SERVICE MANUAL

Field Service

IC-203

2005.08 Ver. 2.0

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 1 to the left of the revised section. A number within 1 represents the number of times the revision has been made. To indicate clearly a section revised, show 1 in the lower outside section of the corresponding page. A number within 1 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.

2005/08 2005/06 Date

2.0 1.0 Service manual Ver. Revision mark

Correction of an error in writing. Issue of the first edition Descriptions of revision

Field Service Ver2.0 August.2005

CONTENTS

CONTENTS
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OUTLINE
1. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MAINTENANCE
2. SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1 Overview of the Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.1.1 2.1.2 2.2 2.2.1 2.2.2 Operating Environment of the Service Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installing / Booting Up Hyper Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Booting Up Service DOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Memory Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How to Use the Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. FIRMWARE VERSION UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4. DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1 Overall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 IC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HDD Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal / Installation of IC Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal / Installation of HDD Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal / Installation of Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal / Installation of PostScript Protection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal / Installation of System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal / Installation of IC Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disassembly / Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ADJUSTMENT / SETTING
5. TECH REP. MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

TROUBLESHOOTING
6. TROUBLESHOOTING THE PRINTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.1 Troubleshooting of the print controller and copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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CONTENTS

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Field Service Ver2.0 August.2005

1. PRODUCT SPECIFICATIONS

OUTLINE
1. PRODUCT SPECIFICATIONS
A. Type Type: B. Functions Resolution Gradation Printable Area Printing System: binary PCLXL: PCL5e: PS: Margine 2.84 mm (left, right, top and bottom without variation) Margine 2.84 mm (left, right, top and bottom without variation) Margine 2.84 mm (left, right, top and bottom without variation) Non-standard paper: 302.979 x 459.994 mm (The maximum paper size: 314 x 460 mm) No. of Print Continuous Print Speed Printer Description Language 1 to 9999 92 ppm (A4, 8.5 x 11) / (600 x 600 dpi) PCL (The Direct Printing of the PDF/TIFF is available. However, an additional application is required.) PostScript 3(TIFF/PDF) (optional PostScript kit required) Built-in fonts Compliant OS Agfa Microtype fonts Adobe PostScript Font (optional PS3 kit required) Windows 98/Me Windows NT 4.0 (NT Service Pack 3 or more) Windows 2000 Windows XP/Server 2003 Mac OS 9.x (optional PS3 kit required) Mac OS X v10.2/v10.3 (optional PS3 kit required) Printer Driver Printer driver for Windows 98/Me/NT 4.0/2000/XP/Server 2003 PS printer driver for Windows (optional PS3 kit required) PS printer driver for Windows/Macintosh (optional PS3 kit required) Protocols Compliant OS (NOS) Multiple Protocols Printing Method TCP/IP, IPX/SPX, NetBEUI, IPP, EtherTalk Novell NetWare (3.x, 4.x-6), Windows 98/Me, Windows NT 4.0, Windows 2000, Windows XP, Mac OS 9.x, Mac OS X v10.2/v10.3 Automatic selection Peer-to-Peer (TCP/IP for Windows 95/98/Me), Pserver (IPX/SPX), lpd/ lpr (TCP/IP for Windows NT 4.0/2000), lpd/lpr (TCP/IP for UNIX), AppleTalk (EtherTalk), NPrinter/RPrinter (IPX/SPX), Port9100(TCP/IP) Dedicated Utilities Compliant Web Browser Peer to Peer Printing Tool Netscape Navigator, Internet Explorer 600 x 600 dpi Built-in box type for the KONICA MINOLTA Printer/Copier

Scanning Resolution: 200 dpi / 300 dpi/ 400 dpi / 600 dpi

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1. PRODUCT SPECIFICATIONS C. Paper Paper Size Paper Type Paper Weight D. Maintenance and Life Same as copier Same as copier Same as copier

Field Service Ver2.0 August.2005

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Maintenance Machine Service Life E. Machine Data

Same as copier Same as copier

CPU System Memory Host Interface Hard Disk Drive Option Power Network Interface Frame Type Ethernet Connection Network Connector LED F. Operating Environment

