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SERVICE MANUAL
MODELS
7915/7920
APRIL 2001
CSM-7915/7920
This page left blank intentionally.
7915/7920
SERVICE MANUAL
APRIL 2001
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 Technolo-
gies strongly recommends that all servicing be per-
formed 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 under-
stood 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.
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7920/7915 Color Imaging System
Machine and Accessories Supplies
Item Description Item Number Item Description Item Number
7915 Copier 950450 Toner (Black) 950476
7920 Copier 950451 Toner (Yellow) 950477
Scanner Unit (SN-231)1 950452 Toner (Magenta) 950478
Copier Stand for scanner unit ( DK-231)1,7 950458 Toner (Cyan) 950479
Fiery X3e embedded print controller (7920/7915) 950467 Imaging Unit (Black)6 950472
Fiery X3e Interface Kit 4
950468 Imaging Unit (Yellow)6 950473
Fiery X3e Command Workstation Software 950445 Imaging Unit (Magenta)6 950474
Fiery Z4 Controller (7920 only) 950469 Imaging Unit (Cyan)6 950475
4
Fiery Z4 Interface Kit 950470 Staples (FS-133) 950495
Fiery Z4 FACI Kit 950449 Staples (FS-134) 950496
(Flat Panel Monitor, Keyboard, Mouse)
1
Fiery Z4 Docbuilder Pro V1.0 Software 950448 Must be ordered with Main Body
2
Fiery Z4 256MB Memory Module 950447 Must use 2 PF-231's when Sorter or
Fiery Z4 Token Ring Card 950446 Finisher unit is installed
950454 3
RADF (DF-331) Must be ordered with PF-231 Cassette
4
RADF Kit 950455 Interface must be orderd with Fiery Controller
5
Mechanical Counter (b&w) 950453 One MU-431must be ordered for Duplex Unit
Platen Cover (CV-131) 950456 on 7915
6
ADU (AD-231) 950457 Supplied with copier
500 Sheet Universal Cassette (PF-231)2 950462
7
Copier Stand is required for Scanner Unit
Drawer Base W/LCT (DB-431) 950464 to be mounted on top of copier
Copy Desk(DK-133) storage 950465
Copy Table (DK-134)3 950463
10 Mail Bin Sorter (ST-134) 950459 Power Requirements: 120V60Hz
Stapler Finisher (FS-133) 950460 ±10%V, ±.3% Hz
Multi-Position Stapler Finisher 950461
w/3-hole punch (FS-134)
Memory 2x128MB (MU-431)(For 7915 only)5 950466 11-Apr-01
7915/7920 System Configuration
4 19 20 21
Scanner
7915/7920 2
1
Engine 3
Basic 22
250MP Tray 23
Configuration 500U Tray
Scanner
2 DF-331RADF
15 17
Options for 5
3 RADF installation kit
Scanner Unit 9
4 CV-131 Platen Cover
5
Horizontal feed unit 1 Engine
(supplied with unit)
6
6 ST-134 10 Bin Sorter
16 18
Finishing 250MPT 10
7 FS-133 Single Stapler
Options
7 500UT
FS-134 Multi-
8 Staple/punch 2 or 3 hole 500UT
8 11 13
9 AD-231 ADU 14 2500LCC
13 500UT
DK-231 Copy stand for
10 Scanner Unit
Accessory
12
DK-133 Copy desk Rubber foot for
11 (storage) 15 Fiery X3e embedded 19 scanner on table
DK-134 Copy table Expansion memory Additional
12 (Note 1) Paper Feed 16 I/F kit X3e 20 (7915 w/ ADU)
Controller Options
13 PF-231 500 sheet tray Options “A” Fiery Z4 External Options Mechanical counter
17 (7920 only) 21 (b&w)
14 PF-431 2500 sheet LCC
Dehumidifying
18 I/F kit Z4
22 heater(DK133 or
Paper Feed
Note 1: Must use 2 PF-231 when Sorter PF231)
or Finisher is installed Dehumidifying Options
23 heater(PF431)
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Power Switch ON
Full-speed rotation
In synchronism with the timing Temperature
at which Scanner Motor is energized Half-speed rotation control
Power Supply Cooling
Fan Motor (M21)
Ozone Ventilation
Fan Motor (M22)
Fusing Cooling Fan Motor 1 (M23)
Fusing Cooling Fan Motor 2 (M24)
Original Glass Cooling
Fan Motor (M2)
IR Cooling Fan Motor 1 (M3)
IR Cooling Fan Motor 2 (M4)
Heating Roller Heater Lamp 1
Lower Fusing Roller Heater Lamp
Fusing Pressure/Retraction Retracted
Retracted Pressed
Motor (M8)
Fusing Drive Motor (M14)
Exposure Lamp (LA1)
Scanner Motor (M1)
Main Motor (M13)
Pressed
1st Image Transfer Pressure
/Retraction Motor (M11) Retracted
Retracted
2nd Image Transfer Pressure Retracted
/Retraction Clutch (CL15) Pressed
2nd Image Transfer Bias (HV2)
'''!*(
+ <, 6 8 /=>
Start key ON
Half-speed rotation
Full-speed rotation End of job
Power Supply Cooling
Fan Motor (M21)
Ozone Ventilation Fan Motor (M22)
Fusing Cooling Fan Motor 1 (M23)
Fusing Cooling Fan Motor 2 (M24)
Original Glass Cooling
Fan Motor (M2)
IR Cooling Fan Motor 1 (M3)
IR Cooling Fan Motor 2 (M4)
Exposure Lamp (LA1)
Scanner Motor (M1)
Developing Bias (HV3)
Imaging Unit Motors
(M15, M16, M17, M18)
Main Erase Lamps
Y, M, C, Bk
PC Drum Charge Bias (HV1)
Developing Clutches
(CL11, CL12, CL13, CL14)
Main Motor (M13)
1st Drawer Paper Take-Up
Clutch (CL1)
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retraction cleaning adjustment stabilization
Operations when a new Imaging Unit is detected:
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This page left blank intentionally.
