Konica DFC-800 INSTRUCTIONS

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SETUP INSTRUCTIONS
CF9001
NOTE
Keep all packing materials out of the reach of children.
Before setting up, be sure to unplug the power cord of the copier.
Keep all packing materials until you transport the machine to the customer.
1179-7744-03 © MINOLTA CO., LTD. Printed in Japan
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UNPACKING
1. Check to see that the following items are contained in the box of accessories.
2. Peel off the pieces of tape and remove the cushions from the copier. For Europe : Unwrap the power cord and plug it into the copier.
Copy Tray.................................................................................................1
PC Drum...................................................................................................1
Fusing Oil (For the U.S.A.).......................................................................1
Tube.........................................................................................................1
Syringe.....................................................................................................1
Cover........................................................................................................1
PC Drum Key ...........................................................................................1
Spring.......................................................................................................1
Starter Chute............................................................................................4
Labels................................................................................................. 1 set
Jumper Harness.......................................................................................1
Operator's Manual (For the U.S.A.)..........................................................1
Operator's Manual Holder ........................................................................1
Creative Image Book................................................................................1
Quick Guide..............................................................................................1
Stopper.....................................................................................................1
Mag Roller Shield.....................................................................................4
Screw (9739-0408-14)..............................................................................1
Power Cord (For the U.S.A.)....................................................................1
Customer Warranty Registration (For the U.S.A.)....................................1
Tape
Tape
Tape
ADJUSTING THE FEET
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Tape
Sheet
Tape
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Using a wrench, turn the Support Feet found underneath the copier near the front two corners.
CAUTION
To reduce the risk of injury due to unstable equipment, adjust the Support Feet before use.
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1. Turn the scanner locking pin about 90
°
counterclockwise and pull it out.
2. Attach the cover to the hole left by the locking pin.
3. Remove the Right Upper Cover.
4. Remove two Original Glass Holders and remove the Original Glass.
5. Remove three cushions and one Fixing Plate.
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6. Install the Original Glass.
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7. Install the Right Upper Cover.
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8. Open the front door and secure the stopper to the door with a screw.
Screw (4x8) x 1
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Holding Plate
9. Remove the cushion packed above the transfer drum lock release handle.
10.Pull off knob M9 and transfer unit lock lever M4.
11.Remove 4 screws and the transfer unit cover.
12.Pull off the stops from the Transfer unit rails. Remove the holding plate from the Transfer unit corona assy.
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Tape
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Cushioning Sheet
Holding Plate
protective sheet
13.Remove the tape and the protective sheet from the hopper unit.
14.Pull out the transfer drum unit and remove the tape from the transfer drum.
15.Remove the cushioned holding plate attached to the frame underneath the Transfer Drum. Then pull out the cushioning sheet.
Check to see if there are any hollows in the Transfer Film while turning the drum counterclockwise. If there are any hollows, tightly wrap the Film around the drum again. Refer to the Service Manual for the procedure.
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NOTES
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PREPARING THE FUSING UNIT
1. Unplug three connectors at the rear of the Fusing Unit, remove 2 screws from underneath the unit.
Fusing Oil
Spout
Rubber Tube
3. Gather th e can of oil (1 000ml ), sp out, sy ring e and rubber tube from the accessories.
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Lift the unit out.
2. Remove the top cover of the fusing unit.
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Syringe
4. Fill the syringe with 10ml of oil and inject it into the fusing unit just inside the right side of the unit between the cover and the blade assy. Repeat with 10ml more. (Only use a total of 20ml of oil.)
Only inject the oil into the space between the cover and blade assy, not on the blade, not over the upper roller, not over the front and rear gear areas.
Be sure to inject the oil evenly.
Let nothing (dust, lint, hair, etc.) fall into the Fusing Unit to contaminate it.
If setting up the copier at the workshop, do not fill the fuser oil bottle until the copier is moved to the user’s premises. In order to make test copies at the workshop, inject oil into the fuser as described in step 4 above. 30ml of oil makes about 20 copies. Inject more oil as needed for testing purposes.
