Konica Minolta bizhub 200, bizhub 250, bizhub 300 Service Manual
SERVICE MANUAL
FIELD SERVICE
The is available only for North America.
The is available only for North America.
This service manual is designed for copier
This service manual is designed for copier
with Firmware Ver. 4040-0100-G10-23-00X and onward.
with Firmware Ver. 4040-0100-G10-23-00X and onward.
2006.042006.04
Ver. 2.0Ver. 2.0
i
FIELD SERVICE TOTAL CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1
IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
WARNING INDICATIONS ON THE MACHINE ........................................................S-17
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-20
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2
bizhub 200/250/350 Main Unit
General ........................................................................................................................... 1
Maintenance ................................................................................................................... 7
Adjustment/Setting...................................................................................................... 111
Troubleshooting........................................................................................................... 223
Appendix..................................................................................................................... 277
Duplex Unit/Switchback Unit
General ........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting.......................................................................................................... 7
Troubleshooting............................................................................................................. 11
Standard Controller
General ........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Troubleshooting............................................................................................................... 5
FK-503
General ........................................................................................................................... 1
Maintenance ................................................................................................................... 5
Adjustment/Setting........................................................................................................ 11
Troubleshooting........................................................................................................... 189
DF-605
General ........................................................................................................................... 1
Maintenance ................................................................................................................... 5
Adjustment/Setting........................................................................................................ 17
Troubleshooting............................................................................................................. 27
ii
PC-102/PC-202
General........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 13
Troubleshooting ............................................................................................................ 21
PC-402
General........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 17
Troubleshooting ............................................................................................................ 25
JS-502
General........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting ......................................................................................................... 5
FS-508/PU-501/OT-601
General........................................................................................................................... 1
Maintenance ................................................................................................................... 5
Adjustment/Setting ....................................................................................................... 23
Troubleshooting ............................................................................................................ 35
MT-501
General........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting ......................................................................................................... 7
Troubleshooting ............................................................................................................ 11
SD-502
General........................................................................................................................... 1
Maintenance ................................................................................................................... 3
Adjustment/Setting ....................................................................................................... 19
Troubleshooting ............................................................................................................ 27
SAFETY AND IMPORTANT WARNING ITEMS
S-1
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 been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this Service Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this Service Manual also for future service.
In this Service Manual, each of three expressions “ DANGER”, “ WARNING”, and
“ CAUTION” is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.
Symbols used for safety and important warning items are defined as follows:
SAFETY AND IMPORTANT WARNING ITEMS
IMPORTANT NOTICE
DESCRIPTION ITEMS FOR DANGER,
WARNING AND CAUTION
DANGER: Action having a high possibility of suffering death or serious injury
WARNING: Action having a possibility of suffering death or serious injury
CAUTION: Action having a possibility of suffering a slight wound, medium
trouble, and property damage
:Precaution when servicing
the product.
General
precaution
Electric hazard High
temperature
:Prohibition when servicing
the product.
General
prohibition
Do not touch
with wet hand
Do not
disassemble
:Direction when servicing the
product.
General
instruction
Unplug Ground/Earth
SAFETY AND IMPORTANT WARNING ITEMS
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 degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reasoning behind this policy.
SAFETY WARNINGS
Prohibited Actions
DANGER
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT.
Safety will not be assured, leading to a risk of fire and
injury.
• Disabling fuse functions or bridging fuse terminals with
wire, metal clips, solder or similar object.
• Disabling relay functions (such as wedging paper between
relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.)
Safety will not be assured, leading to a risk of fire and
injury.
• Making any modification to the product unless instructed
by KMBT
• Using parts not specified by KMBT
SAFETY AND IMPORTANT WARNING ITEMS
S-3
[2] POWER PLUG SELECTION
In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.
Power Cord Set or Power Plug
WARNING
• Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the product's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough current capacity, and
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
• Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connecting to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
• Conductors in the power cable must be connected to terminals of the plug according to the following order:
• Black or Brown: L (line)
• White or Light Blue: N (neutral)
• Green/Yellow: PE (earth)
Wrong connection may cancel safeguards within the
product, and results in fire or electric shock.
kw
SAFETY AND IMPORTANT WARNING ITEMS
S-4
[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to parts wear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.
