ic203_field service_bizhub pro 920

SERVICE MANUAL

2005.08

IC-203

Field Service

Ver. 2.0

Revision historyAfter publication of this service manual, the parts and mechanism may be subject to change for improve-ment 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 beissued with a revision mark added as required.

Revision mark:• To indicate clearly a section revised, show to the left of the revised section.

A number within represents the number of times the revision has been made.

• To indicate clearly a section revised, show in the lower outside section of the correspondingpage. A number within represents the number of times the revision has been made.

NOTERevision 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.

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2005/08 2.0 Correction of an error in writing.

2005/06 1.0 — Issue of the first edition

Date Service manual Ver. Revision mark Descriptions of revision

Field Service Ver2.0 August.2005

CONTENTS

IC-203

OUTLINE

1. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE

2. SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Overview of the Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Operating Environment of the Service Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Installing / Booting Up Hyper Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 How to Use the Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Booting Up Service DOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Memory Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Overall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 IC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 HDD Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Disassembly / Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Removal / Installation of IC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Removal / Installation of HDD Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.3 Removal / Installation of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4 Removal / Installation of PostScript Protection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5 Removal / Installation of System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6 Removal / Installation of IC Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT / SETTING

5. TECH REP. MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

6. TROUBLESHOOTING THE PRINTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Troubleshooting of the print controller and copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTS

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IC-2

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Field Service Ver2.0 August.2005
CONTENTS
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1. PRODUCT SPECField Service Ver2.0 August.2005

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OUTLINE

1. PRODUCT SPECIFICATIONS

A. Type

B. Functions

Type: Built-in box type for the KONICA MINOLTA Printer/Copier

Resolution Printing System: 600 x 600 dpiScanning Resolution: 200 dpi / 300 dpi/ 400 dpi / 600 dpi

Gradation binary

Printable Area PCLXL: Margine 2.84 mm (left, right, top and bottom without varia-tion)

PCL5e: Margine 2.84 mm (left, right, top and bottom without varia-tion)

PS: Margine 2.84 mm (left, right, top and bottom without varia-tion)

Non-standard paper:302.979 x 459.994 mm (The maximum paper size: 314 x 460 mm)

No. of Print 1 to 9999

Continuous Print Speed 92 ppm (A4, 8.5 x 11) / (600 x 600 dpi)

Printer Description Language PCL (The Direct Printing of the PDF/TIFF is available. However, an additional application is required.)PostScript 3(TIFF/PDF) (optional PostScript kit required)

Built-in fonts Agfa Microtype fontsAdobe PostScript Font (optional PS3 kit required)

Compliant OS Windows 98/MeWindows NT 4.0 (NT Service Pack 3 or more)Windows 2000Windows XP/Server 2003Mac OS 9.x (optional PS3 kit required)Mac OS X v10.2/v10.3 (optional PS3 kit required)

Printer Driver Printer driver for Windows 98/Me/NT 4.0/2000/XP/Server 2003PS printer driver for Windows (optional PS3 kit required)PS printer driver for Windows/Macintosh (optional PS3 kit required)

Protocols TCP/IP, IPX/SPX, NetBEUI, IPP, EtherTalk

Compliant OS (NOS) Novell NetWare (3.x, 4.x-6), Windows 98/Me, Windows NT 4.0, Win-dows 2000, Windows XP, Mac OS 9.x, Mac OS X v10.2/v10.3

Multiple Protocols Automatic selection

Printing Method Peer-to-Peer (TCP/IP for Windows 95/98/Me), Pserver (IPX/SPX), lpd/lpr (TCP/IP for Windows NT 4.0/2000), lpd/lpr (TCP/IP for UNIX), AppleTalk (EtherTalk), NPrinter/RPrinter (IPX/SPX), Port9100(TCP/IP)

Dedicated Utilities Peer to Peer Printing Tool

Compliant Web Browser Netscape Navigator, Internet Explorer

IFICATIONS

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SPECIFICATIONS Field Service Ver2.0 August.2005IC