5. Remove the cap of the fuser oil bottle. Attach the spout to the oil can and pour the oil into the fuser oil bottle. Recap the fuser oil bottle.
NOTE
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NOTE Pour the oil no higher than the Max. Level Inicator on the Fusing Unit.
6. Leaving the valve in place, pull off the lower tube from the Oil Pump Assy.
NOTES
Hold the valve when pulling the tube off or the valve will come off with the tube.
Before pulling the tube and drawing the oil, place a paper towel underneath the pump section to catch any priming oil leaking from the pump.
7. Insert the syringe into the tube and draw about 5ml of oil from it.
8. Attach the rubber tube from the accessories box to the syringe.
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9. Attach the tube to the lower end of the pump and inject the 5ml of oil into it.
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10.Remove the tube and syringe, and plug back in the lower tube of the Oil Pump Assy.
Do not turn any of the knobs, gears or rollers of the Fusing Unit when the oil tank is empty. The pump is primed with oil at the factory. If anything is turned in the unit when the tank is empty, the pump will lose its priming oil and may not be able to pump afterwards.
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NOTE
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11.Resecure the top cover.
12.Reinstall the unit with 2 screws and plug in the 3 connectors.
13.Push the Transfer Drum Unit back into the copier.
NOTE Make sure the lock lever is in the unlocked position when pushing the Transfer Drum Unit into the copier.
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TONER LOADING
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14.Open the manual feed table and remove the Left Middle Cover from the copier.
15.Insert a screwdriver through the holes and screw in the two Hexagonal Bolts (front and rear) alternately until they are completely tightened. Then loosen each Bolt four full turns.
When backing off the bolts, do that in two separate sequences by loosening each bolt two turns each (at the front and rear) alternately to achieve a uniform nip width.
1. Pull out the Hopper Unit.
2. Remove the Toner Antispill Plate from the bottom of the Hopper Unit.
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3. Loosen the 2 screws securing the Hopper Unit and remove it.
NOTE Be careful, the Hopper Unit is heavy.
4. Push the hopper rails back into the copier.
NOTE Whenever the Toner Hopper is removed from the copier, cover the exposed ports.
5. Sharply tap the toner bottle 5 times (from about 10cm) on a hard surface. Then turn it over and repeat.
6. Hold the bottle of toner as illustrated and shake it vertically more than ten times. Then remove the cap from the bottle.
7. Making sure not to pour the color toner into the wrong hopper, set the upturned bottle onto the hopper opening and turn clockwise until it is secure.
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8. Tap the bottle to ensure complete emptying.
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9. Turn the bottle counterclockwise, remove it, and close the lid of the hopper.
Repeat the same procedure for all 4 color toners.
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PC DRUM INSTALLATION
1. Unplug and pull out the Drum Charge Corona Unit.
5. Unplug the connector, remove 4 screws, carefully remove the PC unit front flange.
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2. Remove 3 screws and the Developer Unit Cover.
3. Pull the Lock Release Lever handle up and out, then push down.
NOTE Make sure the upper drawer is closed before operating the lock release lever.
4. Remove 2 screws and pull out the developer unit a short distance.
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6. Remove the fixing screw and the Drum Holder from the PC unit. Remove the PC unit from the copier.
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7. Remove 2 screws and the packing holders from the front and rear of the PC drum unit.
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8. Separate t he pa cki ng c olla rs ( blac k) fr om th e holders.
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a
Cleaning Blade
Toner
PC Drum
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9. Unpack the PC drum.
NOTE Do not touch the PC Drum surface with your bare hands.
10.Install the PC Drum with the end having the copper rings facing the front.
NOTE Double-check that the PC Drum is installed in the correct direction (copper rings to the front).
11.Resecure the holders to the front and rear.
12.Dip a brush into one of the toner hoppers.
Any color toner will do.
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13.Apply a light coating of toner along the top of the drum.
