Page 1: Service Manual
SERVICE MANUAL Models 7115/7118 DECEMBER 2001 CSM-7115/7118 KONICA BUSINESS TECHNOLOGIES, INC.
Page 3 7115/7118 SERVICE MANUAL DECEMBER 2001...
Page 4: Important Notice
IMPORTANT NOTICE Because of the possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Business Technolo- gies strongly recommends that all servicing be per- formed by Konica-trained service technicians only. Changes may have been made to this equipment to improve its performance after this service manual was printed.
Page 5 CONTENTS SAFETY PRECAUTIONS ..................v SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE ......P-1 GENERAL ....................... G-1 Contents ......................i MECHANICAL/ELECTRICAL ................M-1 Contents ......................i...
Page 7: General
SAFETY PRECAUTIONS SAFETY PRECAUTIONS know what effect may be caused by altering any Installation Environment aspect of the machine’s design. Such changes have Safety considerations usually are directed toward the potential of degrading product performance and machine design and the possibility of human error. In reducing safety margins.
Page 8 SAFETY PRECAUTIONS • Ensure that the power cord insulation is not dam- Applying Isopropyl Alcohol aged (no exposed electrical conductors). Care should be exercised when using isopropyl alco- • Ensure that the power cord is properly mounted hol, due to its flammability. When using alcohol to to the frame by cord clamps.
Page 9 SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE • When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. • Different markings are used to denote specific meanings as detailed below. Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury.
Page 10 3. Do not throw toner or the toner bottle into a fir. • Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. • For replacement parts, always use the genuine parts specified in the manufac- turer’s parts manual.
Page 11 11. Restore all parts and harnesses to their original positions. • To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and sad- dles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed.
Page 12 3. Precautions for the Working Environment. • The product must be placed on a flat, level surface that is stable and secure. • Never place this product or its parts on an unsteady or tilting workbench when servicing. • Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time.
Page 13 1-4. 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.
Page 14 1-5. Precautions for Service • When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. 1. Precautions Before Service •...
Page 15 4. Precautions for Dis/Reassembly • Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.
Page 16 6. Handling of PWBs < During Transportation/Storage > • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature.
Page 17 8. Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. < During Transportation/Storage > • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. •...
Page 18 C. Soak a small amount of either ethyl alcohol or iso- propyl alcohol into a clean, unused Dust-Free Cot- ton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one con- tinuous movement from its rear edge to its front edge and off its surface one to two times.
Page 19 GENERAL...
Page 21: Table Of Contents
CONTENTS 1. SPECIFICATION ..................... G-1 2. PRECAUTIONS FOR INSTALLATION ............G-5 2-1. Installation Site ..................G-5 2-2. Power Source ..................G-5 2-3. Grounding ....................G-5 3. PRECAUTIONS FOR USE ................G-6 3-1. To ensure that the copier is used in an optimum condition ..... G-6 3-2.
Page 23: Specification
30 sec. or less (23, Rated Voltage) FIRST COPY TIME 7 sec. or less (A4, Drawer, full size mode) CONTINUOUS COPY SPEED (copies/min) Speed Size 7115 7118 8-1/2 × 11 8-1/2 × 11R 11 × 17R 8-1/2 × 14R 11 × 14...
Page 24 ZOOM RATIOS Metric Inch Full Size 100 % 100 % 200 % 200 % Enlargement 141 % 155 % Fixed 115 % 129 % 81 % 77 % Reduction 70 % 64 % 50 % 50 % Variable 50 % to 200 % (in 1 % increments) LENS Through Lens EXPOSURE LAMP...
Page 25 Multiple Bypass (MT-102): option TYPE Multiple Bypass INSTALLATION Mounted on the copier COPY PAPER TYPE Plain Paper (60 to 90 g/m 50 sheets Transparencies 20 sheets Type 20 sheets Thick Paper (91 to 157 g/m Postcards 20 sheets Recycled Paper (60 to 90 g/m 50 sheets Maximum (Width ×...
Page 26 Job Tray (IT-102): option TYPE Multiple Bypass INSTALLATION Mounted on the copier CAPACITY Exit Tray Job Tray of the machine 1Stacking height up 150 sheets (A4/A4R) to 22 mm Plain Paper (60 to 90 g/m 75 sheets 100 sheets (A4/A4R) (except A4/A4R) 50 sheets (except A4/A4R)
Page 27: Precautions For Installation
PRECAUTIONS FOR INSTALLATION 2-1. Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. •...
Page 28: Precautions For Use
PRECAUTIONS FOR USE 3-1. To ensure that the copier is used in an optimum condition • Never place a heavy object on the copier or subject the copier to shocks. • Insert the power plug all the way into the outlet. •...
Page 29: Handling Of Consumables
HANDLING OF CONSUMABLES Before using any consumables, always read the label on its container carefully. • Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place.
Page 30: Other Precautions
OTHER PRECAUTIONS Use the following precautions when performing service jobs for a copier that uses a laser. • When a service job needs to be performed in the laser beam path, such as when working around the printerhead or PC Drum, be sure first to unplug the power cord of the copier from the outlet.
Page 31: System Options
SYSTEM OPTIONS 4021O009AA 1144M172AC 4021O010AA 4021O013AB 4021M073AA 4021M074AA 4021O014AA 1. Plug-In Counter 8. Sifting Unit IS-101 2. Original Cover CV-117 (Illustration none) 3. Automatic Document Feeder DF-217 9. Memory MU-409, MU-410 4. Multiple Bypass MT-102 (Illustration none) 5. Copy Desk 10.
Page 32 G-10...
Page 33 MECHANICAL/ ELECTRICAL...
Page 35 CONTENTS 1. CROSS SECTIONAL VIEW ................M-1 2. COPY PROCESS .................... M-2 3. DRIVE SYSTEM ....................M-4 4. SEQUENTIAL EXPLANATION ................ M-5 5. WATCHDOG FUNCTION (CPU OVERRUN MONITOR) ........ M-6 5-1. Watchdog Function Post-Processing ............M-6 6. IMAGE STABILIZATION SYSTEM ..............M-7 7.
Page 36 15-1.Paper Take Up Drive Mechanism ............M-36 15-2.Paper Take-Up Mechanism ..............M-37 15-3.Paper Empty Detection Mechanism ............M-38 15-4.Paper Take Up Control ................M-38 15-5.Paper Take Up Retry Control ..............M-39 16. IMAGE TRANSFER AND PAPER SEPARATION SECTION ......M-40 17.
Page 37: Cross Sectional View
CROSS SECTIONAL VIEW 4021M001AA 1. IR Section 4. Paper Take-Up/Feed Section 2. Fusing Unit 5. PH Section 3. Imaging Unit...
Page 38: Copy Process
COPY PROCESS 4021M065CB 1. PC Drum • Used as the medium on which a visible developed image of the original is formed. 2. Drum Charging • A uniform negative DC charge is deposited across the entire surface of the PC Drum. 3.
Page 39 9. Bypass Paper Feed • Feeds paper from the Manual Bypass Tray, one piece at a time. • The optional Multiple Bypass Tray (MT-102), when mounted on the machine, permits continuous paper feeding. 10. Image Transfer • A DC positive charge is applied to the Image Transfer Roller to transfer the visible image on the surface of the PC Drum onto the paper.Paper Separation.
Page 40: Drive System
DRIVE SYSTEM Paper Exit Roller Gear Transport Roller Gear Fusing Roller Gear PC Drum Synchronizing Roller Clutch Paper Take-Up Roller Gear 4021M003AA 1. Scanner Motor M5 2. Main Motor M1...
Page 41: Sequential Explanation
SEQUENTIAL EXPLANATION...
Page 42: Watchdog Function (Cpu Overrun Monitor
WATCHDOG FUNCTION (CPU OVERRUN MONITOR) • The watchdog function, or CPU overrun monitor function, monitors whether any of the CPUs mounted in the copier overruns. • If the function detects that a CPU overruns, the copier automatically resets the CPU, thereby restarting the logic circuit and mechanism.
Page 43: Image Stabilization System
IMAGE STABILIZATION SYSTEM The following image stabilization controls are provided to ensure stabilized copy image. Purpose Means Control The Vg/Vb control voltage is varied to bring Vg/Vb to an appropriate level according to the following settings. • Tech. Rep. Choice: ID Adjustment To stabilize image density.
Page 44: Imaging Unit (I/U
IMAGING UNIT (I/U) • The IU integrates the PC Drum, Developing Unit, PC Drum Charge Corona, and the PC Drum Cleaning Mechanism, all in one body. PC Drum PC Drum Cleaning Mechanism 4021M006AB PC Drum Charge Corona Developing Unit 4021M007AB...
Page 45: Imaging Unit (Iu) Drive Mechanism
7-1. Imaging Unit (IU) Drive Mechanism • The IU is driven by the Main Motor. 4021M008AB Main Motor M1 Forward Backward Elevtrical Component Control Signal Wiring Diagram Rotation Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7...
Page 46: Pc Drum Section
PC DRUM SECTION • The PC Drum consists of layers of semiconductive materials placed on an aluminum alloy base, on which an electrostatic latent image is formed. PC Drum (PC Drum Cross-Section) Charge Transport Layer Charge Generation Layer 1167M007AA Aluminum Base 1139M007AA 8-1.
Page 47: Grounding Of The Pc Drum
8-2. Grounding of the PC Drum • The potential on the surface of the PC Drum exposed to the light is grounded to the frame. PC Drum Frame Ground Plate 4021M010AA M-11...
Page 48: Pc Drum Charging Section
PC DRUM CHARGING SECTION • The PC Drum Charge Corona has a scorotron grid to deposit a charge evenly across the surface of the PC Drum. • The corona unit has a comb electrode that discharges only toward the grid mesh, thus minimizing the amount of ozone produced.
