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Field Service Ver. 1.0 Apr. 2005 CONTENTS bizhub 160/160f bizhub 161/161f General Maintenance Adjustment / Setting General 1. System configuration 1 2. Product specifications 2 2.1 bizhub 160 / bizhub 161 2 2.1.1 Main Unit...2 2.1.2 GDI Printer Function (bizhub 160 only 4 2.1.3 PCL Printer Function (bizhub 161 only 5 2.2 bizhub 160f / bizhub 161f 6 2.2.1 Main Unit...6 2.2.2 GDI Printer Function (bizhub 160f only 8 2.2.3 PCL Printer Function (bizhub 161f only 9 2.2.4 FAX Function 10 Maintenance 3. Periodical check ...13 3.1 Maintenance Items 13 3.1.1 Parts to be Replaced by Users (CRU 13 3.1.2 Periodical Parts Replacement (Every 50,000 Print 13 3.2 Maintenance Parts 14 3.3 Concept of parts life 14 3.4 Maintenance procedure (Periodical check parts 15 3.4.1 Remove the Imaging Cartridge 15 3.4.2 Feed Roller 15 3.4.3 Replacement of the Image Transfer Roller 16 3.5 Replacing the Unit 17 3.5.1 Replacement of the Toner Cartridge 17 3.5.2 Replacement of the Drum Cartridge 18 3.5.3 Replacement of the Fusing Unit 19 4. Service tool ...21 4.1 CE Tool List...21 4.2 Copy materials...21 4.2.1 Maintenance Kit 21 5. Firmware upgrade 22 5.1 Preparations for Firmware rewriting 22 5.2 Firmware rewriting 22 5.2.1 Installing the Printer Driver/ TWAIN Driver Using Plug and Play 22 Troubleshooting Appendix i