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C. Paper

D. Maintenance and Life

E. Machine Data

F. Operating Environment

Paper Size Same as copier

Paper Type Same as copier

Paper Weight Same as copier

Maintenance Same as copier

Machine Service Life Same as copier

CPU Low Voltage Pentium III Tualatin 800 MHz

System Memory 256 MB (Standard), Expandable up to 512 MB (Option: EM-701)

Host Interface Parallel port Centronics (IEEE 1284 / amphenol 36 pin male connector)

Hard Disk Drive EIDE drive 40 GB or more

Option PS3 kitMemory: (EM-701: 256 MB)

Power Obtain from main body printer

Network Interface Ethernet (100Base-TX / 10Base-T)

Frame Type IEEE 802.3

Ethernet Connection 100Base-TX / 10Base-T

Network Connector RJ-45

LED Green 2

Temperature Same as copier

Humidity Same as copier

1. PRODUCT

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2. SERField Service Ver2.0 August.2005

MAINTENANCE

2. SERVICE TOOL

2.1 Overview of the Service Tool

The service tool enables the print controller to operate with a terminal communications program for a personalcomputer (PC).This print controller supports for input/output operations of a serial port of the print controller from when theprinter system BIOS boots up, thus making it possible to control the progress in initialization and system test (orPOST: Power On Self Test) by BIOS, which assisting to determine where error conditions may exist when anerror develops at the system start time.Also, memory check and boot up a service DOS by BIOS are available with the terminal communication pro-gram.

2.1.1 Operating Environment of the Service Tool

The following is required to use the service tool.• Computers running on Windows• Hyper Terminal (terminal communications program)

Setting requirements

• RS-232C serial cable (terminated in a female 9-pin D-Sub connector on both ends)

Pin assignment

For information on installation and usage of Hyper Terminal, see the Windows manual and descriptions on thefollowing pages.

Bits/sec.: 9600 bits/sec.(fixed)

Data bit: 8 bits

Parity: None

Stop bit: 1

Flow control: None

12345

6789

9-Pin D-SUB Connector

(female)

1 DCD

2 TxD

3 RxD

4 DTR

5 GND

6 DSR

7 RTS

8 CTS

9 RI

1 DCD

2 TxD

3 RxD

4 DTR

5 GND

6 DSR

7 RTS

8 CTS

9 RI

PC Print Controller

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TOOL Field Service Ver2.0 August.2005

2.1.2 Installing / Booting Up Hyper Terminal

Hyper Terminal is a terminal communications program which comes with Windows 98/Me/NT4.0/2000/XP as standard. If it is not installed in your Windows 98/Me/NT4.0, it is necessary to install it.

Caution

• For Windows 2000/XP, it is installed by default. There is no need to install it.

• To install Hyper Terminal, the system program CD for the Windows PC in use is required.

• The procedure of setting up and booting up Hyper Terminal depends on the Windows version.

G. To install Hyper Terminal

In the following, Windows 98 is used as an example.

1. Insert the CD containing OS of the Windows PC in use into the CD drive.

2. Select [Start]-[Settings]-[Control Panel].• A [Control Panel] window will appear.

3. Double-click [Add/Remove Programs].• An [Add/Remove Programs Properties] window will

appear.

4. Click the [Windows Setup] tab, and check the [Connection] check box under [Components].

5. Click the [Details] button.• A [Communication] window will appear.

6. Check the [Hyper Terminal] check box, and click the [OK] button.

7. When the [Add/Remove Programs] window reopens, click the [OK] button.

• The necessary files are copied and the installation is completed.

2. SERVICE

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H. To Boot Up Hyper Terminal

In the following, Windows XP is used as an example.

1. Select [Start]-[All Programs]-[Accessories]-[Com-munications]-[Hyper Terminal].

• A [Connection Description] window will appear.

NOTE

• Once a connection is made, an icon with the

name entered in the step 2 will be created. If

an icon has already been created (i.e., if the

printer connection settings have already been

done), there is no need to complete the fol-

lowing steps because the connection with

Hyper Terminal is established by double-

clicking that icon.

