konica-minolta-bizhub-163-211-220-service-manual-free.pdf

SERVICE MANUAL

2007.042007.04Ver. 1.0Ver. 1.0

FIELD SERVICE

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iFIELD SERVICE TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1IMPORTANT NOTICE ................................................................................................S-1DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1SAFETY WARNINGS .................................................................................................S-2WARNING INDICATIONS ON THE MACHINE ........................................................S-18

MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-19Composition of the service manual ................................................................................. C-1Notation of the service manual ....................................................................................... C-2

bizhub 163/211/220 Main bodyGeneral ........................................................................................................................... 1Maintenance ................................................................................................................... 7Adjustment/Setting........................................................................................................ 95Troubleshooting........................................................................................................... 153Appendix ..................................................................................................................... 199

FK-506General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting........................................................................................................ 13Troubleshooting........................................................................................................... 117

DF-605/MK-501General ........................................................................................................................... 1Maintenance ................................................................................................................... 5Adjustment/Setting........................................................................................................ 21Troubleshooting............................................................................................................. 31

DF-502General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting........................................................................................................ 17Troubleshooting............................................................................................................. 27

AD-504General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting........................................................................................................ 11Troubleshooting............................................................................................................. 13

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PF-502General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting ....................................................................................................... 11Troubleshooting ............................................................................................................ 17

MB-501General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting ....................................................................................................... 19Troubleshooting ............................................................................................................ 25

JS-503General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Troubleshooting ............................................................................................................ 11

SF-501General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Troubleshooting .............................................................................................................. 9

IC-206/NC-503General ........................................................................................................................... 1Maintenance ................................................................................................................... 3Adjustment/Setting ....................................................................................................... 11Troubleshooting ............................................................................................................ 21

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SERVICE MANUAL

2007.04Ver. 1.0

FIELD SERVICE

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Field Service Ver. 1.0 Apr. 2007

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CONTENTS

bizhub 163/211/220 Main body

General1. System configuration............................................................................................... 12. Product specification ............................................................................................... 3

2.1 Fax kit (FK-506): (Option) ..................................................................................... 6

Maintenance3. Periodical check ...................................................................................................... 7

3.1 Service schedule .................................................................................................. 73.1.1 Main body (bizhub 163) /PF-502/MB-501 ..................................................... 73.1.2 Main body (bizhub 211/220) /PF-502/MB-501 .............................................. 73.1.3 DF-502 .......................................................................................................... 73.1.4 DF-605 .......................................................................................................... 7

3.2 Maintenance items................................................................................................ 83.2.1 Parts to be replaced by users (CRU) ............................................................ 83.2.2 Periodical parts replacement/cleaning 1 (per 30,000-original feed).............. 83.2.3 Periodical parts replacement/cleaning 2 (per 40,000-original feed).............. 83.2.4 Periodical parts replacement/cleaning 3 (per 50,000-original feed).............. 93.2.5 Periodical parts replacement/cleaning 4 (per 80,000-print) .......................... 93.2.6 Periodical parts replacement/cleaning 5 (per 120,000-original feed)............ 93.2.7 Periodical parts replacement/cleaning 6 (per 150,000-print) ...................... 103.2.8 Periodical parts replacement/cleaning 7 (per 200,000-original feed).......... 10

3.3 Maintenance parts .............................................................................................. 113.3.1 Replacement parts...................................................................................... 113.3.2 Cleaning parts............................................................................................. 13

3.4 Concept of parts life............................................................................................ 143.5 Maintenance procedure (periodical check parts)................................................ 15

3.5.1 Cleaning of the original glass and original scanning glass ......................... 153.5.2 Replacing the separation roller assy ........................................................... 153.5.3 Replacing the feed roller ............................................................................. 173.5.4 Replacing the paper dust remover assy...................................................... 183.5.5 Replacing the toner bottle ........................................................................... 183.5.6 Replacing the imaging unit.......................................................................... 203.5.7 Disassembly of the imaging unit ................................................................. 203.5.8 Replacing the PC drum............................................................................... 22

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3.5.9 Replacing the ozone filter ........................................................................... 233.5.10 Replacing the PC drum charge corona assy .............................................. 243.5.11 Replacing the cleaning blade...................................................................... 243.5.12 Cleaning of the PC drum paper separator fingers ...................................... 253.5.13 Cleaning of the Ds collars........................................................................... 253.5.14 Cleaning of the developer scattering prevention plate ................................ 263.5.15 Replacing the developer / toner agitating seal............................................ 273.5.16 Cleaning of the pre-image transfer guide plate........................................... 293.5.17 Replacing the image transfer roller assy..................................................... 303.5.18 Replacing the fusing unit ............................................................................ 30

4. Service tool ........................................................................................................... 324.1 Service material list ............................................................................................ 324.2 CE tool list .......................................................................................................... 32

5. Firmware upgrade................................................................................................. 335.1 Preparations for firmware rewriting..................................................................... 33

5.1.1 Installing the driver...................................................................................... 335.2 Firmware rewriting.............................................................................................. 35

5.2.1 Updating method ........................................................................................ 355.2.2 Procedure when upgrading the firmware has failed.................................... 37

6. Other ..................................................................................................................... 396.1 Disassembly/adjustment prohibited items .......................................................... 396.2 Disassembly/assembly/cleaning list (other parts) .............................................. 40

6.2.1 Disassembly/assembly parts list................................................................. 406.2.2 Cleaning parts list ....................................................................................... 41

6.3 Disassembly/assembly procedure...................................................................... 426.3.1 Original glass/Original scanning glass........................................................ 426.3.2 Control panel .............................................................................................. 426.3.3 Front cover.................................................................................................. 436.3.4 Paper exit cover .......................................................................................... 446.3.5 Front door ................................................................................................... 446.3.6 Tray 1 .......................................................................................................... 446.3.7 Left cover .................................................................................................... 456.3.8 Paper exit tray ............................................................................................. 456.3.9 Rear inside cover ........................................................................................ 466.3.10 Upper rear cover ......................................................................................... 466.3.11 Left rear cover............................................................................................. 476.3.12 Rear cover .................................................................................................. 476.3.13 Right rear cover .......................................................................................... 47