1. Power Supply
Connection to Power Supply
WARNING
• Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.
• Connect power plug directly into wall outlet having same
configuration as the plug.
Use of an adapter leads to the product connecting to
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.
• Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
• If two or more power cords can be plugged into the wall
outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.
• Make sure the power cord is plugged in the wall outlet
securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.
• Check whether the product is grounded properly.
If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.
kw
SAFETY AND IMPORTANT WARNING ITEMS
S-5
Power Plug and Cord
WARNING
• When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
If the power cord (inlet type) is not connected to the product securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
• Check whether the power cord is not stepped on or
pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.
• Check whether the power cord is damaged. Check
whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.
• Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
• Check whether dust is collected around the power plug
and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.
• Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
SAFETY AND IMPORTANT WARNING ITEMS
S-6
2. Installation Requirements
Wiring
WARNING
• Never use multi-plug adapters to plug multiple power cords
in the same outlet.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.
Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.
Prohibited Installation Places
WARNING
• Do not place the product near flammable materials or volatile materials that may catch fire.
A risk of fire exists.
• Do not place the product in a place exposed to water such
as rain.
A risk of fire and electric shock exists.
When not Using the Product for a long time
WARNING
• When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
SAFETY AND IMPORTANT WARNING ITEMS
S-7
Ventilation
CAUTION
• The product generates ozone gas during operation, but it
will not be harmful to the human body.
If a bad smell of ozone is present in the following cases,
ventilate the room.
a. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Stability
CAUTION
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
Inspection before Servicing
CAUTION
• Before conducting an inspection, read all relevant documentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed procedure, using only the prescribed tools. Do not make any
adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the product may break and a risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect
the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
• The area around the fixing unit is hot.
You may get burnt.
SAFETY AND IMPORTANT WARNING ITEMS
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 when servicing with the external cover
detached.
High-voltage exists around the drum unit. A risk of electric shock exists.
Safety Checkpoints
WARNING
• Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and
screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.
• Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or
fire.
• Carefully remove all toner remnants and dust from electrical parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.
• Check high-voltage cables and sheaths for any damage.
Current can leak, leading to a risk of electric shock or
fire.
SAFETY AND IMPORTANT WARNING ITEMS
S-9
• Check electrode units such as a charging corona unit for
deterioration and sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit (P/H unit)
incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• Do not remove the cover of the write unit. Do not supply
power with the write unit shifted from the specified mounting position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.
• When replacing a lithium battery, replace it with a new lithium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.
• After replacing a part to which AC voltage is applied (e.g.,
optical lamp and fixing lamp), be sure to check the installation state.
A risk of fire exists.
• Check the interlock switch and actuator for loosening and
check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).
• Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
Safety Checkpoints
WARNING
SAFETY AND IMPORTANT WARNING ITEMS
S-10
• Make sure that all screws, components, wiring, connectors, etc. that were removed for safety check and maintenance have been reinstalled in the original location. (Pay
special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of product trouble, electric shock, and fire exists.
Safety Checkpoints
WARNING
Handling of Consumables
WARNING
• Toner and developer are not harmful substances, but care
must be taken not to breathe excessive amounts or let the
substances come into contact with eyes, etc. It may be
stimulative.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
Handling of Service Materials
CAUTION
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (acetone-based) are highly flammable and must be handled
with care. A risk of fire exists.
• Do not replace the cover or turn the product ON before
any solvent remnants on the cleaned parts have fully
evaporated.
A risk of fire exists.
SAFETY AND IMPORTANT WARNING ITEMS
S-11
• Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.
• When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to
discomfort.
Handling of Service Materials
CAUTION
SAFETY AND IMPORTANT WARNING ITEMS
S-12
[4] Used Batteries Precautions
ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturer’s instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
AT TENTIO N
Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recommandé par le constructeur.
Mettre au rebut les batteries usagées conformément aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.
Finland, Sweden
VAROlTUS
Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
SAFETY AND IMPORTANT WARNING ITEMS
S-13
[5] Laser Safety
• This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.
