KONICA 7415 SERVICE HANDBOOK
7415
SERVICE HANDBOOK
FIELD SERVICE
KONICA CORPORATION
TECHNOLOGY SUPPORT CENTER
TOKYO JAPAN
INDEX (FIELD SERVICE)
DIS/REASSEMBLY,
ADJUSTMENT
SWITCHES ON PWBs,
TECH. REP. SETTINGS
TROUBLESHOOTING
SAFETY AND IMPORTANT WARNING ITEMS
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 copier, as well as the risk
of damage to the copier, Konica Corporation, strongly recommends that all servicing be performed only by Konica-trained service technicians.
Changes may have been made to t his copier to improv e i ts perf ormance 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 copier while servicing the copier 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 copier. 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 mean-
ing. When servicing, the relevant works (disassembling, assembling, adjustment, repair and
maintenance) need to be conducted with utmost care.
DANGER:
WARNING:
CAUTION:
Actions having a high possibility of suffering death or serious wound
Actions having a possibility of suffering death or serious wound
Actions having a possibility of s uffering a slight wound, medium trouble
and material damage
C-1
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHO-
RIZED 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 termi-
nals with wire, metal clips, s older or
similar. (This applies also to thermal
fuses.)
(4) Removing air filters (except for
replacement).
(5) Dis a bling relay fun ctions (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) Performi ng actions to copier not
described in the instruction manual or
the service handbook.
(8) Usi ng pa rts othe r than specified by
Konica.
[2] CHECKPOINTS WHEN PER-
FORMING ON -S I T E SE RVICE
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 may be subject to parts wear and
eventual failure. In order to maintain safety
and reliability, the customer engineer must
perform regular safety checks.
1. Advance Preparation for
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 equipment may
be powered also when the power
switch is turned of f.
(4) Proceed with special care when per-
forming 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 touc hing parts which c arry
high voltage or electrical charge. The
risk of injury exists when touching
moving parts such as gears or chains.
C-2
SAFETY AND IMPORTANT WARNING ITEMS
2. Safety Checkpoints
The following list is not exhaustive, but it
includes actions which must be carried out at
every on-site service.
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 insulatio n prob-
lems (conductor m us t 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 problem is detected,
establish a proper ground connection.
(2) Connecting the ground lead to an
improper point such as listed below
results in a risk of explosion and elec-
tric shock.
Unsuitable ground points:
a. Gas pipe
b. Lightning rod
c. Telephone line ground
d. Plastic water pipe or water pipe or
faucet that has not been approved
by authorities for grounding use
3. Precautions for on-site service
CAUTION:
(1) Before performing safety check work,
read all relevant documentation (ser-
vice handbook, technical notices, etc.)
and proceed according to the pre-
scribed procedure, using only the pre-
scribed tools. Do not carry out any
adjustments not described in the docu-
mentation.
(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 sec-
tions, short-circuits 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 pinc he d. 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, components, wiring, connectors, etc. that were removed for safety
check maintenance have been reinstalled in the original loc a tion. (Pa y
special attention to forgotten connectors, pinched cables, forgotten scre ws,
etc.)
(8) When installation and preventive main-
tenance, 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) Bef ore disassembling or adjusting the
optical unit or any parts that use a
laser, make sure that the power cord
has been disconnected.
(2) Do not remove the main cover of the
write unit. Direct exposure of the eye to
laser beams may lead to blindness.
(3) Do not turn the copier on while the
write unit is not install e d in its normal
position.
(4) Da nger of explosion if bat ter y is inc or -
rectly replaced, replace only with the
same or equivalent recommended by
the manufacturer. Discard used batteries according to the manufacture’s
instructions.
C-3
SAFETY AND IMPORTANT WARNING ITEMS
VORSICHT:
Expiosionsgefahr dei unsachegemäßem
Austausch der Battetie. Ersatz nur durch
denselben oder einen vom. Hersteller empfohlenen gleichwertigen Typ. Entsorgung
gebrauchter Batterie n na c h Angaben des
Herstellers.
[3] 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.