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6.3.14 Rear right cover........................................................................................... 486.3.15 Right cover .................................................................................................. 486.3.16 Printer control board (PRCB) ...................................................................... 486.3.17 MFP board (MFPB)..................................................................................... 496.3.18 High voltage unit (HV1) ............................................................................... 506.3.19 Power supply unit (DCPU) .......................................................................... 516.3.20 Paper size detect board (PSDTB)............................................................... 536.3.21 Heater relay board (RYB): 200 V areas only............................................... 546.3.22 Pre-image transfer register board (PITRB) ................................................. 546.3.23 Manual bypass tray ..................................................................................... 556.3.24 Toner hopper unit/Toner replenishing motor (M2) ....................................... 556.3.25 PH unit ........................................................................................................ 576.3.26 Disassembly of the fusing unit .................................................................... 586.3.27 CCD unit ..................................................................................................... 616.3.28 Scanner, exposure lamp, and inverter board (PU2).................................... 636.3.29 Scanner motor (M4) .................................................................................... 656.3.30 Scanner drive cables................................................................................... 666.3.31 Main motor (M1).......................................................................................... 766.3.32 Power unit cooling fan motor (FM2) ............................................................ 776.3.33 Fusing cooling fan motor (FM1) .................................................................. 786.3.34 Paper size sensor (S5) assy ....................................................................... 796.3.35 Fusing unit interlock switch (S2) ................................................................. 806.3.36 Inch/metric sensor/1 (PS7) assy (3rd area only)......................................... 836.3.37 Flickerless resistor (R1) (Only for 200 V areas of bizhub 163) ................... 836.3.38 Replacing the TCR sensor (TCRS)............................................................. 846.3.39 Application of toner ..................................................................................... 85

6.4 Cleaning procedure ............................................................................................ 866.4.1 Separation roller.......................................................................................... 866.4.2 Feed roller ................................................................................................... 876.4.3 Upper/Lower Synchronizing Rollers............................................................ 876.4.4 Paper dust remover..................................................................................... 886.4.5 Bypass transport roller/roll .......................................................................... 886.4.6 Mirrors......................................................................................................... 896.4.7 Lens ............................................................................................................ 896.4.8 CCD Sensor................................................................................................ 906.4.9 Scanner rails/bearings ................................................................................ 916.4.10 PH window .................................................................................................. 91

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6.4.11 Pre-Image transfer lower guide plate.......................................................... 926.4.12 Charge neutralizing plate............................................................................ 92

6.5 Option counter.................................................................................................... 936.5.1 Installation of the key counter ..................................................................... 93

Adjustment/Setting7. How to use the adjustment section ....................................................................... 958. Utility Mode ........................................................................................................... 96

8.1 Utility Mode function tree.................................................................................... 968.2 Utility Mode function setting procedure .............................................................. 99

8.2.1 Procedure ................................................................................................... 998.2.2 Exiting ......................................................................................................... 998.2.3 Changing the setting value in Utility Mode functions .................................. 99

8.3 Setting in the Utility Mode................................................................................... 998.3.1 MACHINE SETTING................................................................................... 998.3.2 PAPER SOURCE SETUP......................................................................... 1028.3.3 CUSTOM SIZE MEMORY ........................................................................ 1038.3.4 USER MANAGEMENT ............................................................................. 1038.3.5 ADMIN. MANAGEMENT........................................................................... 1048.3.6 COPY SETTING 1 .................................................................................... 1068.3.7 COPY SETTING 2 .................................................................................... 1088.3.8 DIAL REGISTRATION .............................................................................. 1098.3.9 FAX REGISTRATION................................................................................ 1098.3.10 FAX TX OPERATION................................................................................ 1098.3.11 FAX RX OPERATION ............................................................................... 1098.3.12 REPORTING............................................................................................. 1098.3.13 SCAN SETTING ....................................................................................... 109

9. Adjustment item list............................................................................................. 11010. Service Mode...................................................................................................... 113

10.1 Service Mode function setting procedure ......................................................... 11310.1.1 Procedure ................................................................................................. 11310.1.2 Exiting ....................................................................................................... 11310.1.3 Changing the setting value in Service Mode functions ............................. 113

10.2 Service Mode function tree............................................................................... 11410.3 Setting in the Service Mode ............................................................................. 117

10.3.1 SERVICES CHOICE................................................................................ 11710.3.2 ADJUST.................................................................................................... 12610.3.3 COUNTER................................................................................................ 132

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10.3.4 DISPLAY ................................................................................................... 13610.3.5 FUNCTION ............................................................................................... 13710.3.6 SOFT SWITCH ......................................................................................... 13910.3.7 REPORT ................................................................................................... 13910.3.8 ADMIN. REGISTRATION.......................................................................... 14010.3.9 FIXED ZOOM CHANGE ........................................................................... 14010.3.10 FACTORY TEST ....................................................................................... 14110.3.11 CLEAR DATA ............................................................................................ 142

11. Security ............................................................................................................... 14411.1 Security function setting procedure .................................................................. 144

11.1.1 Procedure ................................................................................................. 14411.1.2 Exiting ....................................................................................................... 14411.1.3 Changing the setting value in Security functions ...................................... 144

11.2 Security function tree........................................................................................ 14411.3 Setting in the Security....................................................................................... 144

11.3.1 TOTAL COUNTER COUNT....................................................................... 14411.3.2 SIZE COUNTER COUNT ......................................................................... 14411.3.3 PLUG-IN COUNTER COPY ..................................................................... 14511.3.4 MACHINE COUNTER............................................................................... 145

12. Mechanical adjustment ....................................................................................... 14612.1 Adjustment of the position of the scanner and 2nd/3rd mirrors carriage .......... 14612.2 CCD unit position adjustment ........................................................................... 14712.3 Adjustment of the gap between the doctor blade and sleeve roller

(Db adjustment) ................................................................................................ 14812.4 Manual bypass (for the optional AD-504) CD registration adjustment

*bizhub 211/220 only ........................................................................................ 151

Troubleshooting13. Jam display ......................................................................................................... 153

13.1 Misfeed display ................................................................................................. 15313.1.1 Display resetting procedure ...................................................................... 153

