43888595 konica minolta bizhub 162 210 service manual

SERVICE MANUAL

2005.042005.04Ver. 1.0Ver. 1.0

2005.04 Ve

r.1.0

2005.04 Ve

r.1.0

2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

FIELD SERVICE

FIELD SERVICE

Printed in JapanPrinted in JapanDD4035PE1-1000DD4035PE1-1000Use of this manual should be strictly supervised to

avoid disclosure of confidential information.Use of this manual should be strictly supervised toavoid disclosure of confidential information.

SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing service work.

Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.Changes may have beManual was printed. Athe information containThe user of this Servicthe product while serviTherefore, this Servicecourse of technical traithe product properly.Keep this Service Man

In this Service Manual CAUTION is definmeaning. When servicing the prorepair, maintenance, e

Symbols used for safe


IMPORTANT NOTICE

DESCRIPTIOWARNING AN

DANGER: Act

WARNING: Act

CAUTION: Acttrou

:Precaution whenproduct.

:Prohibition whenproduct.

:Direction when sproduct.

bizhub_162_210_FS.book 1 S-1

en made to this product to improve its performance after this Service ccordingly, KMBT does not warrant, either explicitly or implicitly, that ed in this Service Manual is complete and accurate.e Manual must assume all risks of personal injury and/or damage to cing the product for which this Service Manual is intended. Manual must be carefully read before doing service work both in the ning and even after that, for performing maintenance and control of

ual also for future service.

, each of three expressions DANGER, WARNING, and ed as follows together with a symbol mark to be used in a limited

duct, the relevant works (disassembling, reassembling, adjustment, tc.) need to be conducted with utmost care.

ty and important warning items are defined as follows:

N ITEMS FOR DANGER, D CAUTION

ion having a high possibility of suffering death or serious injury

ion having a possibility of suffering death or serious injury

ion having a possibility of suffering a slight wound, medium ble, and property damage

servicing theGeneral

precautionElectric hazard High temperature

servicing the General

prohibitionDo not touch with wet hand

Do not disassemble

ervicing the General

instructionUnplug Ground/Earth


S-2

[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradatstrictly prohibited. the ping behind this policy.

SAFETY WARNINGS

Prohibited Acti

Using any cables or

Using any fuse or thSafety will not be asinjury.

Disabling fuse functwire, metal clips, so

Disabling relay funcrelay contacts)

Disabling safety funSafety will not be asinjury.

Making any modificby KMBT

Using parts not spe

bizhub_162_210_FS.book 2 ion in performance and safety. Such modifications are therefore oints listed below are not exhaustive, but they illustrate the reason-

ons

DANGER power cord not specified by KMBT.

ermostat not specified by KMBT. sured, leading to a risk of fire and

ions or bridging fuse terminals with lder or similar object.

tions (such as wedging paper between

ctions (interlocks, safety circuits, etc.) sured, leading to a risk of fire and

ation to the product unless instructed

cified by KMBT


[2] POWER PLUG SELECTIONIn some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.

Power Cord Set or Power Plug

WARNING Use power supply cord set which meets the following

criteria:- provided with a p

the connection touct's rated voltag

- the plug has pin/t- provided with thre

rent capacity, and- the cord set meeUse of inadequate

Attach power plug w- having configurat

outlet appropriatecurrent, and

- the plug has pin/t- meets regulatoryUse of inadequateing to inadequate pgrounding), and m

Conductors in the pminals of the plug a Black or Brown: White or Light B Green/Yellow:Wrong connectionproduct, and resul


lug having configuration intended for wall outlet appropriate for the prod-e and current, anderminal(s) for grounding, ande-conductor cable having enough cur-

ts regulatory requirements for the area. cord set leads to fire or electric shock.

hich meets the following criteria:ion intended for the connection to wall for the product's rated voltage and

erminal(s) for grounding, and requirements for the area. cord set leads to the product connect-ower supply (voltage, current capacity, ay result in fire or electric shock.

ower cable must be connected to ter-ccording to the following order:

L (line)lue: N (neutral)

PE (earth) may cancel safeguards within the ts in fire or electric shock.

kw


S-4

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICEKONICA 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. In order to maintain safety and reliability, the CE must perform regular safety checks.

1. Power Supply

Connection to Power Supply

Check that mains vConnection to wroelectric shock.

Connect power plugconfiguration as theUse of an adapterinadequate powergrounding), and mIf proper wall outleto contact qualified

Plug the power cordcapacity greater thaIf excessive currenresult.

If two or more poweoutlet, the total loadoutlet.If excessive currenresult.

Make sure the powesecurely.Contact problems overheating, and t

Check whether the If current leakage may suffer electricConnect power plu

bizhub_162_210_FS.book 4 WARNINGoltage is as specified.ng voltage supply may result in fire or

directly into wall outlet having same plug. leads to the product connecting to supply (voltage, current capacity, ay result in fire or electric shock.t is not available, advice the customer electrician for the installation.

into the dedicated wall outlet with a n the maximum power consumption.t flows in the wall outlet, fire may

r cords can be plugged into the wall must not exceed the rating of the wall

t flows in the wall outlet, fire may

r cord is plugged in the wall outlet

may lead to increased resistance, he risk of fire.

product is grounded properly.occurs in an ungrounded product, you shock while operating the product.g to grounded wall outlet.

kw


Power Plug and Cord

WARNING When using the power cord set (inlet type) that came with

this product, make sure the connector is securely inserted in the inlet of the product.When securing measure is provided, secure the cord with the fixture properly.If the power cord (uct securely, a conresistance, overhe

Check whether the pinched by a table aOverheating may o

Check whether the whether the sheathIf the power plug, cwith a new power end) specified by Kmay result in fire o

Do not bundle or tieOverheating may o

Check whether dusand wall outlet.Using the power pdust may result in

Do not insert the pohand.The risk of electric

When unplugging thcable.The cable may be electric shock.


inlet type) is not connected to the prod-tact problem may lead to increased ating, and risk of fire.

power cord is not stepped on or nd so on.ccur there, leading to a risk of fire.

power cord is damaged. Check is damaged.ord, or sheath is damaged, replace

cord (with plug and connector on each MBT. Using the damaged power cord

r electric shock.

the power cord. ccur there, leading to a risk of fire.

t is collected around the power plug

lug and wall outlet without removing fire.

wer plug into the wall outlet with a wet

shock exists.

e power cord, grasp the plug, not the

broken, leading to a risk of fire and


S-6

2. Installation Requi

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 flousing a too long extDo not use an exteup. Fire may resul

Prohibited Inst

Do not place the protile materials that mA risk of fire exists

Do not place the proas rain.A risk of fire and e

When not Usin

When the product istime (holidays, etc.)cord.Dust collected arocause fire.

bizhub_162_210_FS.book 6 rements

w in the extension cord is limited, so ension cord may result in fire.nsion cable reel with the cable taken

t.

allation Places

WARNINGduct near flammable materials or vola-ay catch fire..

duct in a place exposed to water such

lectric shock exists.

g the Product for a long time

WARNING not used over an extended period of , switch it off and unplug the power

und the power plug and outlet may


Ventilation

CAUTION The product generates ozone gas during operation, but it

will not be harmful to the human body.If a bad smell of ozone is present in the following cases, ventilate the room.

a. When the product is used in a poorly ventilated roomb. When taking a lot of copiesc. When using mult

Stability

Be sure to lock the In the case of an eslide, leading to a

Inspection befo

Before conducting amentation (service mproceed with the inscedure, using only tadjustment not descIf the prescribed puct may break and

Before conducting athe power plugs fromWhen the power punits are still poweturned OFF. A risk

The area around thYou may get burnt


iple products at the same time

CAUTIONcaster stoppers.arthquake and so on, the product may injury.

re Servicing

CAUTIONn inspection, read all relevant docu-anual, technical notices, etc.) and

pection following the prescribed pro-he prescribed tools. Do not make any ribed in the documentation.

rocedure or tool is not used, the prod- a risk of injury or fire exists.n inspection, be sure to disconnect the product and options.

lug is inserted in the wall outlet, some red even if the POWER switch is of electric shock exists.

e fixing unit is hot..