(1) Disconnect the power cord from the A C
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 enviro n-
ment where sufficient 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 deve lo per are not harmful substances, but care must be taken not to
breathe excessive amounts or let the substances come into contact with eyes etc. If
the substances get in the eye, rinse it with
plenty of water immediately. When symptoms are noticeable, consult a physician.
[4] MEASURES TO TAKE IN CASE
OF AN ACCIDENT
(1) It 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) It 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.
(4) For reports and measures concerning
accidents, consult your superior, and follow the regulations set in “Standards for
the Control Program for Measures Against
Electrical Equipment Accidents”.
[5] CONCLUSION
(1) Safet y of users and customer engineers
depends highly on accurate maintenance
and administration. Therefore, safety can
be maintained by the appropriate by the
proper daily service work conducted by
the customer engineer.
(2) 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.
C-4
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
CAUTION
The following graphic symbols are used to give instructions that need to be observed.
Used to call the service technician’s attention to what is graphically represented
inside the marking (including a warning).
Used to prohibit the service technician’s from doing what is graphically represented inside the marking.
Used to instruct the service technician’s to do what is graphically represented
inside the marking.
1. Always observe precautions.
•
Parts requiring special attention in this product will include a label containing the
mark shown on the left plus precautionary notes. Be sure to observe the precautions.
•
Be sure to observe the “Safety Information” given in the Operator’s Manual.
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
WARNING
2. Before starting the procedures, be sure to unplug the power cord.
•
This product contains a high-voltage unit and a circuit with a large current
capacity that may cause an electric shock or burn.
•
The product also contains parts that can jerk suddenly and cause injury .
•
If this product uses a laser, laser beam leakage may cause eye damage or
blindness.
3. Use the specified parts.
•
For replacement parts, always use the genuine parts specified in the manufacturer’s parts manual. Installing a wrong or unauthorized part could cause
dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire.
•
Replace a blown electrical fuse or thermal fuse with its corresponding genuine
part specified in the manufacturer’s parts manual. Installing a fuse of a different
make or rating could lead to a possible fire. If a thermal fuse blows frequently,
the temperature control system may have a problem and action must be taken
to eliminate the cause of the problem.
P-1
4. Handle the power cord with care and never use a multiple outlet.
•
Do not break, crush or otherwise damage the power cord. Placing a heavy
object on the power cord, or pulling or bending it may damage it, resulting in a
possible fire or electric shock.
•
Do not use a multiple outlet to which any other appliance or machine is connected.
•
Be sure the power outlet meets or exceeds the specified capacity.
5. Be careful with the high-voltage parts.
•
A part marked with the symbol shown on the left carries a high voltage. Touc hing it could result in an electric shock or burn. Be sure to unplug the power cord
before servicing this part or the parts near it.
6. Do not work with wet hands.
•
Do not unplug or plug in the power cord, or perform any kind of service or
inspection with wet hands. Doing so could result in an electric shock.
7. Do not touch a high-temperature part.
•
A part marked with the symbol shown on the left and other parts such as the
exposure lamp and fusing roller can be very hot while the machine is energized.
Touching them may result in a burn.
•
Wait until these parts have cooled down before replacing them or any surrounding parts.
8. Maintain a grounded connection at all times. (This item may not apply in the USA.)
•
Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could
result in an electric shock or fire.
•
Never connect the ground wire to a gas pipe, water pipe, telephone ground wire,
or a lightning conductor.
9. Do not remodel the product.
•
Modifying this product in a manner not authorized by the manufacturer may
result in a fire or electric shock. If this product uses a laser, laser beam leakage
may cause eye damage or blindness.
10. Restore all parts and harnesses to their original positions.
•
To promote safety and prevent product damage, make sure the har nesses are
returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being
crushed.
•
To promote safety, make sure that all tubing and other insulating materials are
returned to their original positions. Make sure that floating components mounted
on the circuit boards are at their correct distance and position off the boards.
P-2
CAUTION
1. Precautions for Service Jobs
•
A toothed washer and spring washer, if used originally, must be reinstalled.
Omitting them may result in contact failure which could cause an electric shock
or fire.
•
When reassembling parts, make sure that the correct screws (size, type) are
used in the correct places. Using the wrong screw could lead to stripped
threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.
•
Take great care to avoid personal injury from possible burrs and sharp edges on
the parts, frames and chassis of the product.