Section	Page
bizhub 160/160f/161/161f	20
General	34
1. System configuration	34
2. Product specifications	35
2.1 bizhub 160 / bizhub 161	35
2.1.1 Main Unit	35
2.1.2 GDI Printer Function (bizhub 160 only)	37
2.1.3 PCL Printer Function (bizhub 161 only)	38
2.2 bizhub 160f / bizhub 161f	39
2.2.1 Main Unit	39
2.2.2 GDI Printer Function (bizhub 160f only)	41
2.2.3 PCL Printer Function (bizhub 161f only)	42
2.2.4 FAX Function	43
Maintenance	46
3. Periodical check	46
3.1 Maintenance Items	46
3.1.1 Parts to be Replaced by Users (CRU)	46
3.1.2 Periodical Parts Replacement (Every 50,000 Print)	46
3.2 Maintenance Parts	47
3.3 Concept of parts life	47
3.4 Maintenance procedure (Periodical check parts)	48
3.4.1 Remove the Imaging Cartridge	48
3.4.2 Feed Roller	48
3.4.3 Replacement of the Image Transfer Roller	49
3.5 Replacing the Unit	50
3.5.1 Replacement of the Toner Cartridge	50
3.5.2 Replacement of the Drum Cartridge	51
3.5.3 Replacement of the Fusing Unit	52
4. Service tool	54
4.1 CE Tool List	54
4.2 Copy materials	54
4.2.1 Maintenance Kit	54
5. Firmware upgrade	55
5.1 Preparations for Firmware rewriting	55
5.2 Firmware rewriting	55
5.2.1 Installing the Printer Driver/ TWAIN Driver Using Plug and Play	55
5.2.2 Procedure for Upgrading the Firmware (Engine firmware/ Copier firmware/ FAX firmware/ PCL firmware)	56
5.2.3 Procedure for Upgrading the FAX Firmware (Upgrading Procedure Using Telephone Line from FAX Machine to FAX Machine)	58
5.3 Remedy for a Failed Updating of the Firmware	59
5.4 Remedy for a Failed Updating of the Firmware for PCL (bizhub 161, bizhub 161f only)	61
6. Other	63
6.1 Disassembly/Adjustment prohibited items	63
6.2 Disassembly/Assembly list (Other parts)	64
6.3 Disassembly/Assembly procedure	65
6.3.1 Identification of Exterior Parts and Removal Procedures for Them	65
6.3.2 Removal of Circuit Boards and Other Electrical Components	66
6.3.3 NIC Board (Option for bizhub 161/160f/161f)	67
6.3.4 NCU Board (bizhub 160f/161f only)	67
6.3.5 PCL Board (bizhub 161/161f only)	68
6.3.6 Controller/Mechanical Control Board	68
6.3.7 Control Panel	69
6.3.8 Interface Board	70
6.3.9 Plate NIC Board (Option for bizhub 161/160f/161f)	71
6.3.10 Power Unit	72
6.3.11 High Voltage Unit	75
6.3.12 IR Unit	75
6.3.13 PH Unit	76
6.3.14 Original Cover Set Sensor	77
6.3.15 Upper Cover Assy. (Original Glass)	77
6.3.16 Scanner Motor	78
6.3.17 Scanner Assy.	78
6.3.18 Belt	79
6.3.19 Main Motor	79
6.3.20 Paper Empty Sensors	80
6.3.21 Paper Take-Up Solenoid	81
6.3.22 Paper Take-Up Clutch Gear	82
6.3.23 Torque Limiter	83
6.4 Option Counter	85
6.4.1 Removal of the Mechanical Counter (Option for bizhub 160/161/160f/161f)	85
Adjustment/Setting	86
7. How to use the adjustment section	86
8. Status Mode	87
8.1 Status Mode function tree	87
8.2 Status Mode setting procedure	88
8.2.1 Procedure	88
8.2.2 Exiting procedure	88
8.2.3 Changing the Status Mode functions	88
8.2.4 TOTAL PAGE	89
8.2.5 TX/ RX RESULT (bizhub 160f/161f only)	89
8.2.6 PRINT REPORT (bizhub 161/160f/161f only)	90
9. Utility Mode (bizhub 160/bizhub 161)	97
9.1 Utility Mode function tree	97
9.2 Utility Mode setting procedure	98
9.2.1 Procedure	98
9.2.2 Exiting procedure	98
9.2.3 Changing the settings for Utility Mode functions	98
9.2.4 MACHINE SETTING	99
9.2.5 PAPER SOURCE SETUP	100
9.2.6 USER MANAGEMENT	101
9.2.7 COPY SETTING	101
9.2.8 NETWORK SETTING	102
10. Utility Mode (bizhub 160f/bizhub 161f)	104
10.1 Utility Mode function tree	104
10.2 Utility Mode setting procedure	107
10.2.1 Procedure	107
10.2.2 Exiting procedure	107
10.2.3 Changing the settings for Utility Mode Functions	107
10.2.4 MACHINE SETTING	108
10.2.5 PAPER SOURCE SETUP	110
10.2.6 USER MANAGEMENT	110
10.2.7 ADMIN. MANAGEMENT	111
10.2.8 COPY SETTING	113
10.2.9 FAX REGISTRATION	114
10.2.10 TX OPERATION	116
10.2.11 RX OPERATION	118
10.2.12 COMM. SETTING	124
10.2.13 REPORTING	125
10.2.14 INITIAL USER DATA	126
10.2.15 NETWORK SETTING	127
10.2.16 E-MAIL SETTING 1	129
10.2.17 E-MAIL SETTING 2	130
10.2.18 SCAN SETTING	132
11. Adjustment item list	133
12. Service Mode (bizhub 160/bizhub 161)	134
12.1 Service Mode function tree	134
12.2 Service Mode setting procedure	136
12.2.1 Procedure	136
12.2.2 Exiting procedure	136
12.2.3 Changing the settings for Service Mode functions	136
12.3 Service Mode functions	137
12.3.1 SERVICE’S CHOICE	137
12.3.2 ADJUST	140
12.3.3 COUNTER	148
12.3.4 DISPLAY	150
12.3.5 FUNCTION	151
12.3.6 FIXED ZOOM CHANGE	153