2. Enter a name, and click the [OK] button.

3. Select [COM (1-3)] under [Connect using], then click the [OK] button.

• A [Port Settings] window will appear.

4. Configure the port settings as shown on the left, and click the [OK] button.

NOTE

• The serial port settings on the copier can not

be changed.

• Leaving all the settings at their defaults

except [Bits per second] and [Flow control] is

required.

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TOOL Field Service Ver2.0 August.2005

2.2 How to Use the Service Tool

The print controller carries DOS (Embedded DOS) along with the BIOS program on a flash ROM. This DOS

allows the print controller system to be recovered.

2.2.1 Booting Up Service DOS

1. Turn the copier’s main power switch (SW1) OFF.2. Connect an RS-232C serial cable between the

PC and the print controller.3. Boot Hyper Terminal. (See “2.1.2 Installing /

Booting Up Hyper Terminal”.)4. While pressing the [k] key, turn the copier’s main

power switch (SW1) ON (i.e., boot up the print controller).

5. The message “Press [a] or [s]” appears (7 sec-onds or less). Enter the [a] key.

• The DOS is boot up.

NOTE

• Do not press the [s] key because it is entry for

production purpose.

• If you do not press any key for 7 seconds, it

boots normally.

6. When the message “Enter new data (mm-dd-yy):” appears, enter the current date (ex: 04-01-2005) and press the Enter key.

7. When the message “Enter new time (hh:mm:ss):” appears, enter the current time (ex: 18:14:20) and press the Enter key.

• Now DOS commands are available for use.

NOTE

• Although the printer system (VxWorks)

acquires time information from the copier, the

service DOS has no way of communicating

with the copier: it is necessary to enter the

current date and time.

2. SERVICE

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2.2.2 Memory Test Methods

The memory test needs to be conducted if, after in the cases such as an unstable operation is observed afterthe memory was expanded or a faulty memory size is detected.

The memory test includes a normal memory test and a detailed memory test.The normal memory test is a test conducted upon normal powering up.

The normal memory test includes the following:

In memory area of lower than 64 KB: Data read/write test, address test, and data test over theentire memory area.

Caution

• The detailed memory test is a test conducted over the entire memory area with a operation from

the service port.

The detailed memory test includes the following:

In memory area of lower than 64 KB: Data read/write test, address test, and data test over theentire memory area.

In memory area of higher than 64 KB: Data read/write test in 64 KB units.

I. Memory Test Procedure

1. Boot Service DOS. (See “2.2.1 Booting Up Ser-vice DOS”.)

2. While pressing the [m] key, turn the copier’s main power switch (SW1) ON.

• The detailed memory test is conducted.

3. Make certain that all memory tests found no problems (“Memory Passed” is displayed).

NOTE

• When all memory is OK, the copier is able to

normally start up.

4. Turn the copier’s main power switch (SW1) OFF.5. Unplug the serial cable.6. Turn the copier back ON to check if it behaves

normally.7. If any test results are faulty (The message “Criti-

cal Error is displayed”. Or, the value after the indi-cation of “Ext. Memory Passed” is less than the expanded memory capacity.), remove the added memory, and run the memory test from the beginning.

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E VERSION UP Field Service Ver2.0 August.2005

3. FIRMWARE VERSION UP

Rewriting firmware (system software) enables the system to be upgraded the version without replacing the

board. Also, even in case the print controller’s firmware is damaged in its software and becomes inoperative,rewriting firmware may restore it.

Firmware’s version is upgraded by ISW.See “5. FIRMWARE VERSION UP” in Field Service for the main body.

3. FIRMWAR

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4. DISASSEMBLY / REField Service Ver2.0 August.2005

4. DISASSEMBLY / REASSEMBLY

4.1 Overall Construction

4.1.1 IC Unit

Caution

• The CPU cannot be removed from the system board. To replace the CPU, the IC board (ICB) needs

to be replaced.