DIAGRAMS
This page left blank intentionally.
CONTENTS
7915/7920 OVERALL WIRING DIAGRAM (1/4)............................................... A-1
7915/7920 OVERALL WIRING DIAGRAM (2/4)............................................... A-2
7915/7920 OVERALL WIRING DIAGRAM (3/4)............................................... A-3
7915/7920 OVERALL WIRING DIAGRAM (4/4)............................................... A-4
7915/7920 ELECTRICAL PARTS LAYOUT ..................................................... A-5
7915/7920 CONECTORS LAYOUT ................................................................. A-6
9020/7915/7920 CIRCUIT DIAGRAM (1/5) ...................................................... A-7
9020/7915/7920 CIRCUIT DIAGRAM (2/5) ...................................................... A-8
9020/7915/7920 CIRCUIT DIAGRAM (3/5) ...................................................... A-9
9020/7915/7920 CIRCUIT DIAGRAM (4/5) ...................................................... A-10
9020/7915/7920 CIRCUIT DIAGRAM (5/5) ...................................................... A-11
7915/7920 ADJUSTMENT ITEM LIST ............................................................. A-12
i
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Electrical.fm Page 1 Friday, February 16, 2001 8:45 AM
SYMBOL PART NAME LOCATION GRID SYMBOL PART NAME LOCATION GRID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 CL1 1st Drawer Paper Take-Up Clutch A-8 G-6 PU2 DC Power Supply 2 A~C-29~30 K-3
CL3 Manual Feed Paper Take-Up Clutch A-1~2 B-6 PWB-A Control Board G~I-7~8 H-5
A
7915/7920 ELECTRICAL PARTS LAYOUT UN M
UN C UN Bk
CL11
CL12
Developing Clutch Y
Developing Clutch M
B-16
B-17~18
G-2
G-2
PWB-A
PWB-C
CCD Sensor Board
Image Processing Board
E~F-23~25
D~I-25~27
K-4
K-4
M24 CL13 Developing Clutch C C-16 G-2 PWB-D IR PRIF Board B~C-25~27 K-3
UN Y
PC9 PWB-LK
CL14 Developing Clutch Bk D-18 G-2 PWB-H MSC Board H~I-23~25 C-1
RY1 CL3 LED Unit CL15
2nd Image Transfer Pressure/
E-6 J-8 PWB-I Master Board E~I-10~18 C-6
Retraction Clutch
M23 CL21 Synchronizing Roller Clutch H-2 K-8 PWB-I1 Paper Size Detecting Board D~E-7~8 H-5
HV2
PWB-IC Scanner Motor Drive Board H-20~21 J-4
CL101 2nd Drawer Paper Take-Up Clutch I-5 H-5
B PC15
CNT1 Mechanical Counter (OP) D-36 — PWB-LK LED Board C~E-20~22 B-14
PWB-PIC
PC10 PWB-N1 ATDC Sensor Y B~C-12 C-13
CNT2 Total Counter D~E-36 C-8
PWB-N3 PWB-N2 ATDC Sensor M C-12 B-13
F4 Temperature Fuse G-21 K-4
SW9 PC29
PWB-H PWB-N2 PWB-N3 ATDC Sensor C D-12 B-14
HSD-IDN Memory Board C-33~34 C-1
SW1 PWB-PIC PIC Board A~C-32~34 B-1
PWB-N1 HV1 High Voltage Unit 1 B-21~22 H-4
PC11 CNT2 PWB-S Paper Type Detection Board C~D-7~8 H-8
C 4004D176AB
HV2 High Voltage Unit 2 A~C-5~6 B-4
PWB-T PC18 HV3 High Voltage Unit 3 B~C-19~20 H-4 PWB-T Tech. Rep. Setting Switches Board E-36 C-8
PWB-I M5
Transfer Belt Unit LA1 Exposure Lamp G-21 K-4 PWB-Z Flat Cable G-21~22 K-3
RY1 Charge Neutralizing Relay A-5 B-5
M1 Scanner Motor H-22 J-4
SW4 SW A Paper Size Detecting Switch 1 H-9 I-4
HSD-IDN M2 Original Glass Cooling Fan Motor I-19~20 K-3
M21 SW B Paper Size Detecting Switch 2 H-9 H-5
M3 IR Cooling Fan Motor 1 H-19~20 K-3
PU1
D M4 IR Cooling Fan Motor 2 H-19~20 K-5 SW C Paper Size Detecting Switch 3 I-5 H-5