5.1 Internal Laser Radiation
*:Laser Aperture of the Print Head Unit
• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.
• The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
Semiconductor laser
Maximum average radiation power(*) 28.9 µW
Wavelength 770-795 nm
4040P0C504DA
Laser Aperture of
the Print Head Unit
SAFETY AND IMPORTANT WARNING ITEMS
S-14
the U.S.A., Canada (CDRH Regulation)
• This machine is certified as a Class I Laser product under Radiation Performance Standard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.
• The label shown to page S-16 indicates compliance with the CDRH regulations and must
be attached to laser products marketed in the United States.
CAUTION
• Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
All Areas
CAUTION
• Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure.
Denmark
ADVARSEL
• Usynlig Laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion.
Undgå udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.
Semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
Semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
Halvlederlaser
Laserdiodens højeste styrke 5 mW
Bølgelængden 770-795 nm
SAFETY AND IMPORTANT WARNING ITEMS
S-15
Finland, Sweden
VARO!
• Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle.
Älä katso säteeseen.
VAROITUS!
• Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa
altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.
VARNING!
• Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan
användaren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.
VARNING!
• Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta
ej strålen.
Norway
ADVERSEL
• Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning,
kan brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser
klass 1.
LOUKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
Puolijohdelaser
Laserdiodin suurin teho 5 mW
Aallonpituus 770-795 nm
Halvledarlaser
Den maximala effekten för laserdioden 5 mW
Våglängden 770-795 nm
Halvleder laser
Maksimal effekt till laserdiode 5 mW
Bølgelengde 770-795 nm
SAFETY AND IMPORTANT WARNING ITEMS
S-16
5.2 Laser Safety Label
• A laser safety labels is attached to the outside of the machine as shown below.
5.3 Laser Caution Label
• A laser caution label is attached to the inside of the machine as shown below.
5.4 Precautions For Handling The Laser Equipment
• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the copier OFF.
• If the job requires that the copier be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.
4040P0C506DA
* Only for the U.S.A.
4040P0C503DA
SAFETY AND IMPORTANT WARNING ITEMS
S-17
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.
WARNING INDICATIONS ON THE MACHINE
4040P0C500DA
CAUTION
SAFETY AND IMPORTANT WARNING ITEMS
S-18
4040P0C501DA
High voltage
SAFETY AND IMPORTANT WARNING ITEMS
S-19
CAUTION:
4040P0C505DA
High voltage
• You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or soiled and therefore the caution cannot be read, contact our Service
Office.
MEASURES TO TAKE IN CASE OF AN ACCIDENT
S-20
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations specified by every distributor.
MEASURES TO TAKE IN CASE OF AN
ACCIDENT
C-1
Composition of the service manual
This service manual consists of Theory of Operation section and Field Service section to
explain the main machine and its corresponding options.
Theory of Operation section gives, as information for the CE to get a full understanding of
the product, a rough outline of the object and role of each function, the relationship
between the electrical system and the mechanical system, and the timing of operation of
each part.
Field Service section gives, as information required by the CE at the site (or at the customer’s premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
<Theory of Operation section>
<Field service section>
OUTLINE: Explanation of system configuration,
product specifications, unit configuration, and paper path
COMPOSITION/OPERATION: Explanation of configuration of each unit,
operating system, and control system
GENERAL: Explanation of system configuration, and product
specifications
MAINTENANCE: Explanation of service schedule, maintenance steps, ser-
vice tools, removal/reinstallation methods of major parts,
and firmware version up method etc.
ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical
adjustment etc.
TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and
their countermeasures etc.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing are attached.
C-2
Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Feeding direction
• When the long side of the paper is parallel with the feeding direction, it is called short
edge feeding. The feeding direction which is perpendicular to the short edge feeding is
called the long edge feeding.
• Short edge feeding will be identified with [S (abbreviation for Short edge feeding)] on the
paper size. No specific notation is added for the long edge feeding.
When the size has only the short edge feeding with no long edge feeding, [S] will not be
added to the paper size.