14.Unlocking the Cleaning Blade with the left hand, grasp the edge of the drum with the right hand and turn the drum counterclockwise until the toner along the top of the drum reaches the Cleaning Blade.
15.Lock the Cleaning Blade, grasp the drum by the edges and turn the drum clockwise 3 full turns. Afterwards, check area "a" to see if any toner has fallen onto the Cleaning Blade. If so, wipe the Blade.
Afterwards, check that the drum turns smoothly.
16.Check to see the Transfer Drum and Developing Unit are installed in the copier and make sure their Lock Levers are in the unlocked position. Carefully reinstall the PC Drum Unit on the rail inside the copier.
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NOTE
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OK
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X
Slide the PC Drum Unit along the rail.
Caution! While sliding the unit into the copier, swing the drum to the left to avoid scratching it on a drum sensor and the Toner Scattering Prevention Seal.
17.Check that the PC Drum Unit is correctly installed.
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Brass
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If the unit cannot be pushed all the way into the copier, insert the PC drum key and turn clockwise about 1/4 turn, then test the Unit by pushing it in. Repeat this procedure until the unit slides into place.
18.Attach the spring and Drum Holder with a fixing screw.
Be careful to avoid the spring's recoil while securing the Drum Holder.
19.Carefully refit the PC Unit front flange. First reset the 3 black screws, then the brass screw. Plug in the connector.
Black
20.Reinstall the Drum Charge Corona and plug it in.
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NOTE
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STARTER LOADING
1. Pull out the Developing Unit.
2. Cover the exposed sleeve/magnet roller area with the Mag Roller Shields.
NOTE Do not permit any contamination of the
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sleeve/magnet rollers.
3. Plug in the single connector of the jumper harness to the left of the unit, the two connectors to the left at the rear of the unit.
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View from above.
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ON
4. Remove 1 screw and black toner feed chute. The colors are in the order from left to right : black, cyan, magenta, yellow.
5. Attach the starter chute.
6. With the front door open and no interlock switch jig set, plug in the power cord and turn ON the main switch.
The front door must be open before the copier is turned ON.
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7. When the "The sectio n indicated by → is open" warning appears on the display, press the keys Stop → 0 → Stop → 2 to access the Developer Change Mode.
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NOTE
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8. With the Developer Change Mode Menu on the display, insert the front door interlock switch jig.
9. Touch "Developer Change."
10.Touch "Ex."
11.Touch “Black.”
Select the color of the starter to be loaded.
12.Press the Start key.
Developer activity will begin.
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13.Pour the starter i nto the replenishing port.
Make sure that the correct color of starter is loaded in the correct developing unit.
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14.Empty the entire contents of the bottle and press the Stop key.
Repeat step 5, 11-14 for each color starter.
15.When all 4 color starters have been loaded, touch "Ex."
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NOTE
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STARTER AGITATION
16.Touch "On" for all four color starters and press the start key to begin agitation. When the activity is completed it will stop automatically.
20.Remove the starter chute.
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Pre-Image Transfer Charge
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OFF
AIDC Sensor
17.After agitating all 4 color starters in the Developer Mixing Chamber, clean the AIDC sensor and the Pre-Image Trans fer Charge section if they are dirty.
18.Turn OFF the main switch and unplug the power cord. Turn OFF the front door interlock switch.
19.Remove the mag. roller shields.
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21.Reinstall the toner feed chute.
When the toner chute is seated, press it downward while securing it with a screw to prevent toner dust leakage.
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22.Unplug the jumper harness.
Please keep the Jumper Harness for future use.
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23.Push the developer unit back into the copier and secure with the 2 screws.
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ATDC/AIDC LEVEL ADJUSTMENT
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ON
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24.Firmly pull up on the developer lock release lever and push the handle in.
25.Slide the lever as shown on the left.
1. Reattach the Transfer Unit lock lever and lock the unit into position.
2. Plug in and turn ON the copier.
NOTE At this time, make sure the front door interlock switch is OFF
3. When the warning appears on the display, press the keys Stop-0-S top-2 (in that order) to enter the Developer Change mode.
