Page 1 SERVICE MANUAL FIELD SERVICE 2007.04 2007.04 Ver. 1.0 Ver. 1.0...
Page 2: Table Of Contents
WARNING INDICATIONS ON THE MACHINE ............S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-19 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub 163/211/220 Main body General ........................... 1 Maintenance ........................7 Adjustment/Setting......................95 Troubleshooting......................
Page 3 PF-502 General ........................... 1 Maintenance ........................3 Adjustment/Setting ....................... 11 Troubleshooting ......................17 MB-501 General ........................... 1 Maintenance ........................3 Adjustment/Setting ....................... 19 Troubleshooting ......................25 JS-503 General ........................... 1 Maintenance ........................3 Troubleshooting ......................11 SF-501 General ........................... 1 Maintenance ........................
Page 4: Safety And Important Warning Items
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.
Page 5: 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.
Page 6 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.
Page 7 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 engi- neer (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.
Page 8 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.
Page 9 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.
Page 10 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.
Page 11 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.
Page 12 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.
Page 13: Handling Of Consumables
SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
Page 14 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. •...
Page 15 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.
Page 16: Internal Laser Radiation
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.
Page 17 SAFETY AND IMPORTANT WARNING ITEMS U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class 1 Laser product under Radiation Performance Stan- dard 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.
Page 18 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 5 mW aallonpituus 770-795 nm VARNING!
Page 19: Laser Safety Label
SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. A09AP0E505DA Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. A09AP0C503DA S-16...
Page 20: Precautions For Handling The Laser Equipment
SAFETY AND IMPORTANT WARNING ITEMS 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 printer OFF.
Page 21: Warning Indications On The Machine
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. High voltage High temperature High voltage...
Page 22: Measures To Take In Case Of An Accident
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.
Page 23 MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-20...
Page 24: Composition Of The Service Manual
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.
Page 25: Notation Of The Service Manual
Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) bizhub 163/211/220: Main body (2) Microsoft Windows 98: Windows 98 Microsoft Windows Me: Windows Me Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT...
Page 26 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 27 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.
Page 28: General
Product specification ....................3 Fax kit (FK-506): (Option) ..................6 Maintenance Periodical check ...................... 7 Service schedule ....................7 3.1.1 Main body (bizhub 163) /PF-502/MB-501 ............. 7 3.1.2 Main body (bizhub 211/220) /PF-502/MB-501 ..........7 3.1.3 DF-502 ......................7 3.1.4 DF-605 ......................
Page 29 Field Service Ver. 1.0 Apr. 2007 3.5.9 Replacing the ozone filter ................23 3.5.10 Replacing the PC drum charge corona assy ..........24 3.5.11 Replacing the cleaning blade..............24 3.5.12 Cleaning of the PC drum paper separator fingers ........25 3.5.13 Cleaning of the Ds collars................
Page 30 Fusing unit interlock switch (S2) ..............80 6.3.36 Inch/metric sensor/1 (PS7) assy (3rd area only)......... 83 6.3.37 Flickerless resistor (R1) (Only for 200 V areas of bizhub 163) ....83 6.3.38 Replacing the TCR sensor (TCRS)............. 84 6.3.39 Application of toner ..................85 Cleaning procedure ....................
Page 31 Field Service Ver. 1.0 Apr. 2007 6.4.11 Pre-Image transfer lower guide plate............92 6.4.12 Charge neutralizing plate................92 Option counter....................93 6.5.1 Installation of the key counter ..............93 Adjustment/Setting How to use the adjustment section ............... 95 Utility Mode ......................96 Utility Mode function tree ..................
Page 32: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 10.3.4 DISPLAY ....................136 10.3.5 FUNCTION ....................137 10.3.6 SOFT SWITCH ..................139 10.3.7 REPORT ....................139 10.3.8 ADMIN. REGISTRATION ................140 10.3.9 FIXED ZOOM CHANGE ................140 10.3.10 FACTORY TEST ..................141 10.3.11 CLEAR DATA .................... 142 Security .......................
Page 33 Field Service Ver. 1.0 Apr. 2007 Malfunction code....................160 14.1 Trouble code ..................... 160 14.1.1 Trouble code list ..................160 14.2 How to reset ..................... 164 14.3 Solution ......................165 14.3.1 C0000: Main motor malfunction..............165 14.3.2 C0045: Fusing cooling fan motor malfunction........... 165 14.3.3 C004E: Power unit cooling fan motor malfunction ........
Page 34 Field Service Ver. 1.0 Apr. 2007 16.2.6 Image reading section: Black spots ............181 16.2.7 Image reading section: White streaks or bands ........182 16.2.8 Image reading section: Uneven image density ......... 183 16.2.9 Image reading section: Gradation reproduction failure ......184 16.2.10 Image reading section: Periodically uneven image ........
Page 35 Field Service Ver. 1.0 Apr. 2007 Blank Page viii...
Page 36: General
Mechanical counter (MC-503) *1: The standard bizhub 220 configuration is the main body plus 1-drawer paper feed unit. *2: Standard only on the bizhub 163 and bizhub 211/220 for china *3: To be mountable only on bizhub 211/220 *4: Standard only the main body for china (but separately packaged upon shipment from...
Page 37 1. System configuration Field Service Ver. 1.0 Apr. 2007 2/2 System rear view A08EE502AA Expanded memory unit (EM-103) Image controller (IC-206) * Fax kit (FK-506) Network interface card (NC-503) * * It is not possible to mount these units at the same time.
Page 38: Product Specification
Multiple copies 1 to 99 15 sec. or less: bizhub 211/bizhub 220 30 sec. or less: bizhub 163 Warming-up time (when the auxiliary power switch is turned ON from a stabilized state, in which the main power switch is ON and auxiliary power switch is OFF, with the rated power source voltage and at a room temperature of 23°C)
Page 39: Maintenance
*2: If the width set 297 mm, the max. length is to 420 mm. If the length set 432 mm, the max. width is to 279 mm. D. Maintenance 300,000 prints or 5 years, whichever is earlier Machine durability (bizhub 211/bizhub 220) 240,000 prints or 5 years, whichever is earlier (bizhub 163)
Page 40 599 (W) x 620 (D) x 520 (H) mm *1 Dimensions 760 (W) x 620 (D) x 604 (H) mm *2 (bizhub 220 for China) 760 (W) x 620 (D) x 520 (H) mm *2 (bizhub 163 for China) 998 (W) x 665 (D) mm (bizhub 211/220) Space requirements...
Page 41: Fax Kit (Fk-506): (Option)
2. Product specification Field Service Ver. 1.0 Apr. 2007 Fax kit (FK-506): (Option) Transmission mode Compatible wiring General subscriber telephone line, NCC each line Connection method Direct connection (using a modular jack) Transmission speed 33.6, 31.2, 28.8, 26.4, 24.0, 21.6, 19.2, 16.8, 14.4, 12.0, 9.6, 7.2, 4.8, 2.4 kbps (automatic switching) Transmission time 3 seconds *1...
Page 42: Maintenance
Field Service Ver. 1.0 Apr. 2007 3. Periodical check Maintenance Periodical check Service schedule 3.1.1 Main body (bizhub 163) /PF-502/MB-501 Guarantee period : 5-year or 240,000 prints x 10,000-print No. of Service item times ● ● ● ● ● 40,000 Main ●...
Page 43: Maintenance Items
3. Periodical check Field Service Ver. 1.0 Apr. 2007 Maintenance items 3.2.1 Parts to be replaced by users (CRU) Descrip- Class Parts to be replaced Cycle Clean Replace tions Processing ● Toner bottle 11,000 sections 3.2.2 Periodical parts replacement/cleaning 1 (per 30,000-original feed) Lubri- Descrip- Class...
Page 44: Periodical Parts Replacement/Cleaning 3 (Per 50,000-Original Feed)
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.2.4 Periodical parts replacement/cleaning 3 (per 50,000-original feed) Lubri- Descrip- Class Parts to be replaced Check Clean Replace cation tions Paper feed and image  ● conditions Overall  ● ● Appearance ...
Page 45: Periodical Parts Replacement/Cleaning 6 (Per 150,000-Print)
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.2.7 Periodical parts replacement/cleaning 6 (per 150,000-print) Lubri- Descrip- Class Parts to be replaced Check Clean Replace cation tions Paper feed and image  ● conditions Overall  ● ● Appearance ●...
Page 46: Maintenance Parts
Field Service Ver. 1.0 Apr. 2007 3. Periodical check Maintenance parts • To ensure that the machine produces good copies and to extend its service life, it is rec- ommended that the maintenance jobs described in this schedule be carried out as instructed.
Page 47 3. Periodical check Field Service Ver. 1.0 Apr. 2007 B. Options Actual Ref.page Classifi- Parts name durable Pats No. Descriptions in this cation ntity cycle *1 manual Pick-up roller 120,000 4688 3032 ## Replace those DF-502 Feed roller 120,000 4688 3033 ## three parts at the same time.
Page 48: Cleaning Parts
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.3.2 Cleaning parts Classifi- Actual cleaning Ref.page in Parts name Descriptions cation cycle *1 this manual Ds collars 40,000 P.25 Developer scattering prevention Imaging 40,000 P.26 plate unit section Pre-image transfer guide plate 40,000 P.29 PC drum paper separator fingers...
Page 49: Concept Of Parts Life
Item Description Copying type 2P/J Paper size bizhub 163 Average 2,000/month, Max. 12,000/month CV/M bizhub 211/220 Average 3,000/month, Max. 16,000/month Original density B/W 6%...
Page 50: Maintenance Procedure (Periodical Check Parts)
Field Service Ver. 1.0 Apr. 2007 3. Periodical check Maintenance procedure (periodical check parts) NOTE • The alcohol described in the cleaning procedure of maintenance represents the isopropyl alcohol. 3.5.1 Cleaning of the original glass and original scanning glass A. Periodically cleaning parts/cycle •...
Page 51 3. Periodical check Field Service Ver. 1.0 Apr. 2007 3. Remove the separation roller fixing plate assy [1]. A09AF2C003DA 4. Take off the rubber stopper [1], shaft [2], spring [3], and guide plate [4] to remove the paper separation roller fixing bracket assy [5].
Page 52: Replacing The Feed Roller
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.5.3 Replacing the feed roller A. Periodically replaced parts/cycle • Feed roller: Every 150,000 prints B. Procedure 1. Slide out the tray/1. 2. Press down the paper lifting plate. 3. Snap off the C-clip [2] from the feed roller assy [1].
Page 53: Replacing The Paper Dust Remover Assy
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.5.4 Replacing the paper dust remover assy A. Periodically replaced parts/cycle • Paper dust remover assy: Every 40,000 prints B. Procedure 1. Open the right door. 2. Remove the imaging unit. See P.20 3.
Page 54 Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3. Turn up the sealing part [1] of the new toner bottle, and remove the seal toward slowly. A09AF2C532DA 4. Turn up the part with “UP” display of the toner bottle [1], and put it into the toner bottle holder [2].
Page 55: Replacing The Imaging Unit
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.5.6 Replacing the imaging unit A. Procedure NOTE • When the developer is to be changed, it is necessary that toner in the recycled toner recycling duct and toner conveying duct be fed into the developer mixing chamber.
Page 56 Field Service Ver. 1.0 Apr. 2007 3. Periodical check 2. Remove two screws [1] in the rear of the IU. A09AF2C536DA 3. Remove two screws [1] at the front of the IU. A09AF2C537DA 4. Widen flaps on both ends (marked with A in the photo on the left) [1] of the drum assy in the direction of the arrow and turn to take off the devel-...
Page 57: Replacing The Pc Drum
3. Periodical check Field Service Ver. 1.0 Apr. 2007 5. Unplug the connector [1] of the main erase. A09AF2C539DA 3.5.8 Replacing the PC drum A. Periodically replaced parts/cycle • PC drum: Every 40,000 prints B. Procedure 1. Remove the developing assy from the imaging unit. See IU disassemble procedure 1 to 4.
Page 58: Replacing The Ozone Filter
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.5.9 Replacing the ozone filter A. Periodically replaced parts/cycle • Ozone filter: Every 150,000 prints B. Procedure 1. Remove the PC drum. See P.22 2. Remove two screws [1], and remove the main erase [2].
Page 59: Replacing The Pc Drum Charge Corona Assy
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.5.10 Replacing the PC drum charge corona assy A. Periodically replaced parts/cycle • PC drum charge corona assy: Every 40,000 prints B. Procedure 1. Remove the PC drum. See P.22 2. Remove the main erase. See P.23 3.
Page 60: Cleaning Of The Pc Drum Paper Separator Fingers
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.5.12 Cleaning of the PC drum paper separator fingers A. Periodically cleaning parts/cycle • PC drum paper separator fingers: Every 40,000 prints B. Procedure 1. Remove the cleaning blade. See P.24 2.
Page 61: Cleaning Of The Developer Scattering Prevention Plate
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.5.14 Cleaning of the developer scattering prevention plate A. Periodically cleaning parts/cycle • Developer scattering prevention plate: Every 40,000 prints B. Procedure 1. Divide the image unit into the PC drum assy and the developing assy. See P.20 2.
Page 62: Replacing The Developer / Toner Agitating Seal
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3.5.15 Replacing the developer / toner agitating seal A. Periodically replaced parts/cycle • Developer: Every 40,000 prints B. Procedure 1. Remove the developer scattering prevention plate. See P.26 2. Dump the developer. A09AF2C556DA <<How to dump developer>>...
Page 63 3. Periodical check Field Service Ver. 1.0 Apr. 2007 4. Put the new toner agitating seal [1]. NOTE • Put the toner agitating seal at the position shown the left. • Check to make sure that the bottom of the toner agitating seal is on the transporting blade.
Page 64: Cleaning Of The Pre-Image Transfer Guide Plate
Field Service Ver. 1.0 Apr. 2007 3. Periodical check 7. Attach the developer scattering pre- vention plate and confirm through the opening [1] that the bottom of the toner agitating seal [2] is on the transporting blade [3]. A09AF2C632DA 3.5.16 Cleaning of the pre-image transfer guide plate A.
Page 65: Replacing The Image Transfer Roller Assy
3. Periodical check Field Service Ver. 1.0 Apr. 2007 3.5.17 Replacing the image transfer roller assy A. Periodically replaced parts/cycle • Image transfer roller assy: Every 150,000 prints B. Procedure 1. Open the right door. 2. Unhook two tabs [1]. and remove the image transfer roller assy [2].
Page 66 Field Service Ver. 1.0 Apr. 2007 3. Periodical check 3. Open the right door. 4. Remove four screws [1], and remove the fusing unit [2]. NOTE When removing the fusing unit, make sure of the correct type of screws that must be removed.
Page 67: Service Tool
4. Service tool Field Service Ver. 1.0 Apr. 2007 Service tool Service material list Name Shape Material No. Remarks  Isopropyl alcohol A00KF2C506DA CE tool list Tool name Shape Parts No. Personnel Remarks Scanner/mirrors carriage 4034 7901 ## 1 for each positioning jigs 4034 7902 ## 4034F2C501DA...
Page 68: Firmware Upgrade
Field Service Ver. 1.0 Apr. 2007 5. Firmware upgrade Firmware upgrade Preparations for firmware rewriting 5.1.1 Installing the driver NOTE • The TWAIN driver must previously be installed in the host computer that is used to upgrade the firmware. • If the TWAIN driver has not been installed, use the procedure below to install it. •...
Page 69 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 (3) For Windows Me/98SE 1. Prepare the files necessary for upgrading the firmware, and copy them to PC. 2. Start the host computer. 3. Turn on the power switch of the machine. 4.
Page 70: Firmware Rewriting
Field Service Ver. 1.0 Apr. 2007 5. Firmware upgrade Firmware rewriting 5.2.1 Updating method 1. Turn ON the power switch of the machine. 2. Start the host computer. 3. Copy the “Update Software” folder and “Update” file to drive C. (Copy them into the highest directory on drive C.) 4.
Page 71 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 8. Click the [Update] button to start the transfer of the firmware data. (Wait until data transfer is completed.) 9. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE •...
Page 72: Procedure When Upgrading The Firmware Has Failed
Field Service Ver. 1.0 Apr. 2007 5. Firmware upgrade 5.2.2 Procedure when upgrading the firmware has failed NOTE • Perform the following procedure only when upgrading from PC using ordinary USB connection has failed and the machine has not started properly. •...
Page 73 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 10. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE • NEVER turn OFF and ON the power switch as long as the above screens are being displayed. 11.
Page 74: Other
Field Service Ver. 1.0 Apr. 2007 6. Other Other Disassembly/adjustment prohibited items A. Paint-locked screws • To prevent loose screws, a screw lock in blue or green series color is applied to the screws. • The screw lock is applied to the screws that may get loose due to the vibrations and loads created by the use of machine or due to the vibrations created during transportation.
Page 75: Disassembly/Assembly/Cleaning List (Other Parts)
6. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/assembly/cleaning list (other parts) 6.2.1 Disassembly/assembly parts list Section Part name Ref.page Original glass/Original scanning glass P.42 Control panel P.42 Front cover P.43 Paper exit cover P.44 Front door P.44 Tray 1 P.44 Left cover P.45...
Page 76: Cleaning Parts List
Field Service Ver. 1.0 Apr. 2007 6. Other Section Part name Ref.page Main motor (M1) P.76 Power unit cooling fan motor (FM2) P.77 Fusing cooling fan motor (FM1) P.78 Paper size sensor (S5) assy P.79 Others Fusing unit interlock switch (S2) P.80 Inch/metric sensor/1 (PS7) assy P.83...
Page 77: Disassembly/Assembly Procedure
6. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/assembly procedure 6.3.1 Original glass/Original scanning glass 1. Remove the right cover. See P.48 2. Remove two screws [1], and remove two fixing holders [2]. 3. Remove the original glass [3]. A09AF2C012DA 4.
Page 78: Front Cover