12.3.7 FACTORY TEST	153
12.3.8 CLEAR DATA	154
13. Service Mode (bizhub 160f/bizhub 161f)	155
13.1 Service Mode function tree	155
13.2 Service Mode setting procedure	158
13.2.1 Procedure	158
13.2.2 Exiting procedure	158
13.2.3 Changing the settings for Service Mode functions	158
13.3 Service Mode functions	159
13.3.1 SERVICE’S CHOICE	159
13.3.2 ADJUST	167
13.3.3 COUNTER	175
13.3.4 DISPLAY	177
13.3.5 FUNCTION	178
13.3.6 Soft Switch Function	180
13.3.7 REPORT	181
13.3.8 T.30 PROTOCOL LIST	185
13.3.9 ADMIN. REGISTRATION (Administrator number registration)	186
13.3.10 FIXED ZOOM CHANGE	187
13.3.11 FACTORY TEST	187
13.3.12 CLEAR DATA	187
14. Board Switch	193
14.1 Names of control panel parts and their functions	193
14.1.1 bizhub 160/ bizhub 161	193
14.1.2 bizhub 160f/ bizhub 161f	194
14.2 Circuit Board Locations	196
14.2.1 bizhub 160	196
14.2.2 bizhub 161	197
14.2.3 bizhub 160f	197
14.2.4 bizhub 161f	198
14.3 Functions of switches and parts on PWBs	198
14.3.1 PWB-P (Controller/Mechanical Control Board)	198
14.3.2 PWB-IF (Interface Board)	199
14.3.3 NCU (Network Control Unit Board)	199
14.3.4 PCL (PCL Controller Board)	199
14.3.5 NC-501: PWB- NIC (Network Interface Card Board)	200
14.3.6 NC-501: NIC-IF (Plate NIC Board)	200
14.4 Adjustment of jumper switches on NCU board	201
15. Security Mode	202
15.1 Security Mode function tree	202
15.2 Security Mode setting procedure	202
15.2.1 Procedure	202
15.2.2 Exiting Procedure	202
15.3 Security Mode functions	202
15.3.1 MACHINE COUNTER	202
16. Soft Switch Set (bizhub 160f/bizhub 161f only)	203
16.1 Description	203
16.2 Default setting	204
16.2.1 Country for each Marketing area	204
16.3 Default soft switch setting for each market area 1	205
16.4 Default soft switch setting for each market area 2	207
16.5 Default soft switch setting for each market area 3	209
16.6 Default soft switch setting for each market area 4	211
16.7 Soft switch list	212
16.8 Soft switch definition	216
16.8.1 SOFT SWITCH: #01	216
16.8.2 SOFT SWITCH: #02	217
16.8.3 SOFT SWITCH: #03	218
16.8.4 SOFT SWITCH: #04	219
16.8.5 SOFT SWITCH: #05	220
16.8.6 SOFT SWITCH: #06	221
16.8.7 SOFT SWITCH: #07	221
16.8.8 SOFT SWITCH: #08	222
16.8.9 SOFT SWITCH: #09	223
16.8.10 SOFT SWITCH: #10	224
16.8.11 SOFT SWITCH: #11	225
16.8.12 SOFT SWITCH: #12	225
16.8.13 SOFT SWITCH: #13	226
16.8.14 SOFT SWITCH: #14	227
16.8.15 SOFT SWITCH: #15	227
16.8.16 SOFT SWITCH: #16	228
16.8.17 SOFT SWITCH: #17	228
16.8.18 SOFT SWITCH: #18	229
16.8.19 SOFT SWITCH: #19	230
16.8.20 SOFT SWITCH: #20	231
16.8.21 SOFT SWITCH: #21	232
16.8.22 SOFT SWITCH: #22	233
16.8.23 SOFT SWITCH: #23	233
16.8.24 SOFT SWITCH: #24	234
16.8.25 SOFT SWITCH: #25	234
16.8.26 SOFT SWITCH: #26	235
16.8.27 SOFT SWITCH: #27	236
16.8.28 SOFT SWITCH: #28	237
16.8.29 SOFT SWITCH: #29	238
16.8.30 SOFT SWITCH: #30	239
16.8.31 SOFT SWITCH: #31	240
16.8.32 SOFT SWITCH: #32	240
16.8.33 SOFT SWITCH: #33	241
16.8.34 SOFT SWITCH: #34	241
16.8.35 SOFT SWITCH: #35	242
16.8.36 SOFT SWITCH: #36	243
16.8.37 SOFT SWITCH: #37	244
16.8.38 SOFT SWITCH: #38	245
16.8.39 SOFT SWITCH: #39	245
16.8.40 SOFT SWITCH: #40	246
16.8.41 SOFT SWITCH: #41	247
16.8.42 SOFT SWITCH: #42	248
16.8.43 SOFT SWITCH: #43	248
16.8.44 SOFT SWITCH: #44	248
16.8.45 SOFT SWITCH: #45	249
16.8.46 SOFT SWITCH: #46	249
16.8.47 SOFT SWITCH: #47	250
16.8.48 SOFT SWITCH: #48	250
16.8.49 SOFT SWITCH: #49	251
16.8.50 SOFT SWITCH: #50	251
16.8.51 SOFT SWITCH: #51	252
16.8.52 SOFT SWITCH: #52	252
16.8.53 SOFT SWITCH: #53	253
16.8.54 SOFT SWITCH: #54	253
16.8.55 SOFT SWITCH: #55	254
16.8.56 SOFT SWITCH: #56	254
16.8.57 SOFT SWITCH: #57	254
16.8.58 SOFT SWITCH: #58	255
16.8.59 SOFT SWITCH: #59 Part 1	256
16.8.60 SOFT SWITCH: #59 Part 2	257
16.8.61 SOFT SWITCH: #59 Part 3	258
16.8.62 SOFT SWITCH: #60	259
16.8.63 SOFT SWITCH: #61	259
16.8.64 SOFT SWITCH: #62	260
16.8.65 SOFT SWITCH: #63	260
16.8.66 SOFT SWITCH: #64	261
17. Fax Protocols	262
17.1 G3 ECM (G3 Error Correction Mode)	262
17.2 Line control	263
17.2.1 Procedure of G3 mode communication	263
17.3 Table of reference code	264
17.4 How to analyze the T30 protocol monitor	265
Troubleshooting	272
18. Introduction	272
18.1 Overall Control Configuration	272
19. Jam display	273
19.1 Misfeed Displays	273
19.1.1 Misfeed Display Resetting Procedure	273
19.2 Sensor layout	274
19.3 Solution	275
19.3.1 Initial Check Items	275
19.3.2 Paper Take-Up/Transport Misfeed	276
19.3.3 Fusing/Exit Misfeed	277