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4. Turn ON the front door interlock switch.
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5. Touch "After Dev. (C/M/Y/BK) has been changed."
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6. Touch "On" for all three colors.
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7. Press the Start key to adjust the ATDC.
8. The activity will automatically stop when the adjustment is completed.
Check that the adjustment result has been OK. Then touch "ON" for Enter Ref. Value on the ATDC Sensor Adjust (Auto) screen and touch "Ex."
9. When the AIDC Sensor Adjust (Auto) screen appears, press the start key. When the activity is completed it will stop automatically.
10.Check that the adjustment result has been OK. Then, on the AIDC Sensor Adjust (Auto) result screen, touch "Ex."
11.When the "AIDC offset" screen appears, press the start key. It will stop when the activity is completed.
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12.Touch "Ex."
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13.Press the start key when the "Black ATDC Adjust" screen appears. The "Black ATDC Adjust" runs for about 5 min. and will stop automatically. Touch "Ex." and turn OFF the copier.
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14.Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.)
15.Touch State Confirm.
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16.Touch Bk Toner Sup. Status.
17.Check that the values for Dev. Constant are not 0.
NOTE If the Bk Developing Unit is defective, all values for “Dev. Constant” are “0.”
If any of the Dev. Constant value is “0” :
Check the value for η of PC Dev. Status.
If the value for η is correct (η ≠ 99, η <
10000), carry out Bk Toner Sup. Status again.
If the value for η is not correct, replace the Bk Developing Unit, then make the check again.
18.Touch Ex. and turn OFF the copier.
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19.Turn OFF the front door interlock switch.
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20.Install the Developer Unit Cover with 3 screws.
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21.Pull out the hopper rails and install the Toner Hopper (secured by 2 thumb screw s). Reattach the Toner Antispill Plate to the bottom of the Hopper Unit and close the front door.
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FUSER NIP LEVEL ADJUSTMENT
ON
1. Turn ON the copier.
At this time, make sure the front door is closed.
6. When the Start key changes from orange to green, press the Start key.
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2. Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.)
3. Touch "Machine Adjust 1."
4. Touch "Fuser Nip."
5. Place an A4(C) or Letter(C) size sheet of paper crosswise into the drawer set for that size.
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7. Measure the width of the stripe at points near the front and rear edges. If should fall within the following range.
Further, subtract the measurement taken at the front from the measurement in the rear (or vice versa) to check that the difference between the two meets the specifications given below.
<Specifications> Fusing nip width (at the center): 8.5 ±0.3mm Difference: Within 0.5mm
If the width measurements of the stripe on the test print deviate from the given target values, adjust the pressure bolts on the fusing unit. If > 6.3mm, loosen the pressure bolts. If < 5.7mm, tighten the pressure bolts.
Make one more test print.
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8. When the adjustment is completed, touch "Ex."
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FUSER SPEED LEVEL ADJUSTMENT 1
1. Load A3 or Ledger-size paper in the drawer set for that size.
Open the Front Door and turn ON the interlock switch.
5. During the copy run, check the paper loop between the Transfer Drum and Fusing Roller.
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2. Touch "Fuser Speed."
3. Touch "CF paper 120mm/s" and make an A3 or Ledger si ze copy.
4. Press the Start key. A half-tone test print will be produced.
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Paper Loop
Transfer Drum
Paper Loop
Transfer Drum
<The fuser speed is normal>
<If the fuser speed is too fast>
The paper is pulled by the Fusing Rollers, preventing a paper loop from forming and causing the paper to straighten.
Decrease the fuser speed by touching the Down key until the loop is correctly formed.
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Paper Loop
Transfer Drum
Paper Loop
<If the fuser speed is too slow>
The paper is pushed by the Transfer Drum, creating a large upward or downward loop.
IF THE TEST PRINT CONTAINS ABRASIONS OR STRESS MARKS,
PERFORM THE FOLLOWING PROCEDURE.