Field Service Ver. 1.0 Apr. 2007 6. Other 2. Remove two screws [1]. A09AF2C015DA 3. Disconnect the flat cable [1] and the connector [2], and remove the con- trol panel [3]. A09AF2C016DA 6.3.3 Front cover 1. Remove the control panel. See P.42 2.
Page 79: Paper Exit Cover
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.4 Paper exit cover 1. Remove the front cover. See P.43 2. Remove the screw [1], and remove the paper exit cover [2]. A09AF2C018DA 6.3.5 Front door 1. Open the front door. 2.
Page 80: Left Cover
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.7 Left cover 1. Remove the front cover. See P.43 2. Remove five screws [1], and remove the left cover [2]. A09AF2C021DA 6.3.8 Paper exit tray 1. Remove the front cover. See P.43 2.
Page 81: Rear Inside Cover
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.9 Rear inside cover 1. Remove the left cover. See P.45 2. Remove the paper exit tray. See P.45 3. Remove two screws [1], and remove the rear inside cover [2]. A09AF2C023DA 6.3.10 Upper rear cover 1.
Page 82: Left Rear Cover
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.11 Left rear cover 1. Remove the upper rear cover. See P.46 2. Remove four screws [1], and remove the left rear cover [2]. A09AF2C025DA 6.3.12 Rear cover 1. Remove nine screws [1], and remove the rear cover [2].
Page 83: Rear Right Cover
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.14 Rear right cover 1. Remove two screws [1], and remove the rear right cover [2]. A09AF2C028DA 6.3.15 Right cover 1. Remove the front cover. See P.43 2. Remove four screws [1], and remove the right cover [2].
Page 84: Mfp Board (Mfpb)
Field Service Ver. 1.0 Apr. 2007 6. Other 3. Remove four screws [1], and remove the printer control board [2]. NOTE • When the printer control board is to be replaced, rewriting the firmware to the latest one. A09AF2C031DA 6.3.17 MFP board (MFPB) 1.
Page 85: High Voltage Unit (Hv1)
6. Other Field Service Ver. 1.0 Apr. 2007 NOTE • When the MFP board (MFPB) is replaced with a new one, parameter chip (U18) must be demounted from the old MFPB and remounted on the new MFPB. Mount the parameter chip (U18) of the old MFPB on the new MFPB. A09AF2C503DA NOTE •...
Page 86: Power Supply Unit (Dcpu)
Field Service Ver. 1.0 Apr. 2007 6. Other 4. Remove two screws [1], and remove the high voltage unit [2]. A09AF2C546DA 6.3.19 Power supply unit (DCPU) 1. Remove the left cover. See P.45 2. Remove the rear cover. See P.47 3.
Page 87 6. Other Field Service Ver. 1.0 Apr. 2007 8. Remove eight screws [1], and remove the protective cover 2 [2]. A09AF2C035DA 9. Disconnect all connectors from the power supply unit [1]. A09AF2C036DA 10. Remove six screws [1], and remove the power supply unit [2]. A09AF2C037DA...
Page 88: Paper Size Detect Board (Psdtb)
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.20 Paper size detect board (PSDTB) 1. Remove the rear cover. See P.47 2. Slide out the tray 1. 3. Unhook two tabs [1], and remove the holder [2]. A09AF2C547DA 4. Remove the lever [1]. A09AF2C548DA 5.
Page 89: Heater Relay Board (Ryb): 200 V Areas Only
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.21 Heater relay board (RYB): 200 V areas only 1. Remove the front cover. See P.43 2. Remove the left cover. See P.45 3. Disconnect two connectors [1] and remove three PWB supports [2], and remove the heater relay board [3].
Page 90: Manual Bypass Tray
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.23 Manual bypass tray 1. Remove the rear right cover. See P.48 2. Open the right door. 3. Remove two screws [1], disconnect the connector [2], and remove the manual bypass tray [3]. A09AF2C038DA 6.3.24 Toner hopper unit/Toner replenishing motor (M2)
Page 91 6. Other Field Service Ver. 1.0 Apr. 2007 7. Disconnect two connectors [1]. A09AF2C562DA 8. Remove the toner hopper unit [1]. A09AF2C563DA 9. Remove two screws [1], and remove the toner replenishing motor [2]. A09AF2C564DA...
Page 92: Ph Unit
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.25 PH unit CAUTION • Do not replace the printer head unit while the power is ON. Laser beam generated during the above mentioned activity may cause blindness. • Do not disassemble or adjust the printer head unit. Laser beam generated during the above mentioned activity may cause blindness.
Page 93: Disassembly Of The Fusing Unit
6. Other Field Service Ver. 1.0 Apr. 2007 8. Remove the harness from the wire saddle [1]. A09AF2C567DA 9. Remove three screws (with springs) [1], and remove the PH unit [2]. A09AF2C568DA 6.3.26 Disassembly of the fusing unit A. Removal of the thermistor and paper separator fingers 1.
Page 94 Field Service Ver. 1.0 Apr. 2007 6. Other 3. Remove the torsion coil spring [1], and remove the movable guide assy [2]. A09AF2C570DA 4. Remove three shoulder screws [1], three washers [2], and remove the fusing roller/rt cover [3]. [1] [2] [1] [2] A09AF2C571DA 5.
Page 95 6. Other Field Service Ver. 1.0 Apr. 2007 NOTE • Install the right and left bearings [1] in the directions shown in the photo on the left. A09AF2C573DA 6. Remove the screw [1]. Then, slide the paper separator fin- ger assy cover [2] in the direction of the arrow and take it off.
Page 96: Ccd Unit
Field Service Ver. 1.0 Apr. 2007 6. Other 8. Unhook springs [1], and remove the four paper separator fingers [2]. A09AF2C576DA 6.3.27 CCD unit A. Removal procedure 1. Remove the original glass. See P.42 2. Remove four screws [1], and remove the CCD unit cover [2].
Page 97 6. Other Field Service Ver. 1.0 Apr. 2007 3. Mark a line along the profile of the CCD unit mounting bracket [1] as shown on the left. A09AF2C578DA 4. Disconnect the connector [1]. A09AF2C579DA 5. Remove three screws [1] (to which green paint has been applied), and remove the CCD unit [2].
Page 98: Scanner, Exposure Lamp, And Inverter Board (Pu2)
Field Service Ver. 1.0 Apr. 2007 6. Other B. Reinstallation procedure 1. Position the CCD unit [2] along the marking line. Then, temporarily secure three screws [1] at the center of each of the screw slots. 2. Adjust the position of the CCD unit. See P.146 A09AF2C580DA 6.3.28...
Page 99 6. Other Field Service Ver. 1.0 Apr. 2007 4. Disconnect the flat cable [1], and remove the scanner assy [2]. A09AF2C583DA 5. Remove two screws [1], disconnect the connector [2], and remove the inverter board [3]. A09AF2C584DA 6. Remove two screws [1], and remove the exposure lamp [2].
Page 100: Scanner Motor (M4)
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.29 Scanner motor (M4) 1. Remove the right rear cover. See P.47 2. Remove the scanner motor harness from five wire saddles [1]. A09AF2C586DA 3. Disconnect the connector [2] from the MFP board [1]. A09AF2C587DA 4.
Page 101: Scanner Drive Cables
6. Other Field Service Ver. 1.0 Apr. 2007 6. Remove two screws [1], and remove the scanner motor [2]. A09AF2C589DA 6.3.30 Scanner drive cables A. Removal procedure 1. Remove the left cover. See P.45 2. Remove the front cover. See P.43 3.
Page 102 Field Service Ver. 1.0 Apr. 2007 6. Other 8. Unhook the springs [1] from the cable hooks at the front and rear. A09AF2C612DA 9. Remove the front cable [1] from the cable pulley [2]. A09AF2C613DA 10. Remove the rear cable [1] from the cable pulley [2].
Page 103 6. Other Field Service Ver. 1.0 Apr. 2007 11. Remove the screw [1] from the front cable pulley. A09AF2C615DA 12. Remove the screw [1] from the rear cable pulley. A09AF2C616DA 13. Snap off the C-ring [1] from the front side of the pulley assy. A09AF2C617DA...
Page 104 Field Service Ver. 1.0 Apr. 2007 6. Other 14. Snap off the C-ring [1] from the rear side of the pulley assy. A09AF2C618DA 15. Pull out the shaft [1], and remove two bearings [2]. A09AF2C619DA 16. Remove two screws [1] from the rear side of the pulley assy and remove the gear [2].
Page 105 6. Other Field Service Ver. 1.0 Apr. 2007 B. Reinstallation procedure <Overall view> Wire pulley 2 Wire pulley 1 Pulley D Pulley C Pulley B Pulley A A09AF2C508DA NOTE • The cables are color-coded and differ in type from each other: the front cable is sil- ver, while the rear cable is black.
Page 106 Field Service Ver. 1.0 Apr. 2007 6. Other 3. Wind the cable on side A around wire pulley 2 [1] four turns clockwise, starting with the slit at the top in the front left of the pulley. A09AF2C511DA 4. Affix tape [1] to secure the cable to wire pulley 2 [2].
Page 107 6. Other Field Service Ver. 1.0 Apr. 2007 7. Wind the cable on side B around wire pulley 1 [1] four turns clockwise, starting with the slit at the top in the rear left of the pulley. A09AF2C515DA 8. Affix tape [1] to secure the cable to wire pulley 1 [2].
Page 108 Field Service Ver. 1.0 Apr. 2007 6. Other 12. Secure the front and rear cable pul- leys [1] to the shaft [3] using the screw [2] each. NOTE • The direction in which the screw is installed differs between the front and rear.
Page 109 6. Other Field Service Ver. 1.0 Apr. 2007 15. Pass the cable from pulley B [1] into the hole [2] in the IR frame. A09AF2C521DA 16. Wind the lower cable of wire pulley 2 around pulley C [1]. A09AF2C522DA 17. Wind the cable from pulley C [1] around pulley D [2].
Page 110 Field Service Ver. 1.0 Apr. 2007 6. Other 18. Pass the cable from pulley D [1] into the hole [2] in the IR frame. A09AF2C524DA 19. Pass the leading edge of each of the front and rear cables [1] into the space between the IR frame and copier frame.
Page 111: Main Motor (M1)
6. Other Field Service Ver. 1.0 Apr. 2007 22. Wind the upper cable of wire pulley 2 around pulley D [1] and hook it onto the hook. NOTE • Wind the cable around the inner groove in pulley D. A09AF2C527DA 23.
Page 112: Power Unit Cooling Fan Motor (Fm2)
Field Service Ver. 1.0 Apr. 2007 6. Other 3. Remove four screws [1], unplug the connector [2], and remove the main motor [3]. A09AF2C039DA 6.3.32 Power unit cooling fan motor (FM2) 1. Remove the left cover, rear cover, and upper rear cover. See P.45, P.47, P.46 2.
Page 113: Fusing Cooling Fan Motor (Fm1)
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.33 Fusing cooling fan motor (FM1) 1. Remove the rear right cover. See P.48 2. Open the right door. 3. Remove the image transfer roller assy. See P.30 4. Remove the screw [1], unhook two tabs [2], and remove the transport unit holder [3]. A09AF2C592DA NOTE •...
Page 114: Paper Size Sensor (S5) Assy
Field Service Ver. 1.0 Apr. 2007 6. Other 7. Remove two screws [1], unplug the connector [2], and remove the fusing cooling fan motor [3]. A09AF2C595DA 6.3.34 Paper size sensor (S5) assy 1. Remove the rear cover. See P.47 2. Slide out the paper feed tray/1. 3.
Page 115: Fusing Unit Interlock Switch (S2)
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.35 Fusing unit interlock switch (S2) 1. Remove the rear cover. See P.47 2. Remove the harness from the wire saddle [1]. A09AF2C040DA 3. Remove two screws [1] (to which red paint has been applied). A09AF2C041DA 4.
Page 116 Field Service Ver. 1.0 Apr. 2007 6. Other 5. Unhook two tabs [1], and remove the fusing unit interlock switch [2]. A09AF2C598DA <Fusing unit interlock switch reinstallation procedure> 1. Fit the switch holder to the fusing unit interlock switch. 2. Connect the four connectors to the fusing unit interlock switch assy. 3.
Page 117 <bizhub 163> <bizhub 211/220> A09AF2E633DA <for bizhub 163> 5. Close the right door, and then use a tester to make sure that the fusing unit interlock switch is conducting between 2A and 2B. 6. Open the right door, and then use a tester to make sure that the fusing unit interlock switch is not conducting between 2A and 2B.
Page 118: Inch/Metric Sensor/1 (Ps7) Assy (3Rd Area Only)
2. Remove the screw [1], disconnect the connector [2], and remove the inch/metric sensor/1 assy [3]. A09AF2E634DA 6.3.37 Flickerless resistor (R1) (Only for 200 V areas of bizhub 163) 1. Remove the rear cover. See P.47 2. Remove the printer control board. See P.48 3.
Page 119: Replacing The Tcr Sensor (Tcrs)
6. Other Field Service Ver. 1.0 Apr. 2007 6.3.38 Replacing the TCR sensor (TCRS) 1. Separate the IU into the drum assy and developing assy. See P.20 2. Remove the developer scattering prevention plate. See P.26 3. Dump the developer. See P.27 4.
Page 120: Application Of Toner
Field Service Ver. 1.0 Apr. 2007 6. Other 6.3.39 Application of toner NOTE • Perform these steps when the PC drum and/or cleaning blade have been replaced. 1. With the IU divided into the drum assy and developing assy, install the PC positioning jig [1] in the rear of the developing assy.
Page 121: Cleaning Procedure
6. Other Field Service Ver. 1.0 Apr. 2007 3. Hold both ends [1] of the PC drum with your both hands and turn the PC drum a half turn in the direction of the arrow. A09AF2C507DA Cleaning procedure NOTE • The alcohol described in the cleaning procedure of maintenance represents the isopropyl alcohol.
Page 122: Feed Roller
Field Service Ver. 1.0 Apr. 2007 6. Other 6.4.2 Feed roller 1. Slide out the tray 1. 2. Using a soft cloth dampened with alcohol, wipe the feed roller [1] clean of dirt. A09AF2C600DA 6.4.3 Upper/Lower Synchronizing Rollers 1. Open the right door. 2.
Page 123: Paper Dust Remover
6. Other Field Service Ver. 1.0 Apr. 2007 6.4.4 Paper dust remover 1. Remove the paper dust remover assy. See P.18 2. Using a brush, whisk dust and dirt off the paper dust remover [1]. A09AF2C602DA 6.4.5 Bypass transport roller/roll 1.
Page 124: Mirrors
Field Service Ver. 1.0 Apr. 2007 6. Other 5. Using a soft cloth dampened with alcohol, wipe the bypass transport roll [1] clean of dirt. A09AF2C046DA 6.4.6 Mirrors 1. Remove the original glass. See P.42 2. Using a soft cloth dampened with alcohol, wipe the mirrors clean of dirt.
Page 125: Ccd Sensor
6. Other Field Service Ver. 1.0 Apr. 2007 6.4.8 CCD Sensor 1. Remove the original glass. See P.42 2. Remove four screws [1], and remove the CCD unit cover [2]. A09AF2C577DA 3. Pulling the tabs [1] on both sides of the lens cover, remove the lens cover [2].
Page 126: Scanner Rails/Bearings
Field Service Ver. 1.0 Apr. 2007 6. Other 6.4.9 Scanner rails/bearings 1. Remove the original glass. See P.42 2. Using a soft cloth dampened with alcohol, wipe the scanner rails and bearings clean of dirt. NOTE • After the scanner rails and bearings have been cleaned, apply oil (copier lubricant A or FLOIL 947P).
Page 127: Pre-Image Transfer Lower Guide Plate
6. Other Field Service Ver. 1.0 Apr. 2007 6.4.11 Pre-Image transfer lower guide plate 1. Open the right door. 2. Using a soft cloth dampened with alcohol, wipe the pre-image transfer lower guide plate [1] clean of dirt. A09AF2C609DA 6.4.12 Charge neutralizing plate 1.
Page 128: Option Counter
Field Service Ver. 1.0 Apr. 2007 6. Other Option counter 6.5.1 Installation of the key counter 1. Cut out the knockout [1] from the right cover. A09AF2C047DA 2. Using two screws [1], secure the counter mounting bracket [2]. A09AF2C048DA 3. Connect the key counter socket con- nector [1].
Page 129 6. Other Field Service Ver. 1.0 Apr. 2007 4. Using two screws [1], secure the key counter socket [2]. A09AF2C050DA 5. Using two screws [1], secure the key counter cover [2]. A09AF2C051DA 6. Plug in the key counter [1]. NOTE •...
Page 130: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 7. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. A.
Page 131: Utility Mode
8. Utility Mode Field Service Ver. 1.0 Apr. 2007 Utility Mode • Utility mode is used to make settings for the utility functions. Utility Mode function tree Utility Mode Ref. page MACHINE SETTING AUTO PANEL RESET P.99 ENERGY SAVE MODE P.99 AUTO SHUT OFF P.99...
Page 132 Field Service Ver. 1.0 Apr. 2007 8. Utility Mode Utility Mode Ref. page ADMIN. MANAGEMENT E-MAIL SETTING 1 *3 SENDER NAME *3 P.106 E-MAIL ADDERSS *3 SMTP SERVER ADDR. *3 SMTP PORT NO. *3 SMTP TIMEOUT *3 TEXT INSERT *3 DEFAULT SUBJECT *3 POP BEFORE SMTP *3 E-MAIL MODE *4...
Page 133 8. Utility Mode Field Service Ver. 1.0 Apr. 2007 Utility Mode Ref. page DIAL REGISTRATION *1 ONE-TOUCH DIAL *1 P.109 SPEED DIAL *1 GROUP DIAL *1 PROGRAM DIAL *1 FAX REGISTRATION *1 MAIL BOX *1 P.109 RELAY BOX *1 FAX TX OPERATION *1 DENSITY LEVEL *1 P.109 QUALITY PRIORITY *1...
Page 134: Utility Mode Function Setting Procedure
Field Service Ver. 1.0 Apr. 2007 8. Utility Mode Utility Mode function setting procedure 8.2.1 Procedure 1. Press the Utility key. 2. The Utility Mode screen will appear. 8.2.2 Exiting • Press the Back key. 8.2.3 Changing the setting value in Utility Mode functions •...
Page 135 8. Utility Mode Field Service Ver. 1.0 Apr. 2007 D. DENSITY (ADF) • This setting is available when the optional DF-502 or DF-605 is mounted. Functions • To set the reading image density level when the automatic document feeder is used. MODE1 : To lower the image density to prevent a dirty copy from being pro- duced.
Page 136 Field Service Ver. 1.0 Apr. 2007 8. Utility Mode H. KEY SPEED SETTING Functions • To set the time that the repetitive input gets started when keeping on pressing the key. • To set the cycle time of the repetitive input. Setting/ <TIME TO START>...
Page 137: Paper Source Setup
8. Utility Mode Field Service Ver. 1.0 Apr. 2007 8.3.2 PAPER SOURCE SETUP A. INCH/METRIC Functions • To set the paper size unit of each tray. • To change the size unit of the paper to be used. NOTE • If it is not set appropriately, auto detection of paper size cannot be made. •...
Page 138: Custom Size Memory
Field Service Ver. 1.0 Apr. 2007 8. Utility Mode C. PAPER TYPE Functions • To set the special paper type of each tray. • To set whether [Auto paper select]/[Auto tray change] is used for each tray according to the paper type to be used. •...
Page 139: Admin. Management
8. Utility Mode Field Service Ver. 1.0 Apr. 2007 B. TONER REPLENISHER Functions • To execute Toner replenishment forcibly to adjust the tone to the T/C level set. • To be used when a large number of copies are made for the original with high density and ID is deteriorated due to the decrease of T/C ratio.
Page 140 Field Service Ver. 1.0 Apr. 2007 8. Utility Mode C. ACCOUNT TRACK (1) ACCOUNT TRACK MODE Functions • To select whether to turn ON or OFF the account track function. Setting/ • The default setting is OFF. Procedure “OFF” (2) ACCESS NO. REG. Functions •...
Page 141: Copy Setting 1
8. Utility Mode Field Service Ver. 1.0 Apr. 2007 F. E-MAIL SETTING 1 See P.15 of the IC-206/NC-503 service manual G. E-MAIL SETTING 2 See P.18 of the IC-206/NC-503 service manual H. COMM.SETTING See P.21 of the FK-506 service manual USER SETTING (1) NTP SERVER ADDRESS See P.19 of the IC-206/NC-503 service manual...
Page 142 Field Service Ver. 1.0 Apr. 2007 8. Utility Mode B. QUALITY PRIORITY Functions • To set the priority image quality mode that is selected when the power switch is turned ON or the Panel Reset key is pressed. Setting/ • The default setting is TEXT/PHOTO. Procedure “TEXT/PHOTO”...
Page 143: Copy Setting 2
8. Utility Mode Field Service Ver. 1.0 Apr. 2007 G. ERASE SETTING Functions • For copies made using CENTER/FRAME ERASE function, you can set an erase width individually on LEFT, UPPER, and FRAME. Setting/ • The default setting is 10 mm for all the positions. Procedure <Step>...
Page 144: Dial Registration
Field Service Ver. 1.0 Apr. 2007 8. Utility Mode D. MIXED ORIGINAL • This setting is available only when the optional DF-502 is installed. Functions • To set whether or not to select the mixed original mode when the power switch is turned ON or Panel Reset key is pressed.
Page 145: Adjustment Item List