SW D 2nd Drawer Set Switch H-5 H-5
M5 Cleaning Web Drive Motor E~F-2 C-8
SW1 Power Switch C-36 C-8
M8 Fusing Pressure/Retraction Motor F-2 F-5
SW2 Right Door Switch B-36 F-6
M9 Toner Replenishing Motor C/Bk A-10 K-14
SW3 Front Door Switch C-36 L-12
M10 Toner Replenishing Motor Y/M B-12 L-12
4004D181AB 1st Image Transfer Pressure/ SW4 Left Door Switch B-36 C-4
E M11
Retraction Motor
C~D-6 G-4
SW5 Toner Empty Switch Bk A-10 K-15
M13 Main Motor A-36 G-5
Oil Coating Unit SW6 Toner Empty Switch C A-12 K-14
4004D174AC M14 Fusing Drive Motor E-2 F-6
SW7 Toner Empty Switch M A-12 K-14
M15 Imaging Unit Motor Y A~B-15 G-1
Fusing Unit SW8 Toner Empty Switch Y A-12 L-13
M14 M16 Imaging Unit Motor M A~B-17 G-1
M8 SW9 Upper Right Door Switch A-21 C-8
PC8 SW2 M17 Imaging Unit Motor C C~D-16 G-1
M11 SW10 Size Reset Switch I-19~20 K-5
F M13 Fusing Web Unit M18 Imaging Unit Motor Bk C~D-17~18 G-1
UN Bk LED Array Bk D-22 A-13
PC28 UN21 M21 Power Supply Cooling Fan Motor E-29 C-4
UN C LED Array C D-21 B-13
M15~18 CL101 M22 Ozone Ventilation Fan Motor A-19 H-4
UN M LED Array M D-20 B-12
M23 Fusing Cooling Fan Motor 1 G-2 B-7
UN Y LED Array Y D-20 B-12
UN23 M24 Fusing Cooling Fan Motor 2 F-2 B-5
UN1 Control Panel H~I-22~23 K-5
CL1 PC105 M101 2nd Drawer Paper Take-Up Motor G-6 H-5
G PC3 1st Drawer Set Sensor C-8 H-5
UN20 AIDC/Resist Sensor 1 D-6 H-7
UN20 UN21 AIDC/Resist Sensor 2 D-6 G-6
1st Drawer Paper Near-Empty
PC4 B-8 H-5
Sensor UN23 Temperature/humidity Sensor D-10 H-7
PC4 4004D226AA PC5 CD Paper Size Detecting Sensor B-8 H-7 2nd Drawer Paper Near-Empty
PC3 PC102 UN101
Board
G~H-6 I-8
CL11~14 PC6 1st Paper Empty Sensor B-8 H-7
Imaging Unit (Bk)
PC8 Fusing Retraction Position Sensor G-2 F-5 ✽1: Optional for the U.S.A.
PC103 PC101 ✽2: Optional for the Europe, U.S.A., and Taiwan
H PC104 PWB-S PC9
Fusing Roller Rotation Detecting
Sensor
G-2 B-6
HV1 PC10 Exit Sensor E~F-8 B-8
SW D M101 PC6
Imaging Unit (Y,M,C)
PC11 Toner Supply Door Sensor B-12 C-7
M22 SW C
PC5 UN101 PC13 1st Double Feed Sensor C-8 H-7
HV3 SW B
PC15 Manual Feed Paper Take-Up Sensor B-1~2 C-7
PWB-I1 SW A
I PWB-A PC13
PC17 Synchronizing Roller Sensor I-2 K-9
PC18 Waste Toner Bottle Set Sensor F-36 C-13
PC19 OHP Detecting Sensor H-2 K-10
2nd Image Transfer Pressure
PC23 F-6 K-9
Position Sensor
M1 4004D175AD
PC24 Scanner Home Sensor G-19~20 K-6
PC33 4004D227AA
PWB-IC 2nd Transfer Unit PC25 Original Cover Detecting Sensor H-19~20 K-2
PC31
J PC28
1st Image Transfer Retraction
C-6 G-4
M2 PWB-A Position Sensor
CL15
Hopper Unit
PC29 Waste Toner Full Detecting Sensor F-36 B-12
PWB-Z M4
PC20 Original Size Detecting Sensor FD1
PWB-C PC30 F-19~20 K-3
M9 (✽1)
SW10 PC31 Original Size Detecting Sensor FD2 G-19~20 K-3
PC25 PC24 CL21 PC32 Original Size Detecting Sensor CD1 G-19~20 K-3
K F4
PC33
Original Size Detecting Sensor FD3
F-21 K-3
PU2 (✽2)
SW5 Original Size Detecting Sensor CD2
M10 PC34 F~G-21 K-3
PC30 (✽2)
SW6
PC23 PC101 2nd Drawer Paper Take-Up Sensor H-6 H-8
PWB-D
UN1 SW7
PC17 PC102 2nd Drawer Paper Empty Sensor I-6 H-7
SW8 2nd Drawer Paper Near-Empty
M3 PC19 PC103 I-6 H-6
Sensor
L 4004D177AA PC104 2nd Drawer Door Set Sensor H~I-5 H-6
PC32 LA1 4004D173AB SW3
2nd Drawer Paper Double Feed
