 160 Clearing readings of all counters at once ................................................. 160 Clearing the reading of a specific counter ................................................ 160 Paper ........................................................................................................ 160 Jam Counter ............................................................................................. 161 Special Parts Counter............................................................................... 161 Service Call Counter................................................................................. 161 Application Counter .................................................................................. 162 Maintenance Counter ............................................................................... 162 F1.............................................................................................................. 162 F2.............................................................................................................. 162 F7-1 .......................................................................................................... 162 F7-2 .......................................................................................................... 163 F8.............................................................................................................. 163
Troubleshooting
11.7.4 11.7.5 11.7.6 11.7.7 11.7.8 11.7.9 11.8.1 11.8.2 11.8.3 11.8.4 11.8.5
11.8 Settings in the Function.................................................................................... 162
Appendix
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11.8.6 11.8.7 11.8.8 11.8.9
F12............................................................................................................ 163 Hard Disk Format ...................................................................................... 163 FD ............................................................................................................. 164 FC ............................................................................................................. 164
11.8.10 Org. Width Detect Adjust .......................................................................... 164 11.8.11 FW Download............................................................................................ 164 11.9 I/O Check.......................................................................................................... 165 11.9.1 11.9.2 11.9.3 Electrical Components Check Procedure Through Input Data Check ...... 165 I/O Check Screens .................................................................................... 166 I/O Check List............................................................................................ 168
11.10 Settings in the Operation Check ....................................................................... 176 11.10.1 ADF ........................................................................................................... 176 11.10.2 Exp. Lamp Check ...................................................................................... 176 11.10.3 Scanner..................................................................................................... 176 11.11 CS Remote Care .............................................................................................. 177 11.11.1 Outlines ..................................................................................................... 177 11.11.2 Setting Up the CS Remote Care ............................................................... 177 11.11.3 Software SW setting for CS Remote Care ................................................ 180 11.11.4 Setup confirmation .................................................................................... 185 11.11.5 Calling the Maintenance ........................................................................... 185 11.11.6 Calling the Center from the Administrator ................................................. 185 11.11.7 Checking the transmission log .................................................................. 185 11.11.8 Detail on settings ...................................................................................... 186 11.11.9 List of the CS Remote Care error code..................................................... 191 11.11.10 Troubleshooting for CS Remote Care ....................................................... 195 11.12 ROM Version .................................................................................................... 196 11.13 Level History ..................................................................................................... 196 12. Counters.............................................................................................................. 197 12.1.1 12.1.2 Procedure ................................................................................................. 197 Exiting ....................................................................................................... 197 12.1 Counters Function Setting Procedure............................................................... 197
12.2 Counters Function Tree .................................................................................... 197 12.3 Settings in the Counters ................................................................................... 198 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 Total Counter............................................................................................. 198 Large Size Counter ................................................................................... 198 Copy Kit Counter....................................................................................... 198 Copy Kit..................................................................................................... 199 Plug-In Counter ......................................................................................... 199
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12.3.6 12.3.7 13.
Key Counter .............................................................................................. 199 Vendor Mode ............................................................................................ 199
Service Security Mode........................................................................................ 200 13.1.1 13.1.2 Procedure ................................................................................................. 200 Exiting ....................................................................................................... 200
13.1 Service Security Mode Function Setting Procedure......................................... 200
13.2 Service Security Mode Function Tree............................................................... 200 13.3 Settings in the Service Security Mode ............................................................. 200
General
13.3.1 14.
Service Code Change .............................................................................. 200
Adjust Mode ........................................................................................................ 201 14.1.1 14.1.2 Procedure ................................................................................................. 201 Exiting ....................................................................................................... 201
14.1 Adjust Mode Function Setting Procedure ......................................................... 201
14.2 Adjust Mode Function Tree............................................................................... 201
Maintenance
14.3 Settings in the Adjust Mode.............................................................................. 202 14.3.1 14.3.2 15. Printer ....................................................................................................... 202 Scanner .................................................................................................... 204
Initial Mode.......................................................................................................... 208 15.1.1 Exiting ....................................................................................................... 208
15.1 Initial Mode Function Setting Procedure .......................................................... 208
Adjustment / Setting
15.2 Initial Mode Function Tree ................................................................................ 209 15.3 Settings in the Initial Mode ............................................................................... 209 15.3.1 15.3.2 15.3.3 15.3.4 15.3.5 Total Clear................................................................................................. 209 Touch Panel Adjustment ........................................................................... 210