9. Adjustment item list Field Service Ver. 1.0 Apr. 2007 Adjustment item list Tray1 Replacement Part/Service Job Adjustment/Setting Items ID ADJUST VG ADJUST LEADING EDGE SER- TRAILING EDGE VICE’S VERTICAL EDGE CHOICE LOOP Ad. (TRAY1) FUSER TEMP. CCD APS SIZE PRN MAIN REGIST PRN SUB REGIST CCD MAIN ZOOM...
Page 146 Field Service Ver. 1.0 Apr. 2007 9. Adjustment item list ✽ This table shows the list of adjustment items when replacing a part. Items are numbered by the priority if there is any. DF-605 DF-502 PF-502 MB-501 1, 3 *: Check when setting is changed.
Page 147 9. Adjustment item list Field Service Ver. 1.0 Apr. 2007 NOTE • Before executing a memory clear, be sure to take notes of the settings and adjust- ment data of Utility Mode, Service Mode., Security Mode, and adjust modes. After the memory clear has been executed, re-enter those data.
Page 148: 10. Service Mode
Field Service Ver. 1.0 Apr. 2007 10. Service Mode 10. Service Mode 10.1 Service Mode function setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the Service Mode. 10.1.1 Procedure 1.
Page 149: 10.2 Service Mode Function Tree
10. Service Mode Field Service Ver. 1.0 Apr. 2007 10.2 Service Mode function tree Service Mode Ref. page SERVICE’S CHOICE MARKETING AREA *1 P.117 SHIPMENT P.117 MAINTENANCE COUNT. P.117 IU LIFT STOP MODE P.117 ID ADJUST P.118 VG ADJUST P.118 FUSER TEMP.
Page 150 Field Service Ver. 1.0 Apr. 2007 10. Service Mode Service Mode Ref. page ADJUST PRN MAIN REGIST P.126 PRN SUB REGIST P.127 CCD MAIN ZOOM P.128 CCD SUB ZOOM P.129 CCD MAIN REGIST P.130 CCD SUB REGIST P.131 ADF SUB ZOOM *3 P.131 ADF MAIN REGIST *3 P.131...
Page 151 10. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Ref. page FUNCTION PAPER FEED TEST P.137 PROCESS CHECK P.138 ATDC AUTO ADJUST P.138 PRN TEST PATTERN P.138 ADF FEED TEST *3 P.138 COPY ADF GLASS P.138 CCD MOVE TO HOME P.139 UPLOAD F/W P.139...
Page 152: 10.3 Setting In The Service Mode
Field Service Ver. 1.0 Apr. 2007 10. Service Mode 10.3 Setting in the Service Mode 10.3.1 SERVICE’S CHOICE A. MARKETING AREA See the FK-506 Service Manual. See P.40 of the FK-506 service manual B. SHIPMENT Functions • To select the display of the fixed zoom ratios and paper sizes according to the appli- cable marketing area.
Page 153 • Used when the type of paper is changed. Setting/ • The default setting is 0. Procedure -1 to +2 <Temperature table for adjusting fusing temperature for plain paper> For bizhub 163 Mode selected in SERVICE’S CHOICE Paper width Mode 1 Mode 3 Setting value...
Page 154 • Used when fusing failure occurs. Setting/ • The default setting is 0. Procedure -1 to +1 <Temperature table for adjusting fusing temperature for special paper> For bizhub 163 Mode selected in SERVICE’S CHOICE Paper width Setting value Mode 1 Mode 3 Fusing heater lamp temperature 210 °C...
Page 155 • Used when fusing failure occurs. Setting/ • The default setting is 0. Procedure -1 to +1 <Temperature table for adjusting fusing temperature for OHP film> For bizhub 163 Mode selected in SERVICE’S CHOICE Paper width Setting value Mode 1 Mode 3...
Page 156 Field Service Ver. 1.0 Apr. 2007 10. Service Mode J. LEADING EDGE Functions • To adjust the erase width on the leading edge of the image by varying the laser emis- sion timing. • Used when the PH unit has been replaced. Setting/ •...
Page 157 10. Service Mode Field Service Ver. 1.0 Apr. 2007 L. VERTICAL EDGE Functions • To adjust the erase width on both edges of the image (in CD direction) by varying the laser emission timing. • Used when the PH Unit has been replaced. Setting/ The default setting is 4 mm.
Page 158 Field Service Ver. 1.0 Apr. 2007 10. Service Mode P. LOOP Ad. (BYPASS) Functions • To adjust the length of the loop formed in the paper feed from the manual bypass tray before the synchronizing roller. • Used when a skew feed, fold, or misfeed of paper occurs. •...
Page 159 10. Service Mode Field Service Ver. 1.0 Apr. 2007 X. CNG LEVEL See P.41 of the FK-506 service manual Y. CED LEVEL See P.41 of the FK-506 service manual Z. ECM MODE See P.41 of the FK-506 service manual AA.CODING SCHEME See P.41 of the FK-506 service manual AB.REPORT DESTINATION See P.42 of the FK-506 service manual...
Page 160 Field Service Ver. 1.0 Apr. 2007 10. Service Mode AG.CCD APS SIZE Functions • To change the original size detection pattern that is used for CCD scan. • To change the original size detection performance settings. • For Inch and Latin America (Inch) areas <Pattern 1>...
Page 161: Adjust
10. Service Mode Field Service Ver. 1.0 Apr. 2007 AH.GDI TIMEOUT Functions • To specify the time for timeout when data from PC is interrupted during GDI printing. Setting/ • The default setting is 6. Procedure 0 (5 sec.) 1 (10 sec.) 2 (20 sec.) 3 (30 sec.) 4 (40 sec.) 5 (50 sec.) “6 (60 sec.)” 10.3.2 ADJUST A.
Page 162 Field Service Ver. 1.0 Apr. 2007 10. Service Mode B. PRN SUB REGIST Functions • To adjust by varying the starting position of image writing in the sub scanning direc- tion. • Used when the image on the copy deviates in the sub scanning direction. •...
Page 163 10. Service Mode Field Service Ver. 1.0 Apr. 2007 C. CCD MAIN ZOOM Functions • To adjust variations in machining and installation accuracy of different IR parts by varying the scanning zoom ratio in the main scanning direction. • Used when the CCD unit has been replaced (After the CCD unit has been adjusted for correct position).
Page 164 Field Service Ver. 1.0 Apr. 2007 10. Service Mode D. CCD SUB ZOOM Functions • To adjust variations in machining and installation accuracy of different IR parts by varying the scanning zoom ratio in the sub scanning direction. • Used when the scanner drive cables have been replaced. Setting/ •...
Page 165 10. Service Mode Field Service Ver. 1.0 Apr. 2007 E. CCD MAIN REGIST Functions • To adjust variations in machining and installation accuracy of different IR parts by varying the starting position of image scanning in the main scanning direction. •...
Page 166 Field Service Ver. 1.0 Apr. 2007 10. Service Mode F. CCD SUB REGIST Functions • To adjust variations in machining and installation accuracy of different IR parts by varying the starting position of image scanning in the sub scanning direction. •...
Page 167: Counter
10. Service Mode Field Service Ver. 1.0 Apr. 2007 K. ADF REG. LOOP1 See P.26 of the DF-605/MK-501 service manual L. ADF REG. LOOP2 See P.27 of the DF-605/MK-501 service manual M. ATDC GAIN Functions • To manually adjust the ATDC sensor voltage. •...
Page 168 Field Service Ver. 1.0 Apr. 2007 10. Service Mode C. PM COUNTER Functions • To display the count of the number of times each of different parts of the machine has been used. • This function is used at the time of maintenance work for the main body and options. •...
Page 169 10. Service Mode Field Service Ver. 1.0 Apr. 2007 G. SCAN COUNTER Functions • To display the count of the scan counter. Setting/ • The number of scan motions carried out for copying is not counted. Procedure • To clear the count, use [CLEAR DATA] of the Service Mode. H.
Page 170 Field Service Ver. 1.0 Apr. 2007 10. Service Mode J. TROUBLE COUNTER Functions • To display the count of the number of malfunctions detected according to the mal- function code. Setting/ C0000: Main motor malfunction Procedure C0044: ADF cooling fan failure (bizhub 211/220 only) C0045: Fusing cooling fan motor malfunction C004E: Power unit cooling fan motor malfunction C0070: Toner replenishing motor malfunction...
Page 171 10. Service Mode Field Service Ver. 1.0 Apr. 2007 10.3.4 DISPLAY A. TONER DENSITY LEVEL Functions • To display the current output value of TCR sensor. • Refer to the following table for actual T/C values. • Used to check the T/C ratio when the image density is defective. Display 8.0%~8.4% 10.0%~10.4%...
Page 172 Field Service Ver. 1.0 Apr. 2007 10. Service Mode F. NIC F/W VER. • This function is available only when the optional NC-503 is installed. Functions • To display the NIC firmware version information. G. ADF F/W VER. • This function is available only when the optional DF-605 is installed. Functions •...
Page 173 10. Service Mode Field Service Ver. 1.0 Apr. 2007 B. PROCESS CHECK Functions • HV output (for factory setting only) *Should not be used C. ATDC AUTO ADJUST Functions • To make an automatic adjustment of the TCR sensor. • Used at setup. •...
Page 174 Field Service Ver. 1.0 Apr. 2007 10. Service Mode G. CCD MOVE TO HOME Functions • To move the scanner to its home position and fix it at the home position. • Used when transporting the machine. Setting/ <Step> Procedure 1.
Page 175 10. Service Mode Field Service Ver. 1.0 Apr. 2007 10.3.8 ADMIN. REGISTRATION Functions • To register or change administrator number. • To change administrator number. • A new administrator number can be set without entering the current registered administrator number. Therefore, this function can be used when an administrator forgets the current registered administrator number.
Page 176 Field Service Ver. 1.0 Apr. 2007 10. Service Mode (4) China Setting name Default fixed zoom ratio Setting range REDUCTION2 51% to 70% REDUCTION1 71% to 99% EXPANSION1 115% 101% to 140% EXPANSION2 141% 141% to 199% (5) Latin America (Metric) Setting name Default fixed zoom ratio Setting range...
Page 177 10. Service Mode Field Service Ver. 1.0 Apr. 2007 E. PANEL BUZZER TEST Functions • To test LEDs and keys on control panel Setting/ PANEL LED TEST Procedure • Make sure that all LEDs on control panel light (for 5 seconds). PANEL SWITCH TEST •...
Page 178 Field Service Ver. 1.0 Apr. 2007 10. Service Mode E. MAINTENANCE COUNTER Functions • To clear the count of the maintenance counter. F. SUPPLIES LIFE COUNT. Functions • To clear the count of the supplies life counter. G. APPLICATION COUNTER Functions •...
Page 179: Security Function Setting Procedure
11. Security Field Service Ver. 1.0 Apr. 2007 11. Security 11.1 Security function setting procedure 11.1.1 Procedure 1. Call the Service mode to the screen. 2. Press the following keys in this order: Stop → 9 3. The Security mode screen will appear. 11.1.2 Exiting •...
Page 180 Field Service Ver. 1.0 Apr. 2007 11. Security 11.3.3 PLUG-IN COUNTER COPY Functions • To select whether to enable or disable copying according to whether the plug-in counter is mounted or not. Setting/ • The default setting is ENABLE. Procedure “ENABLE”...
Page 181 12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 12. Mechanical adjustment 12.1 Adjustment of the position of the scanner and 2nd/3rd mirrors carriage NOTE • This adjustment is to be made when the scanner drive cables has been replaced or rewound.
Page 182: Ccd Unit Position Adjustment
Field Service Ver. 1.0 Apr. 2007 12. Mechanical adjustment NOTE • When the scanner assy is secured to the scanner drive cables [1] using the fixing brackets, make sure that the cables are located as shown on the left. If the cables are not positioned properly, the scanner assy can A09AF3C508DA move askew, resulting an image...
Page 183 12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 3. Loosen the three CCD unit mounting screws [1] (painted in green), slide the CCD unit [2] to the right or left, and secure it in position. Adjustment Instructions If the length on the copy is longer than the actual one, move the CCD unit to the right.
Page 184 Field Service Ver. 1.0 Apr. 2007 12. Mechanical adjustment 6. Remove three screws [1] and the doctor blade [2]. A09AF3C511DA 7. Using a small piece of paper, remove developer from the shaded area on the surface of the sleeve roller [1] and put it in the developer mixing chamber.
Page 185 12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 10. Install the Db gap adjusting jigs [1] in a space between the sleeve roller and doctor blade. A09AF3C514DA 11. Put the developing assy and drum assy together. 12. Press the doctor blade tightly up against the Db gap adjusting jigs and tighten the screws [1] in the order of (1) at the front, (2) at the center, and...
Page 186 Field Service Ver. 1.0 Apr. 2007 12. Mechanical adjustment 12.4 Manual bypass (for the optional AD-504) CD registration adjustment *bizhub 211/220 only NOTE • This adjustment is to be made when the PH unit has been replaced. <Adjustment procedure> 1. Load the paper feed tray/1 with A4 paper. 2.
Page 187 12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 9. Loosen two screws [1] on the manual bypass and adjust the position of the manual bypass. Adjustment Instructions If width A on the copy is smaller than width A on the test pattern, move the manual bypass toward the rear of the machine.
Page 188: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 13. Jam display Troubleshooting 13. Jam display 13.1 Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. A09AF4E504DA Display message Misfeed/paper location Ref.
Page 189 13. Jam display Field Service Ver. 1.0 Apr. 2007 13.2 Sensor layout 13.2.1 System mounted with PF-502 and MB-501. A09AF4C502DA Exit paper sensor (PS3) Paper set sensor/bypass (PS2) Registration sensor (PS1)
Page 190 Field Service Ver. 1.0 Apr. 2007 13. Jam display 13.3 Solution 13.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial checks. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 191 13. Jam display Field Service Ver. 1.0 Apr. 2007 13.3.2 Misfeed at tray1 paper feed section A. Detection timing Type Description Tray1 paper feed • The leading edge of the paper does not unblock the registration sensor (PS1) section misfeed even after the lapse of a given period of time after the paper feed solenoid/1 detection (SD1) has been energized.
Page 192 Field Service Ver. 1.0 Apr. 2007 13. Jam display 13.3.3 Misfeed at the manual bypass tray paper feed section A. Detection timing Type Description Manual bypass tray • The leading edge of the paper does not unblock the registration sensor (PS1) paper feed section even after the lapse of a given period of time after the paper feed solenoid/ misfeed detection...
Page 193 13. Jam display Field Service Ver. 1.0 Apr. 2007 13.3.4 Misfeed at the paper separating section A. Detection timing Type Description • The exit paper sensor (PS3) is not blocked even after the lapse of a given period of time after the paper has unblocked the registration sensor (PS1). Paper separating •...
Page 194 Field Service Ver. 1.0 Apr. 2007 13. Jam display 13.3.5 Misfeed at the fusing/exit section A. Detection timing Type Description Fusing/exit section • The exit paper sensor (PS3) is not unblocked even after the lapse of a given misfeed detection period of time after the registration sensor (PS1) has been blocked.
Page 195: Df-605/Mk
14. Malfunction code Field Service Ver. 1.0 Apr. 2007 14. Malfunction code 14.1 Trouble code • The copier’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the control panel.
Page 196 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code Code Item Description • The thermistor (TH1) does not detect a predetermined Warm-up failure temperature within 30 sec. after a warm-up cycle has been (for the model having two started and thus the warm-up cycle is not completed. C0500 fusing roller heater lamps) •...
Page 197 14. Malfunction code Field Service Ver. 1.0 Apr. 2007 Code Item Description • The measurement taken by the TCR sensor (TSRS) at a time 2.0 sec. after the main motor (M1) has started turning is less than 5% (greater than 4.63 V). C0F32 Faulty TCR sensor •...
Page 198 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code Code Item Description • Contact the responsible people of KMBT before taking C1468 Faulty parameter chip some countermeasures. The exposure lamp (LA1) of the scanner fails to turn ON. C14A3 IR fluorescent lamp fault •...
Page 199: How To Reset
14. Malfunction code Field Service Ver. 1.0 Apr. 2007 14.2 How to reset Code Description Procedure C0000 Main motor malfunction C0044 ADF cooling fan failure C0045 Fusing cooling fan motor malfunction • Turn OFF and ON the power switch. C004E Power supply cooling fan motor malfunction C0070 Toner replenishing motor malfunction C0210 Abnormal image transfer voltage •...
Page 200 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code 14.3 Solution 14.3.1 C0000: Main motor malfunction Relevant electrical components Main motor (M1) Printer control board (PRCB) Power supply unit (DCPU) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check M1 connectors for proper connec- –...
Page 201 14. Malfunction code Field Service Ver. 1.0 Apr. 2007 14.3.3 C004E: Power unit cooling fan motor malfunction Relevant electrical components Power unit cooling fan motor (FM2) Printer control board (PRCB) Power supply unit (DCPU) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check FM2 connectors for proper connec-...
Page 202 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code 14.3.5 C0210: Abnormal image transfer voltage Relevant electrical components Image transfer roller Printer control board (PRCB) High voltage unit (HV1) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check the image transfer roller for installa- –...
Page 203 14. Malfunction code Field Service Ver. 1.0 Apr. 2007 WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check the fusing unit interlock switch (S2) for operation. <Check procedure> Check continuity across the following termi- – L-8 to 9 nals when S2 is ON.
Page 204 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code 14.3.12 C0650: Faulty scanner home position sensor Relevant electrical components Scanner motor (M4) MFP board (MFPB) Scanner home position sensor (PS100) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check M4 connectors for proper connec- –...
Page 205 14. Malfunction code Field Service Ver. 1.0 Apr. 2007 14.3.15 C1038: Engine connection failure Relevant electrical components Printer control board (PRCB) MFP board (MFPB) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Turn OFF and ON the power switch. –...
Page 206 Field Service Ver. 1.0 Apr. 2007 14. Malfunction code 14.3.17 C1300: Polygon motor malfunction 14.3.18 C13F0: Faulty HSYNC Relevant electrical components PH unit Printer control board (PRCB) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Turn OFF and ON the power switch. –...
Page 207 14. Malfunction code Field Service Ver. 1.0 Apr. 2007 14.3.20 C3FFF: Flash ROM error Relevant electrical components Printer control board (PRCB) Control panel MFP board (MFPB) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check the connection status of connectors on each board (PRCB, MFPB, control –...
Page 208: Power Supply Trouble
Field Service Ver. 1.0 Apr. 2007 15. Power supply trouble 15. Power supply trouble 15.1 The copier does not turn ON Step Check Result Action • Go to step 2. A malfunction code appears when the power switch is turned ON. •...
Page 209: Image Quality Problem
16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.1 How to identify problematic part • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.
Page 210 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.1.2 Identification of the faulty system • Determine if the failure is attributable to an input system (scanner) or output system (printer). Check Result Action Full-size Reduced Input system Copy made at a reduced ratio (scanner) A09AF3C520DA Full-size...
Page 211 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2 Solution 16.2.1 Image reading section: Blank copy A. Typical faulty images A09AF3C522DA B. Troubleshooting procedure Step Check Result Action CCD board (CCDB) connector is loose. • Reconnect. • Reconnect. •...