PC34 4004D179AB PC105 H-6 H-7
Sensor
PU1 DC Power Supply 1 F~I-28~30 C-4
4004-B301-0A
A-5
Connect.fm Page 1 Friday, February 16, 2001 8:43 AM
CN No. LOCATION GRID CN No. LOCATION GRID
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
CN1 2P I-5 D-4 CN87 2P I-19 H-6
A
7915/7920 CONNECTORS LAYOUT CN2
CN3
3P
3P
H-19
I-19
H-3
H-2
CN5 12P F-33 G-1
Transfer Belt Unit
CN6 8P B-23 L-5
CN80 CN7 8P A-23 K-5
2
CN8 8P C-23 K-6
B
CN9 8P D~E-23 K-7
6 CN46
CN12 2P H-30 D-4
CN41
CN13 2P D-35 C-7
12
CN33 2 3
CN60 CN55 CN31
CN14 2P E-6 G-8
8
C 2 11
12 CN63 CN36
CN16
4004D170AA
CN16 6P E~F-2 C-7
CN65 7 5 CN64 CN72
11 6 CN17 3P E~F-9 D-7
CN62 10
4 CN13 Oil Coating Unit
CN86 CN70 2
2
3 CN20 7P D-6 D-7
CN52 CN77 2 CN42 2 5 3 CN17 Fusing Unit
CH12 CN21 7P D-6 D-7
CN1 CN45
CN50
CN81 CN22 3P H-19 G-5
D 14 12
CN49 3 4
2 CN20 7
4
CN69
9 14 8 3
CN61 CN21 7 CN30 2P H-2 G-8
3
CN82 4
CN53 4 6 CN54 Fusing Web Unit
2 CN83 CN31 3P G-2 C-6
CN51
CN84 CN35 CN56
CN33 8P A~B-3 C-4
CN35 4P B-12 D-4
E CN36 4P A-11 C-7
CN37 2P A-12 H-13
CN38 2P A-12 H-14
4004D166AB CN39 2P A-12 H-14
2nd Transfer Unit 4004D226AA
F CN40 2P A-11 G-15
CN41 2P A-2 C-4
CN14
Hopper Unit CN42 2P D-35 D-6
2 CN45 5P C-35 D-7
2 CN30
CN46 6P C~D-6 B-4
G
CN49 8P D-19 D-2
CN22 2
CN5 CN50 12P C-13 D-2
12 3
3 CN3 2
CN40 CN51 9P F-35 D-2
2 CN52 14P B-23 D-2
CN39
H 2 2 CN53 14P C~D-23 D-2
CN2 CN38
CN87 CN54 4P C-9 D-7
3
CN37 4004D172AB
CN55 2P A-9 C-4
CN56 6P B-9 D-7
4004D168AB
Imaging Unit (Bk)
4004D165AB CN60 12P F-34 C-2
I
CN61 4P G-6 D-3
Imaging Unit (Y,M,C) CN62 11P G~H-33 C-4
CN63 12P H~I-3 C-4
CN64 5P H-33 C-4
J CN65 7P E-6 C-4
CN69 4P D-11 D-7
CN70 11P G-8 C-4
CN72 10P A-13 C-6
8
K CN77 3P E-28 C-3
8
CN80 3P F-2 B-4
CN9
8
4004D227AA CN81 3P G-35 D-3
CN8
8 CN82 3P G-34 D-3
CN7
Description
CN83 3P G-34 D-3
L Number of Pin ➀ Possible to confirm by removing external cover.
CN6 4004D171AB CN84 2P B-35 D-2
1 Not possible to confirm by removing external cover.
CN86 2P B-35 C-3
4004-B401-0A
A-6
Adjustment Item List.fm Page 1 Friday, February 16, 2001 8:48 AM
7915/7920 Adjustment Item List
Remount ATDC Sensor between old and new LED Units
Machine Adjust Image Adjust Counter
Clear/set Maintenance counter
PRT Area IR Area Stabilizer Life
Adjustment/
Background Voltage Margin
Rest and Stabilizer Mode
Setting Items Top Margin
Remount RAM IC (IC5)
Change RAM IC (IC5)
Color Shift Correction
Input value in counter
Change Imaging Unit
Paper Send Position
2nd Transfer Timing
Make 28 or more copies using A3 paper
Serial # Input (IR)
PRT Max Density
Tech. Rep. Mode
Tech. Rep. Mode
Touch Panel Adj.
Gradation Adjust
Dup. Left Margin
Date/Time Input
Stabilizer Mode
Option Memory
Paper Passage
Security Mode
Security Mode
Memory Clear
User’s Choice
User’s Choice
PRT Highlight
Clear counter
ROM Version
Fuser Speed
Update F/W
Loop Adjust
CCD Check
Left Margin
List Output
Left Image
Top Image
Fuser Nip
CD-Mag
FD-Mag
Units/Parts
No
blotch Auto-
7.0 or 5.0 3.0 3.0 10 200 300 mati- Re- Re- Re-
Check 0±1.0 Re- Re- Re- Re- Re- Re-
±0.5 brush ±1.0 – ±1.0 ±1.1 ±1.0 ±1.0 ±1.5 – – – – – – – – – – – – – cally – – Check Check cord cord cord – – –
Items mm input input input place place mount
mm effect mm mm mm mm mm mm adjust- data. data. data.
allow- ed
ed.