Board Cover

Hard Disk

Parallel CablePostScript

Protection Chip

ICU Cooling Fan

Memory

IC Board

IDE Cable

ASSEMBLY

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BLY / REASSEMBLY Field Service Ver2.0 August.2005

4.1.2 HDD Unit

Hard Disk

Hard Disk Mounting

Bracket

Earth

Plate

Earth

PlateEarth

Plate

Rubber Insert

4. DISASSEM

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4.1.3 Tools Required

• Standard screwdriver• Spanner or needle-nose pliers

• PLCC pull-out tool

Caution

• Be sure to unplug the power cable, not only to turn the copier off, before attempting to make ser-

vicing.

• Do not make service for the IC Unit and the HDD with the condition that they are installed to the

copier.

Caution

• Before engaging in Disassembly/Reassembly, check to make sure that all the cables are

unplugged from the IC unit.

• DO NOT use magnetized tools in Disassembly/Reassembly to prevent the hard disk from being

affected.

• There may be occasions when boards are damaged if no appropriate grounding measures are

taken. Wear a wrist strap or others during servicing.

• Disassembly/Reassembly should be made on cushioning materials.

ASSEMBLY

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4.2 Disassembly / Reassembly

Caution

• Assembly should be made in reverse order of disassembly unless otherwise noted.

4.2.1 Removal / Installation of IC Unit

1. Turn the copier’s main power switch (SW1) OFF, and unplug the power cord from the AC outlet.

2. Remove the network cable and parallel cable from the IC Unit.

3. Remove five screws.

4. Remove the power connector on the lower side of the IC unit.

4. DISASSEM

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5. Remove the IC Unit from the copier.6. Assembly should be made in reverse order from

disassembly.

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4.2.2 Removal / Installation of HDD Unit

When replacing the hard disk, be sure to use one that is designated as spark parts for the print controller.

Caution

• The use of any other hard disks is not allowed.

• Do not change settings for the jumper.

1. Remove the IC Unit.(See “4.2.1 Removal / Installation of IC Unit”.)

2. Remove the nineteen screws and the Board Cover.

3. Remove the IDE cable from board.NOTE

• Lift a transparent film when unplugging the

cable.

4. DISASSEM

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4. Remove four setscrews [4] for the hard disk and remove the hard disk/2 (HDD2) [5] from the hard disk holder [6].

NOTE

• Do not remove the supporting rubber [7] of

the hard disk holder [6].

5. Unplug the power cord and IDE cable from the Hard Disk.

NOTE


cable.

6. Assembly should be made in reverse order from disassembly.

NOTE

• When fixing the hard disk on the hard disk

holder, be cautious that the screw tightening

torque T=0.4-0.5(Nm) and the supporting rub-

ber [7] neither ride up nor run on.

[6]

[4]

[7]

[4]

[5]

Earth Plate

Earth Plate

ASSEMBLY

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4.2.3 Removal / Installation of Memory

About combinations of memory expansion, see “2.2.1 Memory” of Theory of Operation section.

1. Remove the IC Unit. (See “4.2.1 Removal / Installation of IC Unit”.)

2. Remove the board cover and unplug the IDE cable from the board.(See “4.2.2 Removal / Installation of HDD Unit”.)

NOTE


cable.

3. Press the memory slot’s tab [3] outward to remove the memory.


NOTE

• When assembling, fit the memory to the notch

of the memory slot.

[3]

[3]

4. DISASSEM

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4.2.4 Removal / Installation of PostScript Protection Kit

The PostScript protection kit is mounted only in a print controller equipped with PostScript option.Normally, there is no need to remove/reinstall the PostScript protection kit. However, it should be removed and

reinstalled when replacing the system board.Use the PLCC pull-out tool to remove the PostScript protection chip.

Caution

• The PostScript protection kit is sensitive to static electricity. Handle it with care.



NOTE


cable.