•
When moving the product or removing an option, use care not to injure your
back or allow your hands to be caught in mechanisms.
2. Precautions for Servicing with Covers and Parts Removed
•
Wherever feasible, keep all parts and covers mounted when energizing the
product.
•
If energizing the product with a cover removed is absolutely unavoidable , do not
touch any exposed live parts and use care not to allow your clothing to be
caught in the moving parts. Never leave a product in this condition unattended.
•
Never place disassembled parts or a container of liquid on the product. Parts
falling into, or the liquid spilling inside, the mechanism could result in an electric
shock or fire.
•
Never use a flammable spray near the product. This could result in a fire.
•
Make sure the power cord is unplugged before removing or installing circuit
boards or plugging in or unplugging connectors.
•
Always use the interlock switch actuating jig to actuate an interlock s wit ch when
a cover is opened or removed. The use of folded paper or some other object
may damage the interlock switch mechanism, possibly resulting in an electric
shock, injury or blindness.
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.
•
Avoid dusty locations and places exposed to oil or steam.
•
Avoid working positions that may block the ventilation ports of the product.
4. Precautions for Handling Batteries
•
Replace a rundown battery with the same type as specified in the manufacturer’s parts manual.
•
Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.
•
Dispose of used batteries according to the local regulations. Never dispose of
them at the user’s premises or attempt to try to discharge one.
P-3
5. Precautions for the Laser Beam (Only for Products Employing a Laser)
•
Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure
to unplug the power cord before removing this cover.
•
If removing this cover while the power is ON is unavoidab le , be sure to wear protective laser goggles that meet specifications.
•
Make sure that no one enters the room when the machine is in this condition.
•
When handling the laser unit, observe the “Precautions for Handling Laser
Equipment.”
1167P001AA
DANGER
Invisible laser radiation when open.
AVOID DIRECT EXPOSURE
TO BEAM
0947-7127-01
1144D270AA
P-4
Other Precautions
•
To reassemble the product, reverse the order of disassembly unless otherwise specified.
•
While the product is energized, do not unplug or plug connectors into the circuit boards
or harnesses.
•
The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
•
An air gun and vacuum cleaner generates a strong electrostatic charge that can destroy
the ATDC sensor and other sensors. Before cleaning a component with one of these
devices, be sure to remove all the sensors. Otherwise, use a blower brush and cloth
when cleaning parts.
•
When handling circuit boards with MOS ICs, observe the “INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS IC s” (applicable only to the products using MOS ICs).
•
The PC Drum is a very delicate component. Observe the precautions given in “HANDLING OF THE PC DRUM” because mishandling may result in serious image problems.
•
Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.
•
After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
•
Check the area surrounding the service site for any signs of damage, wear or need of
repair.
•
Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged hopper motor or locking mechanism.
•
If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.
P-5
Used Batteries Precautions
ALL Areas
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.
CAUTION
P-6
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.
Precautions Before Service
•
When the user is using a word processor or personal computer from a wall outlet of the
same line, take necessary steps to prevent the circuit breaker from opening due to overloads.
•
Never disturb the LAN by breaking or making a network connection, altering termination,
installing or removing networking hardware or software, or shutting down networked
devices without the knowledge and ex press permission of the network administrator or
the shop supervisor.
How to Use this Book
1. DIS/REASSEMB LY, ADJUST MENT
•
To reassemble the product, reverse the order of disassembly unless otherwise specified.
2. TROUBLESHOOTING
•
If a component on a PWB or any other functional unit including a motor is defec tive, the
text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defect ive unit.
•
All troubleshooting procedures contained herein assume that there are no breaks in the
harnesses and cords and all connectors are plugged into the right positions.
•
The procedures preclude possible malfunctions due to noise and other external causes.
Precautions for Service
•
Check the area surrounding the service site for any signs of damage, wear or need of
repair.
•
Keep all disassembled parts in good order and keep tools under control so that none will
be lost or damaged.
•
After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
•
Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged motor or locking mechanism.
•
If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.
•
Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit
containing these sensors is to be cleaned, first remove the sensors from the unit.
PS-1
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 y our clothing to
be caught in revolving parts such as the timing belt and gears.
