Konica 1216 Service Manual ecsw

1216

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SERVICE HANDBOOK

May. 1998

Ver. 1.0

KONICA CORPORATION

TECHNOLOGY SUPPORT CENTER

TOKYO JAPAN

SERVICE HANDBOOK NOTICE

The Konica 1216 Service handbook has just been
issued. This model is a derivative of the Konica 2223.
Also, this service handbook includes only the
differences between the 2223 and 1216, and the items
that have been changed. Refer to the 2223 Service
handbook for items not included in this new service
handbook.

CONTENTS

INDEX

SAFETY AND IMPORTANT WARNING ITEMS ..... C-1

IMPORTANT NOTICE ....................... C-1

DESCRIPTION ITEMS FOR DANGER, WARNING
AND CAUTION

SAFETY WARNINGS ........................ C-2

SAFETY INFOMATION ...................... C-4

IMPORTANT INFOMATION ................... C-4

SAFETY CIRCUITS ........................................................ C- 5

INDICATION OF WARNING ON THE MACHINE ......

.... C-1

C-7

1. LIST OF DIFFERENCE

LIST OF MAIN DIFFERENCE BETWEEN........1-1

THE K-2223 AND K-1216

2. OPERATION

OPERATION PANEL ........................................2-1

3. MAIN BODY

SYSTEM OUTLINE...........................................3-1

PRODUCT SPECIFICATIONS .........................3-2

[1] Type .............................................................3-2

[2] Functions .....................................................3-2

[3] Copy Paper ..................................................3-2

[4] Options.........................................................3-2

[5] Particulars of Machine .................................3-3

[6] Maintenance ................................................3-3

[7] Copy Materials .............................................3-3

[8] Machine Operating Environment .................3-3

4. DIAGRAMS

1216 OVERALL WIRING DIAGRAM ................4-1

OPERATION BOARD CIRCUIT DIAGRAM......4-2

1216 TIME CHART (A4, Life size, 2 Sheets)....

5. ADJUSTMENT

HOW TO USE THIS SECTION.........................5-1

ADJUSTMENTS WHEN REPLACING PARTS ....

ADJUSTMENTS WITH THE P BUTTON..........5-3

[1] P Function List .............................................5-3

[2] P Function Operating Procedures................5-3

[3] Checking the Total/Copy Count ...................5-3

[4] Setting and Checking the Developing

Bias Shift......................................................5-3

[5] Checking and Resetting the PM Count........5-4

[6] Checking and Resetting the Drum Count ....5-4

[7] Checking the ROM Version .........................5-4

[8] Checking the Count Data in the Service

Management Mode ......................................5-4

4-5

5-1

6. DIAGNOSTICS

25 MODE ..........................................................6-1

[1] Setting procedures.......................................6-1

[2] 25 Mode Address Map.................................6-2

47 MODE ..........................................................6-7

[1] Setting the 47 Mode.....................................6-7

[2] Input/Output Check List ...............................6-8

7. SERVICE

SERVICE SCHEDULE......................................7-2

[1] Service Schedule .........................................7-2

[2] Maintenance Items.......................................7-3

[3] Periodic Check Service Items ......................7-8

COPY MATERIALS ........................................7-10

[1] Toner Kit ....................................................7-10

[2] PM Parts Kit ...............................................7-10

[3] Maintenance Kit .........................................7-11

SERVICE MATERIALS...................................7-12

SPECIAL TOOLS............................................7-13

IMPORTANT SAFETY INFORMATION AND WARNINGS

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SAFETY AND IMPORTANT WARNING ITEMS

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

IMPORTANT NOTICE

Because of possible hazards to an inexperienced person servicing this equipment, as well as the risk of
damage to the equipment, Konica Corporation, strongly recommends that all servicing be performed only
by Konica-trained service technicians.

Changes may have been made to this equipment to improve its performance after this service handbook
was printed. Accordingly, Konica Corporation, makes no representations or warranties, either expressed
or implied, that the information contained in this service handbook is complete or accurate. It is under­stood that the user of this service handbook must assume all risks or personal injury and/or damage to
the equipment while servicing the equipment for which this service handbook is intended.
Therefore, this Service Handbook must be read carefully before doing service work both in the course of
the technical training and even after that, for keeping the correct maintenance and control of the copying
machine. Keep the Service Handbook also for the future service. When it is impossible to read the
description about safety and warning (due to contamination or tear), the relevant page should be re­placed.