13.2 Sensor layout .................................................................................................... 15413.2.1 System mounted with PF-502 and MB-501. ............................................. 154

13.3 Solution............................................................................................................. 15513.3.1 Initial check items...................................................................................... 15513.3.2 Misfeed at tray1 paper feed section .......................................................... 15613.3.3 Misfeed at the manual bypass tray paper feed section ............................. 15713.3.4 Misfeed at the paper separating section ................................................... 15813.3.5 Misfeed at the fusing/exit section .............................................................. 159

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14. Malfunction code................................................................................................. 16014.1 Trouble code ..................................................................................................... 160

14.1.1 Trouble code list ........................................................................................ 16014.2 How to reset ..................................................................................................... 16414.3 Solution ............................................................................................................ 165

14.3.1 C0000: Main motor malfunction................................................................ 16514.3.2 C0045: Fusing cooling fan motor malfunction........................................... 16514.3.3 C004E: Power unit cooling fan motor malfunction .................................... 16614.3.4 C0070: Toner replenishing motor malfunction .......................................... 16614.3.5 C0210: Abnormal image transfer voltage ................................................. 16714.3.6 C0500: Warm-up failure............................................................................ 16714.3.7 C0501: Warm-up failure 2 (bizhub 211/220 Only) .................................... 16714.3.8 C0510: Fusing failure (Abnormally low fusing temperature) ..................... 16714.3.9 C0511: Fusing failure (Abnormally low fusing temperature 2)

(bizhub 211/220 Only) .............................................................................. 16714.3.10 C0520: Fusing failure (Abnormally high fusing temperature) ................... 16714.3.11 C0521: Fusing failure (Abnormally high fusing temperature 2)

(bizhub 211/220 Only) .............................................................................. 16714.3.12 C0650: Faulty scanner home position sensor........................................... 16914.3.13 C0F32: Faulty TCR sensor ....................................................................... 16914.3.14 C0F33: Improperly adjusted TCR sensor ................................................. 16914.3.15 C1038: Engine connection failure ............................................................. 17014.3.16 C1200: Faulty ASIC/Memory .................................................................... 17014.3.17 C1300: Polygon motor malfunction........................................................... 17114.3.18 C13F0: Faulty HSYNC.............................................................................. 17114.3.19 C14A3: IR fluorescent lamp fault .............................................................. 17114.3.20 C3FFF: Flash ROM error .......................................................................... 172

15. Power supply trouble........................................................................................... 17315.1 The copier does not turn ON............................................................................ 173

16. Image quality problem......................................................................................... 17416.1 How to identify problematic part ....................................................................... 174

16.1.1 Initial check items ..................................................................................... 17416.1.2 Identification of the faulty system.............................................................. 175

16.2 Solution ............................................................................................................ 17616.2.1 Image reading section: Blank copy........................................................... 17616.2.2 Image reading section: Black copy ........................................................... 17716.2.3 Image reading section: Low image density............................................... 17816.2.4 Image reading section: Foggy background or rough image...................... 17916.2.5 Image reading section: Black streaks or bands ........................................ 180

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16.2.6 Image reading section: Black spots .......................................................... 18116.2.7 Image reading section: White streaks or bands........................................ 18216.2.8 Image reading section: Uneven image density ......................................... 18316.2.9 Image reading section: Gradation reproduction failure ............................. 18416.2.10 Image reading section: Periodically uneven image ................................... 18516.2.11 Image reading section: Moire.................................................................... 18616.2.12 Printer section: Blank copy........................................................................ 18716.2.13 Printer section: Black copy........................................................................ 18816.2.14 Printer section: Low image density ........................................................... 18916.2.15 Printer section: Foggy background or rough image .................................. 19016.2.16 Printer section: black streaks or bands ..................................................... 19116.2.17 Printer section: Black spots....................................................................... 19216.2.18 Printer section: Blank streaks or bands .................................................... 19316.2.19 Printer section: Void areas ........................................................................ 19416.2.20 Printer section: Smear on back................................................................. 19516.2.21 Printer section: Uneven image density...................................................... 19616.2.22 Printer section: Gradation reproduction failure.......................................... 19716.2.23 Printer section: Periodically uneven image ............................................... 198

Appendix17. Parts layout drawing ............................................................................................ 199

17.1 Main body ......................................................................................................... 19917.2 DF-502 (option)................................................................................................. 20217.3 DF-605 (option)................................................................................................. 20317.4 PF-502 (option)................................................................................................. 20417.5 MB-501 (option) ................................................................................................ 20517.6 AD-504 (option) ................................................................................................ 20617.7 JS-503 (option) ................................................................................................. 20717.8 SF-501 (option)................................................................................................. 208

18. Connector layout drawing.................................................................................... 20919. Timing chart ........................................................................................................ 210

19.1 Main body ......................................................................................................... 21019.2 DF-605.............................................................................................................. 211

19.2.1 1-Sided Mode (A4 two sheets feeding) ..................................................... 21119.2.2 2-Sided Mode (A4 two sheets feeding) ..................................................... 21219.2.3 Fax Fine mode (A4 two sheets feeding).................................................... 21419.2.4 Fax real-time transmission mode (A4 two sheets feeding) ....................... 215

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SERVICE MANUAL

2007.04Ver. 1.0

FIELD SERVICE

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KONICAMINOLTA Bizhub 163 211 220 sm_07.pdf









Bizhub 163/211/220 Service ManualCONTENTSbizhub 163/211/220 Main bodyCONTENTSGeneral1. System configuration2. Product specification2.1 Fax kit (FK-506): (Option)

Maintenance3. Periodical check3.1 Service schedule3.1.1 Main body (bizhub 163) /PF-502/MB-5013.1.2 Main body (bizhub 211/220) /PF-502/MB-5013.1.3 DF-5023.1.4 DF-605

3.2 Maintenance items3.2.1 Parts to be replaced by users (CRU)3.2.2 Periodical parts replacement/cleaning 1 (per 30,000-original feed)3.2.3 Periodical parts replacement/cleaning 2 (per 40,000-original feed)3.2.4 Periodical parts replacement/cleaning 3 (per 50,000-original feed)3.2.5 Periodical parts replacement/cleaning 4 (per 80,000-print)3.2.6 Periodical parts replacement/cleaning 5 (per 120,000-original feed)3.2.7 Periodical parts replacement/cleaning 6 (per 150,000-print)3.2.8 Periodical parts replacement/cleaning 7 (per 200,000-original feed)