<Sample notation>
(1) IC board: Standard printer
(2)
bizhub 200/250/350: Main body
(3) Microsoft Windows 95: Windows 95
Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
When the description is made in combination of the OS’s mentioned above:
Windows 95/98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 95/98/Me/ NT/2000/XP
Paper size Feeding direction Notation
A4
Long edge feeding A4
Short edge feeding A4S
A3 Short edge feeding A3
SERVICE MANUAL
2006.04
Ver. 2.0
FIELD SERVICE
Main Unit
Revision history
After publication of this service manual, the parts and mechanism may be subject to change for
improvement of their performance.
Therefore, the descriptions given in this service manual may not coincide with the actual machine.
When any change has been made to the descriptions in the service manual, a revised version will be
issued with a revision mark added as required.
Revision mark:
• To indicate clearly a section revised, show to the left of the revised section.
A number within represents the number of times the revision has been made.
• To indicate clearly a section revised, show in the lower outside section of the corresponding page.
A number within represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
1
1
1
1
2006/04 2.0 Error corrections / Corresponded to a Phase 2.0.
2005/08 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision
1
bizhub 200/250/350GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 2.0 Apr. 2006
i
CONTENTS
bizhub 200/250/350 Main Unit
General
1. System configuration............................................................................................... 1
2. Product specifications ............................................................................................. 3
Maintenance
3. Periodical check ...................................................................................................... 7
3.1 Service schedule .................................................................................................. 7
3.1.1 bizhub 350 .................................................................................................... 7
3.1.2 bizhub 250 .................................................................................................... 7
3.1.3 bizhub 200 .................................................................................................... 7
3.1.4 Option ........................................................................................................... 8
3.2 Maintenance items................................................................................................ 8
3.2.1 bizhub 350 .................................................................................................... 8
3.2.2 bizhub 250 .................................................................................................. 10
3.2.3 bizhub 200 .................................................................................................. 13
3.3 Maintenance parts .............................................................................................. 15
3.3.1 Replacement parts...................................................................................... 15
3.3.2 Cleaning parts............................................................................................. 16
3.4 Concept of parts life............................................................................................ 17
3.5 Maintenance procedure (Periodical check parts) ............................................... 18
3.5.1 Replacing the Bypass Tray Feed Roller ......................................................18
3.5.2 Replacing the Bypass Tray Separation Roller Assy ....................................19
3.5.3 Replacing the Tray 1 Feed Roller................................................................ 20
3.5.4 Replacing the Tray 1 Pick-up Roller ............................................................ 21
3.5.5 Replacing the Tray 1 Separation Roller Assy.............................................. 23
3.5.6 Replacing the Tray 2 Feed Roller................................................................ 25
3.5.7 Replacing the Tray 2 Pick-up Roller ............................................................ 26
3.5.8 Replacing the Tray 2 Separation Roller....................................................... 28
3.5.9 Replacing of the Registration Roller Bearings and Registration Roller
Gears 1, 2 ................................................................................................... 30
3.5.10 Cleaning of the Paper Dust Remover.......................................................... 31
3.5.11 Replacing of the Toner Filter (Developing Unit)........................................... 32
3.5.12 Replacing of the Toner Filter (Main Unit).....................................................33
3.5.13 Replacement of the Ozone Filter ................................................................ 33
bizhub 200/250/350
GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 2.0 Apr. 2006
ii
3.5.14 Replacement of the Developer ................................................................... 34
3.6 Replacing the unit............................................................................................... 37
3.6.1 Replacement of the Fusing Unit ................................................................. 37
3.6.2 Replacement of the Transfer Roller Unit ..................................................... 38
3.6.3 Replacement of the Photo Conductor Unit ................................................. 39
3.6.4 Replacement of the Developing Unit .......................................................... 40
4. Service tool ........................................................................................................... 41
4.1 CE Tool list ......................................................................................................... 41
4.2 Copy materials ................................................................................................... 41
4.2.1 Developer.................................................................................................... 41
4.2.2 Photo Conductor Unit ................................................................................. 41
4.2.3 Toner Bottle................................................................................................. 41
5. Firmware upgrade................................................................................................. 42
5.1 Preparations for Firmware rewriting ................................................................... 42
5.1.1 Service environment ................................................................................... 42
5.1.2 Writing into the Compact flash.................................................................... 42