S-8

Work Performed with the Product Powered On

WARNING Take every care when making adjustments or performing

an operation check with the product powered.If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.

Take every care whdetached.High-voltage existstric shock exists.

Safety Checkpo

Check the exterior adamage.The user or CE ma

Do not allow any mscrews to fall into thThey can short intor fire.

Check wiring for sqCurrent can leak, lfire.

Carefully remove alcal parts and electrunit.Current can leak, lfire.

Check high-voltageCurrent can leak, lfire.

bizhub_162_210_FS.book 8 en servicing with the external cover

around the drum unit. A risk of elec-

ints

WARNINGnd frame for edges, burrs, and other

y be injured.etal parts such as clips, staples, and e product.ernal circuits and cause electric shock

ueezing and any other damage. eading to a risk of electric shock or

l toner remnants and dust from electri-ode units such as a charging corona

eading to a risk of product trouble or

cables and sheaths for any damage.eading to a risk of electric shock or


Check electrode units such as a charging corona unit for deterioration and sign of leakage.Current can leak, leading to a risk of trouble or fire.

Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.The laser light canloss of eyesight.

Do not remove the cpower with the writeing position.The laser light canloss of eyesight.

When replacing a liium battery specifieof the used lithium blocal authority.Improper replacem

After replacing a paoptical lamp and fixition state.A risk of fire exists

Check the interlock check whether the iIf the interlock doeelectric shock or bthe product (e.g., f

Make sure the wirinedges, burrs, or othCurrent can leak, lfire.

Safety Checkpoints

WARNING


enter your eye, leading to a risk of

over of the write unit. Do not supply unit shifted from the specified mount-

enter your eye, leading to a risk of

thium battery, replace it with a new lith-d in the Parts Guide Manual. Dispose attery using the method specified by

ent can cause explosion.

rt to which AC voltage is applied (e.g., ng lamp), be sure to check the installa-

.

switch and actuator for loosening and nterlock functions properly.s not function, you may receive an e injured when you insert your hand in or clearing paper jam).g cannot come into contact with sharp er pointed parts.eading to a risk of electric shock or


S-10

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.

Safety Checkpoints

WARNING

Handling of Co

Toner and developemust be taken not tosubstances come instimulative.If the substances gimmediately. Whenphysician.

Never throw the useYou may be burne

Handling of Se

Unplug the power cDrum cleaner (isoptone-based) are hiwith care. A risk of

Do not replace the any solvent remnanevaporated.A risk of fire exists

bizhub_162_210_FS.book 10 nsumables

WARNINGr are not harmful substances, but care breathe excessive amounts or let the to contact with eyes, etc. It may be

et in the eye, rinse with plenty of water symptoms are noticeable, consult a

d cartridge and toner into fire.d due to dust explosion.

rvice Materials

CAUTIONord from the wall outlet.ropyl alcohol) and roller cleaner (ace-

ghly flammable and must be handled fire exists.

cover or turn the product ON before ts on the cleaned parts have fully

.


Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off.A risk of fire exists.

When using any solvent, ventilate the room well.Breathing large qudiscomfort.

Handling of Service Materials

CAUTION


antities of organic solvents can lead to


S-12

[4] 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.

4.1 Internal Laser Radiation

*at laser aperture of th

This product employdiode and the scann

The print head unit ishould not be opene

semiconductor laserMaximum power of the laser diode 5 mW

Maximum average radiation power (*) 6.32 WWavelen

T

bizhub_162_210_FS.book 12 e Print Head Unit

s a Class 3b laser diode that emits an invisible laser beam. The laser ing polygon mirror are incorporated in the print head unit.s NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit d under any circumstances.

gth 770-795 nm

Laser Aperture of the Print Head Unit

4035D507AA

his figure shows the view inside the Right Door.


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. Food and Drug Administration of the U.S. Department of Health and Human Services (DHHS). This means that the device does not produce hazardous laser radiation.

The label shown on page S-16 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States.

All Areas

Denmark

CAUTION Use of controls, a

specified in this m

Maximum poweWav

CAUTION Use of controls, a

specified in this m

Maximum poweWav

ADVARSEL Usynlig laserstr

Undg udsttelssikkerheds krave

Laserdiodenblge


djustments or performance of procedures other than those anual may result in hazardous radiation exposure.

semiconductor laserr of the laser diode 5 mWelength 770-795 nm

djustments or performance of procedures other than those anual may result in hazardous radiation exposure.

semiconductor laserr of the laser diode 5 mWelength 770-795 nm

ling ved bning, nr sikkerhedsafbrydere er ude af funktion. e for strling. Klasse 1 laser produkt der opfylder IEC60825-1 ne.

halvlederlasers hjeste styrke 5 mWlngden 770-795 nm


S-14

Finland, Sweden

Norway

LUOKAN 1 LASERLAITEKLASS 1 LASER APPARAT

VAROITUS! Laitteen kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saat-

taa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle laser-steilylle.

puolijohdelaserLaserdiodi

aallo

VARNING! Om apparaten an

kan anvndaren ulaserklass 1.

Den maximala effevgl

VARO! Avattaessa ja suo

steilylle. l kat

VARNING! Osynlig laserstr

Betrakta ej strie

ADVERSEL Dersom apparate

ing, kan brukerenfor laser klass 1.

Maksimal effeblge

bizhub_162_210_FS.book 14 n suurin teho 5 mWnpituus 770-795 nm

vnds p annat stt n i denna bruksanvisning specificerats, tsttas fr osynlig laserstrlning, som verskrider grnsen fr

halvledarlaser kten fr laserdioden 5 mW

ngden 770-795 nm

jalukitus ohitettaessa olet alttiina nkymttomlle laser-so steeseen.

ining nr denna del r ppnad och sprren r urkopplad. n.

t brukes p annen mte enn spesifisert i denne bruksanvisn- utsettes fr unsynlig laserstrlning, som overskrider grensen

halvleder laserkt till laserdiode 5 mWlengde 770-795 nm


4.2 Laser Safety Label A laser safety label is attached to the inside of the machine as shown below.

4.3 Laser Caut A laser caution labe


ion Labell is attached to the outside of the machine as shown below.

4035D510CA

4035D509AA


S-16

4.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT When laser protective goggles are to be used, select ones with a lens conforming to the

above specifications. When a disassembly job needs to be performed in the laser beam path, such as when

working around the printerhead and PC Drum, be sure first to turn the printer OFF. If the job requires that the printer be left ON, take off your watch and ring and wear laser

protective goggles. A highly reflective tool can be dangerous if it is brought into the laser beam path. Use

utmost care when handling tools on the users premises. The Print Head is not to be disassembled or adjusted in the field. Replace the Unit or

Assembly including the Control Board. Therefore, remove the Laser Diode, and do not perform Control Boa

4.5 OTHER PR

A fuse is installed in machine is brought tsome reason, there the machine. To prevmachine before atte

CAUTION

Double pole / neutra

ATTENTION

Double ple / fusibl

bizhub_162_210_FS.book 16 rd trimmer adjustment.

ECAUTIONS

each of both L and N lines of the power source of this machine. If the o a stop as a result of the fuse on the N line having been blown for is still the power source voltage being applied to the primary circuit of ent an electric shock, be sure to unplug the power cord of the

mpting to service the machine.

l fusing

e sur le neutre.


Caution labels shown are attached in some areas on/in the machine.When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock.

CAUTION:

WARNING INDICATIONS ON THE MACHINE

High vo

High voltage

You may be burnetouch by any cauticome off or becomService Office.


ltage

High temperature

4034P0J501DA

d or injured if you touch any area that you are advised not to on label. Do not remove caution labels. If any caution label has e dirty and therefore the caution cannot be read, contact our


S-18

bizhub_162_210_FS.book 18

SERVICE MANUAL

2005.04Ver. 1.0

FIELD SERVICE

Main Unit


After publication of this service manual, the parts and mechanism may be subject to change forimprovement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine.

When any change has been made to the descriptions in the service manual, a revised version will beissued with a revision mark added as required.