20. Malfunction code	278
20.1 Trouble code	278
20.1.1 Trouble code list	278
20.2 Solution	280
20.2.1 C0045: Fuser Fan Motor Error	280
20.2.2 C0210: H.V. Abnormal	280
20.2.3 C0500: Fuser Warm Up Error	281
20.2.4 C0510: Fuser Temperature Low	282
20.2.5 C0520: Fuser Overheat	283
20.2.6 C0650: Scanner Home Sensor Error	283
20.2.7 C1200: ASIC Memory Abnormal	284
20.2.8 C1300: Polygon Mirror Motor Error	284
20.2.9 C133B: Communication with Option Error	285
20.2.10 C133C: Modem Error	285
20.2.11 C133D: ROM Checksum Error	286
20.2.12 C13F0: Laser Error	286
20.2.13 C1468: Parameter Chip Error	287
20.2.14 C14A3: IR Lamp Malfunction	287
21. Power supply trouble	288
21.1 Power is not turned ON.	288
22. Image quality problem	289
22.1 Troubleshooting Image Quality Problems	289
22.2 How to Identify Problematic Part	289
22.2.1 Initial Check Items	289
22.3 Troubleshooting for Specific Image Quality Problems	290
22.4 Solution	291
22.4.1 Image Reading System: Blank or Black Prints	291
22.4.2 Image Reading System: Low Image Density	291
22.4.3 Image Reading System: Foggy Background or Rough Image	292
22.4.4 Image Reading System: Black Streaks or Bands	293
22.4.5 Image Reading System: Black Spots	294
22.4.6 Image Reading System: Blank Streaks or Bands	295
22.4.7 Image Reading System: Uneven Image	296
22.4.8 Printer System: Blank or Black Prints	297
22.4.9 Printer System: Blank Spots	298
22.4.10 Printer System: Smears on Back	298
22.4.11 Printer System: Low Image Density	299
22.4.12 Printer System: Foggy Background	300
22.4.13 Printer System: Blank Streaks or Bands	300
22.4.14 Printer System: Black Streaks or Bands	301
22.4.15 Printer System: Offset Image	301
22.4.16 Printer System: Uneven Image	302
23. FAX error (bizhub 160f/bizhub 161f only)	303
23.1 Communication Error	303
23.1.1 Outline	303
23.1.2 Error occurring during transmission	303
23.1.3 Error occurring during reception	303
23.2 Error Code	304
23.2.1 Reception	304
23.2.2 Transmission	306
Appendix	310
24. Parts layout drawing	310
24.1 Main Unit	310
24.2 DF-501 (Option)	311
24.3 PF-501 (Option)	312
25. Connector layout drawing	313
25.1 Main Unit	313
DF-501	314
General	320
1. Product specification	320
Maintenance	322
2. Periodical check	322
2.1 Maintenance procedure	322
2.1.1 Feed Roller	322
2.1.2 Pick-Up Roller	324
2.1.3 Removal of the Pick-Up Roller	324
2.1.4 Registration Rollers	324
2.1.5 Exit Roller	325
2.1.6 Paper Separation Pad	325
3. Other	326
3.1 Disassembly/Assembly list (Other Parts)	326
3.2 Disassembly/Assembly procedure	326
3.2.1 External Parts	326
3.2.2 Control Board	327
3.2.3 Main Motor	328
Adjustment/Setting	330
4. How to use the adjustment section	330
5. Service Mode	331
5.1 Accessing the Service Mode	331
5.1.1 Accessing the “ADJUST” Menu	331
5.1.2 Printing a Test Page	331
5.2 ADJUST	332
5.2.1 ADF SUB ZOOM	332
5.2.2 ADF MAIN REGIST	333
5.2.3 ADF SUB REGIST	334
5.3 FUNCTION	335
5.3.1 ADF FEED TEST	335
6. Mechanical adjustment	336
6.1 Height Adjustment	336
6.2 Leading Edge Tilt Adjustment	337
Troubleshooting	338
7. Paper Misfeed	338
7.1 Initial Check Items	338
7.2 Paper Misfeed Displays	338
7.3 Locations of Misfeed Detection Sensors	339
7.4 Misfeed Detection Timing and Troubleshooting Procedures	340
7.4.1 The Original misfeeds	340
8. Timing Chart	341
PF-501	342
General	348
1. Product specification	348
Maintenance	350
2. Periodical check	350
2.1 Maintenance procedure	350
2.1.1 Feed Roller	350
3. Other	351
3.1 Disassembly/Assembly list (Other parts)	351
3.2 Disassembly/Assembly procedure	351
3.2.1 External Parts	351
3.2.2 2nd Drawer Control Board	352
3.2.3 2nd Drawer Paper Take-Up Unit	352
3.2.4 Cassette Type Detecting Switch	353
3.2.5 2nd Drawer Take-up Solenoid	353
NC-501/SU-502	354
General	360
1. Product specifications	360
Maintenance	362
2. Other	362
2.1 Disassembly/Assembly list (Other parts)	362
2.2 Disassembly/Assembly procedure	362
2.2.1 Network Interface Card (NC-501)	362
2.2.2 Plate NIC Board (NC-501)	363
2.2.3 Internet Fax & Network Scan Kit (SU-502)	364
3. Firmware upgrade	365
Troubleshooting	368
4. Malfunctions/Warning	368
4.1 Troubleshooting Procedure Overview	368
4.2 Troubleshooting Procedure Chart	368
4.3 Main Error Messages and Their Remedies	369
4.4 Troubleshooting Functions	370
4.4.1 Scan to E-Mail Transmission	370
4.4.2 Internet Fax Transmission	370
4.4.3 Internet Fax Reception	371
4.4.4 Direct Fax Sending (Gateway TX)	372
4.4.5 PageScope Web Connection	372