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

In this Service Handbook, each of three expressions, “ DANGER”, “ WARNING” and “ CAU­TION” is defined as follows together with a symbol mark to be used in a limited meaning.
When servicing, the relevant works (disassembling, assembling, adjustment, repair and maintenance)
need to be conducted with utmost care.

DANGER: Actions having a high possibility of suffering death or serious

wound
WARNING: Actions having a possibility of suffering death or serious wound
CAUTION: Actions having a possibility of suffering a slight wound, medium

trouble and material damage

C - 1

IMPORTANT SAFETY INFORMATION AND WARNIN\GS

SAFETY WARNINGS

[1] MODIFICATIONS NOT AUTHORIZED BY

Konica

Konica copiers are renowned for their high reliability. This
reliability is achieved through high-quality design and a solid
service network.

Photocopier design is a highly complicated and delicate pro­cess where numerous mechanical, physical, and electrical
aspects have to be taken into consideration, with the aim of
arriving at proper tolerances and safety factors. For this rea­son, unauthorized modifications involve a high risk of degrad­ing performance and safety. Such modifications are therefore
strictly prohibited. The points listed below are not exhaustive,
but they illustrate the reasoning behind this policy.

PROHIBITED ACTIONS :

(1) Using extension cables or a different power cord than

specified by Konica.

(2) Using other fuses than specified by Konica. Safety will

not be assured, leading to a risk of fire and injury.

(3) Disabling fuses or bridging fuse terminals with wire,

metal clips, solder or similar. (This applies also to

thermal fuses.)
(4) Removing air filters (except for replacement).
(5) Disabling relay functions (such as wedging paper

between relay contacts, etc.).
(6) Disabling safety functions (interlocks, safety circuits,

etc.). Safety will not be assured, leading to a risk of fire

and injury.
(7) Performing actions to copier not described in the

instruction manual or the service handbook.
(8) Using parts other than specified by Konica.

[2] CHECKPOINTS WHEN PERFORMING

ON-SITE SERVICE

Konica copiers are extensively tested before shipping, to
ensure that all applicable safety standards are met, in order to
protect the customer and customer engineer from the risk of
injury. However, in daily use, any electrical equipment will be
subject to parts wear and eventual failure. In order to maintain
safety and reliability, the customer engineer must perform
regular safety checks.

CAUTION:

(1) Wear clothing that facilitates work and is designed for

safety.
(2) Carry out all procedures carefully to prevent injury.
(3) Be sure to disconnect the power cord of the copier and

all optional equipment from the AC outlet.

Simply turning off the power switch is not sufficient,

because paper feed units or other electrical equip-

ment may be powered also when the power switch is

turned off.
(4) Proceed with special care when performing operation

checks or adjustment while the unit is powered. When

carrying out operation checks or adjustment while

external covers are removed, the risk of electrical

shock exists when touching parts which carry high

voltage or electrical charge. The risk of injury exists

when touching moving parts such as gears or chains.

The following list is not exhaustive, but it includes actions which
must be carried out at every service call.

CAUTION:

(1) Check external covers and the frame for sharp edges,

burrs, or nicks.
(2) Check external covers and hinges for loosening or

damage.
(3) Check wiring for squeezing or damage.
(4) Check power cord for insulation problems (conductor

must not be exposed).
(5) Check power cord and cable ties etc. for loosening

from frame.

WARNING:

(1) Verify that the copier is properly grounded. If a prob-

lem is detected, establish a proper ground connec-

tion.
(2) Connecting the ground lead to an improper point such

as listed below results in a risk of explosion and

electric shock.

Unsuitable ground points:

- Gas pipe

- Lightning rod

- Telephone line ground

- Plastic water pipe or water pipe or faucet that has
not been approved by authorities for grounding use

C - 2

IMPORTANT SAFETY INFORMATION AND WARNINGS

[3] PRECAUTIONS FOR ON-SITE SERVICE

CAUTION:

(1) Before performing maintenance work, read all rel-

evant documentation (service handbook, technical
notices, etc.) and proceed according to the prescribed
procedure, using only the prescribed tools. Do not
carry out any adjustments not described in the docu­mentation.

(2) If the power cord is damaged, replace it only with the

specified power cord. If the power cord insulation has
been damaged and there are exposed sections, short­circuits and overheating may occur, leading to a
serious fire risk.

(3) Do not route the power cord so that it can be stepped

on or pinched. Otherwise overheating may occur,
leading to a serious fire risk.

(4) When disconnecting any cables, always grasp the

connector and not the cable (especially in the case of
AC and high-voltage leads).

(5) Carefully remove all toner remnants from electrical

parts, electrodes, etc.