Page 49: 10. Image Reading Section
10. IMAGE READING SECTION 4021M012AB 1. Scanner /Motor M5 4. Scanner 2. CCD Board PWB-J 5. 2nd/3rd Mirrors Carriage 3. Size Reset Switch S10 6. Scanner Home Position Sensor PC6 M-13...
Page 50: 10-1.Image Processing Process
10-1. Image Processing Process 1. Photoelectric Conversion • Light reflected off the original is read by the CCD Sensor which converts the data to a corresponding analog signal. 2. Analog-to-Digital Conversion • The analog signal output from the CCD Sensor is converted to a corresponding 8-bit dig- ital signal.
Page 51: 10-2.Exposure Components Section
10-2. Exposure Components Section 4021M013AA 1. Auxiliary Reflector When a book or other bound original is copied, the paper in the area near the binding generally fails to come flush against the glass, so that the copy of these areas is gener- ally too dark.
Page 52: 10-3.Scanner And Mirrors Carriage Movement Mechanism
10-3. Scanner and Mirrors Carriage Movement Mechanism Scanner Movement Mechanism • The Scanner is driven by the Scanner Motor. 2nd/3rd Mirrors Carriage Movement Mechanism • The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner, thereby keeping constant the optical path length between the original and the CCD Board.
Page 53: 10-4.Scanner Motor Drive Control
10-4. Scanner Motor Drive Control • The speed at which the Scanner is moved is controlled by varying the period of the motor drive pulse that is timed with the reference clock. High Speed Low Speed Period • The distance over which the Scanner travels is controlled by the number of motor drive pulses that correspond to each paper size and zoom ratio.
Page 54: 11. Memory Storage Image Processing System
11. MEMORY STORAGE IMAGE PROCESSING SYSTEM • Based on the image data output from the IR, a laser light is projected onto the surface of the PC Drum to form a corresponding latent image. PH Unit 4021M068AA M-18...
Page 55: 11-1.Laser Exposure Process
11-1. Laser Exposure Process 1. The Start key is pressed. 2. The laser diode is forced to turn ON and the laser intensity is automatically adjusted. 3. The SOS Sensor Board is illuminated by the laser beam, which generates an SOS sig- nal.
Page 56: 12. Developing Unit Section
12. DEVELOPING UNIT SECTION The Developing Unit agitates and triboelectrically charges toner so that it sticks to the elec- trostatic latent image formed on the surface of the PC Drum, then changing the image to a visible, developed one. 4021M017AA 1.
Page 57: 12-1.Developing Unit Drive Mechanism
12-1. Developing Unit Drive Mechanism The rollers are driven through a gear train from the motor. 1st Toner Conveying Roller Sleeve/Magnet Roller Main Motor M1 2nd Toner Conveying Roller 3rd Toner Conveying Roller 4021M008AB Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G...
Page 58: 12-3.Developing Bias
12-2. Sleeve/Magnet Roller • The Sleeve/Magnet Roller, which consists of an outer sleeve roller and an inner magnet roller, conveys developer to the point of development. • The magnetic force of the magnet roller at the point of development is the strongest so that the developer brush stands straight up to deliver the greatest amount of toner to the point of development.
Page 59: Atdc Sensor Automatic Adjustment
12-4. ATDC Sensor The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer Mixing Chamber. 2nd Toner Conveying Roller 4021M019AA ATDC Sensor UN1 ATDC Sensor Automatic Adjustment The reference value for the ATDC Sensor is automatically adjusted as detailed below using the ATDC Sensor Automatic Adjustment mode.
Page 60: 12-5.Toner Replenishing Mechanism
12-5. Toner Replenishing Mechanism • Toner is supplied from the Toner Bottle to the Developer Mixing Chamber. 1. The coupling is turned by the motor, which turns the Toner Bottle. 2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering Chamber provided in the outer race of the coupling.
Page 61: 12-6.Toner Replenishing Control
12-6. Toner Replenishing Control • Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio. • If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value. •...
Page 62: 12-7.T/C Recovery Mode
12-7. T/C Recovery Mode The machine enters the T/C recover mode when a T/C of 10 % or less is detected. Toner is replenished for 90 sec. T/C is recovered by 1 % or more. T/C is not recovered by 1 % or more, or T/C is less than 12 %.
Page 63: 12-8.Toner Bottle Home Position Detection Mechanism
12-8. Toner Bottle Home Position Detection Mechanism • The Toner Bottle is at its home position (where it remains stationary) when its Toner Sup- ply Port faces up. This position is detected by a sensor. Toner Bottle Home Position Sensor PC7 Toner Supply Port 4021M024AA Elevtrical Component...
Page 64: 13. Paper Take Up/Feed Section
13. PAPER TAKE UP/FEED SECTION 4021M070AA 1. Paper Size Detecting Board PWB-I 4. Paper Take-Up Roll 2. Paper Size Detecting Sensor S11 5. Separator Roll 3. Paper Empty Sensor PC4 6. Paper Lifting Plate M-28...
Page 65: 13-1.Drawer In Position Detection
13-1. Drawer In Position Detection • When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor. The copier then knows that the drawer has been slid in position. Drawer Set Sensor PC5 4021M026AA Elevtrical Component Control Signal Activated Deactivated Wiring Diagram...
Page 66: 13-3.Paper Lifting Plate
13-3. Paper Lifting Plate • The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked when the tray is slid into the unit. • The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times. Paper Lifting Plate Spring 4021M063AA...
Page 67 Paper Size Detecting Board Paper Size Detecting PWB-I Paper Size Sensor S11 — — — — — B4R, 8-1/2 × 14 — — — — Activated 11 × 14 — — — Activated A3R, 11 × 17 — — — A5R, 5-1/2 ×...
Page 68: 13-5.Paper Take Up Mechanism
13-5. Paper Take Up Mechanism • Drive for the paper take-up sequence is transmitted via the Paper Take-Up Solenoid from a motor. Main Motor M1 Paper Take-Up Roll Paper Take-Up Solenoid SL1 4021M027AA Paper Separating Mechanism • The coefficient of friction between the Paper Take-Up Roll and Separator Roll is effec- tively used to prevent double feed of paper.
Page 69: 13-6.Paper Take Up Control
13-6. Paper Take Up Control Start Key ON Main Motor M1 Paper Take-Up Solenoid SL1 Synchronizing Roller Sensor PC1 4021M515CA Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7 Elevtrical Component Control Signal Wiring Diagram PWB-A PJ5A-2 Elevtrical Component Control Signal Activated Deactivated...
Page 70: 14. Manual Bypass Section
14. MANUAL BYPASS SECTION 14-1. Paper Take Up Drive Mechanism • Drive for paper take-up from the Manual Bypass is transmitted from a motor via the Sole- noid. Main Motor M1 Manual Feed Paper Sensor PC2 Manual Bypass Solenoid SL2 4021M028AA 14-2.
Page 71 14-3. Manual Feed Take Up Control Paper Set Start Key ON Manual Feed Paper Sensor PC2 Main Motor M1 Manual Bypass Solenoid SL2 Paper drawing-in sequence completed 4021M511CA Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7 Elevtrical Component Control Signal Wiring Diagram...
Page 72: 14-1.Paper Take Up Drive Mechanism
15. MULTIPLE BYPASS SECTION 4021M031AA 1. Paper Take-Up Roll 3. Multiple Bypass Paper Empty Sensor 2. Multiple Bypass Solenoid SL21 PC21 15-1. Paper Take Up Drive Mechanism • Drive for paper take-up from the Multiple Bypass is transmitted from a motor via the Sole- noid.
Page 73: 15-1.Paper Take Up Drive Mechanism
15-2. Paper Take-Up Mechanism • The Paper Lifting Plate is raised to press the paper stack on the tray up against the Paper Take-Up Roll. • The Paper Lifting Plate is raised and lowered in time with a paper take-up sequence. •...
Page 74: 15-3.Paper Empty Detection Mechanism
15-3. Paper Empty Detection Mechanism • The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass. <When Paper is Present> <When Paper is not Present> Multiple Bypass Paper Empty Sensor PC21 Paper 4021M034AA 4021M035AA 15-4. Paper Take Up Control Paper Set Start Key ON Multiple Bypass Paper Empty Sensor PC21...
Page 75 15-5. Paper Take Up Retry Control • To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo- rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given period of time after the sequence has been started. The paper take-up sequence is then performed again.
Page 76: Image Transfer And Paper Separation Section
16. IMAGE TRANSFER AND PAPER SEPARATION SEC- TION Image Transfer • A positive charge is applied to the Image Transfer Roller to transfer the toner image formed on the surface of the PC Drum onto the paper. • The charge applied to the Image Transfer Roller is varied according to the following con- ditions to ensure that image transfer efficiency is stabilized.
Page 77: 17. Pc Drum Cleaning Section
17. PC DRUM CLEANING SECTION • The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum. • The spent toner is conveyed through the Recycling Duct and eventually back to the Developer Mixing Chamber. •...
Page 78: 18. Main Erase Section
18. MAIN ERASE SECTION • Any potential remaining on the surface of the PC Drum is neutralized by both light from the Main Erase and a negative voltage applied by the Charge Neutralizing Sheet. • A negative charge is applied to the Charge Neutralizing Sheet to neutralize a positive charge on the surface of the PC Drum.
Page 79: 19. Fusing Unit Section
19. FUSING UNIT SECTION • The Fusing Unit fixes permanently the developed image to the paper by applying heat and pressure to the toner and paper. 4021M041AD 1. Paper Exit Roller 7. Fusing Heater Lamp H1 2. Transport Roller 8. Thermistor TH1 3.
Page 80: 19-1.Fusing Unit Drive Mechanism