3.3 Maintenance parts3.3.1 Replacement parts3.3.2 Cleaning parts

3.4 Concept of parts life3.5 Maintenance procedure (periodical check parts)3.5.1 Cleaning of the original glass and original scanning glass3.5.2 Replacing the separation roller assy3.5.3 Replacing the feed roller3.5.4 Replacing the paper dust remover assy3.5.5 Replacing the toner bottle3.5.6 Replacing the imaging unit3.5.7 Disassembly of the imaging unit3.5.8 Replacing the PC drum3.5.9 Replacing the ozone filter3.5.10 Replacing the PC drum charge corona assy3.5.11 Replacing the cleaning blade3.5.12 Cleaning of the PC drum paper separator fingers3.5.13 Cleaning of the Ds collars3.5.14 Cleaning of the developer scattering prevention plate3.5.15 Replacing the developer / toner agitating seal3.5.16 Cleaning of the pre-image transfer guide plate3.5.17 Replacing the image transfer roller assy3.5.18 Replacing the fusing unit

4. Service tool4.1 Service material list4.2 CE tool list

5. Firmware upgrade5.1 Preparations for firmware rewriting5.1.1 Installing the driver

5.2 Firmware rewriting5.2.1 Updating method5.2.2 Procedure when upgrading the firmware has failed

6. Other6.1 Disassembly/adjustment prohibited items6.2 Disassembly/assembly/cleaning list (other parts)6.2.1 Disassembly/assembly parts list6.2.2 Cleaning parts list

6.3 Disassembly/assembly procedure6.3.1 Original glass/Original scanning glass6.3.2 Control panel6.3.3 Front cover6.3.4 Paper exit cover6.3.5 Front door6.3.6 Tray 16.3.7 Left cover6.3.8 Paper exit tray6.3.9 Rear inside cover6.3.10 Upper rear cover6.3.11 Left rear cover6.3.12 Rear cover6.3.13 Right rear cover6.3.14 Rear right cover6.3.15 Right cover6.3.16 Printer control board (PRCB)6.3.17 MFP board (MFPB)6.3.18 High voltage unit (HV1)6.3.19 Power supply unit (DCPU)6.3.20 Paper size detect board (PSDTB)6.3.21 Heater relay board (RYB): 200 V areas only6.3.22 Pre-image transfer register board (PITRB)6.3.23 Manual bypass tray6.3.24 Toner hopper unit/Toner replenishing motor (M2)6.3.25 PH unit6.3.26 Disassembly of the fusing unit6.3.27 CCD unit6.3.28 Scanner, exposure lamp, and inverter board (PU2)6.3.29 Scanner motor (M4)6.3.30 Scanner drive cables6.3.31 Main motor (M1)6.3.32 Power unit cooling fan motor (FM2)6.3.33 Fusing cooling fan motor (FM1)6.3.34 Paper size sensor (S5) assy6.3.35 Fusing unit interlock switch (S2)6.3.36 Inch/metric sensor/1 (PS7) assy (3rd area only)6.3.37 Flickerless resistor (R1) (Only for 200 V areas of bizhub 163)6.3.38 Replacing the TCR sensor (TCRS)6.3.39 Application of toner

6.4 Cleaning procedure6.4.1 Separation roller6.4.2 Feed roller6.4.3 Upper/Lower Synchronizing Rollers6.4.4 Paper dust remover6.4.5 Bypass transport roller/roll6.4.6 Mirrors6.4.7 Lens6.4.8 CCD Sensor6.4.9 Scanner rails/bearings6.4.10 PH window6.4.11 Pre-Image transfer lower guide plate6.4.12 Charge neutralizing plate

6.5 Option counter6.5.1 Installation of the key counter

Adjustment/Setting7. How to use the adjustment section8. Utility Mode8.1 Utility Mode function tree8.2 Utility Mode function setting procedure8.2.1 Procedure8.2.2 Exiting8.2.3 Changing the setting value in Utility Mode functions

8.3 Setting in the Utility Mode8.3.1 MACHINE SETTING8.3.2 PAPER SOURCE SETUP8.3.3 CUSTOM SIZE MEMORY8.3.4 USER MANAGEMENT8.3.5 ADMIN. MANAGEMENT8.3.6 COPY SETTING 18.3.7 COPY SETTING 28.3.8 DIAL REGISTRATION8.3.9 FAX REGISTRATION8.3.10 FAX TX OPERATION8.3.11 FAX RX OPERATION8.3.12 REPORTING8.3.13 SCAN SETTING

9. Adjustment item list10. Service Mode10.1 Service Mode function setting procedure10.1.1 Procedure10.1.2 Exiting10.1.3 Changing the setting value in Service Mode functions

10.2 Service Mode function tree10.3 Setting in the Service Mode10.3.1 SERVICES CHOICE10.3.2 ADJUST10.3.3 COUNTER10.3.4 DISPLAY10.3.5 FUNCTION10.3.6 SOFT SWITCH10.3.7 REPORT10.3.8 ADMIN. REGISTRATION10.3.9 FIXED ZOOM CHANGE10.3.10 FACTORY TEST10.3.11 CLEAR DATA

11. Security11.1 Security function setting procedure11.1.1 Procedure11.1.2 Exiting11.1.3 Changing the setting value in Security functions

11.2 Security function tree11.3 Setting in the Security11.3.1 TOTAL COUNTER COUNT11.3.2 SIZE COUNTER COUNT11.3.3 PLUG-IN COUNTER COPY11.3.4 MACHINE COUNTER

12. Mechanical adjustment12.1 Adjustment of the position of the scanner and 2nd/3rd mirrors carriage12.2 CCD unit position adjustment12.3 Adjustment of the gap between the doctor blade and sleeve roller (Db adjustment)12.4 Manual bypass (for the optional AD-504) CD registration adjustment *bizhub 211/220 only

Troubleshooting13. Jam display13.1 Misfeed display13.1.1 Display resetting procedure