Low Voltage Pentium III Tualatin 800 MHz 256 MB (Standard), Expandable up to 512 MB (Option: EM-701) Parallel port Centronics (IEEE 1284 / amphenol 36 pin male connector) EIDE drive 40 GB or more PS3 kit Memory: (EM-701: 256 MB) Obtain from main body printer Ethernet (100Base-TX / 10Base-T) IEEE 802.3 100Base-TX / 10Base-T RJ-45 Green 2

Temperature Humidity

Same as copier Same as copier

Field Service Ver2.0 August.2005

2. SERVICE TOOL

MAINTENANCE
2. SERVICE TOOL
2.1 Overview of the Service Tool
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4 9 8 3 7 2 6 1

The service tool enables the print controller to operate with a terminal communications program for a personal computer (PC). This print controller supports for input/output operations of a serial port of the print controller from when the printer system BIOS boots up, thus making it possible to control the progress in initialization and system test (or POST: Power On Self Test) by BIOS, which assisting to determine where error conditions may exist when an error develops at the system start time. Also, memory check and boot up a service DOS by BIOS are available with the terminal communication program. 2.1.1 Operating Environment of the Service Tool

The following is required to use the service tool. Computers running on Windows Hyper Terminal (terminal communications program) Setting requirements Bits/sec.: Data bit: Parity: Stop bit: Flow control: 9600 bits/sec.(fixed) 8 bits None 1 None

RS-232C serial cable (terminated in a female 9-pin D-Sub connector on both ends) Pin assignment
PC
1 DCD 2 TxD 3 RxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI

Print Controller
1 DCD 2 TxD 3 RxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI

9-Pin D-SUB Connector (female)

For information on installation and usage of Hyper Terminal, see the Windows manual and descriptions on the following pages.

2. SERVICE TOOL 2.1.2 Installing / Booting Up Hyper Terminal

Field Service Ver2.0 August.2005

Hyper Terminal is a terminal communications program which comes with Windows 98/Me/NT4.0/2000/XP as

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standard. If it is not installed in your Windows 98/Me/NT4.0, it is necessary to install it.

Caution For Windows 2000/XP, it is installed by default. There is no need to install it. To install Hyper Terminal, the system program CD for the Windows PC in use is required. The procedure of setting up and booting up Hyper Terminal depends on the Windows version.

G. To install Hyper Terminal In the following, Windows 98 is used as an example.

1. 2. 3.

Insert the CD containing OS of the Windows PC in use into the CD drive. Select [Start]-[Settings]-[Control Panel].
A [Control Panel] window will appear. An [Add/Remove Programs Properties] window will appear.

Double-click [Add/Remove Programs].

4. 5.

Click the [Windows Setup] tab, and check the [Connection] check box under [Components]. Click the [Details] button.
A [Communication] window will appear.

6. 7.

Check the [Hyper Terminal] check box, and click the [OK] button. When the [Add/Remove Programs] window reopens, click the [OK] button.
The necessary files are copied and the installation is completed.

Field Service Ver2.0 August.2005 H. To Boot Up Hyper Terminal In the following, Windows XP is used as an example. munications]-[Hyper Terminal].

2. SERVICE TOOL

A [Connection Description] window will appear.

NOTE Once a connection is made, an icon with the name entered in the step 2 will be created. If an icon has already been created (i.e., if the printer connection settings have already been done), there is no need to complete the following steps because the connection with Hyper Terminal is established by doubleclicking that icon.

2. 3.

Enter a name, and click the [OK] button. Select [COM (1-3)] under [Connect using], then click the [OK] button.
A [Port Settings] window will appear.

4.

Configure the port settings as shown on the left, and click the [OK] button.

NOTE The serial port settings on the copier can not be changed. Leaving all the settings at their defaults except [Bits per second] and [Flow control] is required.

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1.

Select [Start]-[All Programs]-[Accessories]-[Com-

2. SERVICE TOOL

Field Service Ver2.0 August.2005

2.2
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How to Use the Service Tool

The print controller carries DOS (Embedded DOS) along with the BIOS program on a flash ROM. This DOS allows the print controller system to be recovered. 2.2.1 Booting Up Service DOS

1. 2. 3. 4.