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

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

To indicate clearly aing page. A number within

NOTERevision marks shown in

When a page revisedThe revision marks f

When a page revisedThe revision marks f

11

1

2005/04 1

Date Service m

bizhub_162_210_FS.book 1 section revised, show in the lower outside section of the correspond-

represents the number of times the revision has been made.

a page are restricted only to the latest ones with the old ones deleted. in Ver. 2.0 has been changed in Ver. 3.0: or Ver. 3.0 only are shown with those for Ver. 2.0 deleted. in Ver. 2.0 has not been changed in Ver. 3.0: or Ver. 2.0 are left as they are.

1

.0 Issue of the first edition

anual Ver. Revision mark Descriptions of revision

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Field Service Ver. 1.0 Apr. 2005

CONTENTS

General1. System configuration............................................................................................... 1

1.1 bizhub 210 ............................................................................................................ 11.2 bizhub 162 ............................................................................................................ 2

2. Product specification ............................................................................................... 32.1 Copier ................................................................................................................... 32.2 Fax Kit (FK-505): (Option) .................................................................................... 6

Maintenance3. Periodical che

3.1 Maintenance3.1.1 Replace3.1.2 Cleaning

3.2 Concept of p3.3 Maintenance

3.3.1 Replacin3.3.2 Replacin3.3.3 Replacin3.3.4 Disasse3.3.5 Replacin3.3.6 Replacin3.3.7 Replacin3.3.8 Replacin3.3.9 Cleaning3.3.10 Cleaning3.3.11 Cleaning3.3.12 Replacin3.3.13 Cleaning3.3.14 Replacin3.3.15 Applicat3.3.16 Replacin3.3.17 Replacin3.3.18 Cleaning

4. Service tool ...4.1 CE Tool list..

5. Firmware upgr

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ck ...................................................................................................... 7 parts ................................................................................................ 7ment parts........................................................................................ 7 parts............................................................................................... 8

arts life.............................................................................................. 9 procedure (Periodical check parts) ............................................... 10g the Separation Roller Assy and Feed Roller .............................. 10g the Paper Dust Remover Assy ................................................... 11g the Imaging Unit (IU).................................................................. 11

mbly of the IU ................................................................................. 12g the PC Drum .............................................................................. 13g the Ozone Filter.......................................................................... 14g the PC Drum Charge Corona Assy............................................ 14g the Cleaning Blade..................................................................... 14 of the PC Drum Paper Separator Fingers.................................... 15 of the Ds Collars .......................................................................... 15 of the Developer Scattering Prevention Plate .............................. 15g the Developer............................................................................. 16 of the Pre-Image Transfer Guide Plate ........................................ 16g the ATDC Sensor ....................................................................... 17

ion of Toner .................................................................................... 17g the Image Transfer Roller Assy .................................................. 18g the Fusing Unit ........................................................................... 19 of the Original Glass and Original Scanning Glass...................... 19

........................................................................................................ 20

........................................................................................................ 20ade ................................................................................................. 21

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gField Service Ver. 1.0 Apr. 2005

ii

5.1 Preparations for Firmware rewriting ................................................................... 215.1.1 Installing the Driver ..................................................................................... 21

5.2 Firmware rewriting.............................................................................................. 235.2.1 Updating method ........................................................................................ 235.2.2 Procedure when Upgrading the Firmware has failed.................................. 25

6. Other ..................................................................................................................... 276.1 Disassembly/Adjustment prohibited items.......................................................... 276.2 Disassembly/Assembly/Cleaning list (Other parts) ............................................ 29

6.2.1 Disassembly/Assembly parts list ................................................................ 296.2.2 Cleanin

6.3 Disassembly6.3.1 Exterior6.3.2 Master B6.3.3 Control 6.3.4 High Vo6.3.5 Power S6.3.6 Paper S6.3.7 Heater R6.3.8 Pre-ima6.3.9 Manual 6.3.10 Manual 6.3.11 Toner H6.3.12 PH Unit6.3.13 Disasse6.3.14 CCD Un6.3.15 Scanne6.3.16 Scanne6.3.17 Scanne6.3.18 Main Mo6.3.19 Power U6.3.20 Fusing C6.3.21 Paper S6.3.22 Fusing U6.3.23 Inch/Me6.3.24 Flickerle

6.4 Cleaning pro6.4.1 Separat6.4.2 Feed Ro

bizhub_162_210_FS.book ii g parts list ....................................................................................... 30/Assembly procedure ..................................................................... 31 Parts .............................................................................................. 31oard (PWB-A) ............................................................................... 33

Board (PWB-C/C)........................................................................... 33ltage Unit (HV1).............................................................................. 35upply Unit (PU1) ............................................................................ 35ize Detecting Board (PWB-I).......................................................... 36elay Board (PWB-RY): 200 V area only........................................ 37

ge Transfer Board (PWB-R2) ......................................................... 37Bypass ........................................................................................... 38Bypass (Duplex Unit) ..................................................................... 38opper Unit....................................................................................... 38....................................................................................................... 39mbly of the Fusing Unit .................................................................. 40it..................................................................................................... 43

r, Exposure Lamp, and Inverter Board (PU2) ................................. 44r Motor ............................................................................................ 45r Drive Cables................................................................................. 46tor.................................................................................................. 54nit Cooling Fan Motor .................................................................... 55ooling Fan Motor........................................................................... 55

ize Sensor Assy ............................................................................. 56nit Interlock Switch ....................................................................... 57

tric Sensor/1 Assy (3rd area Only)................................................. 59ss Resistor (Only for 200 V area of bizhub 162)............................ 59cedure ............................................................................................ 60ion Roller ........................................................................................ 60ller ................................................................................................. 60

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6.4.3 Upper/Lower Synchronizing Rollers............................................................ 606.4.4 Paper Dust Remover................................................................................... 616.4.5 Bypass Transport Roller/Roll....................................................................... 616.4.6 Mirrors......................................................................................................... 626.4.7 Lens ............................................................................................................ 626.4.8 CCD Sensor................................................................................................ 626.4.9 Scanner Rails/Bearings .............................................................................. 636.4.10 PH Window ................................................................................................. 636.4.11 Pre-Ima6.4.12 Charge

6.5 Option count6.5.1 Installat

Adjustment/Set7. How to use the8. Utility Mode ...

8.1 Utility Mode f8.2 Utility Mode f

8.2.1 Procedu8.2.2 Exiting .8.2.3 Changin

8.3 Setting in the8.3.1 MACHIN8.3.2 PAPER 8.3.3 USER M8.3.4 ADMIN.8.3.5 COPY S8.3.6 COPY S

9. Adjustment ite10. Service Mode

10.1 Service Mod10.1.1 Procedu10.1.2 Exiting .10.1.3 Changin

10.2 Service Mod10.3 Setting in the

10.3.1 SERVIC10.3.2 ADJUST

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ge Transfer Lower Guide Plate ....................................................... 63Neutralizing Plate ........................................................................... 64er .................................................................................................... 64ion of the Key Counter .................................................................... 64

ting adjustment section ....................................................................... 67

........................................................................................................ 68unction tree .................................................................................... 68unction setting procedure............................................................... 69re ................................................................................................... 69........................................................................................................ 69g the setting value in Utility Mode functions................................... 69 Utility Mode................................................................................... 69E SETTING................................................................................... 69

SOURCE SETUP........................................................................... 70ANAGEMENT ............................................................................... 71

MANAGEMENT............................................................................. 72ETTING 1 ...................................................................................... 73ETTING 2 ...................................................................................... 74m list ............................................................................................... 76........................................................................................................ 79e function setting procedure ........................................................... 79re ................................................................................................... 79........................................................................................................ 79g the Setting Value in Service Mode Functions ............................. 79

e function tree................................................................................. 80 Service Mode................................................................................ 83ES CHOICE .................................................................................. 83...................................................................................................... 90

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10.3.3 COUNTER.................................................................................................. 9710.3.4 DISPLAY................................................................................................... 10110.3.5 FUNCTION ............................................................................................... 10210.3.6 ADMIN. REGISTRATION.......................................................................... 10510.3.7 FIXED ZOOM CHANGE........................................................................... 10510.3.8 FACTORY TEST ....................................................................................... 10610.3.9 CLEAR DATA ............................................................................................ 107

11. Security ............................................................................................................... 10911.1 Security Function Setting Procedure................................................................ 109

11.1.1 Procedu12. Mechanical ad

12.1 Adjustment o12.2 CCD Unit Po12.3 Adjustment o

(Db Adjustme12.4 Manual Bypa

*bizhub 210

Troubleshooting13. Introduction ...