19-1. Fusing Unit Drive Mechanism • The Fusing Unit is driven by a motor. Main Motor M1 Left Fusing Roller Right Fusing Roller 4021M042AA 19-2. Fusing Rollers Pressure Mechanism • To ensure that there is a certain width of area of contact between the Right and Left Fus- ing Rollers, a pressure spring is used to press the Lower Fusing Roller up against the Upper Fusing Roller.
Page 81: Fusing Temperature Control
19-3. Fusing Temperature Control • The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the surface of the Fusing Roller. • The Fusing Roller surface temperature is detected by using a thermistor that translates the temperature to a corresponding electrical signal.
Page 82: 20. Job Tray (It-102): Option
20. JOB TRAY (IT-102): Option 4021M045AC 1. Job Tray 5. Upper Home Position Sensor PC32 2. Main Board PWB-A 6. Lower Home Position Sensor PC33 3. Paper Empty Sensor PC35 7. Paper Detecting Board PWB-B 4. Full Detecting Sensor PC34 8.
Page 83: 20-1.Tray Selecting Mechanism
20-1. Tray Selecting Mechanism • Paper is fed into either the Exit Tray of the machine or the Job Tray. Either is selected according to the application mode (fax, copier, or printer). • The specific tray in which paper is fed is selected by a motor and a sensor. <When feeding paper into the Exit Tray: Copier>...
Page 84: 20-2.Tray-Full Detecting Mechanism
20-2. Tray-Full Detecting Mechanism • Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the low- ered position). • A tray-full condition is detected when the sensor is blocked for a continuous given period of time (approx.
Page 85: 21. Shifting Unit (Is-101): Option
21. SHIFTING UNIT (IS-101): Option 4021M053AB 1. Main Board PWB-A 2. Home Sensor S31 3. Shift Motor M1 M-49...
Page 86: 21-1.Exit Position Shifting Mechanism
21-1. Exit Position Shifting Mechanism • Paper is fed into the Shifting Unit along a straight path or shifted from the reference straight path position. This exit position shifting mechanism allows different finishing functions offered by the machine (Non-Sort, Sort, and Group) to be effected. <Straight Feeding>...
Page 87 Elevtrical Forward Backward Control Signal Wiring Diagram Component Rotation Rotation PWB-A PJ2A-1 to 4 Pulse output 16-C Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PWB-A PJ3A-3 17-D M-51...
Page 88: 22. Other Mechanism
22. OTHER MECHANISM 22-1. Cooling Mechanism Power Supply Section Cooling Mechanism • A cooling fan motor draws air from the area around the Power Supply Unit to the outside to prevent the Power Supply Unit temperature from running high. • The cooling fan motor is turned at full speed when the Main Motor turns and at a speed reduction during other timings, thereby making the machine quieter without sacrificing cooling performance.
Page 89: Fusing Section Cooling Mechanism
Fusing Section Cooling Mechanism • A fan motor draws air from the area around the Fusing Unit to the outside to prevent the machine interior temperature from running high. In addition, the fan motor pulls paper being transported up through suction force to help stabilize paper transport. •...
Page 90 M-54...
Page 91 SERVICE MANUAL FIELD SERVICE 7115/7118 KONICA BUSINESS TECHNOLOGIES, INC.
Page 93 CONTENTS DIS/REASSEMBLY, ADJUSTMENT 1. SAFETY INFORMATION ................. D-1 1-1. LASER SAFETY ..................D-1 1-2. INTERNAL LASER RADIATION .............. D-1 1-3. LASER SAFETY LABEL ................D-4 1-4. LASER CAUTION LABEL ................ D-4 1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ....D-4 2.
Page 94 3-7. Imaging Unit (IU) ..................D-30 (1) Removal of the IU ................D-30 (2) Disassembly of the IU ..............D-30 (3) Application of Toner ................. D-34 (4) Replacement of the ATDC Sensor ..........D-35 3-8. IMAGE TRANSFER SECTION ..............D-36 (1) Removal of the Image Transfer Roller Assy ........
Page 95 (2) CCD Unit Position Adjustment ............D-65 (3) Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjustment) ..............D-66 4-6. MISCELLANEOUS .................. D-68 (1) Remounting the EEPROM (U29) ............. D-68 (2) Installation of the Plug-In Counter Socket (Option) ......D-69 (3) Installation of the Total Counter (Option) .........
Page 96 TROUBLESHOOTING 1. INTRODUCTION ..................... T-1 1-1. Reading the Text ..................T-1 2. PAPER TRANSPORT FAILURE ..............T-2 2-1. Paper Misfeed Detection ................. T-2 (1) Outline ..................... T-2 2-2. Paper Misfeed ..................T-2 2-3. Misfeed Detection Sensor Layout ............T-4 2-4. Types of Misfeed Detection and Detection Timings ........ T-6 3.
Page 97 (2) Black copy ..................T-46 (3) Low image density ................T-47 (4) Foggy background or rough image ..........T-49 (5) Black streaks or bands ..............T-51 (6) Black spots ..................T-52 (7) Blank streaks or bands ..............T-53 (8) Void areas ..................T-54 (9) Smear on back ................
Page 99: Safety Precautions
SAFETY PRECAUTIONS SAFETY PRECAUTIONS know what effect may be caused by altering any Installation Environment aspect of the machine’s design. Such changes have Safety considerations usually are directed toward the potential of degrading product performance and machine design and the possibility of human error. In reducing safety margins.
Page 100 SAFETY PRECAUTIONS • Ensure that the power cord insulation is not dam- Applying Isopropyl Alcohol aged (no exposed electrical conductors). Care should be exercised when using isopropyl alco- • Ensure that the power cord is properly mounted hol, due to its flammability. When using alcohol to to the frame by cord clamps.
Page 101: Safety Precautions For Inspection And Service
SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE • When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. • Different markings are used to denote specific meanings as detailed below. Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury.
Page 102 3. Do not throw toner or the toner bottle into a fir. • Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. • For replacement parts, always use the genuine parts specified in the manufac- turer’s parts manual.
Page 103 11. Restore all parts and harnesses to their original positions. • To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and sad- dles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed.
Page 104 3. Precautions for the Working Environment. • The product must be placed on a flat, level surface that is stable and secure. • Never place this product or its parts on an unsteady or tilting workbench when servicing. • Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time.
Page 105 1-4. 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.
Page 106 1-5. Precautions for Service • When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. 1. Precautions Before Service •...
Page 107 4. Precautions for Dis/Reassembly • Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.
Page 108 6. Handling of PWBs < During Transportation/Storage > • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature.
Page 109 8. Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. < During Transportation/Storage > • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. •...
Page 110 C. Soak a small amount of either ethyl alcohol or iso- propyl alcohol into a clean, unused Dust-Free Cot- ton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one con- tinuous movement from its rear edge to its front edge and off its surface one to two times.
Page 111: Dis/Reassembly, Adjustment
DIS/REASSEMBLY, ADJUSTMENT...
Page 113: Safety Information
SAFETY INFORMATION 1-1. 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. 1-2. INTERNAL LASER RADIATION Semiconductor laser Maximum average radiation power(*)
Page 114 the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
Page 115 Finland, Sweden VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle. Puolijohdelaser Laserdiodin suurin teho 5 mW Aallonpituus 770-795 nm...
Page 116: Laser Safety Label
1-3. LASER SAFETY LABEL • A laser safety labels is attached to the outside of the machine as shown below. Laser safety label 1-4. LASER CAUTION LABEL • A laser caution label is attached to the inside of the machine as shown below. 4022D501AA 1-5.
Page 117: Service Instructions
SERVICE INSTRUCTIONS 2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS Control Board (PWB-C) Thermoswitch 1 (TS1) 125 V 3 A 250 V 7.5 A/125 V 15 A DC Power Supply (PU1) 4021D006AA 100 V system 125 V 15 A (F2) 200 V system 250 V 6.3 A (F2)
Page 118: Parts Which Must Not Be Touched
2-2. PARTS WHICH MUST NOT BE TOUCHED Red Painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted, set, or removed in the field. If it becomes unavoidably necessary to disassemble any of these assemblies and units, disassembly may be done provided that the conditions permitting reassembly are met.
Page 119: Disassembly/Reassembly
DISASSEMBLY/REASSEMBLY 3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES...
Page 120 Part Name Removal Procedure Original Cover Pull the Original Cover straight up. Remove no. 18. → Remove two holding brackets or no. 11 and Original Glass the Original Glass. Remove two control panel mounting screws. → Remove two ground wire mounting screws. → Remove one flat cable and Control Panel unplug one connector.
Page 121: Removal Of Circuit Boards And Other Electrical Components
3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS • When removing a circuit board or other electrical component, refer to “PRECAUTIONS FOR HANDLING THE PWBs” and follow the corresponding removal procedures. • The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board.