Paper Take-Up Roll Replace (3) (1) (2) (3): When setting is changed
Paper Separator Roll
Replace (3) (1) (2) (3): When setting is changed
Assy
Scanner Rail Cleaning (2) (3) (4) (5) (6) (1) (2)-(6): When a fault occurs
Mirrors (1st/2nd/3rd) Cleaning (2) (3) (4) (5) (6) (1) (2)-(6): When a fault occurs
Lens Cleaning (2) (3) (4) (5) (6) (1) (2)-(6): When a fault occurs
Original Glass Cleaning (2) (3) (4) (5) (6) (1) (2)-(6): When a fault occurs
CCD Unit Replace (2) (3) (4) (5) (7) (8) (9) (10) (11) (1) (12) (6) (7)-(11): When a fault occurs
IR Unit Replace (4) (5) (6) (7) (8) (1) (2) (9) (3) (4)-(8): When a fault occurs
(1): When solvent is used
Cleaning (2) (4) (5) (6) (7) (8) (9) (3) (1)
(4)-(8): When a fault occurs
Transfer Belt Unit
Replace (1) (3) (4) (5) (6) (7) (8) (2) (3)-(7): When a fault occurs
Transfer Roller Unit Replace (2) (3) (4) (5) (6) (7) (1) (2)-(6): When a fault occurs
Cleaning
Paper Dust Remover ❍ When Maintenance counter is set
Replace
Imaging Unit Replace (1) (3) (4) (5) (6) (7) (8) (2) (3)-(7): When a fault occurs
LED Cleaning (2) (3) (4) (5) (6) (1) (2)-(6): When a fault occurs
LED Assy Replace (2) (3) (4) (5) (7) (8) (9) (10) (11) (1) (13) (6) (8)-(12): When a fault occurs
(1): Not required if Imaging Unit is also
LED Unit Replace (3) (4) (5) (6) (8) (9) (10) (11) (12) (2) (13) (7) (1) changed at the same time
(9)-(13): When a fault occurs
Ozone Filter Replace ❍ When Maintenance counter is set
Fusing Unit Replace (1) (2) (3)
Fusing Web Unit Replace ❍
Oil Coating Unit Replace (1) (2) (1): When used part is used
MSC Board Replace (2) (3) (1) (3): When version is old
Master Board Replace (4) (3) (1) (2) (2): When version is old
Image Processing
Replace ✽1 (4) (3) (1) (2) (2): When version is old
Board
PIC Board Replace (4) (3) (1) (2) (2): When version is old
ATDC Sensor Replace ❍
Memory Board Add ❍
Exposure Lamp Replace (2) (1)
Control Panel Replace ❍
AIDC/Resist Sensor Replace (2) (1)
RAM IC (IC5) Replace (7) (11) (4) (13) (1) (2) (3) (12) (6) (8) (9) (10) (5)
Memory Clear Replace (6) (10) (4) (12) (1) (2) (3) (11) (5) (7) (8) (9)
F/W update Replace (3) (2) (1)
Ref. Page ☞ D-78 ☞ D-81 ☞ D-70 ☞ D-70 ☞ D-72 ☞ D-73 ☞ D-82 ☞ D-83 ☞ D-84 ☞ D-85 ☞ D-74 ☞ D-75 ☞ D-88 ☞ D-88 ☞ D-89 ☞ S-22 ☞ S-22 ☞ S-25 ☞ S-25 ☞ S-28 ☞ S-29 ☞ S-29 ☞ S-23 ☞ D-69 ☞ S-33 ☞ D-87 ☞ D-13 – ☞ S-30 ☞ S-29 ☞ S-10 ☞ S-17 ☞ S-37 ☞ S-39 ☞ S-7 ☞ S-10 ☞ S-17 ☞ S-37 ☞ D-95 ☞ D-97 ✽2 ☞ D-97
✽1: Adjustment data has been written in the Image Processing Board for replacement and is cleared when the serial number is input.
If the data is cleared, readjust “IR Area” and adjust the Original Size Detecting Sensors. 4004-7993-11
✽2: See “Unit Replacement Manual.”
NOTE: Be sure to record the data of User’s Choice, Tech. Rep. Mode, and Security Mode before performing a memory clear.
A-12
UNIT REPLACEMENT
MANUAL
18605
This page left blank intentionally.
CONTENTS
1. The Unit Life Manual ........................................................................................ 1
2. The Indication of Replacement for CRU/TFU/FRU .......................................... 1
3. Unit Replacement Manual ............................................................................... 1
3-1. Unit Layout ............................................................................................... 1
3-2. Replacing the Units .................................................................................. 2
(1) Replacing the Fusing Web Unit ....................................................... 2
(2) Replacing the Oil Coating Unit ........................................................6
(3) Replacing the Imaging Unit (C, M, Y) .............................................. 11
(4) Replacing the Waste Toner Bottle ................................................... 19
(5) Replacing the Imaging Unit Bk ........................................................21
(6) Replacing the Fusing Unit ............................................................... 22
(7) Replacing the Paper Dust Remover, Image Transfer Roller Unit,
Image Transfer Belt Unit, and Ozone Filter .....................................26
i
This page left blank intentionally.
1. The Unit Life Manual
NOTES
• The life specifications values represent the number of copies made or figures equivalent to it when given conditions are met. They can be more or less depending on the copier operating conditions
of each individual user.
• The initiation of a new copy cycle is inhibited upon 1K after a near life condition has been detected for all units (except the Toner Bottle and Waste Toner Bottle).