13.1 Electrical Co13.1.1 Sensor13.1.2 Switch .13.1.3 Solenoid13.1.4 Clutch..13.1.5 Motor...

14. Jam Display...14.1 Misfeed Disp

14.1.1 Display 14.2 Sensor layou

14.2.1 System 14.3 Solution ......

14.3.1 Initial Ch14.3.2 Misfeed14.3.3 Misfeed14.3.4 Misfeed

(When t14.3.5 Misfeed

(When t

bizhub_162_210_FS.book iv re ................................................................................................. 109justment ....................................................................................... 110f the Position of the Scanner and 2nd/3rd Mirrors Carriage ........ 110sition Adjustment.......................................................................... 111f the Gap between the Doctor Blade and Sleeve Roller nt) ............................................................................................... 112ss (for the optional AD-504) CD Registration Adjustment only............................................................................................... 114

...................................................................................................... 115mponents Check Procedure......................................................... 115...................................................................................................... 115...................................................................................................... 116.................................................................................................... 116

...................................................................................................... 116

...................................................................................................... 117

...................................................................................................... 118lay ................................................................................................ 118Resetting Procedure .................................................................... 118t.................................................................................................... 119Mounted with DF-502, PF-502 and MB-501. ............................... 119...................................................................................................... 120eck Items .................................................................................... 120

at the Paper Feed Tray/1 Paper Take-up Section ........................ 121 at the Manual Bypass Paper Take-up Section............................. 122 at the Multiple Bypass Paper Take-up Section he optional Multiple Bypass MB-501 is mounted) ........................ 123 at the Paper Feed Unit Paper Take-up/Vertical Transport Section he optional Paper Feed Unit PF-502 is mounted) ........................ 124

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14.3.6 Misfeed at the Paper Separating Section.................................................. 12514.3.7 Misfeed at the Fusing/Exit Section............................................................ 12614.3.8 Misfeed at the Document Take-up Section

(When the optional Automatic Document Feeder DF-502 is mounted)..... 12714.3.9 Misfeed at the Document Transport Section

(When the optional Automatic Document Feeder DF-502 is mounted)..... 12814.3.10 Misfeed at the Document Exit Section

(When the optional Automatic Document Feeder DF-502 is mounted)..... 12915. Malfunction code ................................................................................................. 130

15.1 Trouble code15.1.1 Trouble

15.2 How to reset15.3 Solution.......

15.3.1 C0000: 15.3.2 C0044:

(When t15.3.3 C0045: 15.3.4 C004E: 15.3.5 C0070: 15.3.6 C0210: 15.3.7 C0500: 15.3.8 C0501: 15.3.9 C0510: 15.3.10 C0511:

(bizhub 15.3.11 C0520: 15.3.12 C0521:

(bizhub 15.3.13 C0650: 15.3.14 C0F32: 15.3.15 C0F33: 15.3.16 C1038: 15.3.17 C1200: 15.3.18 C1300: 15.3.19 C13F0: 15.3.20 C133B: 15.3.21 C133D: 15.3.22 C1468: 15.3.23 C14A3:

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..................................................................................................... 130code list ........................................................................................ 130...................................................................................................... 134...................................................................................................... 135Main Motor malfunction ................................................................ 135ADF Cooling Fan Failure he optional Duplexing Document Feeder DF-605 is mounted)..... 136Fusing Cooling Fan Motor Malfunction......................................... 137Power Supply Cooling Fan Motor Malfunction ............................. 138Toner Replenishing Motor Malfunction ......................................... 139Abnormal Image Transfer Voltage ................................................ 140Warm-up Failure ........................................................................... 141Warm-up Failure 2 (bizhub 210 Only)........................................... 141Fusing Failure (Abnormally Low Fusing Temperature) ................. 141Fusing Failure (Abnormally Low Fusing Temperature 2) 210 Only)...................................................................................... 141Fusing Failure (Abnormally High Fusing Temperature) ................ 141Fusing Failure (Abnormally High Fusing Temperature 2) 210 Only)...................................................................................... 141Faulty Scanner Home Position Sensor......................................... 144Faulty ATDC Sensor..................................................................... 145Improperly Adjusted ATDC Sensor .............................................. 145Engine Connection Failure ........................................................... 146Faulty ASIC/Memory .................................................................... 147Polygon Motor Malfunction ........................................................... 148Faulty HSYNC .............................................................................. 148Communication with Option Error ................................................ 149ROM Check Error ........................................................................ 149Faulty Parameter Chip.................................................................. 149IR Fluorescent Lamp Fault........................................................... 150

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15.4 Miscellaneous Errors........................................................................................ 15115.4.1 Flash ROM Error....................................................................................... 151

16. Power supply trouble........................................................................................... 15216.1 The copier does not turn ON............................................................................ 152

17. Image quality problem......................................................................................... 15317.1 How to identify problematic part ....................................................................... 153

17.1.1 Initial Check Items .................................................................................... 15317.1.2 Identification of the Faulty System............................................................ 154

17.2 Solution ............................................................................................................ 15517.2.1 Image R17.2.2 Image R17.2.3 Image R17.2.4 Image R17.2.5 Image R17.2.6 Image R17.2.7 Image R17.2.8 Image R17.2.9 Image R17.2.10 Image R17.2.11 Image R17.2.12 Printer S17.2.13 Printer S17.2.14 Printer S17.2.15 Printer S17.2.16 Printer S17.2.17 Printer S17.2.18 Printer S17.2.19 Printer S17.2.20 Printer S17.2.21 Printer S17.2.22 Printer S17.2.23 Printer S

bizhub_162_210_FS.book vi eading Section: Blank copy......................................................... 155eading Section: black copy.......................................................... 156eading Section: Low image density............................................. 157eading Section: Foggy background or rough image.................... 158eading Section: Black streaks or bands ...................................... 159eading Section: Black spots ........................................................ 160eading Section: Blank streaks or bands...................................... 161eading Section: Uneven image density ....................................... 162eading Section: Gradation reproduction failure ........................... 163eading Section: Periodically uneven image................................. 164eading Section: Moire ................................................................. 165ection: Blank copy....................................................................... 166ection: Black copy....................................................................... 167ection: Low image density .......................................................... 168ection: Foggy background or rough image ................................. 169ection: Black streaks or bands.................................................... 170ection: Black spots...................................................................... 171ection: Blank streaks or bands.................................................... 172ection: Void areas ....................................................................... 173ection: Smear on back ................................................................ 174ection: Uneven image density..................................................... 175ection: Gradation reproduction failure......................................... 176ection: Periodically uneven image .............................................. 177

Field Service Ver. 1.0 Apr. 2005 1. System configuration

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General1. System configuration1.1 bizhub 210

*1: Standard for the Ch*2: One drawer PF-502*3: 3rd area only

[1] Automatic Docum[2] Duplexing Docum[3] Original Cover Kit[4] Job Separator (JS[5] Duplex Unit (AD-5[6] Multiple Bypass (M[7] Paper Feed Unit ([8] Copy Desk (DK-7[9] Copy Desk (DK-7

1 32

8

11

12

1516

13

bizhub_162_210_FS.book 1 1

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inese market is standard for the Chinese market.

ent Feeder (DF-502) [10] Copy Table (DK-703)*3ent Feeder (DF-605) [11] Key Counter Kit (OC-504)*1 [12] 32MB Memory (EM-101)-503) [13] 64MB Memory (EM-102)04) [14] Printer Controller (IC-205)B-501) [15] Network Interface Card (NC-502)

PF-502)*2 [16] Internet Fax & Network Scan Kit (SU-502)01)*3 [17] Fax Kit (FK-505)02)*3 [18] Shifting Unit (SF-501) (Illustration none)