Page 122: Removal Of The Master Board
Symbol Part Name Removal Procedure PWB-A Master Board D-10 PWB-C Control Board D-11 Remove the Rear Cover. → Remove the PWB Assy. → Paper Size Detecting PWB-I Remove two screws and the PWB-I Assy. → PWB-I Board D-23 PWB-J CCD Board Remove the CCD Unit as a unit.
Page 123: Removal Of The Control Board
3. Unplug all connectors (but PJ20) from the Master Board. 4. Remove four screws and the Master Board. Removal of the Control Board 1. Remove the Rear Cover. 2. Remove the PWB Cover Assy. 3. Unplug all connectors from the Control Board. 4.
Page 124 5. Unplug three connectors from the High Voltage Unit and remove the harness from one wiring saddle. 6. Remove the harness from one wiring saddle. 7. Remove ten screws and the PWB Assy. 8. Remove the harness from one wiring saddle of the High Voltage Unit cover.
Page 125: Removal Of The Dc Power Supply
9. Remove nine screws and the High Voltage Unit cover. 10. Unplug two connectors from the High Voltage Unit. 11. Remove two screws and the High Voltage Unit. Removal of the DC Power Supply 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2.
Page 126 6. Remove four screws and the Power Supply Left Cover. 7. Unplug one connector and remove the harness from one edge cover. 8. Unplug one connector and remove the harness from one wiring saddle. 9. Unplug one connector and remove the harness from one wiring saddle.
Page 127 11. Remove two screws. 12. Remove two screws. 13. Remove four screws and the DC Power Supply. D-15...
Page 128: Maintenance Schedule
3-3. MAINTENANCE SCHEDULE D-16...
Page 129 D-17...
Page 130: Paper Take-Up/Transport Section
3-4. PAPER TAKE-UP/TRANSPORT SECTION Removal of the Paper Separator Roll Assy and Paper Take-Up Roll 1. Slide out the 1st Tray. 2. Remove two screws and the Paper Separator Roll Assy. 3. Press down the Paper Lifting Plate. 4. Snap off one C-clip from the Paper Take-Up Roll Assy.
Page 131: Cleaning Of The Right And Left Synchronizing Rollers
Cleaning of the Right and Left Synchronizing Rollers 1. Remove the Imaging Unit. 2. Using a soft cloth dampened with alcohol, wipe the Right and Left Synchronizing Rollers clean of dirt. Removal of the Cleaning Pad 1. Remove the Imaging Unit. 2.
Page 132: Cleaning Of The Cleaning Pad
Cleaning of the Cleaning Pad 1. Remove the Cleaning Pad. 2. Using a brush, whisk dust and dirt off the Clean- ing Pad. Cleaning of the Bypass Transport Roller 1. Remove the Imaging Unit. 2. Remove two screws, unplug one connector, and remove the Bypass Transport Roller Assy.
Page 133: Optical Section
3-5. OPTICAL SECTION Cleaning of the Original Glass and ADF Glass 1. Using a soft cloth dampened with alcohol, wipe the Original Glass and ADF Glass clean of dirt. Cleaning of Mirrors 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the mirrors clean of dirt.
Page 134: Cleaning Of The Ccd Sensor
3. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt. Cleaning of the CCD Sensor 1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Remove the Lens cover. 4. Using a soft cloth dampened with alcohol, wipe the CCD Sensor clean of dirt.
Page 135: Removal Of The Ccd Unit
Removal of the CCD Unit 1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Unplug one connector. 4. Remove three screws and the CCD Unit. NOTE • NEVER attempt to loosen or remove screws that are not specified when removing the CCD Unit.
Page 136 3. Remove two Scanner mounting screws (to which no red paint has been applied). 4. Remove one screw and the cable holder. 5. Remove the flat cable from the Inverter Board and then remove the Scanner. 6. Unplug one connector from the Inverter Board. 7.
Page 137: Removal Of The Scanner Drive Cables
Removal of the Scanner Drive Cables 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Right Cover, Original Glass, and ADF Glass. 2. Remove the Scanner. NOTE • Remove the two red painted screws to remove the Scanner in this step. 3.
Page 138 7. Remove the rear cable from the cable pulley. 8. Snap off one C-ring from the front side of the pul- ley assy. 9. Snap off one C-ring from the rear side of the pul- ley assy. 10. Remove the belt and the pulley assy. 11.
Page 139: Winding Of The Scanner Drive Cables
Winding of the Scanner Drive Cables Rear Front 4022D003AA 1. Wind the cable around the rear cable pulley of the pulley assy from side B toward side A and then secure the cable with tape. 2. Wind the cable around the front cable pulley of the pulley assy from side A toward side B and then secure the cable with tape.
Page 140 4. Mount the pulley assy using two C-rings. 4022D006AB 5. Wind the cable at the front. 6. Hook the spring onto the cable hook and hook the spring onto the frame. 4022D007AB 7. Wind the cable in the rear. 8. Secure the cables at the front and rear with a spring. 4022D008AB 9.
Page 141: Removal Of The Ph Unit
3-6. Removal of the PH Unit 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2. Remove the PWB Cover Assy. 3. Remove one flexible harness and unplug one connector from the Master Board. 4. Remove the harness from one edge cover and one wiring saddle.
Page 142: Imaging Unit (Iu
3-7. Imaging Unit (IU) NOTE • When loading developer as part of the IU replacement procedure or when changing the developer, remove the Toner Bottle and run “ATDC Sensor Automatic Adjustment” (F8) twice to allow toner in the Spent Toner Recycling Duct and Toner Conveying Duct into the Developer Mixing Chamber before removing the IU.
Page 143 3. Remove two screws at the front of the IU. 4. Widen flaps on both ends (marked with A in the illustration on the left) of the Cleaning Assy in the direction of arrow and turn to take off the Clean- ing Assy.
Page 144 9. Remove the Ozone Filter. <Removal of the PC Drum Charge Corona Assy> 10. Turn the holder in the rear in the direction of the arrow to remove it from the side bracket. 11. Slide out the PC Drum Charge Corona in the direction of the arrow.
Page 145 <Cleaning of the Ds Collars> 14. Using a soft cloth dampened with alcohol, wipe the Ds Collars clean of dirt. <Cleaning of the Developer Scattering Prevention Plate> 15. Remove three screws and the Developer Scatter- ing Prevention Plate. 16. Using a brush, whisk dust and dirt off the surface of the Developer Scattering Prevention Plate.
Page 146: Application Of Toner
18. Pour one packet of developer. NOTE • Shake the packet of developer well before pouring. • When the developer has been replaced, run “ATDC Sensor Automatic Adjustment.” D-61 <Cleaning of the Pre-Image Transfer Guide Plate> 19. Using a soft cloth dampened with alcohol, wipe the Pre-Image Transfer Guide Plate clean of dirt.
Page 147: Replacement Of The Atdc Sensor
<<Area to which toner is to be applied>> 10 - 15 mm 20 - 25 mm PC Drum 4021U057AA 3. Hold both ends of the PC Drum with your both hands and turn the PC Drum a half turn in the direction of the arrow.
Page 148: Image Transfer Section
3-8. IMAGE TRANSFER SECTION Removal of the Image Transfer Roller Assy 1. Open the Right Door. 2. Loosen one fixing bracket mounting screw. 3. Turn to remove the Pre-Image Transfer Upper Guide Plate. NOTE • When reinstalling the fixing bracket, make sure that the hook of the fixing bracket fits into the slot in the Pre-Image Transfer Upper Guide Plate.
Page 149: Fusing Section
3-9. FUSING SECTION Removal of the Fusing Unit 1. Remove the control panel. NOTE • In this step, free the control panel without removing one flat cable and two ground wires and unplugging one connector. 2. Remove the Front Cover, Rear Cover, and Rear Right Cover. 3.
Page 150 <Removal of the Right Fusing Roller> 2. Unhook the pressure springs at the front and rear. 3. Remove two shoulder screws, two washers, and the Right Roller Assy. 4. Remove the Right Roller. <Removal of the Fusing Heater Lamp> 5. Remove the Pressure Lever Assemblies at the front and rear.
Page 151 7. Remove the harness in the rear of the Heater Lamp from the cover. 8. Remove the thermistor harness from the cover. 9. Remove one mounting screw from the front of the Heater Lamp. 10. Remove one screw and the cover. NOTE •...
Page 152 <Left Fusing Roller> 13. Snap off one retaining ring. 14. Unhook the spring in the rear of the Guide Assy. 15. Unhook the spring at the front of the Guide Assy. 16. Remove the Guide Assy. NOTE • When removing and reinstalling the Guide Assy, use care not to allow the sensor lever spring to be unhooked.
Page 153 20. Snap off the retaining ring at the front of the Left Fusing Roller and remove the washer and bush- ing. 21. Snap off the retaining ring in the rear of the Left Fusing Roller and remove the gear. 22. Remove the collar. 23.
Page 154: Removal Of The Separator Roll Assy
3-10. MULTIPLE BYPASS (MT-102): OPTION Removal of the Separator Roll Assy 1. Open the Right Door. 2. Remove two screws and the Separator Roll Assy. Removal of the Paper Take-Up Roll 1. Remove two screws and the cover. 2. Remove the harness from one cord clamp. 3.
Page 155 4. Unplug two connectors. 5. Remove four screws and the Multiple Bypass. <<Multiple Bypass Installation Procedure>> Temporarily secure the Multiple Bypass using four screws. Install the positioning pin at the location shown in the illustration. (Use the positioning pin furnished as an acces- sory with the Multiple Bypass.) Close the Right Door and correctly position the Multiple Bypass using the positioning pin.
Page 156 6. Remove four screws and the Paper Take-Up Assy. 7. Snap off one C-ring and remove the gear. 8. Snap off one C-ring. 9. Snap off one C-ring and remove the Paper Take- Up Roll Assy. 10. Snap off one C-ring and remove the roll. D-44...
Page 157: Cleaning Of The Separator Roll/Paper Take-Up Roll