•
Before attempting to replace parts and unplug connectors, make sure that the power
cord of the copier has been unplugged from the wall outlet.
•
Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the
Interlock Switch with the covers left open or removed.
•
Do not plug in or unplug print jacks on the PWB or connect or disconnect the PWB connectors while power is being supplied to the copier.
•
Never use flammable sprays near the copier .
•
A battery (lithium, nickel-cadmium, etc.) is used in this machine. Do not charge or short
circuit it and make sure of the correct polarity at replacement.
•
A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the user's premises.
•
When reassembling parts, make sure that the correct screws (size, type) and toothed
washer are used in the correct places.
•
If it becomes necessary to replace the thermal fuse or any other fuse mounted on a
board, be sure to use one of the rating marked on the blown fuse. Always note the rating
marked on the fuse, as the rating and mounting site or number used are subject to
change without notice.
Precautions for Circuit Inspection
•
Never create a closed circuit across connector pins except those specified in the text and
on the printed circuit.
•
When creating a closed circuit and measuring a voltage across connector pins specified
in the text, be sure to use the GND wire.
PS-2
Handling of PWBs
1. During Transpor tation/St orage:
•
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 temperature.
•
When it becomes absolutely necessary to remove a Board from its conductive bag or
case, always place it on its conductive mat in an area as free as possible from static electricity.
•
Do not touch the pins of the ICs with your bare hands.
•
Protect the PWBs from any external force so that they are not bent or damaged.
2. During Inspection/Replacement:
•
Avoid checking the IC directly with a multimeter; use connectors on the Board.
•
Never create a closed circuit across IC pins with a metal tool.
•
Before unplugging connectors from the P.W. Boards, make sure that the power cord has
been unplugged from the outlet.
•
When removing a Board from its conductive bag or conductive case, do not touch the
pins of the ICs or the printed pattern. Place it in position by holding only the edges of the
Board.
•
When touching the PWB, wear a wrist strap and connect its cord to a securely grounded
place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB.
•
Note that replacement of a PWB may call for readjustments or resetting of particular
items.
Handling of Other Parts
•
The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
PS-3
Handling of the PC Drum
✽
Only for Products Not Employing an 7415 Supply Unit.
1. During Transpor tation/St orage:
•
Use the specified carton whenever moving or storing the PC Drum.
•
The storage temperature is in the range between –20°C and +40°C.
•
In summer, avoid leaving the PC Drum in a car for a long time.
2. Handling:
•
Ensure that the correct PC Drum is used.
•
Whenever the PC Drum has been removed from the copier , store it in i ts carton or protect
it with a Drum Cloth.
•
The PC Drum exhibits greatest light fatigue after being exposed to strong light over an
extended period of time. Never, therefore, expose it to direct sunlight.
•
Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.
•
Do not scratch the surface of the PC Drum.
•
Do not apply chemicals to the surface of the PC Drum.
•
Do not attempt to wipe clean the surface of the PC Drum.
If, however, the surface is contaminated with fingerprints, clean it using the following procedure.
1. Place the PC Drum into one half of its carton.
1076D001
1076D002
2. Gently wipe the residual toner off the surface of the
PC Drum with a dry, Dust-Free Cotton Pad.
A. Turn the PC Drum so that the area of its surface on
which the line of toner left by the Cleaning Blade is
present is facing straight up. Wipe the surface in
one continuous movement from the rear edge of
the PC Drum to the front edge and off the surface
of the PC Drum.
B. Turn the PC Drum slightly and wipe the newly
exposed surface area with a CLEAN face of the
Dust-Free Cotton Pad. Repeat this procedure until
the entire surface of the PC Drum has been thoroughly cleaned.
✽
At this time, always use a CLEAN face of the dry
Dust-Free Cotton Pad until no toner is e vident on the
face of the Pad after wiping.
PS-4
3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters.
Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front
edge and off its surface one to two times.
✽
Never move the Pad back and forth.
1076D003
4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the
entire surface of the PC Drum has been wiped.
Always OV ERLA P the areas when wiping. Two
complete turns of the PC Drum would be appropriate for cleaning.
1076D004
NOTES
• Even when the PC Drum is only locally dirtied, wipe the entire surface.
• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under
interior illumination.
• If dirt remains after cleaning, repeat the entire procedure from the beginning one more
time.
Handling of the 7415 Supply Unit
✽
Only for Products Employing an 7415 Supply Unit.
1. During Transpor tation/St orage:
•
The storage temperature is in the range between –20°C and +40°C.
•
In summer, avoid lea v ing the 7415 Supply Unit in a car for a long time.
2. Handling:
•
Store the 7415 Supply Unit in a place that is not exposed to direct sunlight.
3. Precautionary Information on the PC Drum Inside the 7415 Supply Unit:
•
Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.
•
Do not scratch the surface of the PC Drum.
•
Do not attempt to wipe clean the surface of the PC Drum.
PS-5
DIS/REASSEMBLY,
ADJUSTMENT
18605
CONTENTS
1. SERVICE INSTRUCTIONS .............................................................................D-1
1-1. IDENTIFICATION OF FUSES ......................................... ........................D-1
1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ...............D-1
1-3. PARTS WHICH MUST NOT BE TOUCHED ....................... ....................D-2
(1) Red Screws .... ............. ......................... ......................... ..................D-2
(2) Variable Resistors on Board ............................................................D-2
(3) Other Screws ...................................................................................D-2
1-4. READING THE TEXT ..............................................................................D-3
2. DISASSEMBLY/REASSEMBLY ......................................................................D-4
2-1. COVERS AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL
PROCEDURES ....................................................................................... D-4
2-2. REMOVAL OF PWBs ..............................................................................D-6
2-3. MAINTENANCE SCHEDULE .................................................................. D-7
2-4. REMOVAL OF UNITS .............................................................................D-8
(1) Removal of the Upper Half of the Copier .........................................D-8
(2) Removal of the IR Unit .................................................................... D-11
(3) Removal of the PH Unit ...................................................................D-12
(4) Removal of the Fusing Unit .............................................................D-15
2-5. IMAGE TRANSFER SECTION ................................................................D-17
(1) Replacement of the Image Transfer Roller ......................................D-17
2-6. FUSING SECTION ..................................................................................D-18
(1) Removal of the Fusing Backup Roller .............................................D-18
(2) Removal of the Fusing Heater Lamp ............................................... D-20
(3) Removal of the Fusing Roller ..........................................................D-21
2-7. MISCELLANEOUS ..................................................................................D-22
(1) Removal of the Scanner and Timing Belt ........................................D-22
(2) Removal of the Scanner Motor ........................................................D-24
(3) Removal of the Paper Take-Up Roll ................................................D-25
(4) Removal of the Paper Take-Up Solenoid ........................................D-26
(5) Removal of the Main Motor and PH Section Cooling Fan Motor .....D-28
3. ADJUSTMENT .................................................................................................D-30
3-1. ADJUSTMENT REQUIREMENTS LIST .................................................. D-30
3-2. ADJUSTMENT OF UPPER UNIT INTERLOCK SWITCH S2 ..................D-31
3-3. ELECTRICAL/IMAGE ADJUSTMENT .....................................................D-32
(1) Entering the Tech. Rep. Mode .........................................................D-32
(2) Entering the Adjust Mode ................... .............................................D-32
(3) Producing a Test Pattern .................................................................D-32
(4) CD Registration Adjustment (Paper Tray) .......................................D-33
(5) FD Registration Adjustment (Paper Tray) .......................................D-34
(6) CD Zoom Ratio Adjustment (Scanner) ............................................D-35
(7) FD Zoom Ratio Adjustment (Scanner) ............................................D-36
(8) CD Registration Adjustment (Scanner) ...........................................D-37
(9) FD Registration Adjustment (Scanner) ............................................D-38
4. MISCELLANEOUS ..........................................................................................D-39
4-1. TORSION BAR POSITION ADJUSTMENT .............................................D-39
4-2. REMOUNTING EEPROM (U21) .................................. ............................D-40
i
1. SERVICE INSTRUCTIONS
1-1. IDENTIFICATION OF FUSES
Control Board PWB-I
250V 3A (F1)
Power Supply Board PU1
100V Area
250V 6.3A (F1)
250V 15A (F2)
200V Area
4007D040AA
250V 4A(F1)
250V 6.3A(F2)
1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT
• The laser used in this copier is a semiconductor laser with the following specifications:
Max. power: 5 mW
Output wavelength: 770 to 795 nm
• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
• When a disassembly job needs to be performed in the laser beam path, such as when
working around the PH and PC Drum, be sure to turn the copier OFF first.