4034F1E501DA

45

6

7

9 10

14

17

1. System configuration Field Service Ver. 1.0 Apr. 2005

2

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1.2 bizhub 162

*1: Standard*2: One drawer PF-502*3: 3rd area only*4: Optional by dealer

[1] Automatic Docum[2] Original Cover Kit[3] Job Separator (JS[4] Multiple Bypass (M[5] Paper Feed Unit ([6] Copy Desk (DK-7[7] Copy Desk (DK-7[8] Copy Table (DK-7

1

3

2

6

9

10

1314

11

bizhub_162_210_FS.book 2 is standard for the Chinese market.

ent Feeder (DF-502) [9] Key Counter Kit (OC-504)*1 [10] 32MB Memory (EM-101)-503) [11] 64MB Memory (EM-102)B-501) [12] Printer Controller (IC-205)

PF-502)*2 [13] Network Interface Card (NC-502)01)*3 [14] Internet Fax & Network Scan Kit (SU-502)02)*4 [15] Fax Kit (FK-505)03)*4 [16] Shifting Unit (SF-501) (Illustration none)

4035T1E501DA

4

5

7 8

12

15

Field Service Ver. 1.0 Apr. 2005 2. Product specification

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2. Product specification2.1 Copier

Copy Medium

If the width set 297 mIf the length set 432

Type Console/Desktop TypePlaten StationaryOriginal Scanning System CCD Line SensorPhotoconductor Organic PhotoconductorCopying System Electrostatic Dry Powdered Image Transfer to Plain Paper with a LaserResolution 600 600 dpiPaper Feeding SystemExposure SystemDeveloping SystemCharging SystemImage Transfer SystemPaper Separating SystemFusing SystemPaper Discharging SysteMax. Original Size

Type

Plain PapTranspare

Thick PapPostcards

Recycled

SizeWidthLength

Multiple CopiesWarm-up Time

First Copy Time


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m, the max. length is to 420 mm. mm, the max. width is to 279 mm.

Max. Six-way SystemMirror ScanningHMT SystemComb Electrode (1) DC Negative Corona with Scorotron SystemRoller Image TransferPaper Separator Fingers and Charge Neutralizing PlateHeat Roller

m Charge Neutralizing BrushA3

Paper Feed Tray/1 Manual Bypass

er (60 to 90 g/m2) ncies

er (91 to 157 g/m2) , Labels, and Envelopes

Paper (60 to 90 g/m2) 90 297 mm* 90 297 mm

140 432 mm* 140 432 mm

1 to 99bizhub 210: 15 sec. or less (23 C, Rated Voltage)bizhub 162: 30 sec. or less (23 C, Rated Voltage)7 sec. or less (A4/Letter, Paper Feed Tray/1, full size mode)

2. Product specification Field Service Ver. 1.0 Apr. 2005

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Continuous Copy Speed (copies/min)Zoom ratio 1.000, Paper Feed Tray/1

Zoom Ratios

Power/Current Consum

SizeSpeed

bizhub 210 bizhub 162A3 12 10

A4 R 16 13A4 21 16B4 13 11B5 23 18

B5 RLetter

Letter R11 17Legal

11 14

Fixed

Variable

LensExposure Lamp

Max. Current Consumptio(full system)

Current Consumption (full system)

Power Requirements

bizhub_162_210_FS.book 4 ption

18 1520 1617 1411 1014 1214 12

Full Size 1.00

Reduction

0.810.700.500.25

Enlargement

1.151.412.004.00

0.25 to 4.00 (in 0.01 increments)

Through LensRare Gas Fluorescent Lamp

n 1250 W (bizhub 210: 200 V area)1200 W (bizhub 210: 120 V area)1050 W (bizhub 162: 200 V area)1000 W (bizhub 162: 120 V area)5.5 A (bizhub 210: 200 V area)10 A (bizhub 210: 120 V area)4.5 A (bizhub 162: 200 V area)8.5 A (bizhub 162: 120 V area)

110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz

Field Service Ver. 1.0 Apr. 2005 2. Product specification

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Environmental Conditions

Temperature 10 to 30 C with a fluctuation of 10 C or less per hourHumidity 15 to 85 % RH with a fluctuation of 20 % RH or less per hourAmbient Illumination 3000 lux or lessLevelness 1 or less

Copier Dimensions Width = 599 mm, Depth = 620 mm, Height = 487 mm (Copier Only)Copier Mass 38 kg

Printing Speed

MemoryInterface

Printer LanguageFontComplying OS

Web Browser


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bizhub 210: 21 printed pages/min (A4, 300 dpi)12 printed pages/min (A4, 600 dpi)

bizhub 162: 16 printed pages/min (A4, 300 dpi)12 printed pages/min (A4, 600 dpi)

Shared with the copierIEEE 1284 (parallel), USB Revision 1.1 (except for Windows 95 and Windows NT)GDIWindowsWindows XP (SP1 or later), Windows 2000 (SP3 or later), Windows NT Workstation Version 4.0 (SP6a or later), Windows ME, Windows 98 (SP1), Windows 98 SE, and Windows 95 OSR2.5Internet Explorer 4.0 or later

2. Product specification Field Service Ver. 1.0 Apr. 2005

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2.2 Fax Kit (FK-505): (Option)General

Scanning Resolution

Dialing

Transmission

Receiving

Compatibility G3

TX Mode Resolution CD direction (dpi) FD direction (dpi)

Memory TXSTD 204 98FINE 204 196

S_FINE 204 392

Non memory TX

LineData Transmission RateCoding MethodDocument Size

Internet fax

One touch dialSpeed dialGroup dialProgram dialOther dialing

Transmission mode

Receiving modeRX resolutionMax. recording paper siz

bizhub_162_210_FS.book 6 STD 204 98FINE 204 196

S_FINE 408 392

PSTN/ PBX33.6 kbps (V.34 JBIG)MH/ MR/ MMR/ JBIGCCD Scanning- A3/11 17 (297 mm)Sheet Through Scanning- STD/FINE: Max. 297 mm width 1,000 mm- Super Fine: Max. 297 mm width 900 mmEnable when the optional Internet Fax & Network Scan Kit SU-502 and Network Interface Card NC-502 are installed.

27 keys200 fax numbers27 groups (50 destination/group)4 keys (No. 24 ~ 27)On-hook dial, Automatic redial, Manual redial, Chain dial, Combination dial

ADF TX, Memory TX, Batch TX, Broadcast TX, Manual TX, Polling TX, Quick Memory TX, Book TX, Relay initiate TX, Timer TX, Relay Broadcast

Mailbox RX, Manual RX, Memory RX, Substitute RX, Polling RX204 dpi 98 dpi, 204 dpi 196 dpi, 204 dpi 392 dpi

e A3/ 11 17

Field Service Ver. 1.0 Apr. 2005 3. Periodical check

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Maintenance3. Periodical check3.1 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.

Replace with reference to the numeric values displayed on the Life counter.

3.1.1 Replacement partsA. Main unit

*1: Actual durable cycl*2: 110 V/120 V/127 V*3: 220-240 V areas o*4: European area.

No. Classifi-cation Pa

1 Paper take-up section

Feed Ro

2 Separati

3 Transport section Paper D

4

Imaging Unit section

PC Drum5 Ozone F

6 PC DrumCorona 7 Cleaning8 Develop

9Image transfer section

Image TAssy

10 Fusing section Fusing U

FS2.fm 7 7

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e is the Life counter value. areas only.nly.

rts name Quantity

Actual durable cycle *1

Pats No. DescriptionsRef.Page

in this manual

ller 1 150 K 4034-3012-XX 10

on Roller Assy 1 150 K 4034-0151-XX 10

ust Remover 1 40 K 4034-0756-XX 11

1 40 K - 13ilter 1 150 K 1156-4118-XX 14 Charge

Assy 1 40 K 4021-0306-XX 14

Blade 1 40 K 4034-5622-XX 14er 1 40 K - 16

ransfer Roller 1 150 K 4034-0755-XX 18

nit 1 150 K4035-0751-XX *24035-0752-XX *34035-0754-XX *4

19

3. Periodical check Field Service Ver. 1.0 Apr. 2005

8

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B. Option

*1: Actual durable cycl*2: bizhub 210 only

3.1.2 Cleaning pa

*1: Actual cleaning cyc*2: bizhub 210 only

No. Classifi-cation Parts name

Quantity

Actual durable cycle *1

Pats No. DescriptionsRef.Page

in this manual

1DF-502

Pick-up Roller 1 120 K 4688-3032-XX Replace those three parts at the same time.