Turn the copiers main power switch (SW1) OFF. Connect an RS-232C serial cable between the PC and the print controller. Boot Hyper Terminal. (See 2.1.2 Installing / Booting Up Hyper Terminal.) While pressing the [k] key, turn the copiers main power switch (SW1) ON (i.e., boot up the print controller).

5.

The message Press [a] or [s] appears (7 seconds or less). Enter the [a] key.
The DOS is boot up.

NOTE Do not press the [s] key because it is entry for production purpose. If you do not press any key for 7 seconds, it boots normally.

6.

When the message Enter new data (mm-ddyy): appears, enter the current date (ex: 04-012005) and press the Enter key.

7.

When the message Enter new time (hh:mm:ss): appears, enter the current time (ex: 18:14:20) and press the Enter key.
Now DOS commands are available for use.

NOTE Although the printer system (VxWorks) acquires time information from the copier, the service DOS has no way of communicating with the copier: it is necessary to enter the current date and time.

Field Service Ver2.0 August.2005 2.2.2 Memory Test Methods

2. SERVICE TOOL

The memory test needs to be conducted if, after in the cases such as an unstable operation is observed after The memory test includes a normal memory test and a detailed memory test. The normal memory test is a test conducted upon normal powering up. The normal memory test includes the following: In memory area of lower than 64 KB: Data read/write test, address test, and data test over the entire memory area.

Caution The detailed memory test is a test conducted over the entire memory area with a operation from the service port.

The detailed memory test includes the following: In memory area of lower than 64 KB: In memory area of higher than 64 KB: I. Memory Test Procedure Data read/write test, address test, and data test over the entire memory area. Data read/write test in 64 KB units.

1. 2.

Boot Service DOS. (See 2.2.1 Booting Up Service DOS.) While pressing the [m] key, turn the copiers main power switch (SW1) ON.
The detailed memory test is conducted.

3.

Make certain that all memory tests found no problems (Memory Passed is displayed).

NOTE When all memory is OK, the copier is able to normally start up.

4. 5. 6. 7.

Turn the copiers main power switch (SW1) OFF. Unplug the serial cable. Turn the copier back ON to check if it behaves normally. If any test results are faulty (The message Critical Error is displayed. Or, the value after the indication of Ext. Memory Passed is less than the expanded memory capacity.), remove the added memory, and run the memory test from the beginning.

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the memory was expanded or a faulty memory size is detected.

3. FIRMWARE VERSION UP

Field Service Ver2.0 August.2005

3. FIRMWARE VERSION UP
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Rewriting firmware (system software) enables the system to be upgraded the version without replacing the board. Also, even in case the print controllers firmware is damaged in its software and becomes inoperative, rewriting firmware may restore it. Firmwares version is upgraded by ISW. See 5. FIRMWARE VERSION UP in Field Service for the main body.

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4. DISASSEMBLY / REASSEMBLY

4. DISASSEMBLY / REASSEMBLY
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4.1
4.1.1

Overall Construction
IC Unit

Hard Disk

Board Cover

PostScript Protection Chip

Parallel Cable ICU Cooling Fan

IDE Cable

Memory IC Board
Caution The CPU cannot be removed from the system board. To replace the CPU, the IC board (ICB) needs to be replaced.

4. DISASSEMBLY / REASSEMBLY 4.1.2 HDD Unit

Field Service Ver2.0 August.2005

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Rubber Insert

Earth Plate

Earth Plate

Hard Disk Mounting Bracket

Hard Disk

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Field Service Ver2.0 August.2005 4.1.3 Tools Required

4. DISASSEMBLY / REASSEMBLY

Standard screwdriver PLCC pull-out tool

Caution Be sure to unplug the power cable, not only to turn the copier off, before attempting to make servicing. Do not make service for the IC Unit and the HDD with the condition that they are installed to the copier.