Match case Limit results 1 per page

bizhub 160/160f

bizhub 161/161f

General

Maintenance

Adjustment / Setting

Troubleshooting

Appendix

Field Service Ver. 1.0 Apr. 2005

CONTENTS

General

System configuration

...............................................................................................

Product specifications

.............................................................................................

2.1

bizhub 160 / bizhub 161

.......................................................................................

2.1.1

Main Unit

.......................................................................................................

2.1.2

GDI Printer Function (bizhub 160 only)

.........................................................

2.1.3

PCL Printer Function (bizhub 161 only)

........................................................

2.2

bizhub 160f / bizhub 161f

.....................................................................................

2.2.1

Main Unit

.......................................................................................................

2.2.2

GDI Printer Function (bizhub 160f only)

........................................................

2.2.3

PCL Printer Function (bizhub 161f only)

.......................................................

2.2.4

FAX Function

...............................................................................................

Maintenance

Periodical check

....................................................................................................

3.1

Maintenance Items

.............................................................................................

3.1.1

Parts to be Replaced by Users (CRU)

........................................................

3.1.2

Periodical Parts Replacement (Every 50,000 Print)

....................................

3.2

Maintenance Parts

..............................................................................................

3.3

Concept of parts life

............................................................................................

3.4

Maintenance procedure (Periodical check parts)

...............................................

3.4.1

Remove the Imaging Cartridge

...................................................................

3.4.2

Feed Roller

..................................................................................................

3.4.3

Replacement of the Image Transfer Roller

..................................................

3.5

Replacing the Unit

..............................................................................................

3.5.1

Replacement of the Toner Cartridge

...........................................................

3.5.2

Replacement of the Drum Cartridge

...........................................................

3.5.3

Replacement of the Fusing Unit

..................................................................

Service tool

...........................................................................................................

4.1

CE Tool List

.........................................................................................................

4.2

Copy materials

....................................................................................................

4.2.1

Maintenance Kit

..........................................................................................

Firmware upgrade

.................................................................................................

5.1

Preparations for Firmware rewriting

....................................................................

5.2

Firmware rewriting

..............................................................................................

5.2.1

Installing the Printer Driver/ TWAIN Driver Using Plug and Play

................