Copying Condition
Unit Life Spec. Value Description Near Life Value Life Value
Code
Toner Bottle – B/E An approximate life value is 10K under the specified conditions. – 10K
A waste toner full condition is detected when about 4.5K copies are made after a
Waste Toner Bottle 40K B/C/D/E/F – 40K
waste toner near-full condition has been detected.
The life specifications value is based on A4C or Letter C. A near life condition is
Fusing Web Unit 17K B/C/D/F detected when a web empty condition is detected or a predetermined number of 16K 17K
copies are made, whichever arrives earlier.
20-cpm copier Oil Coating Unit 33K The life specifications value is based on A4C or Letter C. A near life condition or a 33K 34K
life condition is detected when the Oil Coating Roller has turned a predetermined
A/B/C/D/F
15-cpm copier Oil Coating Unit 26K period of time or a predetermined number of copies are made, whichever arrives 26K 27K
earlier.
Fusing Unit 101K B/C/D/F The life specifications value is based on A4C or Letter C. 101K ✽1 102K
✽2 120K ✽2 121K
Transfer Belt Unit 120K A/B/C/D/F The life specifications value is based on A4C or Letter C.
(17400M) (17545M)
✽3 4415M ✽3 4562M
20-cpm copier Imaging Unit (C, M, and Y) 30K
1
(30K) (31K)
✽3 4415M ✽3 4562M
15-cpm copier Imaging Unit (C, M, and Y) 27K The near life and life time values are detected when the PC Drum has turned or the (27K) (28K)
A/B/C/D/F Developing Unit has been energized for a predetermined period of time, whichever
arrives earlier. ✽3 6972M ✽3 7122M
20-cpm copier Imaging Unit (Bk) 50K
(50K) (51K)
✽3 6972M ✽3 7122M
15-cpm copier Imaging Unit (Bk) 47k
(47K) (48K)
M: minutes
✽ 1: As a rule, the Fusing Unit is to be replaced at the same time that the Fusing Web Unit is replaced a sixth time (17K × 6 = 102K). If the Fusing Web Unit is replaced before 17K is reached, there
will be a discrepancy in the replacement cycle, resulting in a near life and life value ranging between 90K and 110K.
✽ 2: The life of the Transfer Belt Unit is controlled based on the number of copies made. The life counter gives a time value display.
✽ 3: The life of the Imaging Unit is controlled based on a time value. The life counter gives a time value display.
• Conditions for Life Specifications Values
Copying Condition 7920 7915
Job Type A Making two copies per job
Paper Size B A4 or Letter
Color Ratio C C (color) : Bk (black) = 5 : 1 C (color) : Bk (black) = 2.5 : 1
CV/M D 6K 3.5K
Original Density E B/W = 5% for each color
No. of Operating Days per Month F 20 days (Power Switch turned ON and OFF 20 times per month)
This page left blank intentionally.
2. The Indication of Replacement for CRU/TFU/FRU
✽ K=1,000 copies
✽ The contents of the this list are subject to change without notice.
✽ For details, see the unit life manual about the PM cycle.
PM Cycle Page
No. Unit Name Maintenance Message Display
7920/7915 No.
Imaging Unit 7122 min
1. P-21
(Bk) (51K/48K)
Imaging Unit 4562 min
2. P-11
(C) (31K/28K)
Imaging Unit 4562 min
3. P-11
(M) (31K/28K)
1
PM Cycle Page
No. Unit Name Maintenance Message Display
7920/7915 No.
Imaging Unit 4562 min
4. P-11
(Y) (31K/28K)
5. Fusing Unit 102K/102K P-22
Oil Coating
6. 34K/27K P-6
Unit
2
PM Cycle Page
No. Unit Name Maintenance Message Display
7920/7915 No.
Fusing Web
7. 17K/17K P-2
Unit
Waste Toner
8. 40K/40K P-19
Bottle
Image
17545 min
9. Transfer Belt P-26
(121K/121K)
Unit
3
PM Cycle Page
No. Unit Name Maintenance Message Display
7920/7915 No.
Image
10. Transfer Nothing to indicate 121K/121K P-26
Roller Unit
Paper Dust
11. Nothing to indicate 121K/121K P-26
Cleaner
12. Ozone Filter Nothing to indicate 121K/121K P-26
4
3. Unit Replacement Manual
3-1. Unit Layout
Image Transfer Belt Unit
Replace every 121 K.
Replace the waste toner
bottle about 4.5 K prints
after WASTE TONER
BOTTLE NEARLY FULL is
detected.
Ozone Filter
Replace every 121 K.
4004D301AA
Imaging Unit
C, M, Y: Replace every 4,562 M.
Bk: Replace every 7,204 M.
Fusing Web Unit
Replace the web unit every 17 K prints,
or about 1 K prints after WEB UNIT
NEARLY EMPTY is detected.
Fusing Unit
Replace every 102 K.
Oil Coating Unit
Replace every 34 K or
325,000 sec.
Paper Dust Remover
Replace every 121 K.
Image Transfer Roller Unit
Replace every 121 K.
4004D351CA
1
3-2. Replacing the Units
(1) Replacing the Fusing Web Unit
Removal method
NOTE
• Before replacing the fusing web unit, ensure that it is not hot.
1. Turn OFF the main switch,
then wait for about 20 min-
utes.
2. Open the Upper Right
Door.