11. Snap off one C-ring and one C-clip and remove the paper Take-Up Roll. Cleaning of the Separator Roll/Paper Take-Up Roll 1. Open the Right Door. 2. Remove two screws and the Separator Roll Assy. NOTE • When attempting to reinstall the Separator Roll Assy, try to move the assy in the direction of the arrow.
Page 158: Removal Of The Main Board
3-11. JOB TRAY (IT-102): OPTION Removal of the Main Board 1. Remove the control panel, Front Cover, Rear Cover, Right Cover, and Right Inside Cover. 2. Remove two screws and the fan cover. 3. Remove one screw and the Total Counter (if the copier is so equipped).
Page 159 8. Unplug one connector and remove the harness from one edge cover. 9. Remove two screws and the PWB Assy. 10. Unplug four connectors. 11. Remove two screws, two PWB Supports, and the Main Board. D-47...
Page 160: Paper Detecting Board
Paper Detecting Board 1. Remove the control panel, Rear Cover, and Right Cover. 2. Unplug one harness connector and remove the harness from one edge cover. 3. Press the tabs to remove the Paper Detecting Board Assy from the Front Cover. 4.
Page 161: Removal Of The Main Board
3-12. SHIFTING UNIT (IS-101): OPTION Removal of the Main Board 1. Remove the control panel, Front Cover, Rear Cover, Right Cover, and Right Inside Cover. 2. Remove two screws and the fan cover. 3. Remove one screw and the Total Counter (if the copier is so equipped).
Page 162 8. Remove two screws and the Main Board Assy. 9. Unplug two connectors. 10. Remove two screws, two PWB Supports, and the Main Board. D-50...
Page 163: Adjustment
ADJUSTMENT 4-1. ADJUSTMENT JIGS AND TOOLS USED <Scanner/Mirrors Carriage Positioning Jigs> <Ds Collar Positioning Jigs> 4022D010AA 4022D011AA <Db Gap Adjusting Jigs> <PC Positioning Jig> 4022D012AA 4022D030AA 4-2. TIMING BELT TENSION ADJUSTMENT <Scanner Motor Timing Belt Adjustment> 1. Loosen three screws and move the Scanner Motor Assy to the right or left to give tension to the spring.
Page 164: Accessing The Function, Tech. Rep. Choice, And Adjust Mode
4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, AND ADJUST MODE Function Mode 1. Press the COUNTER. 2. Press the following keys in this order: STOP → 0 → 0 → STOP → 0 → 1. 3. Enter the code number “1” from the KEYPAD. 4.
Page 165: Electrical/Image Adjustment
4-4. ELECTRICAL/IMAGE ADJUSTMENT Edge Erase Adjustment (Leading, Trailing, and Top/Bottom Edges) Requirement • Adjust the erase width on the leading edge (width A), trailing edge (width B), and the top/bottom edge (width C). Default Setting: 4 mm 4022D503AA Mode Code No. Setting Range 5 (leading edge) Tech.
Page 166: Loop Length Adjustment (1St And 2Nd Trays, Bypass Tray
Loop Length Adjustment (1st and 2nd Trays, Bypass Tray) Requirement • Adjust so that a loop of an adequate length is formed in the paper before the Synchroniz- ing Roller as the paper is being fed through the copier. Mode Code No.
Page 167: Printer Cd Registration Adjustment
Printer CD Registration Adjustment Requirement • Adjust so that width A on the test print produced falls within the specified range. 4686D504AA Specifications Mode Code No. Setting Range A4: 20 ± 2.0 mm; 60 to 140, Adjust 8-1/2 × 11: 11.2 ± 2.0 mm 1 step: 0.1 mm NOTES •...
Page 168: Printer Fd Registration Adjustment
Printer FD Registration Adjustment Requirement • Adjust so that width B on the test print produced falls within the specified range. 4022D502AA Specifications Mode Code No. Setting Range 67 to 133, 1 step: 10 ± 1.5 mm Adjust Approx. 0.19 mm NOTES •...
Page 169: Scanner Cd Registration Adjustment
Scanner CD Registration Adjustment Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. 4686D504AA Specifications Mode Code No. Setting Range 20 to 180, 0 ± 2.0 mm Adjust 1 step: 0.1 mm NOTES...
Page 170: Scanner Fd Registration Adjustment
Scanner FD Registration Adjustment Requirement • Adjust so that the deviation between width B on the test print and that on the copy falls within the spec- ified range. 4022D502AA Specifications Mode Code No. Setting Range 60 to 140, 0 ± 1.5 mm Adjust 1 step: 0.1 mm NOTES...
Page 171: Scanner Cd Zoom Adjustment
Scanner CD Zoom Adjustment Requirement • Adjust so that the amount of error falls within ±1.0 % of the length to be measured. • Adjust so that the following specifications are met when the length of the scale is 200 Zoom Ratio Specifications Mode...
Page 172: Scanner Fd Zoom Adjustment
Scanner FD Zoom Adjustment Requirement • Adjust so that the amount of error falls within ±1.0 % of the length to be measured. • Adjust so that the following specifications are met when the length of the scale is 300 Zoom Ratio Specifications Mode...
Page 173: Atdc Sensor Automatic Adjustment (F8
ATDC Sensor Automatic Adjustment (F8) NOTES • This adjustment is made when the developer has been replaced. • Make this adjustment with the Toner Bottle removed from the copier. <Adjustment Procedure> 1. Enter the Function mode. 2. With “F-” shown on the Display, enter the code number “8” from the KEYPAD to set the copier into the “ATDC Sensor Automatic Adjustment”...
Page 174: (11) Manual Bypass Registration Adjustment
(11) Manual Bypass Registration Adjustment Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. Specifications: 0 ± 2.0 mm 4686D504AA NOTES • This adjustment is made when the PH Unit has been replaced and after “Printer Regis- tration Adjustments (CD and FD)”...
Page 175: (12) Multiple Bypass Registration Adjustment (Mt-102): Option
(12) Multiple Bypass Registration Adjustment (MT-102): Option Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. Specifications: 0 ± 2.0 mm 4686D504AA NOTES • This adjustment is made when the Multiple Bypass has been removed. •...
Page 176: Other Adjustments
4-5. OTHER ADJUSTMENTS Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage 1. Fit the Scanner/Mirrors Carriage Positioning Jigs in the space between the Scanner and the 2nd/ Rear 3rd Mirrors Carriage. 4022D013AA 2. Press the 2nd/3rd Mirrors Carriage tightly up 2nd/3rd Mirrors Carriage against the jigs.
Page 177: Ccd Unit Position Adjustment
CCD Unit Position Adjustment NOTE • This adjustment is made when the CCD Unit has been replaced. <Adjustment Procedure> 1. Place a scale on the Original Glass in parallel with the Original Width Scale and make a copy. 2. Measure the length of the scale on the copy. Requirement •...
Page 178: Adjustment Of The Gap Between The Doctor Blade And Sleeve Roller (Db Adjustment
Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjust- ment) Requirement • The gap between the Doctor Blade and the Sleeve Roller should be 0.39 ± 0.04 mm (as set using the jigs). <Adjustment Procedure> 1. Remove the IU. 2.
Page 179 10. Install the Db Gap Adjusting Jigs in a space between the Sleeve Roller and Doctor Blade. 4022D021AB 11. Put the Developing Assy and Cleaning Assy together. 12. Press the Doctor Blade tightly up against the Db Gap Adjusting Jigs and, keeping that position, tighten the screws in the order of at the front, at the center, and...
Page 180: Miscellaneous
4-6. MISCELLANEOUS Remounting the EEPROM (U29) NOTE • When the Control Board (PWB-C) is replaced with a new one, EEPROM (U29) must be demounted from the old PWB-C and remounted on the new PWB-C. Remove the EEPROM (U29) from the new Control Board and mount the EEPROM (U29) of the old Control Board to the new Control Board.
Page 181: Installation Of The Plug-In Counter Socket (Option
Installation of the Plug-In Counter Socket (Option) 1. Cut out the knockout from the Right Cover. 4021S010AA 2. Using two screws, secure the counter mounting bracket. 4021D011AA 3. Connect the Plug-In Counter Socket connector. 4. Using two screws, secure the counter socket. 4021D012AA 5.
Page 182: Installation Of The Total Counter (Option
Installation of the Total Counter (Option) 1. Remove the control panel, Front Cover, Rear Cover, and Right Cover. 2. Cut out the knockout from the Right Cover. 4021D001AA 3. Using one screw, secure the Total Counter to its mounting bracket. 4021D002AA 4.
Page 183: Switches On Pwbs, Tech. Rep. Settings
SWITCHES ON PWBs, TECH. REP. SETTINGS...
Page 185: Control Panel Keys And Touch Panel
CONTROL PANEL KEYS AND TOUCH PANEL 1-1. Control Panel Keys Metric area Inch area...
Page 186 Name Description PRINT Lit while data received from personal computer is being printed JOB STORE Press to select the Job Input mode. Two different jobs can be programmed. COUNTER Press to display the Total Counter or Size Counter value. REVERSE IMAGE Press to copy an original with the original total arrange- ments reversed.
Page 187 Name Description 23 ENTER Press to validate the setting just made. 24 RE Press to select a zoom ratio from among those fixed ratio available as standard. 25 APS/AMS Press to select either Auto Paper or Auto Size. 26 SIZE Press to select the paper size.
Page 188: Utility Mode
UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 2-1. Settings in the Utility Mode Code No. Description User’s Choice Mode Drum Dehumidify Mode Toner Replenisher Mode Custom Size Input Mode Administrator Mode 2-2.
Page 189 2. User’s Choice Mode Setting Procedure <Procedure> 1. Hold down the AUTO RESET for 3 seconds. 2. Enter “1” from the KEYPAD. (Display: U-1) 3. Press the START. 4. Enter the corresponding code number from the KEYPAD. 5. Press the START. Then, the Display will show the current setting value. 6.
Page 190 Code No. Setting (The default is Highlighted <Density Priority> Select the priority exposure mode selected when the Power Switch is turned ON or AUTO RESET pressed. Setting Description Auto Manual Photo Manual <Density Level (Auto)> Select the priority exposure level in the Auto Exposure mode. Setting Description Lighter...
