Konica Minolta 1216 How to use

SERVICE HANDBOOK
KONICA CORPORATION
TECHNOLOGY SUPPORT CENTER
TOKYO JAPAN
1216
May.1998
Ver. 1.0

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.

INDEX
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).... 4-5
5. ADJUSTMENT
HOW TO USE THIS SECTION.........................5-1
ADJUSTMENTS WHEN REPLACING PARTS .... 5-1
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
6. DIAGNOSTICS
25 MODE ..........................................................6-1
CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ..... C-1
IMPORTANT NOTICE ....................... C-1
DESCRIPTION ITEMS FOR DANGER, WARNING .... C-1
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-7

[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
C - 1
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 under-
stood 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 re-
placed.
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION
In this Service Handbook, each of three expressions, “ DANGER”, “ WARNING” and “ CAU-
TION” 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
SAFETY AND IMPORTANT WARNING ITEMS

IMPORTANT SAFETY INFORMATION AND WARNIN\GS
C - 2
SAFETY WARNINGS
[1] MODIFICATIONSNOTAUTHORIZEDBY
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 pro-
cess 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 rea-
son, unauthorized modifications involve a high risk of degrad-
ing 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) Usingextensioncablesor a different powercordthan
specified by Konica.
(2) UsingotherfusesthanspecifiedbyKonica.Safetywill
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) Disablingsafetyfunctions (interlocks,safetycircuits,
etc.). Safetywillnotbeassured,leadingtoariskoffire
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) Wearclothing thatfacilitates workand isdesignedfor
safety.
(2) Carry out all procedures carefully to prevent injury.
(3) Besuretodisconnectthepowercordofthecopierand
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) Proceedwith specialcarewhen performingoperation
checksoradjustmentwhiletheunitispowered.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
whentouchingmovingparts such as gearsorchains.
Thefollowinglistisnotexhaustive,butitincludesactionswhich
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) Checkpowercordforinsulationproblems(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) Connectingthegroundleadtoanimproperpointsuch
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
notbeen approvedbyauthoritiesforgrounding use

IMPORTANT SAFETY INFORMATION AND WARNINGS
C - 3
[3] PRECAUTIONS FOR ON-SITE SERVICE
CAUTION:
(1) Before performing maintenance work, read all rel-
evant documentation (service handbook, technical
notices,etc.)andproceedaccordingtotheprescribed
procedure, using only the prescribed 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
specifiedpowercord. Ifthepower cordinsulationhas
beendamagedandthereareexposedsections,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 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 connec-
tors, pinched cables, forgotten screws, etc.)
(8) When installation and preventive maintenance, verify
that the power cord has been securely plugged into
theACoutlet.Contactproblemsmayleadtoincreased
resistance, overheating, and the risk of fire.
WARNING:
(1) Danger of explosion if battery is incorrectly replaced,
replaceonlywiththesameorequivalentrecommended
by the manufacturer. Discard used batteries accord-
ing to the manufacture's instructions.
VORSICHT:
(1) Expiosionsgefahr dei unsachegemäßem Austausch
der Battetie. Ersatz nur durch denselben oder einen
vom. Hersteller empfohlenen gleichwertigen Typ.
EntsorgunggebrauchterBatteriennachAngabendes
Herstellers.
[4] HANDLING OF MATERIALS FOR SERVIC-
ING
CAUTION: Drum cleaner (alcohol-based) and roller
cleaner (acetone- based) are highly flam-
mable and must be handled with care.
When using these materials for cleaning
ofcopierparts,observethefollowingpre-
cautions.
(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, immedi-
ately wipe it off.
(3) Perform cleaning only in an environment where suffi-
cient ventilation is assured. Breathing large quanti-
ties of organic solvents can lead to discomfort.
(4) Donot replace thecoveror turntheunit onbeforeany
solvent remnants on the cleaned parts have fully
evaporated.
CAUTION: Tonerand developerarenot harmfulsub-
stances, but care must be taken not to
breatheexcessiveamountsorletthesub-
stances come into contact with eyes etc.
If this happens, immediately rinse with
eyewashandplentyofwater,andconsult
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,anon-siteevaluationmustbecarriedoutquickly
and Konica Corporation must be notified.
(3) To determine the cause of the accident, conditions and
materialsmustberecordedthroughdirect on-site checks,
inaccordancewithinstructionsissuedbyKonicaCorpora-
tion.
[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.