See each Option Service

2 Paper Take-up Roller 1 120 K 4688-3033-XX3 Separation Roller 1 120 K 4688-3034-XX4

DF-605 *2

Pick-up Roller 2 200 K 4344-5003-XX Replace those three parts at the same time.

5 Paper Take-up Roller 1 200 K 4582-3014-XX6 Separation Roller 1 200 K 4582-3047-XX7 PF-502 Feed Ro8

MB-501Paper Ta

9 Separati

No. Classifi-cation Pa

1 IR section Original 2

DF-502

Pick-up 3 Paper Ta4 Separati5 Registra6 Registra7 Exit Roll8 Exit Roll9 Transpor

10 Length SSensor (11

DF-605 *2

Pick-up 12 Paper Ta13 Separati14 Rollers a15 Scannin

16 ReflectivSection

bizhub_162_210_FS.book 8 e is the Life counter value.

rts

le is the Life counter value.

Manual.ller 2 150 K 4686-3371-XXke-up Roller 1 150 K 4687-3012-XXon Roller Assy 1 150 K 4034-0151-XX

rts name Actual cleaning cycle *1 DescriptionsRef.Page

in this manual

Glass 80 K 19Roller 30 K

See each Option Service Manual.

ke-up Roller 30 Kon Roller 30 Ktion Roller 30 Ktion Roll 30 Ker 30 K

30 Kt Roll 30 Kize Detection PC7/AF) 30 K

Roller 50 Kke-up Roller 50 Kon Roller 50 Knd rolls 50 K

g Guide 50 Ke Sensor 50 K


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3.2 Concept of parts life

*1: The Service mode copy/print cycle.

A. Conditions for Lif The life value repres

table shown below, omay therefore vary ddifferent users.

DescriptionLife value (Specifica-tion value)

New Copy/Print Cycle Inhibited

PC Drum

The distance traveled by the PC Drum is con-verted to a corresponding number of printed pages of A4 paper at 2P/J.

40 K

Not inhibited *1Cleaning Blade 40 K

PC Drum Charge Corona 40 K

Developer 40 KImage Transfer

AssyThecopPaper Dust Remover Assy

Fusing Unit

ItemCopying typePaper sizeOriginal density


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K = 1,000 copiescan be used to set either enable or disable the initiation of a new

e Specifications Valuesents the number of copies made in the conditions specified in the r a value translated to a corresponding number of copies made. It epending on the conditions, in which the copiers are used among

number of sheets of paper fed out of the ier is counted.

150 K Not applicable

40 K Not applicable

150 K Not applicable

Description2P/JA4B/W 6%


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3.3 Maintenance procedure (Periodical check parts)NOTE The alcohol described in the cleaning procedure of Maintenance represents the

isopropyl alcohol.

3.3.1 Replacing the Separation Roller Assy and Feed Roller

1. Slide out the Paper Feed Tray/1.2. Remove two screws and the mount-

ing bracket.

56

bizhub_162_210_FS.book 10 3. Remove the Separation Roller Assy.

4. Press down the Paper Lifting Plate.5. Snap off one C-clip from the Feed

Roller Assy.6. Slide the Feed Roller Assy to the

rear and pull it off the Bearing at the front.

7. Snap off one C-clip and remove the Feed Roller.

4035D001AB

4035D002AA

4035D003AB

4035D004AA


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3.3.2 Replacing the Paper Dust Remover Assy1. Open the Right Door.2. Remove the Imaging Unit. 113. Unhook the two tabs and remove the Paper Dust Remover Assy.

3.3.3 Replacing tNOTE When the develope

Toner Recycling DuChamber. To do tha

103

1. Open the Front Do2. Open the Right Do


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he Imaging Unit (IU)

r is to be changed, it is necessary that toner in the Recycled ct and Toner Conveying Duct be fed into the Developer Mixing t, remove the Toner Bottle and run ATDC Auto Adjust twice.

or.or.

3. Remove two screws and the IU.Precautions for Installation of the IU When installing the IU, use care not

to damage the PC Drum. Before attempting to install the IU,

be sure to fully open the Right Door. Take care that, if the IU is installed with the Right Door locked halfway, it may interfere with the transfer roller.

When inserting the IU, do that slowly and, when you are sure that the drum gear contacts the mating part, push the IU all the way into position. If this step is done all at once, the drum gear could be dam-aged.

4035D008AB

4035D021AA


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3.3.4 Disassembly of the IU

1. Remove one screw in the rear of the IU and remove the harness cover.

4035D022AA

A

bizhub_162_210_FS.book 12 2. Remove two screws in the rear of the IU.

3. Remove two screws at the front of the IU.

4. Widen flaps on both ends (marked with A in the photo on the left) of the Drum Assy in the direction of the arrow and turn to take off the Devel-oping Assy.

4035D023AA

4035D024AA

4035D025AA

A


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5. Unplug one connector of the Main Erase.

3.3.5 Replacing the PC Drum

4035D026AA


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1. Remove two screws and the pivot shaft.

2. Remove the PC Drum.NOTE Protect the PC Drum that has been

removed with a protective cloth. If the PC Drum has been replaced

with a new one, apply a coat of toner to the surface of the new PC Drum.

17

4035D027AA

4035D028AA


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3.3.6 Replacing the Ozone Filter

1. Remove two screws and the Main Erase.

3.3.7 Replacing t

3.3.8 Replacing t1. Remove the PC D

4035D029AB

3

bizhub_162_210_FS.book 14 2. Remove the Ozone Filter.

he PC Drum Charge Corona Assy

1. Remove the PC Drum.2. Remove the Main Erase.3. Turn the holder in the rear in the

direction of the arrow to remove it from the side bracket.

4. Slide out the PC Drum Charge Corona in the direction of the arrow.

he Cleaning Bladerum Charge Corona Assy.

2. Remove three screws and the Cleaning Blade.

NOTE When securing the Cleaning Blade,

tighten screws in the order of one on one edge, one at the center, and one on the other edge.

When the Cleaning Blade has been replaced, apply a coat of toner to the surface of the PC Drum.

17

4035D030AA

4035D031AB

4

4035D032AA


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3.3.9 Cleaning of the PC Drum Paper Separator Fingers

1. Using a soft cloth dampened with alcohol, wipe the five Paper Separa-tor Fingers clean of dirt.

3.3.10 Cleaning of

3.3.11 Cleaning of

4035D033AA


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the Ds Collars

1. Using a soft cloth dampened with alcohol, wipe the two Ds Collars clean of dirt.

the Developer Scattering Prevention Plate

1. Remove three screws and the Devel-oper Scattering Prevention Plate.

Precautions for Installation of the Developer Scattering Prevention Plate When securing the Developer Scat-

tering Prevention Plate, tighten screws in the order of one on one edge, one at the center, and one on the other edge.

2. Using a brush, whisk dust and dirt off the surface of the Developer Scatter-ing Prevention Plate.

4035D034AA

4035D035AA

4035D036AA


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3.3.12 Replacing the Developer

1. Dump the developer.

3.3.13 Cleaning of

4035D037AA


Dump developer on the surface of the

Sleeve Roller by turning the gear in the direction of the arrow with the Developing Unit tilted as shown.

NOTE Turning the gear backward at this

time could damage the Mylar for cleaning the ATDC Sensor.

Dump developer until almost no devel-oper sticks to the Sleeve Roller.

2. Pour one packet of developer.NOTE Shake the packet of developer well

before pouring. When the developer has been

changed, make the ATDC AUTO ADJUST and enter the adjustment value on the Adjust Label.

103

the Pre-Image Transfer Guide Plate

1. Using a soft cloth dampened with alcohol, wipe the Pre-image Trans-fer Upper Guide Plate clean of dirt.

4035D038AA

4035D039AA

4035D040AB


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3.3.14 Replacing the ATDC Sensor1. Separate the IU into the Drum Assy and Developing Assy. 122. Remove the Developer Scattering Prevention Plate.3. Dump developer.