Page 191 Code No. Setting (The default is Highlighted <Margin Setting> Adjust the margin width for the File Margin copy. Setting 0 ............20 Description (mm) 0 <Erase Setting (Left)> Adjust the erase width for the Left Erase copy. Setting 5 ............
Page 192 Code No. Setting (The default is Highlighted <Density ADF> Adjust the copy image density level when the ADF is being used. Setting Description When the standard original (text, etc.) is used. To give better reproduction of faint original. <Priority Density> Set the image density level for printing Setting Description Lighter.
Page 193 Code No. Setting (The default is Highlighted <Special Paper Setting> Allow Paper of same type to be fed from another tray when paper from one source is empty. Setting Description Enables Auto Paper (selection). Enables Auto Tray C28 to 33 Switching.
Page 194 Administrator Mode (Display: U-5) • The entry on the “Administrator No. Input” set using the Tech. Rep. Mode permits the set- tings of the following functions. 1. Administrator Mode Function Setting Procedure <Procedure> 1. Hold down the AUTO RESET for 3 seconds. 2.
Page 195: Administrator Mode (Display
3. Setting in the Administrator Mode Code No. Setting (The default is Highlighted <Administrator Mode> Allows for setting two functions, “Copy Track” and “Disable Auto Shut OFF.” <Copy Track> Allows for making the six different subfunctions. <Disable Auto Shut OFF> Select whether to allow the option “0”...
Page 196 Code No. Setting (The default is Highlighted <Delete Account> Delete an account (access number) which has previously been stored. <Procedure> 1. Enter “3” from the KEYPAD. (Display: A-3) 2. Press the START. This will blank out the Display. If no accounts are yet to be programmed, the contents of the Dis- play alternate between “A-3”...
Page 197: Tech.rep.mode
TECH.REP.MODE • This mode allows the Tech. Rep. to set adjust, and/program various service functions. 3-1. Tech.Rep.Mode Menu Function Tree ---0: Control Panel LED Check F-1 : Paper Passage Test F-2 : HV Output ---1: Function “F- ” F-8 : ATDC Sensor Automatic Adjustment F12: Test Pattern Output c-1 : Maintenance Counter Count c-2 : IU Life Stop...
Page 198: Tech.rep.mode Function Setting Procedure
---8: Change Fixed Zoom ---9: Marketing Area Setting -10: Memory Clear “CLr” ---: Tech.Rep.Mode -11: Total Clear “tCL” -12: ADF Document Passage Test “doc” -13: ADF Original Glass Check “AdF” -14: Scanner Drive Check “ccd” -20: Serial No. Display “Sn” 3-2.
Page 199: Setting In The Tech.rep.mode
3-3. Setting in the Tech.Rep.Mode Control Panel LED Check (Display: - - 0) • The LEDs on the control panel are made to blink to check for any LED that has burned out. Any LED that is not blinking is considered to be out. Function (Display: - - 1) •...
Page 200: Tech.rep.choice (Display: - - 2
Tech.Rep.Choice (Display: - - 2) • This function allows the Tech. Rep. to make various settings and adjustments. <Procedure> 1. Enter the code number corresponding to the function to be used from the KEYPAD. 2. Press the START to display the current setting value. 3.
Page 201 Code No. Setting (The default is Highlighted <Leading Edge Erase Adjustment> Select whether to enable or disable the leading edge erase. Setting Description (mm) <Trailing Edge Erase Adjustment> Select whether to enable or disable the trailing edge erase. Setting Description (mm) <Top/Bottom Edge Erase Adjustment>...
Page 202: Counter Mode (Display: - - 3
Counter Mode (Display: - - 3) • Shows the number of copies made on each paper size or type. <Procedure> 1. Enter the code number corresponding to the function to be used from the KEYPAD. 2. Press the START to show the count. If the count consists of 4 or more digits, it is displayed in two groups alternately as fol- lows.
Page 203 Code No. Setting <IU Life Counter> Show the count of the IU Life Counter. The count is based on a countdown system and, if counting continues after “0,” a minus sign (-) is appended to the value shown on the Dis- play.
Page 204 Code No. Setting <Trouble Counter> Counts the number of malfunctions that have occurred at different parts of the copier. If all malfunction counters are “0,” “ALL” and “0” alternate. Display Description Main Motor malfunction Fusing Cooling Fan Motor malfunction Power Supply Cooling Fan Motor malfunction Toner Replenishing Motor malfunction Faulty image transfer voltage Warm-up failure...
Page 205: Atdc Sensor Output (Display: - - 4
ATDC Sensor Output (Display: - - 4) • This function displays a T/C ratio representing the current ATDC Sensor output value. • It is used for checking the T/C when image density is not good. It is not possible to change or reset the sensor output data. <Exiting the Mode>...
Page 206: Administrator No. Input (Display: - - 7
Administrator No. Input (Display: - - 7) • Set an ID number for opening the “Administrator Mode” screen of Utility Mode from the KEYPAD. <Procedure> 1. Press the START to alternately display the current administrator number. 2. Press the CLEAR to clear the current administrator number. 3.
Page 207: Memory Clear (Display: - 10
(11) Memory Clear (Display: - 10) • This function is used to clear all data except that of the various electronic counters. <Procedure> 1. Press the START to display “CLr” on the Display. 2. Press the START to blank out the Display. Then, “CLr”...
Page 208: Adf Original Glass Check (Display: - 13
(14) ADF Original Glass Check (Display: - 13) • The original scanning area of the ADF is scanned to check for possible dirt or scratches on the glass. The scanned area is produced as a copy. <Procedure> • Press the START to start the sequence. For details, see the relevant option service manual.
Page 209: Security Mode
SECURITY MODE • Allows the Tech. Rep. to set the various counters. 4-1. Settings in the Security Mode Code No. Description Total Counter Count Mode Size Counter Count Mode Key Counter Total Counter 4-2. Security Mode Setting Procedure <Procedure> 1. Set the machine into the Tech. Rep. Mode. 2.
Page 210: Setting In The Security Mode
4-3. Setting in the Security Mode Code No. Setting (The default is Highlighted <Total Counter Count Mode> Select the condition by which the Counter count is increased. Setting Description 1 Copy per 1 copy cycle. Multiple count-up according to the paper size and copying mode.
Page 211: Adjust Mode
ADJUST MODE • Used at the factory for making adjustments. 5-1. Settings in the Adjust Mode Code No. Description Printer CD Registration adjustment Printer FD Registration adjustment Scanner CD Zoom adjustment Scanner FD Zoom adjustment Scanner CD Registration adjustment Scanner FD Registration adjustment ADF FD Zoom adjustment ADF CD Registration adjustment ADF FD Registration adjustment...
Page 212: Setting In The Adjust Mode
5-3. Setting in the Adjust Mode Code No. Setting (The default is Highlighted <Printer CD Registration adjustment> Adjust registration in the CD direction on the printer (engine) side. It is used when the PH Unit has been replaced. Setting 60 ............
Page 213 Code No. Setting (The default is Highlighted <ADF FD Zoom adjustment> Adjust the zoom ratio in the FD direction on the ADF side. It is used when the machine is set up, the PH Unit or Scanner Drive Cables have been replaced, or the Scanner has been removed. Setting 87......
Page 214 S-30...
Page 215: Troubleshooting
TROUBLESHOOTING...
Page 217: Reading The Text
INTRODUCTION 1-1. Reading the Text 1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward.
Page 218: Paper Transport Failure
PAPER TRANSPORT FAILURE 2-1. Paper Misfeed Detection Outline • A paper misfeed is detected by detecting different states of signals (H, L) of several sen- sors located near the paper take-up section and the Exit Paper Sensor. • The timings of the rising and falling edges of the paper take-up-related sensors and the Exit Paper Sensor are monitored to detect a misfeed of paper being fed through the copier.
Page 219 LED No. Code Misfeed/Paper Location Action Ref. Page Misfeed on paper transport path between PC1 T-11 and PC12 (3rd Tray) Misfeed on paper transport path between PC12 T-11 (3rd Tray) and PC12 (4th Tray) Misfeed on paper transport path between PC12 T-11 (4th Tray) and PC12 (5th Tray) Misfeed at the PC Drum...
Page 220: Misfeed Detection Sensor Layout
2-3. Misfeed Detection Sensor Layout PC4* PC3* PC5* PC12* PC12* PC12* PC12* Paper Path 4022T504AA Copier Symbol Name Synchronizing Roller Sensor Manual Feed Paper Sensor Exit Paper Sensor Paper Feed Cabinet (option) Symbol Name PC12* 2nd Tray Paper Take-Up Sensor PC12* 3rd Tray Paper Take-Up Sensor PC12*...
Page 221 <Resetting the Misfeed Display> Misfeed Location Resetting Procedure Misfeed in Misfeed at 1st Tray J01, Open the Right Door or slide out the copier misfeed at Multiple Bypass Tray J06, the 1st Tray, remove all sheets of misfeed at Manual Bypass Tray J06, paper misfeed and left inside, and misfeed at PC Drum J2, close the Right Door.
Page 222: Types Of Misfeed Detection And Detection Timings
2-4. Types of Misfeed Detection and Detection Timings • The following list the types of misfeed detection and detection timings for different mis- feed locations. • The symbol “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate the particular edge of the paper detected by the sensor.
Page 223: Misfeed Troubleshooting Procedures
MISFEED TROUBLESHOOTING PROCEDURES 3-1. Misfeed at Copier Paper Take-Up J01 and Misfeed at Bypass Tray J06 Relevant Electrical Parts Synchronizing Roller Sensor (PC1) Manual Bypass Solenoid (SL2) Manual Feed Paper Sensor (PC2) Multiple Bypass Solenoid (SL21) Paper Take-Up Solenoid (SL1) Master Board (PWB-A) PWB-A Master Board...