13.2 Sensor layout13.2.1 System mounted with PF-502 and MB-501.

13.3 Solution13.3.1 Initial check items13.3.2 Misfeed at tray1 paper feed section13.3.3 Misfeed at the manual bypass tray paper feed section13.3.4 Misfeed at the paper separating section13.3.5 Misfeed at the fusing/exit section

14. Malfunction code14.1 Trouble code14.1.1 Trouble code list

14.2 How to reset14.3 Solution14.3.1 C0000: Main motor malfunction14.3.2 C0045: Fusing cooling fan motor malfunction14.3.3 C004E: Power unit cooling fan motor malfunction14.3.4 C0070: Toner replenishing motor malfunction14.3.5 C0210: Abnormal image transfer voltage14.3.6 C0500: Warm-up failure14.3.7 C0501: Warm-up failure 2 (bizhub 211/220 Only)14.3.8 C0510: Fusing failure (Abnormally low fusing temperature)14.3.9 C0511: Fusing failure (Abnormally low fusing temperature 2) (bizhub 211/220 Only)14.3.10 C0520: Fusing failure (Abnormally high fusing temperature)14.3.11 C0521: Fusing failure (Abnormally high fusing temperature 2) (bizhub 211/220 Only)14.3.12 C0650: Faulty scanner home position sensor14.3.13 C0F32: Faulty TCR sensor14.3.14 C0F33: Improperly adjusted TCR sensor14.3.15 C1038: Engine connection failure14.3.16 C1200: Faulty ASIC/Memory14.3.17 C1300: Polygon motor malfunction14.3.18 C13F0: Faulty HSYNC14.3.19 C14A3: IR fluorescent lamp fault14.3.20 C3FFF: Flash ROM error

15. Power supply trouble15.1 The copier does not turn ON

16. Image quality problem16.1 How to identify problematic part16.1.1 Initial check items16.1.2 Identification of the faulty system

16.2 Solution16.2.1 Image reading section: Blank copy16.2.2 Image reading section: Black copy16.2.3 Image reading section: Low image density16.2.4 Image reading section: Foggy background or rough image16.2.5 Image reading section: Black streaks or bands16.2.6 Image reading section: Black spots16.2.7 Image reading section: White streaks or bands16.2.8 Image reading section: Uneven image density16.2.9 Image reading section: Gradation reproduction failure16.2.10 Image reading section: Periodically uneven image16.2.11 Image reading section: Moire16.2.12 Printer section: Blank copy16.2.13 Printer section: Black copy16.2.14 Printer section: Low image density16.2.15 Printer section: Foggy background or rough image16.2.16 Printer section: black streaks or bands16.2.17 Printer section: Black spots16.2.18 Printer section: Blank streaks or bands16.2.19 Printer section: Void areas16.2.20 Printer section: Smear on back16.2.21 Printer section: Uneven image density16.2.22 Printer section: Gradation reproduction failure16.2.23 Printer section: Periodically uneven image

Appendix17. Parts layout drawing17.1 Main body17.2 DF-502 (option)17.3 DF-605 (option)17.4 PF-502 (option)17.5 MB-501 (option)17.6 AD-504 (option)17.7 JS-503 (option)17.8 SF-501 (option)

18. Connector layout drawing19. Timing chart19.1 Main body19.2 DF-60519.2.1 1-Sided Mode (A4 two sheets feeding)19.2.2 2-Sided Mode (A4 two sheets feeding)19.2.3 Fax Fine mode (A4 two sheets feeding)19.2.4 Fax real-time transmission mode (A4 two sheets feeding)

FK-506: Fax KitCONTENTSGeneral1. Product specifications

Maintenance2. Firmware upgrade2.1 Preparations for firmware rewriting2.1.1 Installing the driver


3. Other3.1 Disassembly/adjustment prohibited items3.2 Disassembly/assembly/cleaning list (other parts)3.2.1 Disassembly/assembly parts list

3.3 Disassembly/assembly procedure3.3.1 Speaker3.3.2 NCU board3.3.3 FAX board

Adjustment/Setting4. How to use the adjustment section5. Confirm Mode5.1 Confirm mode function tree5.2 Confirm mode function setting procedure5.2.1 Procedure5.2.2 Exiting5.2.3 Changing the setting value in CONFIRM MODE functions

5.3 Setting in the CONFIRM MODE5.3.1 TOTAL PAGE5.3.2 TX/RX RESULT5.3.3 PRINT REPORT

6. Utility Mode6.1 Utility Mode function tree6.2 Utility mode function setting procedure6.2.1 Procedure6.2.2 Exiting6.2.3 Changing the setting value in Utility Mode functions

6.3 Setting in the Utility mode6.3.1 MACHINE SETTING6.3.2 ADMIN. MANAGEMENT6.3.3 DIAL REGISTRATION6.3.4 FAX REGISTRATION6.3.5 FAX TX OPERATION6.3.6 FAX RX OPERATION6.3.7 REPORTING

7. Service Mode7.1 Service mode setting procedure7.1.1 Procedure7.1.2 Exiting7.1.3 Changing the setting value in service mode functions

7.2 Service Mode function tree7.3 Setting in the service mode7.3.1 SERVICES CHOICE7.3.2 FUNCTION7.3.3 SOFTSWITCH7.3.4 FACTORY TEST7.3.5 CLEAR DATA