4. Unplug one connector, and remove one screw and the ATDC Sensor.

5. Install the ATDC S6. Assemble the Drum7. Install the IU in the 1038. Enter the adjustme3.3.15 ApplicationNOTE Perform these step

replaced.

10-15 mm

20-30

mm

PC Dr


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ensor and the Developer Scattering Prevention Plate. Assy to the Developing Assy to reconstruct the IU.

copier and run ATDC Auto Adjust of the Service mode.

nt value on the Adjust Label. of Toner

s when the PC Drum and/or Cleaning Blade have been

1. With the IU divided into the Drum Assy and Developing Assy, install the PC Positioning Jig in the rear of the Developing Assy.

NOTE Ready the PC Positioning Jig (Pivot

Shaft) separately. (See the Parts Manual.)

4035D041AA

4035D511AA

4021U057AA

20-25 mm

um


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2. Using a brush, apply a light coat of toner to the surface of the PC Drum.

3. Hold both ends of the PC Drum with

3.3.16 Replacing t

4021U008AB

bizhub_162_210_FS.book 18 your both hands and turn the PC Drum a half turn in the direction of the arrow.

he Image Transfer Roller Assy

1. Remove the Image Transfer Roller Assy.

NOTE Indentations or dirt on the surface

of the Image Transfer Roller adversely affect the printed image. Do not therefore touch or dirty with toner the surface of the Image Transfer Roller.

When handling the Image Transfer Roller, hold onto the shaft or Bear-ings of the roller.

Do not place a new Image Transfer Roller directly on the floor.

4021U009AA

4035D042AB


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3.3.17 Replacing the Fusing Unit1. Remove the Rear Cover and Rear Right Cover. 31

2. Unplug two connectors of the Fusing Unit.

NOTEWhen removing the F

3.3.18 Cleaning of


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3. Open the Right Door.4. Remove four screws and the Fusing

Unit.NOTEWhen removing the Fusing Unit, make sure of the correct type of screws that must be removed.

using Unit, take care not to confuse the types of screw.

the Original Glass and Original Scanning Glass

1. Using a soft cloth dampened with alcohol, wipe the Original Glass and Original Scanning Glass clean of dirt.

4035D045AA

4035D046AA

4035D144AA

4035D013AA

4. Service tool Field Service Ver. 1.0 Apr. 2005

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4. Service tool4.1 CE Tool list

Tool name Shape Parts No. Personnel Remarks

Scanner/Mirrors Carriage Positioning Jigs

4034-7901-XX4034-7902-XX 1 for each

Ds Collar Positioning Jigs

Db Gap Adjusting Jigs

PC Positioning Jig

Gauge

4034F2C501DA

bizhub_162_210_FS.book 20 4021-7903-XX 2

4021-7904-XX 2

4021-4362-XX 2

1144-7910-XX 2

4034F2C502DA

4034F2C503DA

4034F2C504DA

4034F2C505DA

Field Service Ver. 1.0 Apr. 2005 5. Firmware upgrade

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5. Firmware upgrade5.1 Preparations for Firmware rewriting5.1.1 Installing the DriverNOTE Since USB is used to upgrade the firmware, the host computer must be run on an

OS of Windows 98 or later. 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. If the TWAIN driver has already been installed, proceed with the section on Firm-

ware rewriting to 23

A. Plug and Play Ins

1. Start the host com2. Turn on the power 3. Use a USB cable t4. In the Found New

location (Advanced5. Under Search for

the search, and th6. Specify \(name of

is stored, and then7. Click [Next] and th8. The Found New H

install all drivers.

1. Prepare the files n2. Start the host com3. Turn on the power 4. Use a USB cable t

The Found New H5. In the Install Hard

driver for my devic6. In the Locate Driv

[Next].7. Click [Browse], spe

the TWAIN driver i8. Click [OK]. Then, c

until the Completi9. Click [Finish].10. The Found New H



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upgrade the firmware.

tallation of the GDI Printer/TWAIN Driver

puter.switch of copier.o connect the copier to host computer. Hardware Wizard dialog box, choose Install from a list or specific ), and then click [Next].

the best driver in these locations, choose Include this location in en click [Browse]. any given language)\WinXP in the folder in which the TWAIN driver click [OK].en [Finish].ardware Wizard dialog box will appear again: Repeat steps 4~7 to

ecessary for upgrading the firmware, and copy them to PC.puter.switch of copier.o connect the copier to host computer. ardware Wizard dialog box will appear.ware Device Printers dialog box, choose Search for a suitable e (recommended), and then click [Next].er Files dialog box, choose Specify a location, and then click

cify \(name of any given language)\Win2000 in the folder in which s stored, and then click [OK].ontinue following the instructions in the dialog boxes that will appear ng the Found New Hardware Wizard dialog box appears.

ardware Wizard dialog box will appear again: Repeat steps 4~8 to

5. Firmware upgrade Field Service Ver. 1.0 Apr. 2005

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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 copier.4. Use a USB cable to connect the copier to host computer.

The Add New Hardware Wizard dialog box will appear.5. With Windows Me, choose Specify the location of the driver (Advanced), and then

click [Next].With Windows 98, click [Next]. Then, in the dialog box that will then appear, choose Search for the best driver for your device (recommended), and then click [Next].

6. Choose Specify a location, and then click [Browse].7. Specify \(name of any given language)\Win9X in the folder in which the TWAIN driver

is stored, and then8. Click [Next]. Then,

appear until the F9. Click [Finish].10. The Add New Har


bizhub_162_210_FS.book 22 click [OK]. continue following the instructions in the dialog boxes that will inish button appears.

dware Wizard dialog box will appear again: Repeat steps 4~8 to


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5.2 Firmware rewriting5.2.1 Updating method1. Turn ON the Power Switch of the copier.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. Connect the copier to the host computer using a USB cable. (Wait until the hardware is

detected.)5. Open Properties of My Computer. Then select System Properties/Hardware/Device

Manager/Imaging devices to check that the XXXXXXXXXXX (Model Name) icon has been added.

6. Double-click the UThe A3S/A4S Upd

7. Click the [Browse] C in step 3.

8. Click the [Update] transfer is complet


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pdate file in the Update Software folder.ate F/W-VXXX screen will appear.

button. Then, select the Update file that has been copied onto drive

button to start the transfer of the firmware data. (Wait until data ed.)

4035D525CA 4035D526CA

4980D047AA

4035D531AA


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9. Check the Display for status of the firmware upgrading sequence.

NOTE NEVER turn OFF a

displayed.

10. When the followingfirmware has been

11. Click the [OK] butt

12. Turn OFF and ON

bizhub_162_210_FS.book 24 nd ON the Power Switch as long as the above screens are being

message appears in the Display, it indicates that upgrading of the completed.

on to quit A3S/A4S Update F/W-VXXX.

the Power Switch of the copier.

4035D530CA

4980D051AB

4035D532AA


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5.2.2 Procedure when Upgrading the Firmware has failedNOTE Perform upgrading using BIOS only when upgrading from PC using ordinary USB

connection has failed and the PC has not started properly. To perform this procedure, you need the Fax board, BIOS ROMs (U17, U19) and the

TWAIN Driver dedicated to this specific purpose.

1. Turn off the power switch of copier.2. Disconnect the USB cable from the copier and host computer.3. Remove the rear cover. 314. Disconnect jumper [CJ1] on the Control board (PWB-C/C) from 1-2 and connect it to 2-

3.

5. Disconnect jumper6. Disconnect jumper


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[FJ1] on the Fax board from 1-2 and connect it to 2-3. [FJ2] on the Fax board.

4035D535AA

4035D536AA


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7. Install the BIOS ROMs (U17, U19) on the Fax board.

8. Attach the Fax boa9. Turn on the power

and copier waits fo

10. Perform steps 4~111. Turn power off.12. Remove the Fax b13. Disconnect jumper

2.14. Disconnect jumper15. Connect jumper [F

bizhub_162_210_FS.book 26 rd to Control board (PWB-C/C). switch of copier. Following message will appear on message panel r file data.