Caution Before engaging in Disassembly/Reassembly, check to make sure that all the cables are unplugged from the IC unit. DO NOT use magnetized tools in Disassembly/Reassembly to prevent the hard disk from being affected. There may be occasions when boards are damaged if no appropriate grounding measures are taken. Wear a wrist strap or others during servicing. Disassembly/Reassembly should be made on cushioning materials.

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Spanner or needle-nose pliers

4. DISASSEMBLY / REASSEMBLY

Field Service Ver2.0 August.2005

4.2
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Disassembly / Reassembly

Caution Assembly should be made in reverse order of disassembly unless otherwise noted.

4.2.1

Removal / Installation of IC Unit

1. 2.

Turn the copiers main power switch (SW1) OFF, and unplug the power cord from the AC outlet. Remove the network cable and parallel cable from the IC Unit.

3.

Remove five screws.

4.

Remove the power connector on the lower side of the IC unit.

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4. DISASSEMBLY / REASSEMBLY

5. 6.

Remove the IC Unit from the copier. Assembly should be made in reverse order from

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disassembly.

4. DISASSEMBLY / REASSEMBLY 4.2.2 Removal / Installation of HDD Unit

Field Service Ver2.0 August.2005

When replacing the hard disk, be sure to use one that is designated as spark parts for the print controller.

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Caution The use of any other hard disks is not allowed. Do not change settings for the jumper.

1. 2.

Remove the IC Unit. (See 4.2.1 Removal / Installation of IC Unit.) Remove the nineteen screws and the Board Cover.

3.

Remove the IDE cable from board.

NOTE Lift a transparent film when unplugging the cable.

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Field Service Ver2.0 August.2005

Earth Plate
[7] [4]

4. DISASSEMBLY / REASSEMBLY

4.

Remove four setscrews [4] for the hard disk and remove the hard disk/2 (HDD2) [5] from the hard

NOTE
Earth Plate

Do not remove the supporting rubber [7] of the hard disk holder [6].

[6] [4]

[5]

5.

Unplug the power cord and IDE cable from the Hard Disk.

NOTE Lift a transparent film when unplugging the cable.

6.

Assembly should be made in reverse order from disassembly.

NOTE When fixing the hard disk on the hard disk holder, be cautious that the screw tightening torque T=0.4-0.5(Nm) and the supporting rubber [7] neither ride up nor run on.

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disk holder [6].

4. DISASSEMBLY / REASSEMBLY 4.2.3 Removal / Installation of Memory

Field Service Ver2.0 August.2005

About combinations of memory expansion, see 2.2.1 Memory of Theory of Operation section.

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1. 2.

Remove the IC Unit. (See 4.2.1 Removal / Installation of IC Unit.) Remove the board cover and unplug the IDE cable from the board. (See 4.2.2 Removal / Installation of HDD Unit.)

NOTE Lift a transparent film when unplugging the cable.

3.
[3]

Press the memory slots tab [3] outward to remove the memory. Assembly should be made in reverse order from disassembly.

4.

NOTE When assembling, fit the memory to the notch of the memory slot.

[3]

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Field Service Ver2.0 August.2005 4.2.4 Removal / Installation of PostScript Protection Kit

4. DISASSEMBLY / REASSEMBLY

The PostScript protection kit is mounted only in a print controller equipped with PostScript option. reinstalled when replacing the system board. Use the PLCC pull-out tool to remove the PostScript protection chip. Caution The PostScript protection kit is sensitive to static electricity. Handle it with care.

1. 2.

Remove the IC Unit. (See 4.2.1 Removal / Installation of IC Unit.) Remove the board cover and unplug the IDE cable from the board. (See 4.2.2 Removal / Installation of HDD Unit.)

NOTE Lift a transparent film when unplugging the cable.

3.
[3] [1]

Remove the PostScript protection kit [1] using a PLCC pull-out tool such as shown below. Assembly should be made in reverse order from disassembly.

4.

NOTE Make sure that the circle [3] on the PostScript protection kit faces the triangle [2] on the system board.
PLCC pull-out Tool

[2]

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Normally, there is no need to remove/reinstall the PostScript protection kit. However, it should be removed and

4. DISASSEMBLY / REASSEMBLY 4.2.5 Removal / Installation of System Board

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1. 2.