3. Remove the PostScript protection kit [1] using a PLCC pull-out tool such as shown below.


NOTE

• Make sure that the circle [3] on the PostScript

protection kit faces the triangle [2] on the sys-

tem board.

PLCC pull-out Tool

[2]

[1][3]

ASSEMBLY

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4.2.5 Removal / Installation of System Board



NOTE


cable.

4. DISASSEM

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3. Unplug the parallel cable [2] and the IDE cable [3] from the system board [1].

NOTE


IDE cable [3].

[1] [2]

[3]

ASSEMBLY

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4. Remove two setscrews [4] for the connector.

5. Remove two screws [5] for the compact flash cover and remove the compact flash [6].

[4]

[5]

[6]

4. DISASSEM

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6. Remove ten screws [7] from the system board, then remove the system board.

NOTE

• When disassembling, be careful not to dam-

age the board and the connector.


[7]

[7]

[7]

[7]

ASSEMBLY

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4.2.6 Removal / Installation of IC Cooling Fan

Caution

• The CPU cannot be removed from the system board. To replace the CPU, the system board needs

to be replaced.



3. Remove the system board. (See “4.2.5 Removal / Installation of System Board”)

4. Remove the DC connector [2] of the IC cooling fan (FM24) [1] from the system board.

5. Remove two screws [3] on the backside of the system board and remove the IC cooling fan (FM24).


[2][1]

[3]

4. DISASSEM

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5. TECH RField Service Ver2.0 August.2005

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ADJUSTMENT / SETTING

5. TECH REP. MODE

In the service mode, various adjustments / settings are available. See “10. TECH REP. MODE” in Field Service for the main body.

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. MODE Field Service Ver2.0 August.2005IC

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5. TECH REP

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6. TROUBLESHOOTING THE PRINTINField Service Ver2.0 August.2005

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TROUBLESHOOTING

6. TROUBLESHOOTING THE PRINTING SYSTEM

This table lists information about the symptoms, possible causes, and remedies for problems that may occurwith the printing system (combination of the print controller and copier). It is intended to help engineers findinformation as quickly as possible, and provide basic solutions.

Caution

• See the “Copier Service Manual” for information about Error Cord List.

6.1 Troubleshooting of the print controller and copier

Symptoms Causes Actions

[Controller] key on the Utility Menu screen is kept in gray out for 15 minutes after the power ON.

No power supply to the print controller.

Check if the print controller is con-nected with the copier properly.

“Warming up” does not disappear. Copier is in trouble. Locate the cause of trouble of the copier.

“Initialization” does not disappear on the copier screen.

The print controller has not started properly.

See the column of “Print controller does not start”.

Printout is defective, or nothing can be printed.

The system board or some boards of the copier are defective.

Put the copier in service mode and per-form test. If it operates properly, system board may be failure.

Print controller does not start. The system board is inac-tive.

Check the connector of the controller board. Replace the system board as necessary.

Software of the print con-troller is defective.

Reinstall the software of the print con-troller.

Test print can be produced but not from the parallel port.

The parallel port has something wrong or the cable is wrong or, the problem is on the com-puter side.

Check the cables (internal/external). Perform test using a data generator or a well-proven PC/I/O cable. Replace the system board as necessary.

With the standard printer language PCL, correct outputs are produced, but with PostScript3 even PS Demo Page cannot be printed out at all.

PostScript3 Protection Kit is not correctly installed.

Reinsert PostScript3 Protection Kit. If the problem still occurs, replace PostScript3 Protection Kit with a new one.

Test print can be produced and all ports are good, but user jobs cannot be printed.

Some software error has happened.

Print controller’s software or application program has something wrong. Save the file, which failed to be printed, in the disk and analyze the problem by suit-able means.

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SHOOTING THE PRINTING SYSTEM Field Service Ver2.0 August.2005IC

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6. TROUBLE

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ic203_field service_bizhub pro 920

Documents

adjustment

tx 10base

postscript

postscript

field service

disassembly

terminal communications

ic cooling