NOTE
• When opening the upper
right door, be sure to sup-
port it with your hand until it
is in the fully open position.
If you remove your hand
from the upper right door, it
may drop, and the resulting
impact may cause the
4004D352CA
hinges to bend.
3. Release the two blue lock
levers.
(➀: Push up, ➁: Rotate)
➁
➀
➁
➀
4004D305AA
2
4. Grasp the two blue lock
levers, and remove the
fusing web unit.
4004D306AA
NOTE
• Do not touch the metal ter-
minals beneath the fusing
Terminals (metal)
web unit (on the fusing unit
side).
Failure to observe this pre-
caution may cause an elec-
trostatic discharge, resulting
in a breakdown.
4004D307AA
3
Installation method
1. Remove the fusing web
unit from its box, and
remove the packing mate-
rial.
2. Grasp the two blue lock
levers, and set the fusing
web unit in place.
NOTE
• When setting the fusing web
unit, align the ▼ mark on
the fusing web unit with the
▼ mark on the fusing unit.
4004D308AA
3. Lock the two blue lock
levers.
➀
(➀: Push, ➁: Rotate,
➂: Push down)
➁
➂ ➀
➁
➂
4004D309AA
4
4. Close the Upper Right
Door.
4004D353CA
5
(2) Replacing the Oil Coating Unit
Removal method
NOTE
• Before replacing the oil coating unit, ensure that it is not hot.
• When placing the oil coating unit on a bench, for example, stand it upright.
1. Turn OFF the main switch,
and wait for about 20 min-
utes.
2. Open the Upper Right
Door.
NOTE
• When opening the upper
right door, be sure to sup-
port it with your hand until it
is in the fully open position.
If you remove your hand
from the upper right door, it
may drop, and the resulting
impact may cause the
4004D352CA
hinges to bend.
6
3. Release the two green lock levers.
4004D312AA
4. Grasp the two green han-
dles, and remove the oil
coating unit.
4004D313AA
7
NOTE
Terminal (metal) • Do not touch the metal ter-
minals beneath the fusing
web unit (on the fusing unit
side).
Failure to observe this pre-
caution may cause an elec-
trostatic discharge, resulting
in a breakdown.
4004D314AA
8
Installation method
1. Withdraw the oil coating
unit from its box, and
remove the packing mate-
rial.
2. Grasp the two green han-
dles, and set the oil coat-
ing unit in place.
4004D315AA
3. Lock the two green lock levers.
4004D316AA
9
4. Close the Upper Right
Door.
4004D353CA
10
(3) Replacing the Imaging Unit (C, M, Y)
Removal method
1. Turn OFF the main switch.
2. Unplug the power cord.
3. Disconnect the grounding
cord.
4. Open the Front Door.
4004D317AA
5. Release the lock lever of
the imaging unit.
4004D318AA
11
6. Remove the removal jig of
the imaging unit from the
main unit.
4004D319AA
7. Set the removal jig of the
imaging unit in place.
8. Slowly rotate the jig clock-
wise until it is fixed.
4004D320AA
9. Install the bottom cover of
the imaging unit.
NOTE
• When installing the bottom
cover of the imaging unit,
align it with the blue label on
the lock lever.
4004D321AA
12
10. Grasp the removal jig of
the imaging unit, then
slowly withdraw the imag-
ing unit while supporting
the bottom cover with your
hand.
NOTE
• Do not remove the bottom
cover after removing the
imaging unit.
4004D322AA
11. Remove the removal jig of
the imaging unit, and
return it to the main unit.
4004D323AA
13
Installation method
NOTE
• To prevent damaging the imaging unit by exposure to light, keep the imaging unit in its
light-proof vinyl pouch until immediately before installing it.
• When holding the Imaging Unit, be sure to hold it by its bottom cover.
If the Top Imaging Unit Cover is hold, it may full off or the PC Drum installed on the
Imaging Unit may be damage, resulting in decreased image quality.
1. Remove the imaging unit
from its box, then remove
the light-proof vinyl pouch.
2. Tilt the imaging unit to the
left, and shake it gently
twice in the tilted direc-
tion, then tilt the imaging
unit to the right, and shake
it gently twice in the tilted
direction.
4004D324AA
3. Remove the protective
tapes.
C4004U213AA
14
4. Remove the shipping
cushion.
C4004U214AA
NOTE
• When installing the imaging unit, ensure that the color of the mounting guide of the
imaging unit is the same as the color of the label at the mounting position on the main
unit.
5. Support the bottom of the
imaging unit with your left
hand, and the bottom front
side with your right hand,
hold the unit horizontally,
then push it in until the
front edge stops.
6. Confirm that the imaging
unit is inserted to the posi-
tion where the front edge
of the bottom cover
touches the main unit.
4004D325AA
NOTE
• Do not insert the Imaging Unit into its compartment at an angle.
15
7. Using your left hand, sup-
port the bottom of the
imaging unit, then using
your right hand gently
push in the part shown in
the drawing of the unit.
NOTE
• When installing the imaging
unit, insert it to the position
where it clicks into place.
4004D326AA
8. Pull out the Imaging Unit
Cover.
9. Make sure that the Imag-
ing Unit is inserted as far
as possible.
4004D327AA
10. Gently return the lock lever
of the imaging unit so that
the unit locks.
NOTE
• When locking the imaging
unit, return the lock lever to
the position where it clicks
into place.