• If the job requires that the copier be left ON, take off your watch and ring and wear laser
protective goggles.
• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling such tools near the laser.
• The PH is not maintainable in the field. It is to be replaced as a unit including the control
board. Never, therefore, attempt to remove the laser diode or adjust trimmers on the control board.
D-1
1-3. PARTS WHICH MUST NOT BE TOUCHED
(1) Red 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 should not be readjusted, set, or removed in the field.
Note that when two or more screws are used on the part in question, only one representative screw may be marked with red paint.
(2) Variable Resistors on Board
Do not turn the variable resistors on boards for which no adjusting instructions are given in
“ADJUSTMENT.”
(3) Other Screws
Scanner
PH Unit
4007D043AA
Pulley Fixing Screw
4007D045AA
4007D075AA
D-2
1-4. READING THE TEXT
Disassembly procedures are given under separate titles; illustrations identify each part
only.
Parts that require special attention and service jobs are given at the corresponding part
name in the illustration.
The disassembly procedures omit removal of exterior parts.
☞
D-4
Remove the roller after the Supply Unit has been taken out of the copier.
1. Image Transfer Roller cover
2. Image Transfer Roller
Disassembly
Procedures
Image Transfer Roller
Replace.
Image Transfer Roller Cover
Part requiring
service jobs.
Pusher Spring
Image Transfer Roller Holder
4007D017AA
D-3
2. DISASSEMBLY/REASSEMBLY
2-1. COVERS AND EXTERIOR PARTS: IDENTIFICATION AND
REMOVAL PROCEDURES
1
2
12
10
11
16
3
4
9
8
4007D001AB
7
5
6
13
15
14
4007D002AB
D-4
No. Name Removal Procedure
1 Platen Cover Remove screws that secure the Platen Cover.
2 Original Glass Remove 1. → Remove 13. → Remove 12. → Remove 3. →
Remove 7. → Remove the Original Glass holding brackets (two
at the front).
3 Front Upper Cover Remove screws that secure the Front Upper Cover.
4 Control Panel Remove 3. → Remove screws that secure the control panel.
5 Front Middle
Cover
6 Front Lower Cover Release and swing up the upper half of the copier. → Remove
7 Front IR Cover Remove 3. → Remove screws that secure the Front IR Cover.
8 Paper Tray Remove 9. → Release and swing up the upper half of the copier.
9 Manual Bypass
Tray
10 Paper Exit Tray
Lower Cover
11 Left IR Cover Remove 1. → Remove 3. → Remove 7. → Remove 13. →
12 Rear IR Upper
Cover
13 Rear Upper Cover Remove 14. → Remove screws that secure the Rear Upper
14 Rear Lower Cover Remove screws that secure the Rear Lower Cover.
15 Right Cover Release and swing up the upper half of the copier. → Remove
16 Right IR Cover Remove 3. → Remove 1. → Remove 13. → Remove 12. →
Remove 3. → Remove 4. → Remove screws that secure the
Front Middle Cover.
screws that secure the Front Lower Cover.
→
Remove 6. → Remove 14. → Remove the screw that secures
the Paper Tray.
Remove 9. → Remove 6. → Remove 14. → Remove 8. →
Remove screws that secure the Paper Exit Tray Lower Cover.
Remove 12. → Remove screws that secure the Left IR Cover.
Remove 1. → Remove 13. → Remove screws that secure the
Rear IR Upper Cover.
Cover.
the 14. → Remove screws that secure the Right Cover.
Remove screws that secure the Right IR Cover.
D-5
2-2. REMOVAL OF PWBs
• The removal procedures given below omit the steps of unplugging connectors and
removing the PWB from the PWB support.
• Where it is absolutely necessary to touch the ICs and other electrical components on the
board, be sure to ground your body.