8. Soft Switch Set8.1 Default Setting8.1.1 Country for each marketing area

8.2 Default soft switch setting for each market area 18.3 Default soft switch setting for each market area 28.4 Default soft switch setting for each market area 38.5 Default soft switch setting for each market area 48.6 Soft Switch List8.6.1 SOFT SWITCH: #018.6.2 SOFT SWITCH: #028.6.3 SOFT SWITCH: #038.6.4 SOFT SWITCH: #048.6.5 SOFT SWITCH: #058.6.6 SOFT SWITCH: #068.6.7 SOFT SWITCH: #078.6.8 SOFT SWITCH: #088.6.9 SOFT SWITCH: #098.6.10 SOFT SWITCH: #108.6.11 SOFT SWITCH: #118.6.12 SOFT SWITCH: #128.6.13 SOFT SWITCH: #138.6.14 SOFT SWITCH: #148.6.15 SOFT SWITCH: #158.6.16 SOFT SWITCH: #168.6.17 SOFT SWITCH: #178.6.18 SOFT SWITCH: #188.6.19 SOFT SWITCH: #198.6.20 SOFT SWITCH: #208.6.21 SOFT SWITCH: #218.6.22 SOFT SWITCH: #228.6.23 SOFT SWITCH: #238.6.24 SOFT SWITCH: #248.6.25 SOFT SWITCH: #258.6.26 SOFT SWITCH: #268.6.27 SOFT SWITCH: #278.6.28 SOFT SWITCH: #288.6.29 SOFT SWITCH: #298.6.30 SOFT SWITCH: #308.6.31 SOFT SWITCH: #318.6.32 SOFT SWITCH: #328.6.33 SOFT SWITCH: #338.6.34 SOFT SWITCH: #348.6.35 SOFT SWITCH: #358.6.36 SOFT SWITCH: #368.6.37 SOFT SWITCH: #378.6.38 SOFT SWITCH: #388.6.39 SOFT SWITCH: #398.6.40 SOFT SWITCH: #408.6.41 SOFT SWITCH: #418.6.42 SOFT SWITCH: #428.6.43 SOFT SWITCH: #438.6.44 SOFT SWITCH: #448.6.45 SOFT SWITCH: #458.6.46 SOFT SWITCH: #468.6.47 SOFT SWITCH: #478.6.48 SOFT SWITCH: #488.6.49 SOFT SWITCH: #498.6.50 SOFT SWITCH: #508.6.51 SOFT SWITCH: #518.6.52 SOFT SWITCH: #528.6.53 SOFT SWITCH: #538.6.54 SOFT SWITCH: #548.6.55 SOFT SWITCH: #558.6.56 SOFT SWITCH: #568.6.57 SOFT SWITCH: #578.6.58 SOFT SWITCH: #588.6.59 SOFT SWITCH: #59 Part 18.6.60 SOFT SWITCH: #59 Part 28.6.61 SOFT SWITCH: #59 Part 38.6.62 SOFT SWITCH: #608.6.63 SOFT SWITCH: #618.6.64 SOFT SWITCH: #628.6.65 SOFT SWITCH: #638.6.66 SOFT SWITCH: #64

9. Fax Protocols9.1 G3 ECM (G3 Error Correction Mode)9.2 Line Control9.2.1 Procedure of G3 mode communication

9.3 Table of Reference Code9.4 How to Analyze the T30 Protocol Monitor

Troubleshooting10. Fax Error10.1 Communication Error10.1.1 Outline10.1.2 Error occurring during transmission10.1.3 Error occurring during reception

10.2 Error Code10.2.1 Reception10.2.2 Transmission

DF-605/MK-501: Reverse automatic document feederCONTENTSGeneral1. Product specifications

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)2.1.1 Replacing the pick-up roller and feed roller2.1.2 Replacing the separation roller2.1.3 Cleaning of the pick-up roller, feed roller and separation roller2.1.4 Cleaning of miscellaneous rolls2.1.5 Cleaning of miscellaneous rollers2.1.6 Cleaning of the scanning guide2.1.7 Cleaning of the reflective sensor section

3. Other3.1 Disassembly/Adjustment prohibited items3.2 Disassembly/Assembly/Cleaning list (Other parts)3.2.1 Disassembly/Assembly parts list

3.3 Disassembly/Assembly procedure3.3.1 Front cover/rear cover/original feed tray rear cover3.3.2 ADF (DF-605)3.3.3 Mount kit (MK-501)3.3.4 Main control board3.3.5 Variable resistor3.3.6 Complete stamp unit 23.3.7 Replacing the replace stamp 2

4. Firmware upgrade

Adjustment/Setting5. How to use the adjustment section6. Service Mode6.1 Service mode function setting procedure6.1.1 Procedure6.1.2 Exiting6.1.3 Changing the setting value in service mode functions

6.2 Service Mode function tree6.3 Setting in the Service mode6.3.1 ADJUST6.3.2 FUNCTION6.3.3 CLEAR DATA

7. Mechanical adjustment7.1 Leading edge skew adjustment

Troubleshooting8. Jam display8.1 Sensor layout8.2 Solution8.2.1 Initial check items8.2.2 Misfeed at paper take-up section8.2.3 Misfeed at transport section8.2.4 Misfeed at turnover section8.2.5 Misfeed at paper exit section

9. Malfunction code9.1 Solution9.1.1 C0044: ADF cooling fan motor failure

DF-502: Automatic document feederCONTENTSGeneral1. Product specification

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)2.1.1 Pick-up roller/feed roller2.1.2 Separation roller2.1.3 Cleaning of the registration rollers/rolls2.1.4 Cleaning of the exit rollers/rolls2.1.5 Cleaning of the transport rolls2.1.6 Cleaning of length size sensor 2


3.3 Disassembly/Assembly procedure3.3.1 ADF3.3.2 Document feed section cover3.3.3 Rear cover3.3.4 Document feeding tray3.3.5 Document feeding tray cover3.3.6 DF control board

Adjustment/Setting4. How to use the adjustment section5. Service Mode5.1 Service mode setting procedure5.1.1 Procedure5.1.2 Exiting5.1.3 Changing the setting value in service mode functions

5.2 Service Mode function tree5.3 Setting in the service mode5.3.1 ADJUST5.3.2 FUNCTION

6. Mechanical adjustment6.1 ADF Height Adjustment6.2 ADF Leading Edge Skew Adjustment

Troubleshooting7. Jam Display7.1 Misfeed display7.1.1 Display resetting procedure

7.2 Sensor layout7.3 Solution7.3.1 Initial Check Items7.3.2 Misfeed at the document feed section7.3.3 Misfeed at the document transport section7.3.4 Misfeed at the document exit section

AD-504: Automatic duplex unitCONTENTSGeneral1. Product specifications

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)

3. Other3.1 Disassembly/Adjustment prohibited items3.2 Disassembly/Assembly/Cleaning list (Other parts)3.2.1 Disassembly/Assembly parts list3.2.2 Cleaning parts list