5.1.3 Checking ROM version............................................................................... 42
5.2 Firmware rewriting.............................................................................................. 42
5.2.1 MSC............................................................................................................ 42
5.2.2 Engine......................................................................................................... 44
6. Other ..................................................................................................................... 46
6.1 Disassembly/Adjustment prohibited items.......................................................... 46
6.2 Disassembly/Assembly/Cleaning list (Other parts) ............................................ 47
6.2.1 Disassembly/Assembly parts list ................................................................ 47
6.2.2 Cleaning parts list....................................................................................... 48
6.3 Disassembly/Assembly procedure ..................................................................... 49
6.3.1 IR Upper Left Cover/Original Scanning Glass/Front Holding Bracket/
Original Glass ............................................................................................. 49
6.3.2 Lower Rear Cover/Lower Right Rear Cover/Tray Rear Cover..................... 49
6.3.3 Upper Rear Cover....................................................................................... 50
6.3.4 Rear Right Cover/Front Right Cover........................................................... 50
6.3.5 IR Right Cover/Rear Cover ......................................................................... 51
6.3.6 Front Door................................................................................................... 51
6.3.7 Paper Output Cover/Lower Front Cover...................................................... 52
6.3.8 Upper Front Cover/Front Cover................................................................... 53
6.3.9 IR Left Cover/Rear Left Cover/Left Cover................................................... 54
6.3.10 Rear Manual Bypass Cover/Front Manual Bypass Cover/Lower Right
Cover .......................................................................................................... 55
6.3.11 Control Panel .............................................................................................. 56
bizhub 200/250/350GeneralMaintenanceAdjustment / Setting
Troubleshooting
Appendix
Field Service Ver. 2.0 Apr. 2006
iii
6.3.12 Tray 1 .......................................................................................................... 56
6.3.13 Tray 2 .......................................................................................................... 57
6.3.14 Mechanical Control Board Cover ................................................................ 57
6.3.15 FD Paper Size Board 1 ............................................................................... 58
6.3.16 FD Paper Size Board 2 ............................................................................... 59
6.3.17 Power Supply Unit.......................................................................................60
6.3.18 High Voltage Unit ........................................................................................ 61
6.3.19 MFBS Board ............................................................................................... 62
6.3.20 Inverter Board ............................................................................................. 63
6.3.21 BCRS Board ............................................................................................... 64
6.3.22 CCD Unit ..................................................................................................... 65
6.3.23 Operation Board.......................................................................................... 69
6.3.24 Manual Bypass Unit .................................................................................... 71
6.3.25 PH Unit........................................................................................................ 71
6.3.26 Toner Hopper Unit .......................................................................................74
6.3.27 Toner Replenishing Drive Unit.....................................................................74
6.3.28 Duplex Unit.................................................................................................. 76
6.3.29 Switch Back Unit ......................................................................................... 76
6.3.30 Scanner Motor ............................................................................................ 77
6.3.31 Exposure Unit ............................................................................................. 78
6.3.32 Exposure Lamp ........................................................................................... 79
6.3.33 Scanner Drive Cables ................................................................................. 80
6.3.34 Main Motor .................................................................................................. 85
6.3.35 IU Motor ...................................................................................................... 85
6.3.36 Fusing Unit Cooling Fan Motor ................................................................... 86
6.3.37 Toner Suction Fan Motor............................................................................. 86
6.3.38 Temperature/humidity Sensor ..................................................................... 87
6.3.39 ATDC Sensor .............................................................................................. 87
6.3.40 Thermistor ................................................................................................... 89
6.3.41 Paper Exit Roll 1 ......................................................................................... 91
6.3.42 Paper Exit Roll 2 ......................................................................................... 91
6.3.43 Separation Claw.......................................................................................... 92
6.4 Cleaning procedure ............................................................................................ 94
6.4.1 Manual Bypass Feed Roller ........................................................................ 94
6.4.2 Manual Bypass Separation Roller............................................................... 94
6.4.3 Tray 1 Feed Roller....................................................................................... 95
6.4.4 Tray 1 Pick-up Roller ................................................................................... 96
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