Page 224 Step Check Result Action Paper Take-Up Roll (1st Tray) is dirty, YES • Clean or change. scratchy, deformed, or worn. Paper Separator Roll (1st Tray) is YES • Clean or change. dirty, scratchy, deformed, or worn. Paper Take-Up Roll drive shaft turns •...
Page 225 Step Check Result Action Manual Bypass Solenoid (SL2) is • Change Manual Bypass Solenoid operational when the Start key is (SL2). pressed. <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND. • Voltage across PJ4A-2 and GND In standby: DC24 V When pressed: DC0 V Manual Feed Paper Sensor (PC2) is...
Page 226 Step Check Result Action Multiple Bypass Solenoid (SL21) is • Change Multiple Bypass Solenoid operational when the Start key is (SL21). pressed. <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND. • Voltage across PJ4A-2 and GND In standby: DC24 V When pressed: DC0 V Paper Take-Up Roll (Multiple Bypass...
Page 227: Misfeed At Paper Feed Cabinet Paper Take-Up And Transport Section J02, J03, J04, J05, J1
3-2. Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05, J1 (PF-121) Relevant Electrical Parts Paper Take-Up Solenoid (SL11) Master Board (PWB-A) Synchronizing Roller Sensor (PC1) Control Board (PWB-A): PF-121 Paper Take-Up Sensor (PC12) PJ6A-1(PC1 ANODE) Synchronizing PJ6A-2(GND) Roller Sensor...
Page 228 Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05, J1 (PF-121) Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. • Change paper. Paper is curled, wavy, or damp. YES •...
Page 229: Misfeed At Pc Drum J2
3-3. Misfeed at PC Drum J2 Relevant Electrical Parts Synchronizing Roller Sensor (PC1) Synchronizing Roller Clutch (CL1) Fusing Cooling Fan Motor (M3) Master Board (PWB-A) PWB-A Master Board TRANSPORT SECTION Synchronizing Roller Clutch Synchronizing Roller Senser PC1 ANODE FUSING SECTION Fusing Cooling Fan Motor 4022T523AA...
Page 230 Step Check Result Action Synchronizing Roller Sensor (PC1) is • Change Synchronizing Roller Sen- operational. sor (PC1). <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND when the sensor is blocked. • Voltage across PJ6A-3 and GND When blocked: DC5 V When unblocked: DC0 V The following voltage is supplied to...
Page 231 • Paper is at a stop at the transport section. Step Check Result Action Transport guide plate is dirty, YES • Clean or change. scratchy, deformed, worn, or dam- aged. The following voltage is supplied to YES • Change Fusing Cooling Fan Motor the Fusing Cooling Fan Motor (M3).
Page 232: Misfeed At Fusing Unit J3
3-4. Misfeed at Fusing Unit J3 Relevant Electrical Parts Exit Paper Sensor (PC3) Master Board (PWB-A) Fusing Cooling Fan Motor (M3) FUSING SECTION Fusing Cooling Fan Motor PC3 ANODE PWB-A PAPER EXIT SECTION Master Board Exit Paper Sensor 4022T511AA Misfeed at Fusing Unit J3 Troubleshooting Procedures •...
Page 233 Step Check Result Action Exit Paper Sensor (PC3) is opera- • Change Exit Paper Sensor (PC3). tional. YES • Change Master Board (copier: <Check Procedure> PWB-A). Check voltage across a Master Board (copier: PWB-A) pin and GND when the sensor is blocked. •...
Page 234: Malfunction
MALFUNCTION The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Display. 4-1. Detection Timing by Malfunction Code Code Description Detection Timing C0000 Main Motor malfunc- • The Main Motor (M1) Lock signal remains HIGH for a tion continuous 1-sec.
Page 235 Code Description Detection Timing C0650 Faulty Scanner Home • The Scanner Home Position Sensor (PC6) does not Position Sensor go from HIGH to LOW when the Scanner Motor (M5) is energized for a given number of steps after the sequence to bring the Scanner back to its home posi- tion has been started at the end of a scan motion and during re-shading.
Page 236 Code Description Detection Timing C0B60 Bin Switching Motor If both the Upper Home Position Sensor and the Lower malfunction Home Position Sensor are HIGH during an initial opera- tion: • If the Lower Home Position Sensor (PC33) does not go LOW at a time 2.5 sec. after the Bin Switching Motor (M1) has started turning forward, the Bin Switching Motor is kept deenergized for a given period of time and then energized again to turn back-...
Page 237 Code Description Detection Timing C1200 Faulty ASIC/memory ASIC/memory (for image and control) fault • A write or read error occurs with SRAM on the Control Board (PWB-C). C1300 Polygon Motor mal- Startup failure function • A LOW Polygon Motor (M2) Lock signal is not detected within a given period of time that begins 1 sec.
Page 238: Resetting Procedure By Malfunction Code
4-2. Resetting Procedure by Malfunction Code Code Description Resetting Procedure C0000 Main Motor malfunction • Turn OFF and ON the Power Switch. C0045 Fusing Cooling Fan Motor mal- function C004E Power Supply Cooling Fan Motor malfunction C0070 Toner Replenishing Motor mal- function C0210 Abnormal image transfer voltage...
Page 239: Troubleshooting Procedures By Malfunction Code
4-3. Troubleshooting Procedures by Malfunction Code C0000: Main Motor malfunction Relevant Electrical Parts Main Motor (M1) Master Board (copier: PWB-A) PWB-A Master Board PJ7A Main Motor 4022T525AA Step Check Result Action Main Motor (M1) turns when the Start • Check for overload. key is pressed.
Page 240: C0045: Fusing Cooling Fan Motor Malfunction
C0045: Fusing Cooling Fan Motor malfunction Relevant Electrical Parts Fusing Cooling Fan Motor (M3) Master Board (copier: PWB-A) PWB-A Master Board FUSING SECTION Fusing Cooling Fan Motor 4022T526AA Step Check Result Action Fusing Cooling Fan Motor (M3) turns • Check for overload. when the Power Switch is turned ON.
Page 241: C004E: Power Supply Cooling Fan Motor Malfunction
C004E: Power Supply Cooling Fan Motor malfunction Relevant Electrical Parts Power Supply Cooling Fan Motor (M4) Master Board (copier: PWB-A) PWB-A Master Board POWER SUPPLY SECTION Power Supply Cooling Fan Motor 4022T527AA Step Check Result Action Power Supply Cooling Fan Motor •...
Page 242: C0070: Toner Replenishing Motor Malfunction
C0070: Toner Replenishing Motor malfunction Relevant Electrical Parts Toner Replenishing Motor (M6) Master Board (copier: PWB-A) Toner Bottle Home Position Sensor (PC7) PWB-A Master Board DEVELOPING SECTION Toner Replenishing Motor Toner Bottle Home PC7 ANODE Position Sensor 4022T528AA Step Check Result Action The coupling of the Toner Hopper...
Page 243: C0210: Abnormal Image Transfer Voltage
C0210: Abnormal image transfer voltage Relevant Electrical Parts High Voltage Unit (HV1) Master Board (copier: PWB-A) DEVELOPING SECTION PWB-A Master Board High Voltage Unit Developing Bias P.C/I.T._REM Not Use I.T.Control Image Transfer I.T.Voltage Monitor P.C/I.T._REM VG Voltage I.T.Control I.T.Voltage Monitor Charge Neutralizing Cloth Photo Conductor 4022T529AA...
Page 244: C0500: Warm-Up Failure C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature
C0500: Warm-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Fusing Heater Lamp (H1) Fusing Unit Interlock Switch (S2) Thermistor (TH1) DC Power Supply (PU1) Thermoswitch 1 (TS1) Master Board (copier: PWB-A) Thermoswitch 1 (TS2) PWB-A Master Board Not Use...
Page 245 Step Check Result Action Fusing Unit Interlock Switch (S2) is • Change Fusing Unit Interlock operational. Switch (S2). <Check Procedure> YES • Change DC Power Supply (PU1). Check continuity across terminals when the Fusing Unit Interlock Switch (S2) is turned ON. •...
Page 246: C0650: Faulty Scanner Home Position Sensor
C0650: Faulty Scanner Home Position Sensor Relevant Electrical Parts Scanner Motor (M5) Control Board (copier: PWB-C) Scanner Home Position Sensor (PC6) PWB-C IR SECTION Contorol Board PWB-A Scanner Master Moter Board Scanner Home Position Sensor 4022T531AA Step Check Result Action Scanner Motor (M5) turns when the •...
Page 247: C0B60: Bin Switching Motor Malfunction
C0B60: Bin Switching Motor malfunction Relevant Electrical Parts Bin Switching Motor (IT-102: M1) Main Board (IT-102: PWB-A) Upper Home Position Sensor (IT-102: PC32) Master Board (copier: PWB-A) Lower Home Position Sensor (IT-102: PC33) IT-102 PWB-A PWB-A Master Main Board Board Bin Switching Motor Upper Home...
Page 248 Step Check Result Action Lower Home Position Sensor (IT-102: • Change Lower Home Position Sen- PC33) is operational. sor (PC33). <Check Procedure> YES • Change Master Board (copier: Check voltage across a Main Board PWB-A). (IT-102: PWB-A) pin and GND when the sensor is blocked.
Page 249: C0B80 Shift Motor Malfunction
C0B80 Shift Motor malfunction Relevant Electrical Parts Shift Motor (IS-101: M1) Main Board (IS-101: PWB-A) Home Sensor (IS-101: S31) Master Board (copier: PWB-A) IS-101 PWB-A PWB-A Master Main Board Board IS-101 CN55 Shift Motor PJ3A PJ58 S31 ANODE Home Sensor S31 ON Not Use 4022T536AA...
Page 250: C0F32: Faulty Atdc Sensor C0F33: Improperly Adjusted Atdc Sensor
(10) C0F32: Faulty ATDC Sensor C0F33: Improperly adjusted ATDC Sensor Relevant Electrical Parts ATDC Sensor (UN1) Master Board (copier: PWB-A) PWB-A Master Board DEVELOPING SECTION ATDC Sensor 4022T533AA Step Check Result Action Developer is not even in the Devel- YES • Gently swing the IU in the horizon- oper Mixing Chamber.
Page 251: (11) C1038: Engine Connection Failure
(11) C1038: Engine connection failure Relevant Electrical Parts Master Board (copier: PWB-A) Control Board (copier: PWB-C) Step Check Result Action C1038 reappears when the copier is YES • Go to step 2. turned OFF and ON again. <Check Procedure> Turn OFF and ON the Power Switch to check to see if C1038 reappears.
Page 252: C1300: Polygon Motor Malfunction (Startup Failure, Lock Signal Failure, Faulty Lock Signal) C13F0: Faulty Hsync