3.3 Disassembly/Assembly procedure3.3.1 Lower right cover3.3.2 Right cover3.3.3 AD drive board3.3.4 Transport motor

3.4 Cleaning procedure3.4.1 Duplex unit transport rollers/rolls3.4.2 Switch back unit transport rollers/roll3.4.3 Duplex unit ventilation section3.4.4 Bypass transport roller/rolls

Adjustment/Setting4. How to use the adjustment section5. Service Mode5.1 Service mode function setting procedure5.1.1 Procedure5.1.2 Exiting5.1.3 Changing the setting value in service mode functions

5.2 Service Mode function tree5.3 Setting in the service mode5.3.1 SERVICES CHOICE

Troubleshooting6. Jam display6.1 Misfeed display6.1.1 Misfeed display resetting procedure

6.2 Sensor layout6.3 Solution6.3.1 Initial check items6.3.2 Duplex reversal housing block

PF-502: Add-on paper feed unitCONTENTSGeneral1. Product specification

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)2.1.1 Replacing the feed roller


3.3 Disassembly/Assembly procedure3.3.1 Paper feed unit3.3.2 Tray3.3.3 Paper feed unit rear cover3.3.4 PF drive board3.3.5 Paper size detect board

3.4 Cleaning procedure3.4.1 Feed roller3.4.2 Vertical transport rollers/rolls

Adjustment/Setting4. How to use the adjustment section5. Service mode5.1 Service mode setting procedure5.1.1 Procedure5.1.2 Exiting5.1.3 Changing the setting value in service mode functions

5.2 Service Mode function tree5.3 Setting in the service mode5.3.1 SERVICES CHOICE5.3.2 FUNCTION

6. Mechanical adjustment6.1 Paper feed unit main scanning registration adjustment

Troubleshooting7. Jam display7.1 Misfeed display7.1.1 Misfeed display resetting procedure

7.2 Sensor layout7.3 Solution7.3.1 Initial check items7.3.2 Misfeed at the tray2 to 5 paper feed/vertical transport section

MB-501CONTENTSGeneral1. Product specification

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)2.1.1 Replacing the separation roller assy2.1.2 Replacing the feed roller


3.3 Disassembly/Assembly procedure3.3.1 Multi bypass tray3.3.2 Paper feed solenoid3.3.3 Removal and disassembly of the paper feed mechanical clutch

3.4 Cleaning procedure3.4.1 Separation roller3.4.2 Feed roller3.4.3 Bypass transport roller/rolls

Adjustment/Setting4. How to use the adjustment section5. Service Mode5.1 Service mode setting procedure5.1.1 Procedure5.1.2 Exiting5.1.3 Changing the setting value in service mode functions

5.2 Service Mode function tree5.3 Setting in the service mode5.3.1 SERVICES CHOICE

6. Mechanical adjustment6.1 Multiple Bypass main scanning Registration Adjustment6.2 Multiple bypass mechanical clutch adjustment

Troubleshooting7. Jam Display7.1 Misfeed display7.1.1 Display resetting procedure

7.2 Sensor layout7.3 Solution7.3.1 Initial Check Items7.3.2 Misfeed at the multiple bypass paper feed section

JS-503CONTENTSGeneral1. Product specification

Maintenance2. Other2.1 Disassembly/Adjustment prohibited items2.2 Disassembly/Assembly/Cleaning list (Other parts)2.2.1 Disassembly/Assembly parts list

2.3 Disassembly/Assembly procedure2.3.1 JS drive board2.3.2 Paper detecting board2.3.3 Bin switching motor

Troubleshooting3. Malfunction code3.1 Trouble code3.2 Trouble code list3.3 Solution3.3.1 C0B60: Bin switching motor malfunction

SF-501CONTENTSGeneral1. Product specifications

Maintenance2. Periodical check2.1 Maintenance procedure (Periodical check parts)


3.3 Disassembly/Assembly procedure3.3.1 Shift motor3.3.2 SF drive board

Troubleshooting4. Malfunction code4.1 Solution4.1.1 C0B80: Shift motor malfunction

IC-206/NC-503CONTENTSGeneral1. Product specifications1.1 Printing (IC-206)1.2 Network printing (NC-503)1.3 Scan to E-mail/Scan to Server (FTP) (IC-206/NC-503)

Maintenance2. Firmware upgrade2.1 Preparations for firmware rewriting2.1.1 Installing the driver


3. Other3.1 Disassembly/Adjustment prohibited items3.2 Disassembly/Assembly procedure3.2.1 Image controller/Network interface card

Adjustment/Setting4. How to use the adjustment section5. Utility Mode5.1 Utility Mode function tree5.2 Utility mode function setting procedure5.2.1 Procedure5.2.2 Exiting5.2.3 Changing the setting value in UTILITY MODE functions

5.3 Setting in the UTILITY MODE5.3.1 ADMIN. MANAGEMENT5.3.2 SCAN SETTING

Troubleshooting6. Troubleshooting6.1 Troubleshooting procedure overview6.2 Troubleshooting procedure chart6.3 Action taken if network print cannot be done

bizhub 163/211/220 THEORY OF OPERATIONCONTENTSbizhub 163/211/220 main bodyCONTENTSOutline1. System configuration2. Product specification2.1 Fax kit (FK-506): (Option)

3. Cross sectional view4. Paper path5. Copy process

Composition/Operation6. Overall configuration6.1 Timing Chart at Power ON6.2 Control Block Diagram

7. Scanner (IR)7.1 Composition7.2 Drive7.3 Operation7.3.1 Scanner Moving Mechanism/Control7.3.2 Original Size Detection7.3.3 Determination of Original Size7.3.4 For Metric, China and Latin America (Metric) areas

8. PH (Writing section)8.1 Composition8.2 Drive

9. Imaging unit9.1 Construction9.2 Operation

10. PC Drum10.1 Composition10.2 Drive10.3 Operation10.3.1 Grounding of the PC Drum

11. PC Drum charging11.1 Composition11.2 Operation

12. Developing12.1 Composition12.2 Drive12.3 Operation12.3.1 Developing Roller12.3.2 Developing Bias12.3.3 TCR Sensor12.3.4 TCR Sensor Automatic Adjustment