(6) Make sure that wiring cannot come into contact with

sharp edges, burrs, or other pointed parts.

(7) Double-check to make sure that all screws, compo-

nents, wiring, connectors, etc. that were removed for
maintenance have been reinstalled in the original
location. (Pay special attention to forgotten connec­tors, pinched cables, forgotten screws, etc.)

(8) When installation and preventive maintenance, verify

that the power cord has been securely plugged into
the AC outlet. Contact problems may lead to increased
resistance, overheating, and the risk of fire.

WARNING:

(1) Danger of explosion if battery is incorrectly replaced,

replace only with the same or equivalent recommended
by the manufacturer. Discard used batteries accord­ing to the manufacture's instructions.

VORSICHT:

(1) Expiosionsgefahr dei unsachegemäßem Austausch

der Battetie. Ersatz nur durch denselben oder einen
vom. Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des
Herstellers.

(1) Disconnect the power cord from the AC outlet.
(2) Use only a small amount of cleaner at a time and take

care not to spill any liquid. If this happens, immedi­ately wipe it off.

(3) Perform cleaning only in an environment where suffi-

cient ventilation is assured. Breathing large quanti­ties of organic solvents can lead to discomfort.

(4) Do not replace the cover or turn the unit on before any

solvent remnants on the cleaned parts have fully
evaporated.

CAUTION: Toner and developer are not harmful sub-

stances, but care must be taken not to
breathe excessive amounts or let the sub­stances come into contact with eyes etc.
If this happens, immediately rinse with
eye wash and plenty of water, and consult
a physician.

[5] MEASURES TO TAKE IN CASE OF AN

ACCIDENT

(1) If an accident has occurred, the distributor who has been

notified first must immediately take emergency measures
to provide relief to affected persons and to prevent further
damage.

(2) If a report of a serious accident has been received from a

customer, an on-site evaluation must be carried out quickly
and Konica Corporation must be notified.

(3) To determine the cause of the accident, conditions and

materials must be recorded through direct on-site checks,
in accordance with instructions issued by Konica Corpora­tion.

[6] CONCLUSION

Safety of users and customer engineers has topmost priority,
ranking even higher than operability. Safety depends on a
appropriate maintenance work and is maintained by proper
daily service work conducted by customer engineers. When
performing service, each copier on the site must be tested for
safety. The customer engineer must verify the safety of parts
and ensure appropriate management of the equipment.

[4]

HANDLING OF MATERIALS FOR SERVIC­ING

CAUTION: Drum cleaner (alcohol-based) and roller

cleaner (acetone- based) are highly flam­mable and must be handled with care.
When using these materials for cleaning
of copier parts, observe the following pre­cautions.

C - 3

IMPORTANT SAFETY INFORMATION AND WARNIN\GS

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SAFETY INFORMATION

IMPORTANT INFORMATION

The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration
implemented regulations for laser products manufactured since August 1, 1976. Compliance is manda­tory for products marketed in the United States.

This copier is certified as a "Class 1" laser product under the U.S.
Department of Health and Human Services (DHHS) Radiation Performance Standard according to the
Radiation Control for Health and Safety Act of 1968. Since radiation emitted inside this copier is com­pletely confined within protective housings and external covers, the laser beam cannot escape during
any phase of normal user operation.

C - 4

SAFETY CIRCUITS

IMPORTANT SAFETY INFORMATION AND WARNING

The electrical circuit of this machine contains the following
safety circuits to prevent an accident from occurring in the event
of an abnormality.

[1] Overall safety circuit protector
[2] L1 (exposure lamp) overheating protection circuit
[3] L2 (fixing heater lamp) overheating protection circuit

The following explanations are provided to prevent service
engineers from unintentionally disabling the safety circuits.

[1] Overall Safety Circuit Protector

PSB

MS1

CBR1

CBR2

1. Protection function provided by CBR (circuit
breaker)

This function breaks the AC line instantaneously in the
event that there is excessive current flow due to a short
between the AC lines, for example.

Caution: The function of CBR must not be deacti-

2. Protection function provided by LBR (current
leakage detecting circuit)

This function turns RL1 and RL2 (main relays) OFF and
breaks the AC line instantaneously in the event that leakage
current flows due to a ground short in one side of the AC line,
for example.

Caution: The function of LBR must not be deacti-

RL1

RL1

LBR

RL2

RL2

vated under any circumstances.

vated under any circumstances.

NF

[2] L1 (Exposure Lamp) Overheating

Protection Circuit

PSB

AC

RL1

RL1

CVR

CB

(H. T.)