Page 212 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.2 Image reading section: Black copy A. Typical faulty images A09AF3C523DA B. Troubleshooting procedure Step Check Result Action Exposure lamp turns ON when the power switch is turned Go to step 3. Exposure lamp is abnormally lit (flickers or abnormally Go to step 4.
Page 213 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.3 Image reading section: Low image density A. Typical faulty images A09AF3C524DA B. Troubleshooting procedure Step Check Result Action Shading sheet reading portion (the portion on the back- side of the original glass to which original width scale is •...
Page 214 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.4 Image reading section: Foggy background or rough image A. Typical faulty images A09AF3C525DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty. • Clean. Scanner mirrors are dirty. •...
Page 215 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.5 Image reading section: Black streaks or bands A. Typical faulty images Black streaks Black bands A09AF3C526DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. •...
Page 216 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.6 Image reading section: Black spots A. Typical faulty images A09AF3C527DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty or scratchy. • Clean. CCD board (CCDB) connector is loose. •...
Page 217 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.7 Image reading section: White streaks or bands A. Typical faulty images White streaks White bands A09AF3C528DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. •...
Page 218 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.8 Image reading section: Uneven image density A. Typical faulty images A09AF3C529DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the original glass to which original width scale is •...
Page 219 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.9 Image reading section: Gradation reproduction failure A. Typical faulty images A09AF3C530DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the original glass to which original width scale is •...
Page 220 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.10 Image reading section: Periodically uneven image A. Typical faulty images A09AF3C531DA B. Troubleshooting procedure Step Check Result Action Scanner motor (M4) is securely fastened using the dedi- • Secure in position. cated fixing screws.
Page 221 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.11 Image reading section: Moire A. Typical faulty images A09AF3C532DA B. Troubleshooting procedure Step Check Result Action • Change the original Moire distortions recur even after the orientation of original mode (select one other has been changed.
Page 222 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.12 Printer section: Blank copy A. Typical faulty images A09AF3C522DA B. Troubleshooting procedure Step Check Result Action Imaging unit is installed correctly. • Reinstall. Connector between the imaging unit and copier is dirty. •...
Page 223 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.13 Printer section: Black copy A. Typical faulty images A09AF3C523DA B. Troubleshooting Procedure Step Check Result Action PC drum charge corona grid mesh and comb electrode • Reinstall. are loose. PC drum charge corona contact is dirty, scratchy, folded, •...
Page 224 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.14 Printer section: Low image density A. Typical faulty images A09AF3C524DA B. Troubleshooting procedure Step Check Result Action The image changes when “TONER REPLENISHER” is • Replenish the supply of executed.
Page 225 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.15 Printer section: Foggy background or rough image A. Typical faulty images A09AF3C525DA B. Troubleshooting procedure Step Check Result Action The image changes when “ID ADJUST” and “VG • Readjust. For details, see ADJUST”...
Page 226 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.16 Printer section: black streaks or bands A. Typical faulty images Black streaks Black bands A09AF3C526DA B. Troubleshooting procedure Step Check Result Action PC drum is dirty or scratchy. • Clean or change. Foreign matter (such as paper dust) sticks to the cleaning •...
Page 227 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.17 Printer section: Black spots A. Typical faulty images A09AF3C527DA B. Troubleshooting Procedure Step Check Result Action Toner is present along the paper path. • Clean. PC drum is dirty or scratchy. •...
Page 228 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.18 Printer section: Blank streaks or bands A. Typical faulty images White streaks White bands A09AF3C528DA B. Troubleshooting procedure Step Check Result Action PC drum ground terminal is dirty, scratchy, deformed, or •...
Page 229 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.19 Printer section: Void areas A. Typical faulty images A09AF3C533DA B. Troubleshooting procedure Step Check Result Action Foreign matter is present along the paper path. • Remove foreign matter. Paper dust plugs up the paper dust remover. •...
Page 230 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.20 Printer section: Smear on back A. Typical faulty images A09AF3C534DA B. Troubleshooting procedure Step Check Result Action Toner is spilled over area inside copier. • Clean interior. Toner is present along the paper path. •...
Page 231 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.21 Printer section: Uneven image density A. Typical faulty images A09AF3C529DA B. Troubleshooting Procedure Step Check Result Action PC drum ground plate is dirty, scratchy, deformed, worn, or • Clean, correct, or damaged.
Page 232 Field Service Ver. 1.0 Apr. 2007 16. Image quality problem 16.2.22 Printer section: Gradation reproduction failure A. Typical faulty images A09AF3C530DA B. Troubleshooting Procedure Step Check Result Action PC drum is dirty. • Clean. Image transfer roller is dirty, scratchy, deformed, worn, or •...
Page 233 16. Image quality problem Field Service Ver. 1.0 Apr. 2007 16.2.23 Printer section: Periodically uneven image A. Typical faulty images A09AF3C531DA B. Troubleshooting procedure Step Check Result Action IU is securely fastened using the dedicated fixing screws. • Secure in position. PH unit is securely fastened using the dedicated fixing •...
Page 234: Parts Layout Drawing
[10] MFP board (MFPB) Eraser lamp (EL1) [11] Paper feed solenoid/1 (SD1) Paper feed solenoid/bypass (SD2) [12] Main motor (M1) Toner replenishing motor (M2) [13] Switchback motor (M3) *2 PH unit *1: 200 V areas of bizhub 163/211/220 only *2: bizhub 211/220 only...
Page 235 17. Parts layout drawing Field Service Ver. 1.0 Apr. 2007 [15] [14] [13] [12] [11] [10] A09AF5E511DA Pre-image transfer register board (PITRB) Paper empty sensor/1 (PS4) Thermistor (TH1) [10] Paper set sensor/bypass (PS2) Exit paper sensor (PS3) [11] FAX board (FAXB) *1 TCR sensor (TCRS) [12] NCU board (NCUB) *1 Registration sensor (PS1)
Page 236 [14] Original cover sensor (PS8) Power switch (S1) [15] Exposure lamp (LA1) Tray set sensor/1 (PS5) [16] Inverter board (INVB) Inch/metric sensor/1 (PS7) [17] Original size sensor 1 (PS101) Paper size detect board (PSDTB) *1: Only for 200 V areas of bizhub 163...
Page 237 17. Parts layout drawing Field Service Ver. 1.0 Apr. 2007 17.2 DF-502 (option) [2] [3] [15] [14] [13] [12] [11] [10] A09AF5C506DA Width sensor/3 (PS12) Paper exit sensor (PS5) Width sensor/2 (PS11) [10] Registration sensor (PS3) Width sensor/1 (PS10) [11] Separator sensor (PS4) Length sensor/1 (PS6) [12] Paper feed clutch (CL1) Length sensor/3 (PS8)
Page 238 Field Service Ver. 1.0 Apr. 2007 17. Parts layout drawing 17.3 DF-605 (option) [20] [19] [18] [17] [16] [15] [14] [13] [12] [11] [10] 4040F5C525DA Interface Board (PWA-TRAY) [11] Stamp Solenoid (SL2-ADF) FD Paper Size Detection Sensor 1 [12] Original Detection Sensor (PC8-ADF) (PC1-ADF) FD Paper Size Detection Sensor 3 [13] Exit/Turnover Sensor (PC10-ADF)
Page 239 17. Parts layout drawing Field Service Ver. 1.0 Apr. 2007 17.4 PF-502 (option) A09AF5C514DA Tray set sensor (PS3) Paper feed sensor (PS2) Paper size detect switch (SW1) Paper size detect board (PSDTB) Door sensor (PS4) PF drive board (PFDB) Paper empty sensor (PS1) Paper feed solenoid (SD1)
Page 240 Field Service Ver. 1.0 Apr. 2007 17. Parts layout drawing 17.5 MB-501 (option) A09AF5C515DA Paper feed solenoid (SD1) Paper empty sensor (PS1)
Page 241 17. Parts layout drawing Field Service Ver. 1.0 Apr. 2007 17.6 AD-504 (option) A09AF5E508DA Transport motor (M1) Transport sensor (PS2) Door sensor (PS1) AD drive board (ADDB) Paper set sensor/bypass (PS3)
Page 242 Field Service Ver. 1.0 Apr. 2007 17. Parts layout drawing 17.7 JS-503 (option) A09AF5C507DA JS drive board (JSDB) Upper home position sensor (PS1) Paper detecting board (PSDB) Paper full sensor (PS3) Bin switching motor (M1) Paper empty sensor (PS4) Lower home position sensor (PS2)
Page 243 17. Parts layout drawing Field Service Ver. 1.0 Apr. 2007 17.8 SF-501 (option) A09AF5E509DA SF drive board (SFDB) Home sensor (PS1) Shift motor (M1)
Page 244: Connector Layout Drawing
Field Service Ver. 1.0 Apr. 2007 18. Connector layout drawing 18. Connector layout drawing Description ➀ Number of pin Possible to confirm by removing external cover. Not possible to confirm by removing external cover. [16] [15] [14] [13] [12] [10] [11] A09AF5C504DA CN No.
Page 245: Timing Chart
19. Timing chart Field Service Ver. 1.0 Apr. 2007 19. Timing chart 19.1 Main body...
Page 246 Field Service Ver. 1.0 Apr. 2007 19. Timing chart 19.2 DF-605 19.2.1 1-Sided Mode (A4 two sheets feeding)
Page 247 19. Timing chart Field Service Ver. 1.0 Apr. 2007 19.2.2 2-Sided Mode (A4 two sheets feeding)
Page 248 Field Service Ver. 1.0 Apr. 2007 19. Timing chart...
Page 249 19. Timing chart Field Service Ver. 1.0 Apr. 2007 19.2.3 Fax Fine mode (A4 two sheets feeding)
Page 250 Field Service Ver. 1.0 Apr. 2007 19. Timing chart 19.2.4 Fax real-time transmission mode (A4 two sheets feeding)
Page 251 19. Timing chart Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 252 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 253 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.
Page 254: General
Field Service Ver. 1.0 Apr. 2007 CONTENTS FK-506 General Product specifications ..................... 1 Maintenance Firmware upgrade ....................3 Preparations for firmware rewriting ............... 3 2.1.1 Installing the driver ..................3 Firmware rewriting ....................5 2.2.1 Updating method................... 5 2.2.2 Procedure when upgrading the firmware has failed........7 Other ........................
Page 255 Field Service Ver. 1.0 Apr. 2007 6.2.1 Procedure ....................19 6.2.2 Exiting ......................19 6.2.3 Changing the setting value in Utility Mode functions ........19 Setting in the Utility mode................... 19 6.3.1 MACHINE SETTING................... 19 6.3.2 ADMIN. MANAGEMENT................20 6.3.3 DIAL REGISTRATION ................
Page 256 Field Service Ver. 1.0 Apr. 2007 8.6.8 SOFT SWITCH: #08 ................... 66 8.6.9 SOFT SWITCH: #09 ................... 67 8.6.10 SOFT SWITCH: #10 ................... 68 8.6.11 SOFT SWITCH: #11 ................... 69 8.6.12 SOFT SWITCH: #12 ................... 69 8.6.13 SOFT SWITCH: #13 ................... 70 8.6.14 SOFT SWITCH: #14 ...................
Page 257 Field Service Ver. 1.0 Apr. 2007 8.6.45 SOFT SWITCH: #45 ................... 93 8.6.46 SOFT SWITCH: #46 ................... 94 8.6.47 SOFT SWITCH: #47 ................... 94 8.6.48 SOFT SWITCH: #48 ................... 95 8.6.49 SOFT SWITCH: #49 ................... 96 8.6.50 SOFT SWITCH: #50 ................... 96 8.6.51 SOFT SWITCH: #51 ...................
Page 258: General
Field Service Ver. 1.0 Apr. 2007 1. Product specifications General Product specifications Transmission mode Compatible wiring General subscriber telephone line, NCC each line Connection method Direct connection (using a modular jack) Transmission speed 33.6, 31.2, 28.8, 26.4, 24.0, 21.6, 19.2, 16.8, 14.4, 12.0, 9.6, 7.2, 4.8, 2.4 kbps (automatic switching) Transmission time 3 seconds *1...
Page 259 1. Product specifications Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 260: Maintenance
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade Maintenance Firmware upgrade Preparations for firmware rewriting 2.1.1 Installing the driver NOTE • The TWAIN driver must previously be installed in the host computer that is used to upgrade the firmware. •...
Page 261 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 (3) For Windows Me/98SE 1. Prepare the files necessary for upgrading the firmware, and copy them to PC. 2. Start the host computer. 3. Turn on the power switch of the machine. 4.
Page 262: Firmware Rewriting
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade Firmware rewriting 2.2.1 Updating method 1. Turn ON the power switch of the machine. 2. Start the host computer. 3. Copy the “Update Software” folder and “Update” file to drive C. (Copy them into the highest directory on drive C.) 4.
Page 263 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 8. Click the [Update] button to start the transfer of the firmware data. (Wait until data transfer is completed.) 9. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE •...
Page 264: Procedure When Upgrading The Firmware Has Failed
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade 2.2.2 Procedure when upgrading the firmware has failed NOTE • Perform the following procedure only when upgrading from PC using ordinary USB connection has failed and the machine has not started properly. •...
Page 265 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 10. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE • NEVER turn OFF and ON the power switch as long as the above screens are being displayed. 11.
Page 266: Other
Field Service Ver. 1.0 Apr. 2007 3. Other Other Disassembly/adjustment prohibited items A. Paint-locked screws • To prevent loose screws, a screw lock in blue or green series color is applied to the screws. • The screw lock is applied to the screws that may get loose due to the vibrations and loads created by the use of machine or due to the vibrations created during transportation.
Page 267: Disassembly/Assembly/Cleaning List (Other Parts)
3. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/assembly/cleaning list (other parts) 3.2.1 Disassembly/assembly parts list Section Part name Ref.page NCU board P.11 Board and etc. FAX board P.12 Others Speaker P.10 Disassembly/assembly procedure 3.3.1 Speaker 1. Remove nine screws [1] and then remove the rear cover [2] of the main body.
Page 268: Ncu Board
Field Service Ver. 1.0 Apr. 2007 3. Other 3. Remove two scerws [1] and remove the speaker [2]. A0CJF2C502DA 3.3.2 NCU board 1. Remove the speaker. See P.10 2. Remove the screw [1] of the ground- ing wire and disconnect the connec- tor [2].
Page 269: Fax Board
3. Other Field Service Ver. 1.0 Apr. 2007 3.3.3 FAX board 1. Remove the speaker. See P.10 2. Remove the NCU board. See P.11 3. Remove four screws [1], disconnect the connector [2] and remove the FAX board [3]. A0CJF2C505DA NOTE •...
Page 270: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 271: Confirm Mode
5. Confirm Mode Field Service Ver. 1.0 Apr. 2007 Confirm Mode Confirm mode function tree CONFIRM MODE Ref. page TOTAL PAGE TOTAL COUNT P.15 SIZE COUNT P.15 TOTAL SCAN P.15 TX PAGES P.15 RX PAGES P.15 TX/RX RESULT P.15 PRINT REPORT TX RESULT REPORT P.16 RX RESULT REPORT...
Page 272: Setting In The Confirm Mode
Field Service Ver. 1.0 Apr. 2007 5. Confirm Mode Setting in the CONFIRM MODE 5.3.1 TOTAL PAGE A. TOTAL COUNT Functions • Displays the total number of pages printed since this machine was installed. B. SIZE COUNT Functions • Displays the size count of pages printed since this machine was installed. C.
Page 273: Print Report
5. Confirm Mode Field Service Ver. 1.0 Apr. 2007 5.3.3 PRINT REPORT A. TX RESULT REPORT Functions • The document number, recipient name, date sent, starting time of transmission, num- ber of document pages, time required, mode, and transmission result are printed. B.
Page 274 Field Service Ver. 1.0 Apr. 2007 5. Confirm Mode J. MACHINE STATUS Functions • The current machine settings are printed. K. CONFIGURATION PAGE Functions • The list of print settings are printed. L. PCL FONT LIST Functions • The list of PCL fonts are printed. NOTE •...
Page 275: Utility Mode
6. Utility Mode Field Service Ver. 1.0 Apr. 2007 Utility Mode Utility Mode function tree • Utility mode is used to make settings for the utility functions. NOTE • The setting menu contains only the cases in which FK-506 is mounted. UTILITY MODE Ref.
Page 276: Utility Mode Function Setting Procedure
Field Service Ver. 1.0 Apr. 2007 6. Utility Mode Utility mode function setting procedure 6.2.1 Procedure 1. Press the Utility key. 2. The UTILITY MODE screen will appear. 6.2.2 Exiting • Press the Reset key. 6.2.3 Changing the setting value in Utility Mode functions •...
Page 277: Admin. Management
6. Utility Mode Field Service Ver. 1.0 Apr. 2007 6.3.2 ADMIN. MANAGEMENT A. REMOTE MONITOR Functions • To set the access right when monitoring a user machine from a remote location on the Service side. • RSD is used for remote monitoring. Setting/ •...
Page 278 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode • As is the case with the RSD, operations from the control panel of the local machine, PC print, and Scanner function are not accepted while a connection is being established with the local machine using the LSD (Local Setup Diagnostic) and Page Scope Web Connection/Admin.
Page 279: Dial Registration
6. Utility Mode Field Service Ver. 1.0 Apr. 2007 C. USER SETTING (1) DATE&TIME Functions • This function is used to set the date, time and zone for FAX. (2) USER FAX NO. Functions • This function is used to register the user’s telephone number. (3) USER NAME Functions •...
Page 280: Fax Registration
Field Service Ver. 1.0 Apr. 2007 6. Utility Mode D. PROGRAM DIAL Functions • This function can be used to register the destination number and TX/RX function on one-touch dial keys. Setting/ The function of registration Procedure • Broadcast transmission •...
Page 281: Fax Rx Operation
6. Utility Mode Field Service Ver. 1.0 Apr. 2007 C. DEFAULT TX Functions • This function can be used to set the default of TX mode. Setting/ • The default setting is “MEMORY TX”. Procedure “MEMORY TX” ADF TX D. HEADER Functions •...
Page 282 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode C. REDUCTION RX Functions • This function can be used to set whether documents longer than the paper are printed reduced ([ON]), split ([OFF]), or discarded ([CUT]). However, when sending a document more than 24 mm (1 inch) longer than the paper, [CUT] is not available.
Page 283 6. Utility Mode Field Service Ver. 1.0 Apr. 2007 Recording Length of received Footer Printing paper size image Less than 356 mm 1 page in 193mm or less, it prints to B5 357 mm to 396 mm 1 page with (356 mm / image length)% reduction 397 mm to 704 mm Divide into 2 pages with 100% 705 mm to 1,052 mm Divide into 3 pages with 100%...