13. Toner replenishing13.1 Composition13.2 Drive13.3 Operation13.3.1 Toner Replenishing Mechanism

13.4 Toner Replenishing Control13.4.1 T/C Recovery Mode13.4.2 Toner Bottle Home Position Detection

14. Image transfer and paper separation section14.1 Composition14.2 Drive14.3 Operation14.3.1 Image Transfer Section14.3.2 Paper Separation Section

15. Toner recovery15.1 Composition15.2 Drive15.3 Operation

16. Paper feed16.1 Composition16.2 Drive16.3 Operation16.3.1 Paper Separating Mechanism16.3.2 Drawer in Position Detection16.3.3 Paper Empty Detection Mechanism16.3.4 Paper Lifting Plate16.3.5 Universal Tray Paper Size Detection Mechanism16.3.6 ON/OFF Positions of Paper Size Detecting Switches and Corresponding Paper Size Detected16.3.7 Paper feed Control16.3.8 Paper feed Retry Control

17. Manual bypass section17.1 Composition17.2 Drive17.3 Operation17.3.1 Paper Detection Mechanism17.3.2 Manual Feed Take Up Control

18. Registration roller section18.1 Composition18.2 Drive18.3 Operation18.3.1 Paper Dust Remover

19. Fusing unit section19.1 Composition (for bizhub 163)19.2 Composition (for bizhub 211/220)19.3 Drive19.4 Operation19.4.1 Fusing Roller Pressure Mechanism19.4.2 Fusing Temperature Control (for bizhub 163)19.4.3 Fusing Temperature Control (for bizhub 211/220)19.4.4 PPM Control (bizhub 163 Only)

20. Paper exit (for bizhub 163)20.1 Composition20.2 Drive

21. Paper exit (for bizhub 210/220)21.1 Construction21.2 Operation

22. Image stabilization system22.1 Composition

23. Others23.1 Fan Control23.1.1 Composition23.1.2 Operation

DF-605/MK-501CONTENTSOutline1. Product specifications2. Paper Feed Path2.1 In 1-sided mode2.2 In 2-sided mode

Composition/Operation3. Composition4. Drive5. Operation5.1 Document pick-up mechanism5.1.1 Pick-up operation

5.2 Document feed/transport mechanism5.3 Raised/lowered position detecting mechanism5.3.1 Document size detection5.3.2 Raised/lowered position detection

DF-502CONTENTSOutline1. Product specification

Composition/Operation2. Automatic Document Feeder (DF-502)2.1 Composition2.2 Drive2.3 Operation2.3.1 Document Pick-Up and Feed2.3.2 Document Transport2.3.3 Document Separating Mechanism2.3.4 Document Exit Mechanism2.3.5 Document Size Detection Mechanism2.3.6 Raised/Lowered Position Detection Mechanism

AD-504CONTENTSOutline1. Product specifications

Composition/Operation2. Duplex Unit (AD-504)2.1 Composition2.2 Drive2.3 Operation2.3.1 Switchback Operation2.3.2 2-sided Copying with a Single Sheet of Paper Resident in the Unit2.3.3 2-sided Copying with Two Sheets of Paper Resident in the Unit

PF-502CONTENTSOutline1. Product specification

Composition/Operation2. Paper Feed Unit (PF-502)2.1 Composition2.2 Drive2.3 Operation2.3.1 Edge Guide and Trailing Edge Stop2.3.2 Paper Lifting Plate2.3.3 Tray-in-Position Detection2.3.4 Paper Empty Detection2.3.5 Paper Size Detecting Mechanism2.3.6 Paper Separating Mechanism2.3.7 Paper Feed Control2.3.8 Paper Feed Retry Control

MB-501CONTENTSOutline1. Product specification

Composition/Operation2. Multiple Bypass (MB-501)2.1 Composition2.2 Drive2.3 Operation2.3.1 Paper Feed Mechanism2.3.2 Paper Empty Detection Mechanism2.3.3 Paper Feed Control2.3.4 Paper Feed Retry Control

JS-503CONTENTSOutline1. Product specification

Composition/Operation2. Job Separator (JS-503)2.1 Construction2.2 Operation2.2.1 Tray Selecting Mechanism2.2.2 Tray-Full Detecting Mechanism2.2.3 Job Tray Paper Detecting Mechanism

SF-501CONTENTSOutline1. Product specifications

Composition/Operation2. SHIFTING UNIT (SF-501)2.1 Composition2.2 Operation2.2.1 Exit Position Shifting Mechanism

bizhub 163/7616 PARTS GUIDE MANUALINFORMATION FOR PARTS GUIDE MANUALGENERAL CONTENTSCONTENTSindexORIGINAL COVERCONTROL PANELHOUSINGIR SECTIONIR SECTIONSLIDER SECTIONFRAMESFRAMESPAPER TAKE-UP SECTIONPAPER TAKE-UP SECTIONMANUAL FEED SECTIONHOPPER SECTIONCHARGE SECTIONDEVELOPING SECTIONCLEANER SECTIONTRANSPORT SECTIONFUSING SECTIONPAPER EXIT SECTIONDRIVE SECTIONELECTRICAL COMPONENTSCASSETTE SECTIONCASSETTE SECTIONWIRING ACCESSORIES AND JIGSACCESSORY PARTSMAINTENANCE LISTDESTINATION

bizhub 181/211/220/7621/7622 PARTS GUIDE MANUALINFORMATION FOR PARTS GUIDE MANUALGENERAL CONTENTSCONTENTSindexORIGINAL COVERCONTROL PANELHOUSINGIR SECTIONIR SECTIONSLIDER SECTIONFRAMESFRAMESPAPER TAKE-UP SECTIONPAPER TAKE-UP SECTIONMANUAL FEED SECTIONHOPPER SECTIONCHARGE SECTIONDEVELOPING SECTIONCLEANER SECTIONTRANSPORT SECTIONFUSING SECTIONPAPER EXIT SECTIONDRIVE SECTIONELECTRICAL COMPONENTSCASSETTE SECTIONCASSETTE SECTIONPAPER FEEDER UNITPAPER FEEDER UNITPAPER FEEDER UNITWIRING ACCESSORIES AND JIGSACCESSORY PARTSMAINTENANCE LISTDESTINATION

konica-minolta-bizhub-163-211-220-service-manual-free.pdf

Documents

service manual2007

s notice

important warning items

main bodygeneral

safety warnings