(13) C1300: Polygon Motor malfunction (startup failure, Lock signal failure, faulty Lock signal) C13F0: Faulty HSYNC Relevant Electrical Parts Polygon Motor (M2) Master Board (copier: PWB-A) PWB-A Master Board IR/PH SECTION Polygon Motor 4022T534AA Step Check Result Action C1300/C13F0 reappears when the YES •...
Page 253: (14) C1468: Faulty Eeprom
(14) C1468: Faulty EEPROM Relevant Electrical Parts Control Board (copier: PWB-C) Step Check Result Action C1468 reappears when the copier is YES • Go to step 2. turned OFF and ON again. <Check Procedure> Turn OFF and ON the Power Switch to check to see if C1468 reappears.
Page 254: (15) C14A3: Ir Fluorescent Lamp Fault
(15) C14A3: IR fluorescent lamp fault Relevant Electrical Parts Exposure Lamp (LA2) Control Board (copier: PWB-C) Inverter Board (copier: PU2) IR SECTION PWB-C PWB-J Control Board Not Use Not Use Inverter Board Exposure Lamp Not Use Not Use 4022T535AA T-38...
Page 255 Step Check Result Action Exposure Lamp turns ON when the • Go to step 3. Power Switch is turned ON. Exposure Lamp is abnormally lit • Go to step 4. (flickers or abnormally dark) when the Power Switch is turned ON. Inverter Board (copier: PU2) connec- YES •...
Page 256: (16) The Copier Does Not Turn On
(16) The copier does not turn ON. Relevant Electrical Parts Power Switch (S1) Fuse (F3) DC Power Supply (PU1) Control Board (copier: PWB-C) Control Panel (UN2) Master Board (copier: PWB-A) 4022T545AA Step Check Result Action A malfunction code appears when YES •...
Page 257 Step Check Result Action Power supply voltage check • Check wall outlet for volt- <Check Procedure> age. Check voltage across pins of DC Power Sup- • Check power cord for con- ply (PU1) when the Power Switch is turned tinuity. •...
Page 258: Image Failure
IMAGE FAILURE 5-1. Image Failure Troubleshooting • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.
Page 259 • Determine if the failure is attributable to an input system (IR) or output system (engine). Check Result Action Copy made at a reduced Full-size copy Reduced copy ratio. Input system Original 1177T04YA Full-size copy Reduced copy 1177T03YA Output system 1177T05YA T-43...
Page 260: Image Failure Samples
5-3. Image Failure Samples 1. Blank copy 2. Black copy 3. Low image density 4. Foggy background or rough 5. Black streaks or bands 6. Black spots image 7. Blank streaks or bands 8. Void areas 9. Smear on back 12.
Page 261: Troubleshooting Procedures By Image Failure
5-4. Troubleshooting Procedures by Image Failure Blank copy Section Step Check Result Action Output system Imaging Unit is installed correctly. • Reinstall. Connector between the Imaging YES • Clean. Unit and copier is dirty. PH Shutter (located along the YES • Correct or reinstall. laser path between the PH Unit and PC Drum) is not in correct position or malfunctions.
Page 262: Black Copy
Black copy Section Step Check Result Action Output PC Drum Charge Corona grid mesh and YES • Reinstall. system Comb Electrode are loose. PC Drum Charge Corona contact is dirty, YES • Correct or change. scratchy, folded, bent, or damaged. Grid bias contact is dirty, folded, or bent.
Page 263: Low Image Density
Low image density Section Step Check Result Action Output Image density changes after “Toner YES • Replenish the supply of system Replenisher” has been run. toner using “Toner • “Toner Replenisher” of Utility Replenisher.” Image density changes after “ID Adjust- YES •...
Page 264 Section Step Check Result Action Input Shading sheet reading portion (the por- YES • Clean. system tion on the backside of the Original Glass to which Original Width Scale is affixed) is dirty. CCD Board (copier: PWB-J) connector YES • Reconnect. is loose.
Page 265: Foggy Background Or Rough Image
Foggy background or rough image Section Step Check Result Action Output Image condition changes after “ID YES • Readjust. system Adjustment” and “VG Adjustment” have For more details, see been made. SWITCHES ON PWBs/ TECH. REP. SET- TINGS. PC Drum surface and the areas in con- YES •...
Page 266 Section Step Check Result Action Input Exposure Lamp is abnormally lit (flickers • Go to step 7. system or abnormally dark) when the Start key is pressed. Inverter Board (copier: PU2) connector YES • Reconnect. CN1PU2 is loose. • Change Exposure Lamp (LA2).
Page 267: Black Streaks Or Bands
Black streaks or bands Section Step Check Result Action Output PC Drum is dirty or scratchy. YES • Clean or change. system Foreign matter (such as paper dust) YES • Remove foreign mat- sticks to the Cleaning Blade of IU or the ter, correct, or change.
Page 268: Black Spots
Black spots Section Step Check Result Action Output Toner is present along the paper path. YES • Clean. system PC Drum is dirty or scratchy. YES • Clean or change. Tip of the PC Drum Paper Separator YES • Clean or change. Finger is dirty, scratchy, deformed, worn, or damaged.
Page 269: Blank Streaks Or Bands
Blank streaks or bands Section Step Check Result Action Output PC Drum ground terminal is dirty, YES • Clean, correct, or system scratchy, deformed, or damaged. change. DB of IU is plugged with foreign matter YES • Remove foreign matter. (such as paper dust).
Page 270: Void Areas
Void areas Section Step Check Result Action Output Foreign matter is present along the YES • Remove foreign matter. system paper path. Paper dust plugs up the Paper Dust YES • Clean or change. Remover. PC Drum Charge Corona, grid mesh, YES •...
Page 271: Smear On Back
Smear on back Section Step Check Result Action Output Toner is spilled over area inside copier. YES • Clean interior. system Toner is present along the paper path. YES • Clean. Right Fusing Roller is dirty, scratchy, or YES • Clean or change. damaged.
Page 272: (10) Uneven Image Density
(10) Uneven image density Section Step Check Result Action Output PC Drum ground plate is dirty, scratchy, YES • Clean, correct, or system deformed, worn, or damaged. change. PC Drum Charge Corona grid mesh and YES • Clean, correct, or Comb Electrode are dirty, scratchy, change.
Page 273 Section Step Check Result Action Input Control Board (copier: PWB-C) connec- YES • Reconnect. system tor PJ1A is loose. • Change CCD Unit. • Change Control Board (copier: PWB-C). T-57...
Page 274: (11) Gradation Reproduction Failure
(11) Gradation reproduction failure Section Step Check Result Action Output PC Drum is dirty. YES • Clean. system Image Transfer Roller is dirty, scratchy, YES • Clean or change. deformed, worn, or damaged. PH Unit connectors PJ12A and PJ13A are YES •...
Page 275: (12) Periodically Uneven Image
(12) Periodically uneven image Section Step Check Result Action Output IU is securely fastened using the dedi- • Secure in position. system cated fixing screws. PH Unit is securely fastened using the • Secure in position. dedicated fixing screws. IU drive mechanism is dirty or damaged. YES •...
Page 276: Other Error Codes
OTHER ERROR CODES • When an error that does not fall into the category of paper transport failure or malfunc- tion, a corresponding error code is displayed in the Display. 4022T503AA Code Description Resetting Procedure Toner empty stop • Change Toner Bottle. Paper size is physically changed of •...
Page 277 Code Description Resetting Procedure Plug-In Counter not plugged in • Plug in the Plug-In Counter. • Change setting in Security mode. For details, see SWITCHES ON PWBs/TECH. REP. SETTINGS. A numeral outside the specified set- • Automatically reset 1 sec. after the ting range is entered.
Page 278 T-62...
Page 279: Service/Adjustment Item List
Service/Adjustment Item List Tech.Rep.Mode Adjust Mode Mechanical Others Function Tech.Rep.Choice Counter Adjustment/Setting Items Note Service Items Check Items Paper Take-Up Roll (1st Tray) Replace * Check when setting is changed. Paper Take-Up/Transport Section Paper Separator Roll Assy (1st Tray) Replace * Check when setting is changed.
Page 280: Electrical Parts Layout
SYMBOL PART NAME LOCATION GRID Synchronizing Roller Clutch CNT1 Total Counter (Option) 17-I — ELECTRICAL PARTS LAYOUT CNT2 Key Counter (Option) 17-I — Fusing Heater Lamp 4~6-C~D High Voltage Unit 4~5-C~D 3~4-D~E Main Erase 4~5-A 5~6-D~E Exposure Lamp 11-F 2~4-C~D Job Tray (IT-102) Main Motor 16~17-G...
Page 281: Connector Layout
CN No. LOCATION GRID 11-I 2~3-F CONNECTORS LAYOUT 11-G CN11 CN12 Job Tray (IT-102) CN13 3~4-D CN14 CN15 2-C~D 4-C~D CN16 CN17 CN18 CN19 16-I CN20 16-I 6-C~D CN17 CN16 CN20 CN21 CN15 CN27 CN19 CN22 CN56 CN23 11-I 4-F~G CN14 CN24 CN13...
Page 282: Wiring Diagrams
WIRING DIAGRAMS...

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7118

Konica Minolta 7115 Service Manual

Table of Contents

1 Specification

2 Precautions for Installation

3 Precautions for Use

4 Handling of Consumables

5 Other Precautions

6 System Options

Table of Contents

1 Cross Sectional View

2 Copy Process

3 Drive System

4 Sequential Explanation

5 Watchdog Function (Cpu Overrun Monitor

6 Image Stabilization System

7 Imaging Unit (I/U

8 Pc Drum Section

9 Pc Drum Charging Section

10 Image Reading Section

11 Memory Storage Image Processing System

12 Developing Unit Section

13 Paper Take Up/Feed Section

14 Manual Bypass Section

15 Multiple Bypass Section

16 Image Transfer and Paper Separation Section

17 Pc Drum Cleaning Section

18 Main Erase Section

19 Fusing Unit Section

20 JOB TRAY (IT-102): Option

21 SHIFTING UNIT (IS-101): Option

22 Other Mechanism

Table of Contents

Dis/Reassembly, Adjustment

SWITCHES on Pwbs, TECH. REP. SETTINGS

Troubleshooting

Quick Links

SERVICE MANUAL

Chapters

Troubleshooting

Related Manuals for Konica Minolta 7115

Summary of Contents for Konica Minolta 7115