L1 CONT

L1 ACK

AC

RL2

RL2

1. Protection function provided by software

When the L1 CONT signal output from the protection
function by software on the CB (control board) becomes [L],
L1 lights. Simultaneously, the L1 ACK signal, which indi­cates that L1 is lit, is output from the CVR on the PSB (power
supply board) to the CB.
The CB monitors both the L1 CONT and L1 ACK signals. If
they differ from each other, RL1 and RL2 (main relays) will
be turned OFF and power to L1 will be cut off.

Caution: The function of RL1 and RL2 must not be

deactivated under any circumstances.

2. Protection function using HT (Hardware Timer
circuit)

If L1 remains lit for more than approximately 15±5 seconds
because of some abnormality, the hardware timer on the
CVR in the PSB will operate, forcibly cutting off RL1 and
RL2.

Caution: The function of RL1 and RL2 must not be

deactivated under any circumstances.

3. Protection function using f1 (optics temperature
fuse)

If the temperature in the vicinity of f1 rises above 169°C, f1
will blow, cutting off the flow of current to L1.

Caution: Do not use a piece of wire in place of f1

under any circumstances.

f1

L1

C - 5

IMPORTANT SAFETY INFORMATION AND WARNING

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[3] L2 (Fixing Heater Lamp) Overheating

Protection Circuit

CB

TH1

Comparator
Section

RL1

RL2

TH2

TS1

L2

PSB

TRC

RL1

RL2

Control
Section

1. Protection function provided by software

This function turns OFF L2 (fixing heater lamp), RL1, and
RL2 (main relays) in the event that the output voltage from
TH1 (fixing temperature sensor 1), read by the CB (control
board), is abnormal.

Caution: Periodically check the surfaces of TH1 and

TH2 that contact the roller, and replace
them if they are abnormal.
The function of RL1 and RL2 must not be
deactivated under any circumstances.

2. Protection function provided by hardware

This function uses a comparator circuit which compares the
output voltage of TH1 and TH2(fixing temperature sensor 2)
with the abnormal judgment reference value.
It disconnects L2, RL1, and RL2 from the circuit in the event
that the output voltage of TH1 or TH2 exceed the reference
value.

3. Protection function using TS1 (Thermostat)

If the surface temperature of the upper fixing roller exceeds
a specified value, TS1 will blow, directly cutting off the flow
of current to L2.

Caution: Periodically check the surfaces of TH1 and

TH2 that contact the roller, and replace
them if they are abnormal.
The function of RL1 and RL2 must not be
deactivated under any circumstances.

Caution: Do not use a piece of wire in place of TS1

under any circumstances.

C - 6

IMPORTANT SAFETY INFORMATION AND WARNING

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INDICATION OF WARNING OF THE MACHINE

In the machine, each unit shown below is provided with a label of caution or warning concerning safety. In the case of maintenance,
repair and adjustment of the machine, take good care in doing work so that a burn or an electric shock may be avoided.

Copier with ST-104

Label 5

Label 2

Label 1

Label 1

CAUTION
ATTENTION
VORSICHT

HIGH TEMPERATURE

TEMPERATURE ELEVEE

HEISS

TAKE CARE WHEN REMOVING JAM

SOYEZ PRUDENT EN RETIRANT

UNE FEUILLE COINCEE

Bitte Vorsicht bei Entfernen von Papierstau

Label 2

CAUTION
ATTENTION
VORSICHT

Label 3

HIGH VOLTAGE CAUTION
VORSICHT HOCHSPANNUNG
CAUTION HAUTE TENTION

HIGH TEMPERATURE

TEMPERATURE ELEVEE

HEISS

TAKE CARE WHEN REMOVING JAM

SOYEZ PRUDENT EN RETIRANT

UNE FEUILLE COINCEE

Bitte Vorsicht bei Entfernen von Papierstau

Label 4

Label 5

To avoid injury, keep figners away from the staple unit.
Pour éviter toute blessure, ne pas mettre les doigts dans l’agrafeuse.

Label 3

Label 4

CAUTION

This internal area is very hot.
To avoid getting burned
DO NOT TOUCH.

CAUTION

This area generates high voltage.
To avoid an electrical shock
DO NOT TOUCH.

CAUTION

DO NOT INSERT your finger into staple
drive poartion, otherwise you may
cause injury.

CAUTION

You may be burned or injured if you touch any area that you are advised by any caution label
to keep yourself away from.
Do not remove caution labels. If any caution label or caution indicator is soiled, clean the label.
If you cannot make it legible or if the caution label is removed, please contact your Service Centre.

C - 7