1. If stress marks are at the front of the page, loosen the front pressure bolt. If abrasions are at the front of the page, tighten the front pressure bolt.
Do not adjust the rear pressure bolt.
abrasion
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stress marks
2. If stress marks are at the rear of the page, tighten the front pressure bolt. If abrasions are at the rear of the page, loosen the front pressure bolt.
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abrasion
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Transfer Drum
stress marks
Increase the fuser speed by touching the Up key until the loop is correctly formed.
6. Check the test print for copy quality.
Do not adjust the rear pressure bolt.
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FUSER SPEED LEVEL ADJUSTMENT 2 (Fine Adjustment)
Since repeatedly adjusting the nip level an d fuser speed may leave abrasions or stress marks in the test print, tighten both the front and rear pressure bolts of the Fusing Unit, then start from the "FUSER NIP LEVEL ADJUSTMENT" and perform the adjustment again. When the adjustment is completed, touch "Ex." twice.
(a) Solid black adjustment
1. Load A3 or Ledger-size paper in the drawer set for that size.
Open the Front Door and turn ON the interlock switch.
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2. Touch "Test Print."
3. Touch "Halftone."
4. Touch "4 Color."
5. Press the Clear key and enter "200."
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Oil Tank
Oil Tank
Paper Loop
Transfer Drum
Paper Loop
Transfer Drum
6. Press the Start key.
*Following the same procedures as in FUSER
SPEED LEVEL ADJUSTMENT 1, check the loop formed in the paper.
<The fuser speed is normal>
The loop in the paper does not touch the bottom of the oil tank.
<If the fuser speed is too slow>
The loop in the paper bulges upward to tou ch the bottom of the oil tank.
Increase the fuser speed by touching the Up key so that the loop does not touch the bottom of the oil tank.
Decrease the fuser speed by touching the Down key until the loop is correctly formed.
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NOTE
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(b) Blank sheet adjustment: Only when the speed has been changed in
(a) Solid black adjustment
"
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"
1. Load A3 or Ledger-size paper in the drawer set for that size.
Open the Front Door and turn ON the interlock switch.
2. Touch "Test Print."
3. Touch "Halftone."
4. Check that "Cyan" is selected.
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Oil Tank
Paper Loop
Transfer Drum
5. Press the Clear key.
6. Press the Start key.
*Check the loop in the paper once again.
<The fuser speed is normal>
The loop in the paper does not touch the bottom of the oil tank.
Decrease the fuser speed by touching the Down key so that the loop does not touch the bottom of the oil tank.
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Using the same procedures, make only FUSER SPEED LEVEL ADJUSTMENT 1 for "Thick Paper 1" and "OHP Film.
"
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7. Reattach the Left Middle Cover to the copier.
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8. Reattach the Transfer Unit Cover, knob M9 and M4 lock lever.
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GRADATION ADJUSTMENT
1. Turn OFF the front door interlock switch and close the front door. Touch "Gradation Adjust."
Touch "Gradation Adjust."
4. Place the gamma test pattern onto the original glass with the corner mark in the corner indicated on the original glass. (Follow the instruction on the display of the Touch Panel.)
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2. Place an A3 or Ledger size sheet of paper into the drawer set for that size.
3. Press the Start key to produce a gamma test pattern.
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5. Cover the test pattern with 10 Sheets of blank, white A3 or Ledger size paper and close the Original Cover.
6. Press the Start key to read the gamma test pattern. The test pattern doesnt print out at this time.
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7. When this step is completed, the Service Mode Menu will reappear.
Touch "Gradation Adjust."
8. Press the Start key to produce another test pattern. Repeat steps 4-8 two more times using the latest produced test pattern each time.
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9. After Gradation Adjust has been completed, check that the value for “Conv. Value falls within the reference value range.
Reference Value Range
High image density: 0±100 Low image density : 0±60
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If the value falls within the reference value range, press the Panel Reset key and go to Image Quality Check on the next page.
10.If the value falls outside the reference value range, perform Gradation Adjust once again and then check Conv. Value.