2 in the firmware upgrading procedure to upgrade the firmware.

oard. [CJ1] on the Control board (PWB-C/C) from 2-3 and connect it to 1-

[FJ1] on the Fax board from 2-3 and connect it to 1-2.J2] to 1-2 on the Fax board.

4035D537AA

4035D538AA

Field Service Ver. 1.0 Apr. 2005 6. Other

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6. Other6.1 Disassembly/Adjustment prohibited itemsA. Paint-locked Screws

NOTE Paint-locked screws show that the assembly or unit secured can only be adjusted

or set at the factory and should not be adjusted, set, or removed in the field.

B. Red Painted Screws

NOTES When the screws a

justment is require Once the red painte

Accordingly checkadjustment. Note thonly one represent

C. Variable Resistor

NOTE Do not turn the var

are given in Adjust

D. Removal of PWBs

NOTES When removing a c

PWBs and follow The removal proce

screws securing th Where it is absolut

on the board, be su


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re removed, the red paint is coated on the points where read-d.d screw is removed or loosened, you should make adjustment.

the adjustment items in operation manual and make necessary at when two or more screws are used on the part in questions,

ative screw may be marked with red paint.

s on Board

iable resistors on boards for which no adjusting instructions ment/Setting.

ircuit board or other electrical component, refer to Handling of the corresponding removal procedures.dures given in the following omit the removal of connectors and e circuit board support or circuit board.ely necessary to touch the ICs and other electrical components re to ground your body.

6. Other Field Service Ver. 1.0 Apr. 2005

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E. Other Screws not Marked with Red Paint(1) PH Unit Section

(2) IR Unit Section

PH Unit PH Unit Base Plate

Lef

bizhub_162_210_FS.book 28 4035D137AA

t Side Right Side

4035D136AA


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6.2 Disassembly/Assembly/Cleaning list (Other parts)6.2.1 Disassembly/Assembly parts list

No. Section Part name Ref.Page1

Exterior parts

Original Glass 312 Control Panel 313 Control Panel Left Cover 314 Front Cover 315 Paper Exit Cover 316 Front Door 317

89101112131415161718

Board and etc

19202122232425

Unit2627282930

IR313233

FS2.fm 29 29

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Tray 1 31Left Cover 31Paper Exit Tray 31Rear Inside Cover 31Original Scanning Glass 31Right Rear Cover 31Left Rear Cover 31Upper Rear Cover 31Rear Cover 31Rear Right Cover 31Right Cover 31

.

Master Board 33Control Board 33High Voltage Unit 35Power Supply Unit 35Paper Size Detecting Board 36Heater Relay Board 37Pre-image Transfer Board 37Manual Bypass 38Manual Bypass (Duplex Unit) 38Toner Hopper Unit 38PH Unit 39Disassembly of the Fusing Unit 40CCD Unit 43Scanner, Exposure Lamp, and Inverter Board 44Scanner Motor 45Scanner Drive Cables 46


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6.2.2 Cleaning p

34

Others

Main Motor 5435 Power Unit Cooling Fan Motor 5536 Fusing Cooling Fan Motor 5537 Paper Size Sensor Assy 5638 Fusing Unit Interlock Switch 5739 Inch/Metric Sensor/1 Assy 5940 Flickerless Resistor 5941 Separation Roller 6042 Feed Roller 60434445

No. Section Part name Ref.Page

No. Section1

IU2345

IR67

89 PH10

Image transfer se11

FS2.fm 30 arts list

Upper/Lower Synchronizing Rollers 60Paper Dust Remover 61Bypass Transport Roller/Roll 61

Part name Ref.PagePC Drum Paper Separator Fingers 15Ds Collars 15Developer Scattering Prevention Plate 15Pre-Image Transfer Guide Plate 16Mirrors 62Lens 62CCD Sensor 62Scanner Rails/Bearings 63PH Window 63

ctionPre-Image Transfer Lower Guide Plate 63Charge Neutralizing Plate 64


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6.3 Disassembly/Assembly procedure6.3.1 Exterior Parts

No. Part Nam

1 Original Glass

2 Control Panel

3 Control Panel Left

4 Front Cover

5 Paper Exit Cover

6 Front Door

7 Tray 1

8 Left Cover

9 Paper Exit Tray

10 Rear Inside Cover

11 Original Scanning

1

10

9

2

8

3

11


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e Removal ProcedureRemove the Original Scanning Glass. Remove one screw. Remove the holding bracket. Remove the Original Glass.Remove the Control Panel Left Cover. Remove two screws. Remove one flat cable and unplug one connector. Remove the Control Panel.

Cover Remove one screw. Remove the Control Panel Left Cover.Remove the Control Panel. Slide out the Paper Feed Tray/1. Open the Front Door. Remove six screws. Remove the Front Cover.Remove the Front Cover. Remove one screw. Remove the Paper Exit Cover.Open the Front Door. Snap off one C-clip. Slide the Front Door to the right and pull it off.Slide out Tray/1. Remove two screws. Remove the fixing brackets on the right and left ends of Tray/1. Remove Tray/1.Remove the Front Cover. Remove five screws. Remove the Left Cover.Remove the Front Cover. Remove two screws. Remove the Paper Exit Tray.Remove the Left Cover. Remove the Paper Exit Tray. Remove two screws. Remove the Rear Inside Cover.

Glass Remove the Left Cover. Remove two screws. Remove the Original Scanning Glass.

4035D047AB

6

4

5

7


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No. Part Nam

12 Right Rear Cover

13 Left Rear Cover

14 Upper Rear Cover

15 Rear Cover

16 Rear Right Cover

17 Right Cover

17

13

15

12

14

bizhub_162_210_FS.book 32 e Removal ProcedureRemove the Upper Rear Cover. Remove three screws. Remove the Right Rear Cover.Remove the Upper Rear Cover. Remove four screws. Remove the Left Rear Cover.Remove four screws. Remove the Upper Rear Cover.Remove nine screws. Remove the Rear Cover.NOTEWhen the Rear Cover is to be installed, make sure of type of screw.(9735-0306-14 8 Screw, 9770-0308-14 1 Screw)Remove two screws. Remove the Rear Right Cover.Remove the Upper Rear Cover. Remove the Front Cover. Remove four screws. Remove the Right Cover.

4035D048AB

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6.3.2 Master Board (PWB-A)1. Remove the Rear Cover. 31

2. Unplug all connectors from the Mas-ter Board.

6.3.3 Control Boa1. Remove the Rear 312. Remove the Maste 33


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3. Remove four screws and the Master Board.

rd (PWB-C/C)Cover and Upper Rear Cover.

r Board.

3. Unplug all connectors from the Con-trol Board.

4. Remove two screws and two hold-ers.

4035D049AA

4035D050AA

4035D051AB

4035D052AA


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5. Remove six screws and the Control Board.

Cautions in replacing the Control Board: When the Control B

(U16) must be demC/C. Mount the Paramet

4035D053AB

bizhub_162_210_FS.book 34 oard (PWB-C/C) is replaced with a new one, Parameter Chip ounted from the old PWB-C/C and remounted on the new PWB-

er Chip (U16) of the old PWB-C/C on the new PWB-C/C.

NOTE Note the alignment notch marked

with A on the Parameter Chip (U16) when mounting the IC.

4035D514AA

1171D049AA


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6.3.4 High Voltage Unit (HV1)1. Remove the Rear Cover. 312. Remove the Master Board. 33

3. Unplug all connectors from the High Voltage Unit.

6.3.5 Power Supp1. Remove the Left C 312. Remove the Maste3. Remove the Contr 33


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4. Remove two screws and the High Voltage Unit.

ly Unit (PU1)over, Rear Cover, and Upper Rear Cover.

r Board.ol Board.

4. Remove the harness from four wiring saddles and one edge cover.

5. Remove four screws and protective cover 1.

4035D054AA

4035D055AA

4035D522AA


3

43888595 konica minolta bizhub 162 210 service manual

Documents

service manual caution

service work

service manin

future service

service manual2005

act warning

product design

important warning itemsread