Remove the IC Unit. (See 4.2.1 Removal / Installation of IC Unit.) Remove the board cover and unplug the IDE cable from the board. (See 4.2.2 Removal / Installation of HDD Unit.)

NOTE Lift a transparent film when unplugging the cable.

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4. DISASSEMBLY / REASSEMBLY

3.

Unplug the parallel cable [2] and the IDE cable [3] from the system board [1].

[1]

[2]

NOTE Lift a transparent film when unplugging the IDE cable [3].

[3]

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4. DISASSEMBLY / REASSEMBLY

Field Service Ver2.0 August.2005

4.
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Remove two setscrews [4] for the connector.

[4]

5.

Remove two screws [5] for the compact flash cover and remove the compact flash [6].

[5]

[6]

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4. DISASSEMBLY / REASSEMBLY

[7]

6.

Remove ten screws [7] from the system board, then remove the system board.

NOTE When disassembling, be careful not to dam-

[7]

[7]

age the board and the connector.

7.

Assembly should be made in reverse order from disassembly.

[7]

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4. DISASSEMBLY / REASSEMBLY 4.2.6 Removal / Installation of IC Cooling Fan

Field Service Ver2.0 August.2005

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Caution The CPU cannot be removed from the system board. To replace the CPU, the system board needs to be replaced.

1. 2.

Remove the IC Unit. (See 4.2.1 Removal / Installation of IC Unit.) Remove the board cover and unplug the IDE cable from the board. (See 4.2.2 Removal / Installation of HDD Unit.)

3. 4.

Remove the system board. (See 4.2.5 Removal / Installation of System Board) Remove the DC connector [2] of the IC cooling fan (FM24) [1] from the system board.

[1]

[2]

[3]

5.

Remove two screws [3] on the backside of the system board and remove the IC cooling fan (FM24).

6.

Assembly should be made in reverse order from disassembly.

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5. TECH REP. MODE

ADJUSTMENT / SETTING
5. TECH REP. MODE
In the service mode, various adjustments / settings are available. See 10. TECH REP. MODE in Field Service for the main body.

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5. TECH REP. MODE

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6. TROUBLESHOOTING THE PRINTING SYSTEM

TROUBLESHOOTING
6. TROUBLESHOOTING THE PRINTING SYSTEM
This table lists information about the symptoms, possible causes, and remedies for problems that may occur with the printing system (combination of the print controller and copier). It is intended to help engineers find information as quickly as possible, and provide basic solutions.

Caution See the Copier Service Manual for information about Error Cord List.

6.1

Troubleshooting of the print controller and copier

Causes Actions Check if the print controller is connected with the copier properly. Locate the cause of trouble of the copier.

Symptoms

[Controller] key on the Utility Menu screen No power supply to the is kept in gray out for 15 minutes after the print controller. power ON. Warming up does not disappear. Initialization does not disappear on the copier screen. Printout is defective, or nothing can be printed. Print controller does not start. Copier is in trouble.

The print controller has not See the column of Print controller started properly. does not start. The system board or some Put the copier in service mode and perboards of the copier are form test. If it operates properly, system defective. board may be failure. The system board is inac- Check the connector of the controller tive. board. Replace the system board as necessary. Software of the print con- Reinstall the software of the print controller is defective. troller.

Test print can be produced but not from the parallel port.

The parallel port has something wrong or the cable is wrong or, the problem is on the computer side.

Check the cables (internal/external). Perform test using a data generator or a well-proven PC/I/O cable. Replace the system board as necessary. Reinsert PostScript3 Protection Kit. If the problem still occurs, replace PostScript3 Protection Kit with a new one. Print controllers software or application program has something wrong. Save the file, which failed to be printed, in the disk and analyze the problem by suitable means.

With the standard printer language PCL, PostScript3 Protection Kit is not correctly installed. correct outputs are produced, but with PostScript3 even PS Demo Page cannot be printed out at all. Test print can be produced and all ports Some software error has are good, but user jobs cannot be printed. happened.

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6. TROUBLESHOOTING THE PRINTING SYSTEM

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