Page 284 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode Recording Length of received Footer Printing paper size image Less than 208 mm 1 page. 209 mm to 297 mm 1 page with (208 mm / image length)% reduction 298 mm to 408 mm Divide into 2 pages with 100% 409 mm to 608 mm Divide into 3 pages with 100%...
Page 285 6. Utility Mode Field Service Ver. 1.0 Apr. 2007 100% RX mode • All receiving data is divided into 2 pages or more, and is printed. Recording Length of received Footer Printing paper size image Less than 412 mm 1 page in 202 mm or less, it prints to A4 413 mm to 816 mm Divide into 2 pages 817 mm to 1,220 mm Divide into 3 pages...
Page 286 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode Recording Length of received Footer Printing paper size image Less than 174 mm 1 page 175 mm to 340 mm Divide into 2 pages 341 mm to 506 mm Divide into 3 pages 507 mm or more Divide into 4 pages or more Less than 170 mm...
Page 287 6. Utility Mode Field Service Ver. 1.0 Apr. 2007 Recording Length of received Footer Printing paper size image Less than 348 mm 1 page 349 mm to 688 mm Divide into 2 pages 689 mm to 1,028 mm Divide into 3 pages 1,029 mm or more Divide into 4 pages or more Legal...
Page 288 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode Recording Length of received Footer Printing paper size image Less than 202 mm 1 page 203 mm to 226 mm Print into 1 page. 1 mm to 24 mm of end is cut. 227 mm to 396 mm Divide into 2 pages 397 mm to 420 mm...
Page 289 6. Utility Mode Field Service Ver. 1.0 Apr. 2007 Recording Length of received Footer Printing paper size image Less than 174 mm 1 page 175 mm to 198 mm Print into 1 page. 1 mm to 24 mm of end is cut. 199 mm to 340 mm Divide into 2 pages 341 mm to 364 mm...
Page 290 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode Recording Length of received Footer Printing paper size image Less than 208 mm 1 page 209 mm to 232 mm Print into 1 page. 1 mm to 24 mm of end is cut. 233 mm to 408 mm Divide into 2 pages 409 mm to 432 mm...
Page 291 6. Utility Mode Field Service Ver. 1.0 Apr. 2007 Recording Length of received Footer Printing paper size image Less than 132 mm 1 page 133 mm to 156 mm Print into 1 page. 1 mm to 24 mm of end is cut. 157 mm to 256 mm Divide into 2 pages 257 mm to 280 mm...
Page 292 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode G. FOOTER Functions • This function can be used to set whether or not the reception information (RX data and time, RX management number, RX page number, Transmitter's ID) is printed at the bottom of each received document.
Page 293: Reporting
6. Utility Mode Field Service Ver. 1.0 Apr. 2007 H. SELECT TRAY • This function can be used to select which paper tray can be used to supply paper Functions when printing received documents or transmission reports. (A paper tray that cannot be used for supplying paper can also be specified.) •...
Page 294 Field Service Ver. 1.0 Apr. 2007 6. Utility Mode D. RX RESULT REPORT Functions • This function can be used to set whether the report showing the result of a reception is printed automatically after mailbox reception is finished. (If regular reception is not finished normally, a report will always be printed, regard- less of the selected setting.) Setting/ •...
Page 295: Service Mode
7. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Service mode setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 7.1.1 Procedure 1.
Page 296: Service Mode Function Tree
Field Service Ver. 1.0 Apr. 2007 7. Service Mode Service Mode function tree NOTE • This setting menu contains only the cases in which the FK-506 is mounted. SERVICE MODE Ref. page SERVICE’S CHOICE MARKETING AREA P.40 TX SPEED P.40 RX SPEED P.40 TX LEVEL...
Page 297: Setting In The Service Mode
7. Service Mode Field Service Ver. 1.0 Apr. 2007 Setting in the service mode 7.3.1 SERVICE’S CHOICE A. MARKETING AREA Functions • Set the marketing area. • If you change the marketing area, the soft switch will change automatically. • Using ▲ / ▼ key, select the marketing area. Setting/ Procedure STANDARD...
Page 298 Field Service Ver. 1.0 Apr. 2007 7. Service Mode E. RX LEVEL Functions • Reception sensitivity level. Setting/ • The default setting is “-43 dBm”. Procedure -36 dBm -37 dBm to -42 dBm “-43 dBm” -44 dBm to -48 dBm -49 dBm F.
Page 299 7. Service Mode Field Service Ver. 1.0 Apr. 2007 K. REPORT DESTINATION Functions • Enter the telephone number for which the report is to be produced. When any of the following conditions happens, the report is sent to the destination. •...
Page 300: Function
Field Service Ver. 1.0 Apr. 2007 7. Service Mode O. PROTOCOL REPORT Functions • Print communication report. • Choose one from among the following. Setting/ • The default setting is “OFF”. Procedure “OFF” ON (ERROR) “OFF”: Disable T.30 communication report. ON: Print T.30 communication report.
Page 301: Softswitch
7. Service Mode Field Service Ver. 1.0 Apr. 2007 7.3.3 SOFTSWITCH See P.47 7.3.4 FACTORY TEST A. SIGNAL TEST • This test is for factory adjustment only and should NOT be used. B. RELAY TEST • This test is for factory adjustment only and should NOT be used. C.
Page 302: Clear Data
Field Service Ver. 1.0 Apr. 2007 7. Service Mode 7.3.5 CLEAR DATA A. DRAM CLEAR • Clear all data in the memory file and free all memory to 100%, the user data are not affected. But only clear DRAM data on Printer control board. NOTE •...
Page 303 7. Service Mode Field Service Ver. 1.0 Apr. 2007 MODE Initialized Items Default Report/ List UTILITY MODE E-MAIL SETTING 1 SENDER NAME None MACHINE STATUS LIST E-MAIL ADDRESS None SMTP SERVER ADDR. None SMTP PORT NO. SMTP TIMEOUT TEXT INSERT DEFAULT SUBJECT None E-MAIL SETTING 2...
Page 304: Soft Switch Set
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Soft Switch Set • This machine is provided with a total of 64 soft switches used for making various adjust- ments. The initial values can be changed, defined to comply with the requirements unique to each individual country.
Page 305: Default Setting
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 Default Setting 8.1.1 Country for each marketing area NOTE • A different country may be applicable depending on the communications stan- dard. • The marketing area settings can be set using the [SERVICE’S CHOICE] of [SER- VICE MODE].
Page 306: Default Soft Switch Setting For Each Market Area 1
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Default soft switch setting for each market area 1 MARKETING AREA STANDARD U.S.A. WEST EUROPE ASIA Soft switch (Initial setting) Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 # 02...
Page 307 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 MARKETING AREA STANDARD U.S.A. WEST EUROPE ASIA Soft switch (Initial setting) Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 38 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 # 39...
Page 308 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Default soft switch setting for each market area 2 MARKETING AREA AUSTRIA CHINA GERMANY JAPAN Soft switch Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 # 02...
Page 309 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 MARKETING AREA AUSTRIA CHINA GERMANY JAPAN Soft switch Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 38 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 # 39...
Page 310 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Default soft switch setting for each market area 3 MARKETING AREA KOREA NEW ZEALAND SOUTH AFRICA TAIWAN Soft switch Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 01 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 # 02...
Page 311 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 MARKETING AREA KOREA NEW ZEALAND SOUTH AFRICA TAIWAN Soft switch Bit No. Bit No. Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 38 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 1 0 # 39...
Page 312 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Default soft switch setting for each market area 4 MARKETING AREA MARKETING AREA SINGAPORE SINGAPORE Soft switch Soft switch Bit No. Bit No. 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 # 01 0 0 0 0 0 0 0 0...
Page 313: Soft Switch List
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 Soft Switch List Switch Bit No. Designation Page No. # 01 Reserved P.61 Time between phase C to phase D signal in V.17 Header TX selection open to user # 02 P.61 Transmit RTN signal level criteria Sent N.G page...
Page 314 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Switch Bit No. Designation Page No. ECM Mode capability V.34 fall back level for V.34 TX. # 12 Send CTC after 4th PPR P.69 Send EOR after lowest speed TCF transmission timing after DCS MR capability for G3 Delay time between transaction Super fine printing capability for receiving...
Page 315 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 Switch Bit No. Designation Page No. Pause delay time within digit # 30 P.83 6/5/4/3/2/1 Signal tone Insensitivity after dial for busy tone # 31 – Reserved P.84 # 32 –...
Page 316 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set Switch Bit No. Designation Page No. Daylight savings timer RX print mode # 46 Default TX mode P.94 Header for FAX TX Print model name on top of TX page if machine name not register RX mode # 47 P.94...
Page 317 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 Switch Bit No. Designation Page No. # key definition in PBX mode # 63 FAX Tx image adjust P.105 TX result report with image Print RX error report on RX side if no FAX signal is detected # 64 P.105 10 pps &...
Page 318: Soft Switch: #01
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.1 SOFT SWITCH: #01 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 8.6.2 SOFT SWITCH: #02 Initial Setting Designation Function Time between phase C...
Page 319 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.3 SOFT SWITCH: #03 Initial Setting Designation Function 1: Yes Send out NSF frame with station ID 0: No 0: No limitation Number of pause within phone number 1: Max. up to 2 “P” within inputted telephone number 0: Continue to dial Re-dial prohibit for NO 1: Not allowed to re-dial if no any FAX signal or detected...
Page 320: Soft Switch: #04
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.4 SOFT SWITCH: #04 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 0: No Visible alarm for RTN 1: Yes - display message while sending / receiving signal RTN signal (RTN= Return To Negative).
Page 321: Soft Switch: #05
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.5 SOFT SWITCH: #05 Initial Setting Designation Function Timing Push button on/off timing (ms) (PB) Bit 8 Bit 7 Relation between dialed Reserved 10-key and No. of dial pulse Bit 6 Bit 5 Reserve Reserve...
Page 322 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.7 SOFT SWITCH: #07 Initial Setting Designation Function 0: Disable Dial tone or busy tone detection 1: Enable - Detect dial tone before dial 0: PSTN PSTN/PBX setting 1: PBX - Select PBX line type 0: Not to detect dial tone before pre-fix number PBX dial tone detect 1: Detect dial tone before the pre-fix number in PBX...
Page 323 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.8 SOFT SWITCH: #08 Initial Setting Designation Function 0: (Normal, Fine)=(12,24) continue error line Sending RTN signal level 1: (Normal, Fine)=(6,12) continue error line 0: Not to detect Detect busy tone after dialing 1: Detect busy tone after dialing 0: Not to send...
Page 324 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.9 SOFT SWITCH: #09 Initial Setting Designation Function Ringer 10 to 20 to 20 to 10 to frequency Ringer frequency 75 Hz 57.5 Hz 75 Hz 75 Hz range detection Bit 8 Bit 7 Reserved...
Page 325 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.10 SOFT SWITCH: #10 Initial Setting Designation Function 0: Not to Print Print out RTN page 1: Print Out RTN page report after transaction for report TX/RX RTN signal 0: Print “OK” Confirmation report result field 1: Print “NG”...
Page 326 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.11 SOFT SWITCH: #11 Initial Setting Designation Function Reserved Reserved 0: No Detect dial tone after pre-fix number 1: Yes 0: Yes Pulse dial allowed to select 1: Not allowed 0: Not to display Protocol signal display mode...
Page 327 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.13 SOFT SWITCH: #13 Initial Setting Designation Function 0: Yes MR capability for G3 1: No Description 20 sec 60 sec 120 sec 240 sec Delay time between Bit 7 transaction Bit 6 0: No...
Page 328 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.14 SOFT SWITCH: #14 Initial Setting Designation Function Reserved Reserved Reserved Reserved 1: Up to 128 KB Memory size level To RX 0: Based on system configuration Reserved Reserved Reserved Reserved Timer Time between V.34...
Page 329 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.16 SOFT SWITCH: #16 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Coding JBIG Fax communication method coding method Bit 2 Bit 1 8.6.17 SOFT SWITCH: #17 Initial...
Page 330 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.18 SOFT SWITCH: #18 Initial Setting Designation Function Reserved Reserved Reserved Reserved Definition Level1 Level2 Level3 Level4 G3 mode training qual- Bit 6 ity level Bit 5 Counter 9 10 Bit 4 Bit 3 Bit 2...
Page 331 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.19 SOFT SWITCH: #19 Initial Setting Designation Function Level (dBm) -17 -16 -15 -14 -13 -12 -11 Bit 8 Bit 7 Bit 6 Bit 5 CNG signal level Level (dBm) Bit 8 Bit 7 Bit 6...
Page 332 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.20 SOFT SWITCH: #20 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Interval (min) 1 2 3 4 5 6 7 8 9 10 11 Bit 5 0 0 0 0 0 0 0 0 0 0 0 Bit 4 0 0 0 0 0 0 0 1 1 1 1 Bit 3...
Page 333 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.21 SOFT SWITCH: #21 Initial Setting Designation Function 0: Not to send NSS signal if remote side is same model NSS signal before DCS 1: Send NSS signal if remote side is same model Duration 40 sec 60 sec...
Page 334 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.22 SOFT SWITCH: #22 Initial Setting Designation Function 1: Check busy tone within dial tone detection Detect busy tone before dial 0: Not to check 1: Yes - Check dial tone after dialing Regard dial tone as busy tone after dialing 0: No...
Page 335 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.24 SOFT SWITCH: #24 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 8.6.25 SOFT SWITCH: #25 Initial Setting Designation Function Reserved...
Page 336 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.26 SOFT SWITCH: #26 Initial Setting Designation Function Time 10 sec 15 sec 20 sec 25 sec Dial tone detection time Bit 8 before disconnected Bit 7 Level (dBm) 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 Bit 6 Bit 5 Bit 4...
Page 337 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.27 SOFT SWITCH: #27 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Level (dBm) Bit 4 Bit 3 Bit 2 Bit 1 Immunity for dial tone receiver Level (dBm) -9 -10 -11 -12 -13 -14 -15...
Page 338 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.28 SOFT SWITCH: #28 Initial Setting Designation Function Time (ms) 100 200 300 400 500 600 700 Bit 8 Bit 7 Bit 6 Bit 5 Time (ms) 1000 1100 1200 1300 Bit 8 Time to dial after dial Bit 7...
Page 339 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.29 SOFT SWITCH: #29 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Time 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 (sec) Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Time...
Page 340 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.30 SOFT SWITCH: #30 Initial Setting Designation Function Pause delay time within Time 2.0 sec 2.5 sec 3.0 sec 3.5 sec digits Bit 8 Ex. 002Pxxxxxx Bit 7 Level 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 (dBm) Bit 6 Bit 5...
Page 341 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.31 SOFT SWITCH: #31 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 8.6.32 SOFT SWITCH: #32 Initial Setting Designation Function Reserved...
Page 342 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.33 SOFT SWITCH: #33 Initial Setting Designation Function Reserved Reserved 0: Off V.17 echo protection tone 1: On 0: Off V.29 echo protection tone 1: On Compromise equalize 0: No enable (CEQ) in the 1: Yes transmit path (TCEQ)
Page 343 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.35 SOFT SWITCH: #35 Initial Setting Designation Function Time 300 ms 600 ms 1 sec 2 sec Dial tone table switch Bit 8 time Bit 7 Frequency 375 Hz to 310 Hz to 462 Hz to range...
Page 344 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.36 SOFT SWITCH: #36 Initial Setting Designation Function 0: No any limitation Re-dial attempts continue fail counter 1: limit up to bit 1 to 4 Reserved Reserved Reserved Reserved Reserved Reserved Counter Bit 4...
Page 345 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.37 SOFT SWITCH: #37 Initial Setting Designation Function 0: V.34 Polling TX type for V.34 modem 1: V.17 0: Yes- skip V.34 handshaking with remote side Auto dial learning for V.34 modem 1: No - retry from V.8 handshake 3429...
Page 346 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.38 SOFT SWITCH: #38 Initial Setting Designation Function Reserved Reserved 0: Reset Set/Reset V.34 transmit level deviation 1: Set Flags number V.34 flag number Bit 6 between ECM frame Bit 5 0: Normal power level Phase 2 guard tone power level (V.34)
Page 347 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.40 SOFT SWITCH: #40 Initial Setting Designation Function V.17 V.17 V.17 V.17 Speed 14400 bps 12200 bps 9600 bps 7200 bps Bit 8 Bit 7 Bit 6 Bit 5 V.29 V.29 V.27 V.27 ter...
Page 348 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.41 SOFT SWITCH: #41 Initial Setting Designation Function V.17 V.17 V.17 V.17 Speed 14400 bps 12200 bps 9600 bps 7200 bps Bit 8 Bit 7 Bit 6 Bit 5 V.29 V.29 V.27 V.27 ter...
Page 349 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.42 SOFT SWITCH: #42 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 8.6.43 SOFT SWITCH: #43 Initial Setting Designation Function Reserved...
Page 350 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.45 SOFT SWITCH: #45 Initial Setting Designation Function Reserved Reserved Reserved Reserved 0: OFF Closed network 1: ON 0: OFF Call transfer 1: ON Value Bit 4 Bit 3 Bit 2 Bit 1 NO.
Page 351: Soft Switch: #45
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.46 SOFT SWITCH: #46 Initial Setting Designation Function 0: No Daylight savings timer 1: Yes Reserved Reserved Reserved Reserved Reserved Reserved 0: RX one page then print one page. (PRINT RX) RX print mode 1: Start to print after receiving all pages.
Page 352: Soft Switch: #48
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.48 SOFT SWITCH: #48 Initial Setting Designation Function 0: No Activity report 1: Yes 0: No Reservation report 1: Yes 0: No TX result report 1: Yes 0: No RX result report 1: Yes 0: No TX/ RX error report...
Page 353: Soft Switch: #49
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.49 SOFT SWITCH: #49 Initial Setting Designation Function Reserved Reserved Reserved Reserved 0: Based on RX RESULT REPORT setting Print RX mailbox report method 1: Always printing 0: Redial again Redial method if communication fail 1: Based on redial time interval...