4004D328AA
16
11. Close the Front Door.
4004D329AA
12. Separate the top and bot-
tom halves of the Imaging
Unit Cover.
4004D330AA
17
13. Install the top cover on the
imaging unit that you
removed in step 10 on
Page 13.
NOTE
• The four claws of the top
cover must be engaged with
the four claw holders.
14. Connect the grounding
lead.
15. Connect the power cord.
16. Turn ON the main switch.
4004D331AA
NOTE
• The bottom cover of the imaging unit is needed the next time you replace the imaging
unit, so store it carefully.
18
(4) Replacing the Waste Toner Bottle
NOTE
• If the paper exit system option is installed, remove it from the main unit before replac-
ing the waste toner bottle.
• When removing the paper exit system option, support the horizontal transport unit with
your hand to prevent it from dropping.
1. Turn OFF the main switch.
2. Open the Left Door.
4004D332AA
3. Grasp the handle, and
remove the waste toner
bottle.
4004D354CA
19
NOTE
• Raise the waste toner bottle gently before removing it.
• If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt
the waste toner bottle when removing it.
• Do not leave the waste toner bottle in a tilted condition after removing it.
4. Remove the seals from the
two toner collecting ports.
4004D337AA
5. Peel off the seals for block-
ing the two toner collecting
ports, and place them over
the toner collecting ports.
4004D334AA
20
Installation method
1. Remove the waste toner
bottle from its box, and
remove the packing mate-
rial.
2. Grasp the handle, and set
the waste toner bottle in
place.
4004D355CA
3. Close the Left Door.
4. Turn ON the main switch.
4004D336AA
(5) Replacing the Imaging Unit Bk
For the method of replacing the imaging unit, refer to “(3) Replacing the Imaging Unit (C, M,
Y)”.
☞ page 11
21
(6) Replacing the Fusing Unit
Removal method
NOTE
• Before replacing the fusing unit, ensure that it is not hot.
1. Turn OFF the main switch,
then wait for about 20 min-
utes.
2. Open the Right Door.
4004D356CA
3. Open the Upper Right
Door.
NOTE
• When opening the upper
right door, be sure to sup-
port it with your hand until it
is in the fully open position.
If you remove your hand
from the upper right door, it
may drop, and the resulting
impact may cause the
hinges to bend.
4004D352CA
22
4. Grasp the blue lever, and
remove the fusing unit.
4004D357CA
5. Grasp the two handles
with the blue labels, and
remove the fusing unit.
4004D338AA
23
Installation method
1. Remove the fusing unit
from its box, and remove
the packing material.
2. Grasp the two handles
with the blue labels, and
install the fusing unit.
NOTE
• When installing the fusing
unit, align it with the posi-
tioning pin on the main unit.
4004D339AA
3. Grasp the blue lever, and
push in the fusing unit.
4004D358CA
4. Close the Upper Right
Door.
4004D353CA
24
5. Close the Right Door.
NOTE
• Ensure that both the front
and rear sides are locked.
4004D359CA
25
(7) Replacing the Paper Dust Remover, Image Transfer Roller Unit, Image Transfer
Belt Unit, and Ozone Filter
Removal method
NOTE
• If the paper exit system option is installed, remove it from the main unit before replac-
ing the paper dust remover.
• When removing the paper exit system option, support the horizontal transport unit with
your hand to prevent it from dropping.
1. Turn OFF the main switch.
2. Open the Right Door.
4004D356CA
3. Remove the paper dust
remover while pushing the
hook with the gray label at
the front to the rear.
4004D340AA
26
4. Release the two blue lock levers.
5. Grasp the two blue lock levers, and remove the image transfer roller unit.
4004D341AA
6. Open the Left Door.
4004D332AA
27
7. Grasp the handle, and
remove the waste toner
bottle.
4004D354CA
NOTE
• Raise the waste toner bottle gently before removing it.
• If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt
the waste toner bottle when removing it.
• Do not leave the waste toner bottle in a tilted condition after removing it.
NOTE
• Do not attempt to pull out the image transfer belt unit when the right door is not open
because you may damage the belt.
8. Pull out the image transfer
belt unit.
4004D360CA
28
9. Remove the ozone filter
while grasping the hooks
at both ends.
4004D343AA
29
Installation method
1. Install the Ozone Filter.
4004D344AA
NOTE
• When installing the image transfer belt unit, wear the gloves packed with the unit.
(This is to prevent the possibility of a defective image due to finger marks adhering to
the transfer film.)
• When inserting the image transfer belt unit, align the boss on the transfer belt unit with
the part of the main unit guide section marked with the arrow.
• When installing the transfer belt, insert it until into clicks into place.
Boss Boss
4004D361CA
30
2. Insert the Image Transfer
Belt Unit.
4004D346AA
3. Grasp the handle, and
install the waste toner bot-
tle.
4004D355CA
4. Close the Left Door.
4004D336AA
31
5. Grasp the two blue lock levers, and install the image transfer roller unit.
6. Lock the two blue lock levers.
4004D347AA
7. Install the paper dust
remover.
NOTE
• Push in the hook with the
gray label until it clicks into
place.
4004D348AA
32
8. Close the Right Door.
NOTE
• Both the front and rear
sides must be locked.
9. Turn ON the main switch.
4004D359CA
33
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