PWB-I
PWB-M
PWB-A
Symbol Name Removal Procedure
PWB-A Master Board
PWB-B Control Panel
PWB-G
PWB-I Control Board
PWB-M Memory Board
PWB-S
PU1
HV1 High Voltage Unit
Toner Empty
Board
Scanner Interface
Board
Power Supply
Board
Remove the Rear Upper Cover and Rear Lower Cover. →
Remove the protective cover. → PWB-A
Remove the Front Upper Cover. → Remove the Control
Panel. → PWB-B
Remove all exterior covers . → Remove the upper half of the
copier. → Remove the rear side plate. → Remove the Paper
Take-Up Roll Cover Assy. → PWB-G
Remove the Rear Lower Cover and Rear Upper Cover. →
Remove the protective cover. → PWB-I
Remove the Rear Lower Cover and Rear Upper Cover. →
Remove the protective cover. → PWB-M
Remove the Front Upper Cover, Front IR Cover, Rear IR
Upper Cover , Rear Upper Cov er, and Rear Lower Cover. →
Remove the Original Glass bracket . → Remove the Original
Glass. → Remove the protective cover. → PWB-S
Release and swing up the upper half of the copier. →
Remove the Right Cover. → Remove the Power Switch. →
Remove the Fusing Section Cooling Fan Motor . → Remove
the Fusing Section Cooling Fan Motor mounting brack et. →
Remove the Inlet mounting bracket. → PU1
Remove the Paper Exit Tray Lower Cover. → Remove the
Paper Exit Tray. → Release and swing up the upper half of
the copier. → Remove the Cover. → Remove the Supply
Unit. → Remove the PH Unit. → HV1
PWB-S
4007D003AB
PU1
PWB-B
PWB-G
HV1
D-6
2-3. MAINTENANCE SCHEDULE
• To ensure that the copier produces good copies and to extend its service life, it is recommended that the maintenance jobs described in this schedule be carried out as
instructed.
Maintenance Schedule
PM Parts
Fusing Section
Fusing Unit — 50
Image Transfer Section
Image Transfer Roller — 50 4110-4103-01 1
Cleaning Replacement
(K)
Part No. Qty
100V Area
4007-0431-02
200V Area
4007-0432-02
1
Reference
Page
☞
D-15
☞
D-17
D-7
2-4. REMOVAL OF UNITS
(1) Removal of the Upper Half of the Copier
Remove the upper half of the copier after the Front Upper Cover, control panel, Front Middle Cover, Rear Upper Cover, and Paper Exit Tray Lower Cover have been removed.
1. Protective cover
2. Control Board
NOTE
Unplug all print jacks from the PWB.
Protective Cover
Control Board
4007D010AB
3. IR Lower Cover
4. Paper Exit Tray
Paper Exit Tray
IR Lower Cover
4007D062AA
4007D005AC
D-8
5. Torsion Bars A and B
Torsion Bar B
Torsion Bar Mounting Position
Torsion Bar B
Torsion Bar A
4007D006AB
Front Side
Torsion Bar A
4007D063AA
Rear Side
Torsion Bar B
Torsion Bar A
4007D064AA
NOTE
Before removing or reinstalling the torsion bars, be sure to release and swing up the upper
half of the copier to release pressure.
When reinstalling them, install torsion bar A first, then torsion bar B.
D-9
6. Lock Plate
Lock Plate
7. Shoulder screws and other screws
Front Side Rear Side
4007D073AA
Screws
Shoulder Screw
Shoulder Screw
4007D007AA 4007D008AA
NOTE
When mounting the shoulder screws, make sure that the round hole and the slot in the
frames are properly aligned with each other.
8. Upper half of the copier
Upper Half of the Copier
4007D009AA
D-10
(2) Removal of the IR Unit
Remove the IR Unit after the Front Upper Cover, Front IR Cover, Rear IR Upper Cover,
Rear Upper Cover, Rear Lower Cover, and Right IR Cover have all been removed.
1. Protective Cover
2. Control Board
NOTE
Unplug all print jacks from the PWB.
Protective Cover
Control Board
4007D010AB
3. ADF Set Switch hookup connector
4. IR Unit
IR Unit
ADF Set Switch
Hookup Connector
4007D011AB
D-11
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