Page 354: Soft Switch: #51
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.51 SOFT SWITCH: #51 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Print report Print report Descrip- Not to for each while report- T.30 monitor report tion print used...
Page 355: Soft Switch: #54
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.54 SOFT SWITCH: #54 Initial Setting Designation Function 0: Digits format (example: 2006. 11. 19) Report/ LCD date/time type 1: Alpha numeric format (example: 2006. NOV. 19) When bit No.8 is “1”. 2006.
Page 356: Soft Switch: #56
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.56 SOFT SWITCH: #56 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 8.6.57 SOFT SWITCH: #57 Initial Setting Designation Function Reserved...
Page 357 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.59 SOFT SWITCH: #59 Part 1 Initial Setting Designation Function Reserved Reserved Reserved Reserved Time between Greenwich mean time + T mean time +00:00 +00:30 +01:00 +01:30 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...
Page 358 Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.60 SOFT SWITCH: #59 Part 2 Initial Setting Designation Function Reserved Reserved Reserved Reserved Time between Greenwich mean time + T mean time +10:00 +10:30 +11:00 +11:30 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...
Page 359 8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.61 SOFT SWITCH: #59 Part 3 Initial Setting Designation Function Reserved Reserved Reserved Reserved Time between Greenwich mean time + T mean time -06:00 -06:30 -07:00 -07:30 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2...
Page 360: Soft Switch: #60
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.62 SOFT SWITCH: #60 Initial Setting Designation Function Reserved Reserved Fax data divide printer 0: Enable (A3→A4; B4→B5, A4 1: Disable A4→A5) 0: Ineffective Quick memory TX 1: Effective 0: A3 size B4/ A3 declaration for Ledger 1: B4 size...
Page 361: Soft Switch: #61
8. Soft Switch Set Field Service Ver. 1.0 Apr. 2007 8.6.63 SOFT SWITCH: #61 Initial Setting Designation Function Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved No. of rings Bit 4 Bit 3 Bit 2 Bit 1 Max. No. of rings No.
Page 362: Soft Switch: #63
Field Service Ver. 1.0 Apr. 2007 8. Soft Switch Set 8.6.65 SOFT SWITCH: #63 Initial Setting Designation Function 0: default is internal # key definition in PBX mode 1: default is external Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 0: Normal...
Page 363: Fax Protocols
9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 Fax Protocols G3 ECM (G3 Error Correction Mode) • G3 ECM is the error correction system newly recommended by Consultative Committee of International Telephone & Telegraph of 1988. • By G3 ECM, documents are divided into blocks (called partial page) for transmission. If any error takes place in any frame (one partial page consists of 256 frames) on a partial page, the receiving party generates the retransmit request with erroneous frame num- bers.
Page 364: Line Control
Field Service Ver. 1.0 Apr. 2007 9. Fax Protocols Line Control 9.2.1 Procedure of G3 mode communication • Basic communications diagram of G3 mode. This machine G3 machine (Transmission) (Receiving) Phase [START] Button press R side start G3 machine This machine (Transmission) (Receiving) Phase...
Page 365: Table Of Reference Code
9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 Table of Reference Code Code Function Confirmation to Receive. 1,850 Hz or 1,650 Hz 3 sec. Calling Station Identification. Command Repeat. Called Subscriber Identification. Disconnect. Digital Identification Signal. Digital Transmit Command. Digital Transmit Command.
Page 366: How To Analyze The T30 Protocol Monitor
Field Service Ver. 1.0 Apr. 2007 9. Fax Protocols How to Analyze the T30 Protocol Monitor • DCS or DIS • HEX Data as printed on page. • Example: V.17 Communication PROTOCOL MONITOR REPORT NAME: ABC TEL:886 3 4733507 DATE: APR.23’04 12:20 SESSION FUNCTION DESTINATION STATION...
Page 367 9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 DIS (DTC)/ DCS Bit Allocation Table of FIF (Facsimile Information Field) Designation DIS/ DTC “0”= Invalid “1”= Store-and-forward switching Internet fax simple mode Set to “0” “0”= Invalid “1”= Real-time Internet fax Set to “0”...
Page 368 Field Service Ver. 1.0 Apr. 2007 9. Fax Protocols Designation DIS/ DTC Recording width Bit No. Bit No. capabilities Data signalling rate Data signalling rate 18 17 18 17 Scan line length Scan line length 215 mm ± 1% 215 mm ± 1% Scan line length Scan line length 215 mm ±...
Page 369 9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 Designation DIS/ DTC “0”= Invalid “1”= Field not valid capability “0”= Invalid Set to “0” “1”= Multiple selective polling capability “0”= Invalid Set to “0” “1”= Polling subaddress transmission (DTC) by Polled SubAddress (DIS)/PSA “0”= Invalid “1”= T.43 coding...
Page 370 Field Service Ver. 1.0 Apr. 2007 9. Fax Protocols Designation DIS/ DTC Extend field 0: Without 1: With “0”= Invalid “1”= Basic Transfer Mode (BTM) Set to “0” “0”= Invalid Set to “0” “1”= Ready to transmit a character or mixed mode document (polling) “0”= Invalid “1”= Character mode...
Page 371 9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 Designation DIS/ DTC “0”= Invalid “1”= Single layer sequential encoding, optional L0 capacity Extend field “0”= Without “1”= With “0”= Invalid “0”= Invalid “1”= HKM key management capacity “1”= HKM key management selection “0”= Invalid “0”= Invalid...
Page 372 Field Service Ver. 1.0 Apr. 2007 9. Fax Protocols Designation DIS/ DTC 100 Set to “0” 101 Set to “0” 102 Set to “0” 103 Set to “0” Extend field “0”= Without “1”= With...
Page 373 9. Fax Protocols Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 374: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 10. Fax Error Troubleshooting 10. Fax Error 10.1 Communication Error 10.1.1 Outline • Error caused by a problem of communication functioning. Five possible causes of errors are: 1. Communication is discontinued by a machine error. 2.
Page 375: 10.2 Error Code
10. Fax Error Field Service Ver. 1.0 Apr. 2007 10.2 Error Code 10.2.1 Reception Code Possible Causes of Error. 0001 No G3 signal received within 35 sec. in manual receive mode. 0003 Received DIS after sending DIS signal. 0004 Received DCN after sending DTC signal. 0006 Detect busy tone within receiving phase B.
Page 376 Field Service Ver. 1.0 Apr. 2007 10. Fax Error Code Possible Causes of Error. 003F Remote side TSI not programmed in machine one touch or speed dial directory. 0040 Did not receive carrier signal within 6 sec. after sending CTR. 0041 Did not receive carrier signal within 6 sec.
Page 377: Transmission
10. Fax Error Field Service Ver. 1.0 Apr. 2007 10.2.2 Transmission Code Possible Causes of Error. 0080 Did not detect any G3 signal within 35 sec. specified by ITU-T in phase B. 0081 Received DTC signal in transmission phase. 0082 Transmitting unit receives a signal other than DIS or DTC.
Page 378 Field Service Ver. 1.0 Apr. 2007 10. Fax Error Code Possible Causes of Error. 00B8 Remote side disconnect after our side sent DCS signal in V.34. 00B9 Receive T.30 signal other than DIS,DCS,CFR after sending DCS signal in V.34. 00BA Did not receive correct signal after our side sent DTC signal in V.34.
Page 379 10. Fax Error Field Service Ver. 1.0 Apr. 2007 Code Possible Causes of Error. 00E8 At phase-D, transmitting unit sends out PPS_EOP 3 times consecutively but no answer. 00E9 Receive PIN signal after sent last page three times. 00EA Did not receive any response in RR response procedure after sending PPS_EOP. 00EB At phase-D, transmitting unit sends out PPS_EOM 3 times consecutively but no answer.
Page 380 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 381 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.
Page 382 Field Service Ver. 1.0 Apr. 2007 CONTENTS DF-605/MK-501 General Product specifications ..................... 1 Maintenance Periodical check ...................... 5 Maintenance procedure (Periodical check parts) ..........5 2.1.1 Replacing the pick-up roller and feed roller........... 5 2.1.2 Replacing the separation roller ..............6 2.1.3 Cleaning of the pick-up roller, feed roller and separation roller .....
Page 383 Field Service Ver. 1.0 Apr. 2007 Service Mode function tree................. 22 Setting in the Service mode ................23 6.3.1 ADJUST...................... 23 6.3.2 FUNCTION ....................27 6.3.3 CLEAR DATA ....................28 Mechanical adjustment ..................29 Leading edge skew adjustment ................29 Troubleshooting Jam display ......................
Page 384: General
Field Service Ver. 1.0 Apr. 2007 1. Product specifications General Product specifications A. Type Name Reverse automatic document feeder Paper feed Paper feed from top of stack Type Turnover Switch back system Paper exit Straight exit system Installation Screw cramp to the main unit Document alignment Center Document loading...
Page 385: Product Specifications
1. Product specifications Field Service Ver. 1.0 Apr. 2007 D. Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of original Possible trouble Feed failure, damage to the original, or drive Original that is stapled or clipped. failure due to clip clogging Feed failure, damage to the original, or drive Book original...
Page 386 Field Service Ver. 1.0 Apr. 2007 1. Product specifications F. Mixed original feed chart For Metric Max. original size 297 mm 257 mm 210 mm 182 mm 148 mm Mixed original size 297 mm 257 mm 210 mm 182 mm 148 mm 128 mm For Inch...
Page 387 1. Product specifications Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 388: Maintenance
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 2.1.1 Replacing the pick-up roller and feed roller A. Periodically replaced parts/cycle •...
Page 389: Replacing The Separation Roller
2. Periodical check Field Service Ver. 1.0 Apr. 2007 4. Remove two levers [1]. 5. Remove five C-rings [2]. 6. Remove the arm [3]. 7. Remove the belt [4]. 8. Remove two pick-up rollers [5]. 4344F2C503DA 9. Remove the C-ring [1], and remove the gear [2] and the bushing [3].
Page 390: Cleaning Of The Pick-Up Roller, Feed Roller And Separation Roller
Field Service Ver. 1.0 Apr. 2007 2. Periodical check 3. Remove the separation roller assy [1]. NOTE • Use care not to lose the spring at the bottom side of the separation roller assy. 4344F2C506DA 4. While opening up the holder [1], remove the shaft [2].
Page 391: Cleaning Of Miscellaneous Rolls
2. Periodical check Field Service Ver. 1.0 Apr. 2007 2.1.4 Cleaning of miscellaneous rolls A. Periodically cleaning parts/cycle • Miscellaneous rolls: Every 50,000 prints 1. Open the upper door [1]. 2. Using a soft cloth dampened with alcohol, wipe the roll [2]. 4344F2C510DA 3.
Page 392 Field Service Ver. 1.0 Apr. 2007 2. Periodical check 3. Lift up the original feed tray [1]. 4. Using a soft cloth dampened with alcohol, wipe the roller [2]. 4344F2C520DA 5. Remove the front cover and rear cover. See P.12 6.
Page 393: Cleaning Of The Scanning Guide
2. Periodical check Field Service Ver. 1.0 Apr. 2007 9. Using a soft cloth dampened with alcohol, wipe the roller [1]. 4344F2C532DA 2.1.6 Cleaning of the scanning guide A. Periodically cleaning parts/cycle • Scanning guide: Every 50,000 prints 1. Open the duplexing document feeder.
Page 394: Other
Field Service Ver. 1.0 Apr. 2007 3. Other Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 395 3. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref.Page Front cover P.12 Exterior parts Rear cover P.12 Original feed tray rear cover P.12 ADF (DF-605) P.13 Unit Mount kit (MK-501) P.13 Main control board P.16...
Page 396: Adf (Df-605)
Field Service Ver. 1.0 Apr. 2007 3. Other 3.3.2 ADF (DF-605) 1. Disconnect the connector [1]. 4344F2C538DA 2. Remove two screws [1] and remove the ADF [2]. 4344F2C539DA 3.3.3 Mount kit (MK-501) 1. Remove the ADF. See P.13 2. Remove nine screws [1] and then remove the rear cover [2] of the main body.
Page 397 3. Other Field Service Ver. 1.0 Apr. 2007 3. Remove four screws [1] and remove the rear upper cover [2]. NOTE • Make sure to hold the angle detect- ing lever [3] with fingers at the time of removing or installing. 4344F2C541DA 4.
Page 398 Field Service Ver. 1.0 Apr. 2007 3. Other 6. Remove two screws [1] and remove the rear right cover [2]. 4344F2C544DA 7. Disconnect three connectors [1], the screw of the grounding wire [2] and the wire saddle [3]. 4344F2C545DA 8. Remove four screws [1] and remove the rear right hinge mounting bracket [2].
Page 399: Main Control Board
3. Other Field Service Ver. 1.0 Apr. 2007 3.3.4 Main control board 1. Turn OFF the main power switch. 2. Remove the rear cover. See P.12 3. Disconnect all the connectors on the board. 4. Remove three screws [1], and then remove the main control board [2].
Page 400 Field Service Ver. 1.0 Apr. 2007 3. Other B. Reinstallation procedure 1. Close the side edge stop [1] of the original feed tray. NOTE • Be sure to perform document width detection adjustment after replac- ing the variable resistor (PBA-VR). See P.16 4344F2C525DA 2.
Page 401: Complete Stamp Unit 2
3. Other Field Service Ver. 1.0 Apr. 2007 8. Initialize the backup data. See P.28 9. Perform document width detection adjustment. See P.27 10. Turn OFF the main power switch and turn it ON again and check whether size detec- tion operates normally.
Page 402: Replacing The Replace Stamp 2
Field Service Ver. 1.0 Apr. 2007 3. Other 3.3.7 Replacing the replace stamp 2 1. Open the upper door [1]. 2. Open the processing guide [2]. 4344F2C534DA 3. Remove the stamp. 4. Reinstall the new replace stamp 2 [1]. NOTE •...
Page 403: Firmware Upgrade
4. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 Firmware upgrade 1. Prepare the firmware upgrade EEPROM. 2. Turn OFF the main power switch. 3. Remove the rear cover. See P.12 4. Insert the prepared EEPROM [2] to the IC socket section [1] of the main control board.
Page 404: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 5. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 405: Service Mode
6. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Service mode function setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 6.1.1 Procedure 1.
Page 406: Setting In The Service Mode
Field Service Ver. 1.0 Apr. 2007 6. Service Mode Setting in the Service mode 6.3.1 ADJUST A. ADF SUB ZOOM Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning zoom ratio in the sub scanning direction when the automatic document feeder is used.
Page 407 6. Service Mode Field Service Ver. 1.0 Apr. 2007 B. ADF MAIN REGIST Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the main scanning direction when the automatic docu- ment feeder is used.
Page 408 Field Service Ver. 1.0 Apr. 2007 6. Service Mode C. ADF SUB RESIST1 Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the sub scanning direction when the automatic document feeder is used.
Page 409 6. Service Mode Field Service Ver. 1.0 Apr. 2007 D. ADF SUB RESIST2 Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the sub scanning direction when the automatic document feeder is used.
Page 410: Function
Field Service Ver. 1.0 Apr. 2007 6. Service Mode F. ADF REG. LOOP2 Functions • To adjust the length of loop formed in the original before the registration roller. (2-sided) • When a skew feed, fold, or misfeed of the original occurs Setting/ •...
Page 411: Clear Data
6. Service Mode Field Service Ver. 1.0 Apr. 2007 D. ADF WIDTH Ad. (Min) Functions • To adjust the original size detection VR. • When PBA-VR board is replaced Adjustment 1. Display the Service mode. procedure 2. Choose [ADF WIDTH Ad. (Min)] from [FUNCTION].
Page 412: Mechanical Adjustment
Field Service Ver. 1.0 Apr. 2007 7. Mechanical adjustment Mechanical adjustment Leading edge skew adjustment 1. Load the test chart [1] in the reverse automatic document feeder and make one 1-sided copy five consecu- tive times. 4344F3C501DA 2. Fold each of the sample copies as illustrated and check for any devia- tion.
Page 413 7. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 6. If there is a deviation as shown on the figure, turn the screw clockwise to adjust it. 7. After the adjustment procedure has been completed, tighten the decora- tive screw and the nut which has been loosened in step 4.
Page 414: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 8. Jam display Troubleshooting Jam display Sensor layout 4344F4C500DA [1] Original detection sensor PC8-ADF [3] Separator sensor PC6-ADF [2] Registration sensor PC9-ADF [4] Exit/turnover sensor PC10-ADF Solution 8.2.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications?
Page 415: Misfeed At Paper Take-Up Section
8. Jam display Field Service Ver. 1.0 Apr. 2007 8.2.2 Misfeed at paper take-up section A. Detection timing Type Description The separator sensor (PC6-ADF) is not blocked even after the set period of time has elapsed after the paper feed motor (M1-ADF) is energized. Detection of misfeed at paper take-up section The registration sensor (PC9-ADF) is not blocked even after the set period...
Page 416: Misfeed At Transport Section
Field Service Ver. 1.0 Apr. 2007 8. Jam display 8.2.3 Misfeed at transport section A. Detection timing Type Description The original detection sensor (PC8-ADF) is not blocked even after the set Detection of misfeed at period of time has elapsed after the registration sensor (PC9-ADF) is transport section blocked by the paper.
Page 417: Misfeed At Paper Exit Section
8. Jam display Field Service Ver. 1.0 Apr. 2007 8.2.5 Misfeed at paper exit section A. Detection timing Type Description The exit/turnover sensor (PC10-ADF) is not blocked even after the set Detection of misfeed at period of time has elapsed after the original detection sensor (PC8-ADF) is paper exit section blocked by the paper.
Page 418: Malfunction Code
Field Service Ver. 1.0 Apr. 2007 9. Malfunction code Malfunction code Solution 9.1.1 C0044: ADF cooling fan motor failure A. Detection timing Trouble code Description • The Lock signal remains HIGH for a predetermined continuous period of time C0044 while ADF cooling fan motor is rotating. B.
Page 419 9. Malfunction code Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 420 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 421 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.
Page 422: General
Field Service Ver. 1.0 Apr. 2007 CONTENTS DF-502 General Product specification ....................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Pick-up roller/feed roller ................3 2.1.2 Separation roller.................... 5 2.1.3 Cleaning of the registration rollers/rolls............7 2.1.4 Cleaning of the exit rollers/rolls ..............
Page 423 Field Service Ver. 1.0 Apr. 2007 5.3.2 FUNCTION ....................22 Mechanical adjustment ..................23 ADF Height Adjustment..................23 ADF Leading Edge Skew Adjustment ..............24 Troubleshooting Jam Display......................27 Misfeed display ....................27 7.1.1 Display resetting procedure ................ 27 Sensor layout...................... 27 Solution ......................
Page 424: Product Specification