IMPORTANT SAFETY INFORMATION AND WARNIN\GS
C - 4
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 manda-
tory 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 com-
pletely confined within protective housings and external covers, the laser beam cannot escape during
any phase of normal user operation.
SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION AND WARNING
C - 5
RL1
RL1
RL2
RL2
L1 CONT
L1 ACK
CVR
(H. T.)
L1
PSB
f1
AC
AC
CB
The electrical circuit of this machine contains the following
safetycircuitstopreventanaccidentfromoccurringintheevent
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
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-
vated under any circumstances.
2. Protection function provided by LBR (current
leakage detecting circuit)
This function turns RL1 and RL2 (main relays) OFF and
breakstheAClineinstantaneouslyintheeventthatleakage
currentflowsduetoagroundshortinonesideoftheACline,
for example.
Caution: The function of LBR must not be deacti-
vated under any circumstances.
RL1
LBR NF
RL1
RL2
CBR1
CBR2
RL2
MS1
PSB
[2] L1 (Exposure Lamp) Overheating
Protection Circuit
1. Protection function provided by software
When the L1 CONT signal output from the protection
functionbysoftwareontheCB(control board)becomes[L],
L1 lights. Simultaneously, the L1 ACK signal, which indi-
catesthatL1islit,isoutputfromtheCVRonthePSB(power
supply board) to the CB.
TheCBmonitorsboththe L1 CONTandL1ACKsignals. 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)
IfL1remains lit for morethanapproximately 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.
SAFETY CIRCUITS

IMPORTANT SAFETY INFORMATION AND WARNING
C - 6
Comparator
Section
RL1
Control
Section
RL2
RL1
RL2
TRC
PSB
L2
TH1
TH2
TS1
CB
[3] L2 (Fixing Heater Lamp) Overheating
Protection Circuit
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: PeriodicallycheckthesurfacesofTH1and
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
Thisfunctionusesacomparatorcircuitwhichcomparesthe
outputvoltageofTH1andTH2(fixingtemperaturesensor2)
with the abnormal judgment reference value.
ItdisconnectsL2,RL1,andRL2fromthecircuitintheevent
thattheoutputvoltageof TH1 orTH2exceedthereference
value.
Caution: PeriodicallycheckthesurfacesofTH1and
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.
3. Protection function using TS1 (Thermostat)
Ifthesurfacetemperatureoftheupperfixingrollerexceeds
a specified value, TS1 will blow, directly cutting off the flow
of current to L2.
Caution: Do not use a piece of wire in place of TS1
under any circumstances.

IMPORTANT SAFETY INFORMATION AND WARNING
C - 7
INDICATION OF WARNING OF THE MACHINE
Inthemachine,eachunit shown below is provided withalabelofcautionor warning concerning safety. In the caseofmaintenance,
repair and adjustment of the machine, take good care in doing work so that a burn or an electric shock may be avoided.
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.
Ifyoucannotmakeitlegibleorif thecautionlabelisremoved,pleasecontactyourServiceCentre.
Copier with ST-104
Label 5
Label 2
Label 1
Label 3 Label 4
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 3
Label 2
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 4
Pour éviter toute blessure, ne pas mettre les doigts dans l’agrafeuse.
To avoid injury, keep figners away from the staple unit.
HIGH VOLTAGE CAUTION
VORSICHT HOCHSPANNUNG
CAUTION HAUTE TENTION
DONOTINSERTyourfingerintostaple
drive poartion, otherwise you may
cause injury.
This internal area is very hot.
To avoid getting burned
DO NOT TOUCH.
This area generates high voltage.
To avoid an electrical shock
DO NOT TOUCH.
CAUTION
CAUTION
CAUTION
Label 5