SERVICE MANUAL Models ST-723/724 FEBRUARY 1999 CSM-ST723/724 KONICA BUSINESS TECHNOLOGIES, INC. ST-723/724 SERVICE MANUAL FEBRUARY 1999 Used on Konica Model 7823 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 Business Technologies strongly recommends that all servicing be performed by Konica-trained service technicians only. Changes may have been made to this equipment to improve its performance after this service manual was printed. Accordingly, Konica Business Technologies, 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 damage to the equipment while servicing the equipment for which this service manual is intended. Corporate Publications Department © 2001, KONICA BUSINESS TECHNOLOGIES, INC. All rights reserved. Printed in U.S.A. CONTENTS GENERAL, MECHANICAL/ELECTRICAL 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 2. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 3. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3 4. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 5. ELECTRICAL COMPONENTS LAYOUT . . . . . . . . . . . . . . . . . . . . M-5 6. OUTLINE OF OPERATION IN EACH MODE 6-1. INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. NON-SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. GROUP MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5. SORT STAPLE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. MANUAL STAPLE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. BIN MOVEMENT AT END OF COPY CYCLE . . . . . . . . . . . . 7. OPERATION OF EACH MECHANISM 7-1. PAPER TRANSPORT MECHANISM . . . . . . . . . . . . . . . . . . . 7-2. PAPER ALIGNING MECHANISM . . . . . . . . . . . . . . . . . . . . . . 7-3. BIN MOVING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. PAPER CLAMPING MECHANISM . . . . . . . . . . . . . . . . . . . . . 7-5. PAPER DETECTION AT STAPLING MECHANISM . . . . . . . 7-6. STAPLING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. SORTER SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. BIN EMPTY DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. OPERATION IN EACH MODE 8-1. NON-SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. SORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. GROUP MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. SORT STAPLE MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-6 M-6 M-7 M-9 M-10 M-11 M-11 M-12 M-13 M-17 M-21 M-25 M-25 M-35 M-36 M-37 M-38 M-40 M-42 iii CONTENTS ... ...... TEST. MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 DIS/REASSEMBLY, ADJUSTMENT 1. DISASSEMBLY/REASSEMBLY 1-1. REMOVAL OF EXTERIOR COVERS . . . . . . . . . . . . . . . . . . . 1-2. REMOVAL OF THE TRANSPORT GUIDE PLATE ASSY . . 1-3. REMOVAL OF THE BIN MOVING MOTOR M1 UNIT. . . . . . 1-4. REMOVAL OF PAPER CLAMP SOLENOID SL1 . . . . . . . . . 1-5. REMOVAL OF THE STAPLE UNIT . . . . . . . . . . . . . . . . . . . . 1-6. REMOVAL OF THE SORTER LOCK RELEASE LEVER . . . 1-7. REMOVAL OF THE BINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 D-2 D-3 D-4 D-4 D-5 D-6 2. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9 TROUBLESHOOTING 1. MISFEED DETECTION/TROUBLESHOOTING PROCEDURES 1-1. MISFEED DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-2. TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . T-1 2. MALFUNCTION DETECTION/TROUBLESHOOTING PROCEDURES 2-1. MALFUNCTION DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . T-3 2-2. TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . T-5 xELECTRICAL WIRING DIAGRAM xELECTRICAL CIRCUIT DIAGRAM iv SAFETY PRECAUTIONS SAFETY PRECAUTIONS Installation Environment Safety considerations usually are directed toward machine design and the possibility of human error. In addition, the environment in which a machine is operated must not be overlooked as a potential safety hazard. Most electrical equipment is safe when installed in a normal environment. However, if the environment is different from what most people consider to be normal, it is conceivable that the combination of the machine and the room air could present a hazardous combination. This is because heat (such as from fusing units) and electrical arcs (which can occur inside switches) have the ability to ignite flammable substances, including air. When installing a machine, check to see if there is anything nearby which suggests that a potential hazard might exist. For example, a laboratory might use organic compounds which, when they evaporate, make the room air volatile. Potentially dangerous conditions might be seen or smelled. The presence of substances such as cleaners, paint thinners, gasoline, alcohol, solvents, explosives, or similar items should be cause for concern. If conditions such as these exist, take appropriate action, such as one of the following suggestions. · Determine that the environment is controlled (such as through the use of an exhaust hood) so that an offending substance or its fumes cannot reach the machine. Remove the offending substance. Install the machine in a different location. effect may be caused by altering any aspect of the machine's design. Such changes have the potential of degrading product performance and reducing safety margins. For these reasons, installation of any modification not specifically authorized by Konica Business Machines U.S.A., Inc., is strictly prohibited. The following list of prohibited actions is not all-inclusive, but demonstrates the intent of this policy. · · · · · · · · Using an extension cord or any unauthorized power cord adapter. Installing any fuse whose rating and physical size differs from that originally installed. Using wire, paper clips, solder, etc., to replace or eliminate any fuse (including temperature fuses). Removing (except for replacement) any air filter. Defeating the operation of relays by any means (such as wedging paper between contacts). Causing the machine to operate in a fashion other than as it was designed. Making any change which might have a chance of