Field Service Ver. 1.0 Apr. 2007 1. Product specification General Product specification A. Type Name Automatic document feeder Installation Inserted in top portion of the copier Modes Standard = 1-sided original Mixed original = 1-sided original Document loading Left-hand side, face up B.
Page 425 1. Product specification Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 426: Periodical Check
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 2.1.1 Pick-up roller/feed roller A. Periodically cleaning parts/cycle • Pick-up roller: Every 30,000 prints •...
Page 427 2. Periodical check Field Service Ver. 1.0 Apr. 2007 D. Replacing procedure 1. Open the upper door. 2. Open the document feed section cover. See P.14 3. Snap off two C-clips [1]. 4. Remove two bearings [2] and the pick-up roller/feed roller assy [3]. 4688F2C502DA 5.
Page 428: Separation Roller
Field Service Ver. 1.0 Apr. 2007 2. Periodical check 7. Remove the pin [1], snap off one C- clip [2], and remove the feed roller [3]. 4688F2C505DA 8. To reinstall, reverse the order of removal. 2.1.2 Separation roller A. Periodically cleaning parts/cycle •...
Page 429 2. Periodical check Field Service Ver. 1.0 Apr. 2007 D. Replacing procedure 1. Open the upper door. 2. Remove two screws [1] and the sep- arator section protective cover [2]. 4688F2C506DA 3. Unhook the spring [1] and remove the separation roller assy [2]. 4688F2C508DA 4.
Page 430: Cleaning Of The Registration Rollers/Rolls
Field Service Ver. 1.0 Apr. 2007 2. Periodical check 2.1.3 Cleaning of the registration rollers/rolls A. Periodically cleaning parts/cycle • Registration rollers: Every 30,000 prints • Registration rolls: Every 30,000 prints B. Cleaning procedure 1. Raise the automatic document feeder. 2.
Page 431: Cleaning Of The Exit Rollers/Rolls
2. Periodical check Field Service Ver. 1.0 Apr. 2007 7. Using a soft cloth dampened with alcohol, wipe the registration roller [1] clean of dirt. 4688F2C513DA 2.1.4 Cleaning of the exit rollers/rolls A. Periodically cleaning parts/cycle • Exit rollers: Every 30,000 prints •...
Page 432 Field Service Ver. 1.0 Apr. 2007 2. Periodical check 2.1.5 Cleaning of the transport rolls A. Periodically cleaning parts/cycle • Transport rolls: Every 30,000 prints B. Cleaning procedure 1. Remove the rear cover. See P.14 2. Remove the document feeding tray. See P.14 3.
Page 433 2. Periodical check Field Service Ver. 1.0 Apr. 2007 2.1.6 Cleaning of length size sensor 2 A. Periodically cleaning parts/cycle • Length size sensor 2: Every 30,000 prints B. Cleaning procedure 1. Using a brush, whisk dust and dirt off the surface of the sensor window [1].
Page 434: Other
Field Service Ver. 1.0 Apr. 2007 3. Other Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 435 3. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page Uniut P.12 Document feed section cover P.14 Rear cover P.14 Exterior parts Document feeding tray P.14 Document feeding tray cover P.15 Board and etc.
Page 436 Field Service Ver. 1.0 Apr. 2007 3. Other 3. Remove the screw [1] to remove the grounding wire. 4688F2C519DA 4. Disconnect three connectors [1] and remove the harness out of the wire saddle [2]. 4688F2C001DA 5. Remove the ADF [1]. 4688F2C520DA...
Page 437: Document Feed Section Cover
3. Other Field Service Ver. 1.0 Apr. 2007 3.3.2 Document feed section cover 1. Open the upper door. 2. Remove two screws [1] and remove the document feed section cover [2]. 4688F2C002DA 3.3.3 Rear cover 1. Open the upper door. 2.
Page 438 Field Service Ver. 1.0 Apr. 2007 3. Other 4. Remove three screws [1] and remove the document feeding tray [2]. 4688F2C005DA 3.3.5 Document feeding tray cover 1. Remove the document feeding tray. See P.14 2. Remove four screws [1] and remove the document feeding tray cover [2].
Page 439: Df Control Board
3. Other Field Service Ver. 1.0 Apr. 2007 3.3.6 DF control board 1. Open the upper door. 2. Remove the rear cover. See P.14 3. Disconnect all connectors from the interface board. 4. Remove the screw [1] and remove the grounding wire. 5.
Page 440: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 441: Service Mode
5. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Service mode setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 5.1.1 Procedure 1.
Page 442: Setting In The Service Mode
Field Service Ver. 1.0 Apr. 2007 5. Service Mode Setting in the service mode 5.3.1 ADJUST A. ADF SUB ZOOM Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning zoom ratio in the sub scanning direction when the automatic document feeder is used.
Page 443 5. Service Mode Field Service Ver. 1.0 Apr. 2007 B. ADF MAIN REGIST Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the main scanning direction when the automatic docu- ment feeder is used.
Page 444 Field Service Ver. 1.0 Apr. 2007 5. Service Mode C. ADF SUB RESIST1 Functions TEST COPY ADJUST • To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the sub scanning direction when the automatic document feeder is used.
Page 445: Function
5. Service Mode Field Service Ver. 1.0 Apr. 2007 5.3.2 FUNCTION A. ADF FEED TEST Functions • To check for correct paper passage of the paper take-up and transport system in the automatic (duplexing) document feeder alone as a single unit. •...
Page 446: Mechanical Adjustment
Field Service Ver. 1.0 Apr. 2007 6. Mechanical adjustment Mechanical adjustment ADF Height Adjustment 1. Turn the screw [1] so that the spacer contacts the glass at the scale posi- tion of the copier. Turn the screw clockwise to raise the ADF.
Page 447: Adf Leading Edge Skew Adjustment
6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 ADF Leading Edge Skew Adjustment NOTE • This adjustment is to be made when a tilted image occurs. 1. Load the test chart [1] in the ADF and make five 1-sided copies. NOTE •...
Page 448 Field Service Ver. 1.0 Apr. 2007 6. Mechanical adjustment 4. If the deviation is as shown on the left, move the graduations [1] of the ADF to the front. 4688F3C507DA 5. If the deviation is as shown on the left, move the graduations [1] of the ADF to the rear.
Page 449 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 450: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 7. Jam Display Troubleshooting Jam Display Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. 4688F4J502DA Display message Misfeed/paper location Ref. page Document feed section P.28 ORIGINAL DOC.
Page 451: Solution
7. Jam Display Field Service Ver. 1.0 Apr. 2007 Solution 7.3.1 Initial Check Items • When a paper misfeed occurs, first perform the following initial checks. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper. Is paper curled, wavy, or damp.
Page 452: Misfeed At The Document Transport Section
Field Service Ver. 1.0 Apr. 2007 7. Jam Display 7.3.3 Misfeed at the document transport section A. Detection timing Type Description Document trans- • The registration sensor (PS3) is not blocked even after the lapse of a given port section mis- period of time after the main motor (M1) has been energized.
Page 453: Misfeed At The Document Exit Section
7. Jam Display Field Service Ver. 1.0 Apr. 2007 7.3.4 Misfeed at the document exit section A. Detection timing Type Description Document exit sec- • The paper exit sensor (PS5) is not blocked even after the lapse of a given tion misfeed detec- period of time after the main motor (M1) has been energized.
Page 454 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 455 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.
Page 456: General
Field Service Ver. 1.0 Apr. 2007 CONTENTS AD-504 General Product specifications ..................... 1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 Other ........................4 Disassembly/Adjustment prohibited items ............4 Disassembly/Assembly/Cleaning list (Other parts)..........5 3.2.1 Disassembly/Assembly parts list..............5 3.2.2 Cleaning parts list ..................
Page 457 Field Service Ver. 1.0 Apr. 2007 Troubleshooting Jam display ......................13 Misfeed display ....................13 6.1.1 Misfeed display resetting procedure ............13 Sensor layout...................... 14 Solution ......................15 6.3.1 Initial check items ..................15 6.3.2 Duplex reversal housing block ..............15...
Page 458: Product Specifications
Field Service Ver. 1.0 Apr. 2007 1. Product specifications General Product specifications A. Type Name Automatic duplex unit Type Sheet duplex paper take-up section Installation Installed to the right side door Power requirements DC24 V (supplied from the copier) DC5 V B.
Page 459 1. Product specifications Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 460: Periodical Check
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) • Periodically replaced parts are not employed.
Page 461: Other
3. Other Field Service Ver. 1.0 Apr. 2007 Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 462: Disassembly/Assembly/Cleaning List (Other Parts)
Field Service Ver. 1.0 Apr. 2007 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page Lower right cover Exterior parts Right cover Board and etc. AD drive board Others Transport motor 3.2.2 Cleaning parts list Section Part name Ref.
Page 463: Disassembly/Assembly Procedure
3. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/Assembly procedure 3.3.1 Lower right cover 1. Remove the screw [1] and the lower right cover [2]. 4532F2C001DA 3.3.2 Right cover 1. Remove the lower right cover. See P.6 2. Remove two screws [1] and the right cover [2].
Page 464: Ad Drive Board
Field Service Ver. 1.0 Apr. 2007 3. Other 3.3.3 AD drive board 1. Remove the lower right cover. See P.6 2. Remove the right cover. See P.6 3. Remove two screws [1], disconnect all connectors, and remove the AD drive board [2]. 4532F2C003DA 3.3.4 Transport motor...
Page 465: Cleaning Procedure
3. Other Field Service Ver. 1.0 Apr. 2007 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Duplex unit transport rollers/rolls 1. Open the front door of the duplex unit. 2. Using a soft cloth dampened with alcohol, wipe the duplex unit trans- port rollers/rolls [1] clean of dirt.
Page 466: Duplex Unit Ventilation Section
Field Service Ver. 1.0 Apr. 2007 3. Other 3.4.3 Duplex unit ventilation section 1. Using a soft cloth dampened with alcohol, wipe the outside of the duplex unit ventilation section [1] clean of dirt. 4532F2C007DA 2. Open the front door of the duplex unit. 3.
Page 467 3. Other Field Service Ver. 1.0 Apr. 2007 4. Using a soft cloth dampened with alcohol, wipe the bypass transport rollers [1] clean of dirt. 4532F2C501DA 5. Using a soft cloth dampened with alcohol, wipe the bypass transport rolls [1] clean of dirt. 4687F2C003DA...
Page 468: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 469: Service Mode
5. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Service mode function setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 5.1.1 Procedure 1.
Page 470: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 6. Jam display Troubleshooting Jam display Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. 4532F4E501DA Display message Misfeed processing location Ref. page PAPER JAM Duplex reversal housing block P.15...
Page 471 6. Jam display Field Service Ver. 1.0 Apr. 2007 Sensor layout 4532F4C502DA [1] Transport sensor...
Page 472 Field Service Ver. 1.0 Apr. 2007 6. Jam display Solution 6.3.1 Initial check items • When a paper misfeed occurs, first check the following initial check items. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper. Is paper curled, wavy, or damp.
Page 473 6. Jam display Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 474 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 475 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.
Page 476: General
Field Service Ver. 1.0 Apr. 2007 CONTENTS PF-502 General Product specification ....................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the feed roller ................3 Other ........................4 Disassembly/Adjustment prohibited items ............4 Disassembly/Assembly/Cleaning list (Other parts)..........
Page 477 Field Service Ver. 1.0 Apr. 2007 Paper feed unit main scanning registration adjustment........14 Troubleshooting Jam display ......................17 Misfeed display ....................17 7.1.1 Misfeed display resetting procedure ............17 Sensor layout...................... 18 Solution ......................19 7.3.1 Initial check items ..................19 7.3.2 Misfeed at the tray2 to 5 paper feed/vertical transport section ....
Page 478 Field Service Ver. 1.0 Apr. 2007 1. Product specification General Product specification A. Type Name Add-on paper feed unit Installation Installed on the underside of the copier B. Paper Plain paper (60 to 90 g/m Type 250 sheets Recycled paper (60 to 90 g/m Metric areas: A3, A4S, A4, A5, B4, B5S, and B5 Sizes Inch areas: Ledger (11 x 17), 11 x 14, Legal (8-1/2 x 14), LetterS (8-1/2 x 11S),...
Page 479 1. Product specification Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 480: Maintenance
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the feed roller A. Periodically replaced parts/cycle • Feed roller: Every 150,000 prints B. Replacing procedure 1. Remove the paper feed unit. See P.5 2.
Page 481 3. Other Field Service Ver. 1.0 Apr. 2007 Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 482 Field Service Ver. 1.0 Apr. 2007 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page Unit Paper feed unit Tray Exterior parts Paper feed unit rear cover PF drive board Board and etc. Paper size detect board 3.2.2 Cleaning parts list Section...
Page 483 3. Other Field Service Ver. 1.0 Apr. 2007 3. Remove two screws [1] in the rear. 4686F2C506DA 4. Open the tray 1 [1] of the main body and tray [2] of the paper feeder unit, and remove the two screws [3] in the front.
Page 484 Field Service Ver. 1.0 Apr. 2007 3. Other 3.3.2 Tray 1. Slide out the tray. 2. Remove two screws [1], two fixed metal plates [2] and remove the tray [3]. 4686F2C002DA 3.3.3 Paper feed unit rear cover 1. Remove the screw [1] and remove the paper feed unit rear cover [2].
Page 485 3. Other Field Service Ver. 1.0 Apr. 2007 3.3.4 PF drive board 1. Remove the paper feed unit rear cover. See P.7 2. Disconnect all connectors on the PF drive board. 3. Remove two screws [1] and remove PF drive board [2]. 4686F2C003DA 3.3.5 Paper size detect board...
Page 486 Field Service Ver. 1.0 Apr. 2007 3. Other Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Feed roller 1. Remove the feed rollers. See P.3 2. Using a soft cloth dampened with alcohol, wipe the two feed rollers [1] clean of dirt.
Page 487 3. Other Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 488 Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 489 5. Service mode Field Service Ver. 1.0 Apr. 2007 Service mode Service mode setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 5.1.1 Procedure 1.
Page 490 Field Service Ver. 1.0 Apr. 2007 5. Service mode Setting in the service mode 5.3.1 SERVICE’S CHOICE A. LOOP Ad. (TRAY2-5) • To adjust the length of the loop formed in the paper before the synchronizing roller Functions when the optional paper feed unit is used. •...
Page 491 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 Mechanical adjustment Paper feed unit main scanning registration adjustment NOTE • This adjustment is to be made when the PH unit has been replaced. 1. Load the tray2 with A4 crosswise paper. 2.
Page 492 Field Service Ver. 1.0 Apr. 2007 6. Mechanical adjustment 10. If width A is smaller than the speci- fied range, move the edge guide in the direction of the arrow. 11. After the adjustment has been made, produce a new test pattern and check for deviation.
Page 493 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 494: Misfeed Display Resetting Procedure
Field Service Ver. 1.0 Apr. 2007 7. Jam display Troubleshooting Jam display Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. 4686F4E501DA Ref. Display message Misfeed/paper location Page PAPER JAM Tray2 paper feed/vertical transport section of the paper feed unit OPEN 2nd SIDE COVER...
Page 495: Sensor Layout
7. Jam display Field Service Ver. 1.0 Apr. 2007 Sensor layout 4686F4C500DA Registration sensor (PS1) Paper feed sensor (PS2)
Page 496: Solution
Field Service Ver. 1.0 Apr. 2007 7. Jam display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first check the following initial check items. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper. Is paper curled, wavy, or damp.
Page 497: Initial Check Items
Location Step Action Control signal (Electrical component) Initial check items — — bizhub 163/163f/ PS1 sensor check PRCB PJ17PRCB-3 (ON) 181/211/220 SD1 operation check PFDB PJ3PFDB A-1 (ON) C to D-4 PS2 sensor check PFDB PJ3PFDB B-2 (ON) C to D-6 Replace DFDB —...
Page 498 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 499 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.
Page 500: General
Field Service Ver. 1.0 Apr. 2007 CONTENTS MB-501 General Product specification ....................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the separation roller assy ............. 3 2.1.2 Replacing the feed roller ................3 Other ........................
Page 501 Field Service Ver. 1.0 Apr. 2007 Multiple bypass mechanical clutch adjustment........... 23 Troubleshooting Jam Display......................25 Misfeed display ....................25 7.1.1 Display resetting procedure ................ 25 Sensor layout...................... 26 Solution ......................27 7.3.1 Initial Check Items ..................27 7.3.2 Misfeed at the multiple bypass paper feed section ........28...
Page 502 Field Service Ver. 1.0 Apr. 2007 1. Product specification General Product specification A. Type Name Multiple bypass tray Installation Screwed to the copier B. Paper Plain paper (60 to 90 g/m 100 sheets OHP film Thick paper (91 to 157 g/m 20 sheets Type Postcards and labels...
Page 503: Product Specification
1. Product specification Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 504: Periodical Check
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the separation roller assy A. Periodically replaced parts/cycle • Separation roller assy: Every 150,000 prints B. Replacing procedure 1. Open the right door. 2.
Page 505 2. Periodical check Field Service Ver. 1.0 Apr. 2007 3. Remove four screws [1], disconnect the connector [2], and remove the paper feed assy [3]. 4687F2C521DA 4. Snap off three C-rings [1] and slide the shaft to remove the gear [2]. 4687F2C522DA 5.
Page 506 Field Service Ver. 1.0 Apr. 2007 2. Periodical check 6. Snap off the C-clip [1] and two C- rings [2] and remove the feed roller [3]. 4687F2C524DA 7. To reinstall, reverse the order of removal.
Page 507: Other
3. Other Field Service Ver. 1.0 Apr. 2007 Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 508 Field Service Ver. 1.0 Apr. 2007 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page Unit Multi bypass tray Paper feed solenoid P.12 Others Paper feed mechanical clutch P.13 3.2.2 Cleaning parts list Section Part name Ref.
Page 509 3. Other Field Service Ver. 1.0 Apr. 2007 4. Remove two screws [1] and remove the upper cover [2]. 4687F2C001DA 5. Remove four screws [1] and remove the multiple bypass [2]. 4687F2C002DA 6. Remove two screws [1] and remove the guide plate [2]. 4687F2C502DA...
Page 510 Field Service Ver. 1.0 Apr. 2007 3. Other B. Reinstallation procedure 1. Remove two screws [1] and remove the right rear cover [2] of the main body. 4687F2C500DA 2. Remove two screws [1] and remove the upper cover [2]. 4687F2C503DA 3.
