Konica Minolta PK-120A, PK-120 User Manual

SERVICE MANUAL

Models

PK-120/PK-120A

JANUARY 2004

CSM-PK120

KONICA MINOLTA BUSINESS SOLUTIONS U.S.A., INC.

PK-120/PK-120A SERVICE MANUAL

JANUARY 2004

Used on Konica Models FORCE 65/7155/7165/7255/7272

IMPORTANT NOTICE

Because of the possible hazards to an inexperienced person servicing this equipment, as well as the risk of damage to the equipment, Konica Minolta Business Solutions U.S.A., Inc. strongly recommends that all servicingbeperformedbyKonica-trainedservicetech- nicians only.

Changes may have been made to this equipment to improve its performance after this service manual was printed. Accordingly, Konica Minolta Business Solutions U.S.A., Inc., makes no representations or warranties, either expressed or implied, that the information contained in this service manual is complete or accurate. It is understood that the user of this manual must assume all risks or personal injury and/or damagetotheequipmentwhileservicingtheequipmentfor which this service manual is intended.

Corporate Publishing Department

Printed in U.S.A.

SAFETY AND IMPORTANT WARNING ITEMS

Refer to the 7155/7165/7255/7272 Service Manual

CONTENTS

1. OUTLINE

PK-120 PRODUCT SPECIFICATIONS .....................		1-1
CENTER CROSS-SECTIONAL VIEW ......................		1-2
DRIVE SYSTEM DIAGRAM ......................................		1-3
[1]	Punch section.............................................	1-3
[2]	Moving section ...........................................	1-3
PUNCHING PROCESS .............................................		1-4
[1] Movement of the standby position of
	the punch unit .............................................	1-5
[2]	Formation of a Registration Loop ...............	1-5
[3]	Correction of the punch position .................	1-6
[4]	Punch .........................................................	1-6

2. UNIT EXPLANATION

PUNCH SECTION .....................................................		2-1
[1]	Composition ...............................................	2-1
[2]	Mechanisms ...............................................	2-1
[3]	Punch Control.............................................	2-2
PUNCH SCRAPS BOX SECTION.............................		2-4
[1]	Composition ...............................................	2-4
[2]	Mechanisms ...............................................	2-4
[3] Punch Scraps Conveyance Control ...........		2-5

3. DISASSEMBLY/ASSEMBLY

PUNCH SECTION .....................................................		3-1
[1]	Replacing the Punch unit ...........................	3-1
[2]	Cleaning the Punch Edges and Punch
	Scraps Full PS (PS802) .............................	3-2

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SAFETY WARNINGS

[1] Modifications Not Authorized by Konica Minolta

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

Unauthorized modifications involve a high risk of degradingperformanceandsafety.Suchmodificationsaretherefore 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 Minolta.

(2)Using other fuses than specified by Konica Minolta. 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 equipment not described in the instruction manual or the service handbook.

(8)Using parts other than specified by Konica Minolta.

[2] Checkpoints When Performing Onsite Service

Konica Minolta equipment is 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, thecustomerengineermustperformregularsafetychecks.

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 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 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 partswhichcarryhighvoltageorelectricalcharge. The risk of injury exists when touching moving parts such as gears or chains.

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 insulation problems (conductor must not be exposed).

(5)Check power cord and cable ties etc. for loosening from frame.

WARNING:

(1)Verify that the equipment 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 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

3. Description of Safety Checks

CAUTION:

(1)Before performing safety check work, read all relevantdocumentation(servicehandbook,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, components, wiring, connectors, etc. that were removed for safety check maintenance have been reinstalled in the original location. (Pay special attentiontoforgottenconnectors,pinchedcables, 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:

Before disassembling or adjusting the equipment, make sure that the power cord has been disconnected.

[3] Handling of Materials for Servicing

CAUTION: Alcohol-based and acetonebased cleaners are highly flammable and must be handled with care. When using these materials for cleaning parts, observe the following precautions.

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

(4)Do not replace the cover orturn the unit on before any solvent remnants on the cleaned parts have fully evaporated.

[4] 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 Minolta must be notified.

(3)To determine the cause of the accident, conditions and materials must be recorded through direct onsite checks, in accordance with instructions issued by Konica Minolta.

(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)Safety 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, equipment on the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.

OUTLINE

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