defeating built-in safety features. Using any unspecified replacement parts. General Safety Guidelines This copier has been examined in accordance with the laws pertaining to various product safety regulations prior to leaving the manufacturing facility to protect the operators and service personnel from injury. However, as with any operating device, components will break down through the wear-and-tear of everyday use, as will additional safety discrepancies be discovered. For this reason, it is important that the technician periodically performs safety checks on the copier to maintain optimum reliability and safety. The following checks, not all-inclusive, should be made during each service call: CAUTION: Avoid injury. Ensure that the copier is disconnected from its power source before continuing. · · · Look for sharp edges, burrs, and damage on all external covers and copier frame. Inspect all cover hinges for wear (loose or broken). Inspect cables for wear, frays, or pinched areas. · · The specific remedy will vary from site to site, but the principles remain the same. To avoid the risk of injury or damage, be alert for changes in the environment when performing subsequent service on any machine, and take appropriate action. Unauthorized Modifications Konica copiers have gained a reputation for being reliable products. This has been attained by a combination of outstanding design and a knowledgeable service force. The design of the copier is extremely important. It is the design process that determines tolerances and safety margins for mechanical, electrical, and electronic aspects. It is not reasonable to expect individuals not involved in product engineering to know what v SAFETY PRECAUTIONS · · · Ensure that the power cord insulation is not damaged (no exposed electrical conductors). Ensure that the power cord is properly mounted to the frame by cord clamps. Check the continuity from the round lug (GND) of the power cord to the frame of the copier -- ensure continuity. An improperly grounded machine can cause an electrically-charged machine frame. Applying Isopropyl Alcohol Care should be exercised when using isopropyl alcohol, due to its flammability. When using alcohol to clean parts, observe the following precautions: · · Remove power from the equipment. Use alcohol in small quantities to avoid spillage or puddling. Any spillage should be cleaned up with rags and disposed of properly. Be sure that there is adequate ventilation. Allow a surface which has been in contact with alcohol to dry for a few minutes to ensure that the alcohol has evaporated completely before applying power or installing covers. Safeguards During Service Calls Confirm that all screws, parts, and wiring which are removed during maintenance are installed in their original positions. · When disconnecting connectors, do not pull the wiring, particularly on AC line wiring and high voltage parts. Do not route the power cord where it is likely to be stepped on or crushed. Carefully remove all toner and dirt adhering to any electrical units or electrodes. After part replacement or repair work, route the wiring in such a way that it does not contact any burrs or sharp edges. Do not make any adjustments outside of the specified range. · · Summary It is the responsibility of every technician to use professional skills when servicing Konica products. There are no short cuts to high-quality service. Each copier must be thoroughly inspected with respect to safety considerations as part of every routine service call. The operability of the copier, and more importantly, the safety of those who operate or service the copier, are directly dependent upon the conscientious effort of each and every technician. Remember...when performing service calls, use good judgement (have a watchful eye) to identify safety hazards or potential safety hazards that may be present, and correct these problem areas as they are identified -- the safety of those who operate the copier as well as those who service the copier depend on it! · · · · vi GENERAL, M E C H A N ICAL/ ELECTRICAL 1 Type S P E C IFICATIONS : 10-Moving-Bin Sorter 10-Moving-Bin Sorter : Appendant to copier : 11 : Non-Sort Sort Group Sort Staple Manual Staple (ST-723) with Automatic Stapler (ST-724) Installation No. of Bins Modes *1 ST-724 only*2 ST-724 only *1: Not available for an ST-724 mounted together with an DF-723. *2: Available only for a system equipped also with an DF-723. In the Non-Sort Mode Copy Medium : Recommended paper weighing 60 to 90 g/m2 or 16 to 24 lbs., translucent paper, transparencies, heavy paper (91 to 157 g/m2 or 25 to 41 lbs.). : A5 lengthwise to A3, and A3 Wide or 5-1/2" × 8-1/2" to 11" × 17" and Full Bleed : Recommended paper : 1st Bin - 50 : 2nd to 10th Bin - 25/Bin (80 g/m2 or 22 lb.) : Transparencies: 10 (max. size: A4 or 8-1/2" × 11") : Other special paper: 10 Size Max. Capacity In the Sort/Group Mode Copy Medium : Recommended paper weighing 60 to 80 g/m2 or 16 to 22 lbs. Size : A5 lengthwise to A3, 5-1/2" × 8-1/2" to 11" × 17" Max. Capacity : 25 sheets of 80 g/m2 or 22 lb. paper per Bin In the Sort Staple Mode Copy Medium : Recommended paper weighing 60 to 80 g/m2 or 16 to 22 lbs. Size : A4 to A3, 8-1/2" × 11" to 11" × 17" Max. Capacity : 25 sheets of 80 g/m2 or 22 lb. paper per Bin No. of Copies That Can : 2 to 25 copies of 80 g/m2 or 22 lb. paper be Stapled Power Requirement Power Consumption Dimensions : DC24V (supplied from copier) : 72W or less : Width - 400 mm or 15-3/4" Depth - 562 mm or 22-1/4" Height - 404 mm or 16" : ST-723 - 15.8 kg or 34-3/4 lbs. (excl. Mounting Bracket) ST-724 - 18.1 kg or 40 lbs. (excl. Mounting Bracket) : Same as copier Weight Environmental Requirements M-1 2 P A R T S IDENTIFICATION 1 2 3 4 7 10 9 6 3 5 4428M060AA 8 11 4428M061AA 1. 2. 3. 4. 5. 6. 7. Sorter Lock Release Lever Hookup Connector Sorter Lock Lever Drive Coupling Gear Transport Guide Plates Sorter Set Detector Stapler Cover (Cannot ...