Page 511 3. Other Field Service Ver. 1.0 Apr. 2007 4. Remove the screw [1] and remove the rear cover [2]. 4687F2C505DA 5. Install the multiple bypass [2] and temporarily tighten the four screws [1]. NOTE • Put the middle hook [3] of the multi- ple bypass on the right door.
Page 512 Field Service Ver. 1.0 Apr. 2007 3. Other 7. Install the guide plate assy [2] with two screws [1]. 4687F2C507DA 8. Open the right door and install the positioning pin [1] at the position as illustrated. 9. Close the right door. Correctly posi- tion the multiple bypass with refer- ence to the positioning pin.
Page 513: Tray
3. Other Field Service Ver. 1.0 Apr. 2007 12. Loosen the screw [1] shown. 4687F2C510DA 13. Make the lever [1] contact the gear shaft [2]. 14. Tighten the screw [3] to fix it. 0 mm 4687F2C511DA 15. Reinstall the rear cover, lower cover, and upper cover. 3.3.2 Paper feed solenoid 1.
Page 514 Field Service Ver. 1.0 Apr. 2007 3. Other 3. Remove four screws [1] and remove feed roller assy [2]. NOTE • Use care not to lose the two springs. 4687F2C512DA 4. Remove two wire saddle [1] and dis- connect the connector [2]. 5.
Page 515 3. Other Field Service Ver. 1.0 Apr. 2007 3. Remove the collar [1]. 4687F2C515DA 4. Remove the coupling [1]. 4687F2C516DA 5. Remove the torque limiter [1] from the gear. 4687F2C517DA...
Page 516 Field Service Ver. 1.0 Apr. 2007 3. Other Precautions for reassembly of the paper feed mechanical clutch • At reassembly, make sure that the protrusions on both ends [2] of the torque lim- iter [1] fit into the center slit in the collar [3] and coupling [4]. 4687F2C518DA...
Page 517: Cleaning Procedure
3. Other Field Service Ver. 1.0 Apr. 2007 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation roller 1. Remove the separation roller assy. See P.3 2. Using a soft cloth dampened with alcohol, wipe the separation roller [1] clean of dirt.
Page 518 Field Service Ver. 1.0 Apr. 2007 3. Other 3.4.3 Bypass transport roller/rolls 1. Open the right door. 2. Remove two screws [1] and remove the guide plate [2]. 4687F2C502DA 3. Using a soft cloth dampened with alcohol, wipe the bypass transport roller [1] clean of dirt.
Page 519 3. Other Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 520: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 521: Service Mode
5. Service Mode Field Service Ver. 1.0 Apr. 2007 Service Mode Service mode setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the service mode. 5.1.1 Procedure 1.
Page 522: Mechanical Adjustment
Field Service Ver. 1.0 Apr. 2007 6. Mechanical adjustment Mechanical adjustment Multiple Bypass main scanning Registration Adjustment NOTE • This adjustment is to be made when the PH Unit has been replaced. 1. Load the paper feed tray1 with A4 paper. 2.
Page 523 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 9. Check width A on the copy of the test pattern. If width A falls outside the specified range, perform the following steps to make an adjustment. Specifications: 20 ± 2.0 mm 4686F3C500DA 10.
Page 524 Field Service Ver. 1.0 Apr. 2007 6. Mechanical adjustment Multiple bypass mechanical clutch adjustment • The assembled position of the collar/coupling on the torque limiter of the paper feed Mechanical clutch is varied so that the clutch operates properly. NOTE •...
Page 525 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 526: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 7. Jam Display Troubleshooting Jam Display Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. 4687F4E502DA Display message Misfeed/paper location Ref. page PAPER JAM Paper feed section of the multiple bypass P.28...
Page 527: Sensor Layout
7. Jam Display Field Service Ver. 1.0 Apr. 2007 Sensor layout 4687F4C501DA Registration sensor (PS1)
Page 528: Solution
Field Service Ver. 1.0 Apr. 2007 7. Jam Display Solution 7.3.1 Initial Check Items • When a paper misfeed occurs, first perform the following initial checks. Check Item Action Does the paper meet product specifications? Change the paper. Change the paper. Is paper curled, wavy, or damp.
Page 529 Printer control board (PRCB) Paper feed solenoid (SD1) WIRING DIAGRAM Location Step Operations Control signal (Electrical components) Initial checks — — bizhub 163/163f/ PS1 sensor check PRCB PJ17PRCB-3 (ON) 181/211/220 bizhub 163/163f/ SD1 operation check PRCB PJ12PRCB-2 (REM) 181/211/220 Replace PRCB — —...
Page 530 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 531 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.
Page 532 Field Service Ver. 1.0 Apr. 2007 CONTENTS JS-503 General Product specification ....................1 Maintenance Other ........................3 Disassembly/Adjustment prohibited items ............3 Disassembly/Assembly/Cleaning list (Other parts)..........4 2.2.1 Disassembly/Assembly parts list..............4 Disassembly/Assembly procedure................ 4 2.3.1 JS drive board ....................4 2.3.2 Paper detecting board...................
Page 533 Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 534 Field Service Ver. 1.0 Apr. 2007 1. Product specification General Product specification A. Type Type Add-on drawer Installation Built into the exit section of the copier Paper storage system Moving drawer system B. Paper Type Upper drawer Lower drawer 100 sheets (A4S), 150 sheets (A4S), Plain paper (60 to 90 g/m 50 sheets (other than A4S)
Page 535: Product Specification
1. Product specification Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 536: Other
Field Service Ver. 1.0 Apr. 2007 2. Other Maintenance Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose.
Page 537: Disassembly/Assembly/Cleaning List (Other Parts)
2. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/Assembly/Cleaning list (Other parts) 2.2.1 Disassembly/Assembly parts list Section Part name Ref. page JS drive board Board and etc. Paper detecting board Other Bin switching motor Disassembly/Assembly procedure 2.3.1 JS drive board 1.
Page 538 Field Service Ver. 1.0 Apr. 2007 2. Other 6. Remove the screw [1] and remove the sensor assy mounting bracket [2]. 4689F2C002DA 7. Disconnect two connectors [1]. 8. Remove the harness from two edge covers [1] and remove the sensor assy [3].
Page 539 2. Other Field Service Ver. 1.0 Apr. 2007 10. Disconnect the connector [1] from the main body. 4689F2C005DA 11. Remove two screws [1] and remove the JS drive board assy [2]. 4689F2C006DA 12. Disconnect four connectors [1] from the JS drive board. 4689F2C505DA...
Page 540: Paper Detecting Board
Field Service Ver. 1.0 Apr. 2007 2. Other 13. Remove two screws [1], two PWB supports [2], and remove the JS drive board [3]. 4689F2C506DA 2.3.2 Paper detecting board 1. Remove the control panel. See P.42 of the main body service manual. 2.
Page 541 2. Other Field Service Ver. 1.0 Apr. 2007 4. Press down the tab [1] and remove the paper detecting board [2]. 4689F2C008DA 5. Remove the screw [1] and remove the paper detecting board assy [2]. 4689F2C009DA 6. Disconnect the connector [1] and remove the paper detecting board [2].
Page 542: Bin Switching Motor
Field Service Ver. 1.0 Apr. 2007 2. Other 2.3.3 Bin switching motor 1. Remove the control panel. See P.42 of the main body service manual. 2. Disconnect the connector [1]. 4689F2C001DA 3. Remove the front cover. See P.43 of the main body service manual. 4.
Page 543 2. Other Field Service Ver. 1.0 Apr. 2007 7. Disconnect two connectors [1]. 8. Take the harness out of the two edge covers [2] and remove the sensor assy. 4689F2C003DA 9. Disconnect the connector [1] and remove two screws [2] and remove the bin switching motor [3].
Page 544: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 3. Malfunction code Troubleshooting Malfunction code Trouble code • The main unit's cpu performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code on the touch panel. 4689F4C500DA...
Page 545: Trouble Code List
3. Malfunction code Field Service Ver. 1.0 Apr. 2007 Trouble code list Code Description Detection timing If the upper home position sensor is LOW during an ini- tial operation: • The lower home position sensor (PS2) is LOW when the bin switching motor (M1) starts turning forward. •...
Page 546 Field Service Ver. 1.0 Apr. 2007 3. Malfunction code Code Description Detection timing If both the upper home position sensor (PS1) and the lower home position sensor (PS2) are HIGH during an initial operation: • If the lower home position sensor (PS2) does not go LOW for a given period of time after the bin switching motor (M1) has started turning forward, the bin switch- ing motor (M1) is kept deenergized for a given period...
Page 547: Solution
Check M1 connectors for proper connec- — — tion and correct as necessary. Check M1 for correct drive coupling and — — correct as necessary. bizhub 163/163f/ M1 operation check JSDB PJ2JSDB-1 to 4 181/211/220 bizhub 163/163f/ PS1 sensor check JSDB PJ4DSDB-3 (ON) 181/211/220...
Page 548 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 549 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.
Page 550 Field Service Ver. 1.0 Apr. 2007 CONTENTS SF-501 General Product specifications ..................... 1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 Other ........................4 Disassembly/Adjustment prohibited items ............4 Disassembly/Assembly/Cleaning list (Other parts)..........5 3.2.1 Disassembly/Assembly parts list..............5 Disassembly/Assembly procedure................
Page 551 Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 552: Product Specifications
Field Service Ver. 1.0 Apr. 2007 1. Product specifications General Product specifications A. Machine specifications Shifting amount 28 mm Paper capacity 250 sheets Power consumption Less than 63 W B. Operating environment • Conforms to the operating environment of the main body. NOTE •...
Page 553 1. Product specifications Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 554: Periodical Check
Field Service Ver. 1.0 Apr. 2007 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) • Periodically replaced parts are not employed.
Page 555: Other
3. Other Field Service Ver. 1.0 Apr. 2007 Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 556: Disassembly/Assembly/Cleaning List (Other Parts)
Field Service Ver. 1.0 Apr. 2007 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page Others Shift motor Board and etc. SF drive board Disassembly/Assembly procedure 3.3.1 Shift motor 1. Remove the control panel. See P.42 of the main body service manual.
Page 557: Sf Drive Board
3. Other Field Service Ver. 1.0 Apr. 2007 3.3.2 SF drive board 1. Remove the control panel. See P.42 of the main body service manual. 2. Remove the front cover. See P.43 of the main body service manual. 3. Remove the right cover. See P.48 of the main body service manual.
Page 558 Field Service Ver. 1.0 Apr. 2007 3. Other 7. Disconnect two connectors [1]. 4690F2C500DA 8. Remove two screws [1], two PWB supports [2], and the SF drive board [3]. 4690F2C501DA...
Page 559 3. Other Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 560: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 4. Malfunction code Troubleshooting Malfunction code Solution 4.1.1 C0B80: Shift motor malfunction A. Detection timing Trouble code Description • The home sensor (PS1) is LOW at a timing immediately before the shift motor (M1) starts turning backward. C0B80 •...
Page 561 4. Malfunction code Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 562 SERVICE MANUAL FIELD SERVICE 2007.04 Ver. 1.0...
Page 563 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.
Page 564 Field Service Ver. 1.0 Apr. 2007 CONTENTS IC-206/NC-503 General Product specifications ..................... 1 Printing (IC-206) ....................1 Network printing (NC-503)..................1 Scan to E-mail/Scan to Server (FTP) (IC-206/NC-503)........1 Maintenance Firmware upgrade ....................3 Preparations for firmware rewriting ............... 3 2.1.1 Installing the driver ..................
Page 565 Field Service Ver. 1.0 Apr. 2007 Action taken if network print cannot be done ............. 22...
Page 566: Product Specifications
Field Service Ver. 1.0 Apr. 2007 1. Product specifications General Product specifications Printing (IC-206) bizhub 163 16 ppm (when printing on A4/Letter paper at 600 x 600 dpi) bizhub 181 Print speed *1 18 ppm (when printing on A4/Letter paper at 600 x 600 dpi)
Page 567 1. Product specifications Field Service Ver. 1.0 Apr. 2007 Blank Page...
Page 568: Firmware Upgrade
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade Maintenance Firmware upgrade Preparations for firmware rewriting 2.1.1 Installing the driver NOTE • The TWAIN driver must previously be installed in the host computer that is used to upgrade the firmware. •...
Page 569 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 (3) For Windows Me/98SE 1. Prepare the files necessary for upgrading the firmware, and copy them to PC. 2. Start the host computer. 3. Turn on the power switch of the machine. 4.
Page 570: Firmware Rewriting
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade Firmware rewriting 2.2.1 Updating method 1. Turn ON the power switch of the machine. 2. Start the host computer. 3. Copy the “Update Software” folder and “Update” file to drive C. (Copy them into the highest directory on drive C.) 4.
Page 571 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 8. Click the [Update] button to start the transfer of the firmware data. (Wait until data transfer is completed.) 9. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE •...
Page 572: Procedure When Upgrading The Firmware Has Failed
Field Service Ver. 1.0 Apr. 2007 2. Firmware upgrade 2.2.2 Procedure when upgrading the firmware has failed NOTE • Perform the following procedure only when upgrading from PC using ordinary USB connection has failed and the machine has not started properly. •...
Page 573 2. Firmware upgrade Field Service Ver. 1.0 Apr. 2007 10. Check the display for status of the firmware upgrading sequence. A09AF2E636DA NOTE • NEVER turn OFF and ON the power switch as long as the above screens are being displayed. 11.
Page 574: Other
Field Service Ver. 1.0 Apr. 2007 3. Other Other Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
Page 575: Disassembly/Assembly Procedure
3. Other Field Service Ver. 1.0 Apr. 2007 Disassembly/Assembly procedure 3.2.1 Image controller/Network interface card 1. Remove nine screws [1] and then remove the rear cover [2] of the main body. NOTE • Make sure that the screws illus- trated right with arrows have wash- ers when installing.
Page 576: Adjustment/Setting
Field Service Ver. 1.0 Apr. 2007 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 577: Utility Mode
5. Utility Mode Field Service Ver. 1.0 Apr. 2007 Utility Mode Utility Mode function tree • Utility mode is used to make settings for the utility functions. NOTE • The setting menu contains only the cases in which the Image Controller (IC-206) or Network Interface Card (NC-503) is mounted.
Page 578: Utility Mode Function Setting Procedure
Field Service Ver. 1.0 Apr. 2007 5. Utility Mode Utility mode function setting procedure 5.2.1 Procedure 1. Press the Utility key. 2. The UTILITY MODE screen will appear. 5.2.2 Exiting • Press the Reset key. 5.2.3 Changing the setting value in UTILITY MODE functions 1.
Page 579: Setting In The Utility Mode
5. Utility Mode Field Service Ver. 1.0 Apr. 2007 Setting in the UTILITY MODE 5.3.1 ADMIN. MANAGEMENT A. NETWORK SETTING (1) IP ADDRESS SETTING Functions • This function is used to specify the IP address for the copier. NOTE • Please consult customer’s network administrator for information about the IP address to use.
Page 580 Field Service Ver. 1.0 Apr. 2007 5. Utility Mode (3) GATEWAY TX Functions • This function is used to enable the direct fax function. NOTE • FIt will be displayed only when the FK-506 is mounted. Setting/ • The default setting is “DISABLE”. Procedure “DISABLE”...
Page 581 5. Utility Mode Field Service Ver. 1.0 Apr. 2007 (2) E-MAIL ADDERSS Functions • This function is used to specify the e-mail address of the sender. NOTE • Please consult customer's network administrator for information about the e- mail address to use. Setting/ •...
Page 582 Field Service Ver. 1.0 Apr. 2007 5. Utility Mode (8) POP BEFORE SMTP Functions • This function is used to set whether or not to use POP before SMTP. Setting/ • The default setting is “OFF”. Procedure “OFF” • When [ON] is selected, set the time (second) for POP BEFORE SMTP. The default setting is “5sec”.
Page 583 5. Utility Mode Field Service Ver. 1.0 Apr. 2007 C. E-MAIL SETTING 2 (1) POP3 SERVER ADDR. Functions • This function is used to enter the IP address or host name of an POP3 server. NOTE • Please consult customer's network administrator for information about the IP address to use.
Page 584 Field Service Ver. 1.0 Apr. 2007 5. Utility Mode (6) AUTO RECEPTION Functions • This function is used to specify the time interval (in minutes) for checking E-mail, when Auto Reception is enabled. Setting/ • The default setting is “OFF”. Procedure “OFF”...
Page 585: Scan Setting
5. Utility Mode Field Service Ver. 1.0 Apr. 2007 5.3.2 SCAN SETTING A. RESOLUTION Functions • The default settings for resolution used by the scan to e-mail functions can be speci- fied. Setting/ • The default setting is “300x300dpi”. Procedure 150x150dpi “300x300dpi”...
Page 586: Troubleshooting
Field Service Ver. 1.0 Apr. 2007 6. Troubleshooting Troubleshooting Troubleshooting Troubleshooting procedure overview • If the following symptoms occur when the machine is restarted after the Network Inter- face Card (NC-503) or Image Controller (IC-206) has been mounted, check the board and connectors for proper connection.
Page 587 6. Troubleshooting Field Service Ver. 1.0 Apr. 2007 Action taken if network print cannot be done Step Check Result Possible cause Action Has the print job reached A copier error (paper run- Check the copier and cor- the copier? ning out, toner, etc.) rect the cause of the error.
Page 588 © 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. © 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Printed in Japan Use of this manual should be strictly supervised to Use of this manual should be strictly supervised to DDA09A-M-FE1-1050 DDA09A-M-FE1-1050 avoid disclosure of confidential information.

This manual is also suitable for:

Bizhub 211 Bizhub 220Bizhub 163

Konica Minolta BIZHUB 163 Service Manual

Field Service Total

General

1 System Configuration

Appendix General

2 Product Specification

Maintenance

3 Periodical Check

4 Service Tool

5 Firmware Upgrade

6 Other

Adjustment/Setting

7 How to Use the Adjustment Section

8 Utility Mode

9 Adjustment Item List

10 Service Mode

General

General

1 Product Specifications

Maintenance

2 Firmware Upgrade

3 Other

Adjustment/Setting

4 How to Use the Adjustment Section

5 Confirm Mode

6 Utility Mode

Pf-502

Table of Contents

1 Product Specifications

Maintenance

2 Periodical Check

3 Other

4 Firmware Upgrade

Adjustment/Setting

5 How to Use the Adjustment Section

6 Service Mode

7 Mechanical Adjustment

Troubleshooting

8 Jam Display

Quick Links

Chapters

Troubleshooting

Related Manuals for Konica Minolta BIZHUB 163

Summary of Contents for Konica Minolta BIZHUB 163