If the value falls within the reference value range, press the Panel Reset key and go to Image Quality Check on the next page.
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11.Press the Panel Reset key.
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IMAGE QUALITY CHECK
1. Place the color chart on the original glass and make a copy.
2. Check for any streaks or voids in the halftone band.
Halftone Band
3. If there are any streaks or voids, refer to the "Image Quality Problems" section in the Troubleshooting guide of the Service Manual.
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MACHINE SETTING
1. Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.)
2. Touch "Setting 2."
6. Set the paper size for each tray, then touch "Ex."
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3. Touch "Serial # Input."
4. Enter the serial number for the copier and each installed option, then touch "Ex."
5. Touch "Paper Size."
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7. Select another mode according to your needs.
When all settings are completed, touch "Ex."
8. Press the Panel Reset key and turn OFF the copier.
OFF
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DRAWER SIZE CHANGE
1. Pull out the Drawer and remove the Side and End Guide Plates.
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2. Reposition the Side and End Guide Plates in accordance with the size of paper being used.
*Positions for the Side and End Guide Plates
are shown in the Table below.
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Drawer Size Conversion Table
Paper Size
A5(T)/(L) 13 G 5-1/2 x8-1/2 (T)/(L) 14 H B5(T)/(L) 11 K 8 x10-1/2 (T)/(L) 10 L A4(T)/(L) 9 O 10-1/2 x8 (Y)/(C) 3 F A4(Y)/(C) 1 G 8 x13 (T)/(L) 10 Q B4(T)/(L) 4 S 8-1/2 x11 (T)/(L) 8 N A3(T)/(L) 1 U 11 x8-1/2 (Y)/(C) 2 H
Guide Plate
Side End Side End
Paper Size
8-1/2 x13 (T)/(L) 8 Q 8-1/2 x14 (T)/(L) 8 R 11 x14 (T)/(L) 2 R 11 x17 (T)/(L) 2
Guide Plate
CHECKING THE 1-SIDED IMAGE REGISTRATION
1. Pull out the Drawer and load the paper into it. Close the Drawer.
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2. Turn ON the copier.
Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.)
3. Touch " Machine Adjust. "
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4. Touch " PRT Area. "
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5. Touch "Left Margin."
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6. Touch the key for the Tray that was changed. Press the Start Key and make a test print.
PAPER LOADING FOR DRAWERS
Pull out the Drawer and load the paper into it. Close the Drawer.
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Feeding direction
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7. Measure the width of the white margin along the edge of the test print.
Tolerance A : 3
8. If the width deviates from the tolerance value, adjust with the Up / Down keys. Then make another test print. If the range of deviation is within the Tolerance, touch "Ex."
Press the Panel Reset key and turn OFF/ON the copier.
1.5 mm
±
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AFFIXING THE LABELS
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DEHUMIDIFYING SWITCH CHECK
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Stick the Labels into the positions shown in the illustration.
Check that the Dehumidifying Switch is turned ON. If the switch is turned OFF, please turn it ON.
123
456
789
0C
NOTE
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LIST OUTPUT
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1. Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.)
2. Touch "List Output."
3. Touch "Image Processing."
4. Place a stack of 15 sheets of A4 or Letter size lengthwise paper on the manua l feed table.
5. Press the Start key to output the Machine Data.
Do steps 3-5 for each List (Setting/Adjust, Counter).
Please keep the output Machine Data. Press the Panel Reset key and turn OFF/ON the copier.
Date/Time Input Check
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1. Press the f oll o wi n g ke y s on t h e c o ntr ol pa ne l in this order to show "Date/Time Input" on the screen.
(1) Stop key (2) "1," "1," "4," and "4" of 10-Key pad (3) Clear key
2. On the Date/Time Input screen, check the "Present Date/Time."
If the date/time data is correct, touch "Ex."
3. If the date/time data is wrong, enter the current correct time of day and date from the 10-Key Pad.
4. Touch "OK."
5. Touch "Ex."
When the Copier location is changed, the Support Feet must be readjusted bef ore use.
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