SERVICE MANUAL

MODEL

AD-231
Automatic Duplexing Unit
(With Parts Section)

DECEMBER 2002
CSM-AD231

AD-231
SERVICE MANUAL
Used On 7915/7920/8020/8031
December 2002

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 Publishing Department

2002, KONICA BUSINESS TECHNOLOGIES, INC.

All rights reserved.
Printed in U.S.A.

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LY

Safety Precautions for Inspection and Service

When performing inspection and service procedures, observe the following precautions to
prevent accidents and ensure utmost safety.
Depending on the model, some of the precautions given in the following do not apply.

Different markings are used to denote specific meanings as detailed below.

WARNING
CAUTION

Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.

The following graphic symbols are used to give instructions that need to be observed.
Used to call the service technicians attention to what is graphically represented
inside the marking (including a warning).
Used to prohibit the service technicians from doing what is graphically represented inside the marking.
Used to instruct the service technicians to do what is graphically represented
inside the marking.

WARNING
1. Always observe precautions.
Parts requiring special attention in this product will include a label containing the
mark shown on the left plus precautionary notes. Be sure to observe the precautions.
Be sure to observe the Safety Information given in the Operators Manual.
2. Before starting the procedures, be sure to unplug the power cord.
This product contains a high-voltage unit and a circuit with a large current
capacity that may cause an electric shock or burn.
The product also contains parts that can jerk suddenly and cause injury.
If this product uses a laser, laser beam leakage may cause eye damage or
blindness.
3. Use the specified parts.
For replacement parts, always use the genuine parts specified in the manufacturers parts manual. Installing a wrong or unauthorized part could cause
dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire.
Replace a blown electrical fuse or thermal fuse with its corresponding genuine
part specified in the manufacturers parts manual. Installing a fuse of a different
make or rating could lead to a possible fire. If a thermal fuse blows frequently,
the temperature control system may have a problem and action must be taken
to eliminate the cause of the problem.

P-1

4. Handle the power cord with care and never use a multiple outlet.
Do not break, crush or otherwise damage the power cord. Placing a heavy
object on the power cord, or pulling or bending it may damage it, resulting in a
possible fire or electric shock.
Do not use a multiple outlet to which any other appliance or machine is connected.
Be sure the power outlet meets or exceeds the specified capacity.
5. Be careful with the high-voltage parts.
A part marked with the symbol shown on the left carries a high voltage. Touching it could result in an electric shock or burn. Be sure to unplug the power cord
before servicing this part or the parts near it.
6. Do not work with wet hands.
Do not unplug or plug in the power cord, or perform any kind of service or
inspection with wet hands. Doing so could result in an electric shock.

7. Do not touch a high-temperature part.

A part marked with the symbol shown on the left and other parts such as the
exposure lamp and fusing roller can be very hot while the machine is energized.
Touching them may result in a burn.
Wait until these parts have cooled down before replacing them or any surrounding parts.
8. Maintain a grounded connection at all times. (This item may not apply in the USA.)
Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could
result in an electric shock or fire.
Never connect the ground wire to a gas pipe, water pipe, telephone ground wire,
or a lightning conductor.
9. Do not remodel the product.
Modifying this product in a manner not authorized by the manufacturer may
result in a fire or electric shock. If this product uses a laser, laser beam leakage
may cause eye damage or blindness.
10. Restore all parts and harnesses to their original positions.
To promote safety and prevent product damage, make sure the harnesses are
returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being
crushed.
To promote safety, make sure that all tubing and other insulating materials are
returned to their original positions. Make sure that floating components mounted
on the circuit boards are at their correct distance and position off the boards.

P-2

CAUTION
1. Precautions for Service Jobs
A toothed washer and spring washer, if used originally, must be reinstalled.
Omitting them may result in contact failure which could cause an electric shock
or fire.
When reassembling parts, make sure that the correct screws (size, type) are
used in the correct places. Using the wrong screw could lead to stripped
threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.
Take great care to avoid personal injury from possible burrs and sharp edges on
the parts, frames and chassis of the product.
When moving the product or removing an option, use care not to injure your
back or allow your hands to be caught in mechanisms.
2. Precautions for Servicing with Covers and Parts Removed
Wherever feasible, keep all parts and covers mounted when energizing the
product.
If energizing the product with a cover removed is absolutely unavoidable, do not
touch any exposed live parts and use care not to allow your clothing to be
caught in the moving parts. Never leave a product in this condition unattended.
Never place disassembled parts or a container of liquid on the product. Parts
falling into, or the liquid spilling inside, the mechanism could result in an electric
shock or fire.
Never use a flammable spray near the product. This could result in a fire.
Make sure the power cord is unplugged before removing or installing circuit
boards or plugging in or unplugging connectors.
Always use the interlock switch actuating jig to actuate an interlock switch when
a cover is opened or removed. The use of folded paper or some other object
may damage the interlock switch mechanism, possibly resulting in an electric
shock, injury or blindness.
3. Precautions for the Working Environment
The product must be placed on a flat, level surface that is stable and secure.
Never place this product or its parts on an unsteady or tilting workbench when
servicing.
Provide good ventilation at regular intervals if a service job must be done in a
confined space for a long period of time.
Avoid dusty locations and places exposed to oil or steam.
Avoid working positions that may block the ventilation ports of the product.
4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)
Replace a rundown battery with the same type as specified in the manufacturers parts manual.
Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.
Dispose of used batteries according to the local regulations. Never dispose of
them at the users premises or attempt to try to discharge one.

P-3

5. Precautions for the Laser Beam (Only for Products Employing a Laser)
Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure
to unplug the power cord before removing this cover.
If removing this cover while the power is ON is unavoidable, be sure to wear
protective laser goggles that meet specifications.
Make sure that no one enters the room when the machine is in this condition.
When handling the laser unit, observe the Precautions for Handling Laser
Equipment.
.

1167P001AA

DANGER
Invisible laser radiation when open.

AVOID
DIRECT
TO BEAM

EXPOSURE
0947-7127-01
1144D270AA

P-4

Other Precautions
To reassemble the product, reverse the order of disassembly unless otherwise specified.
While the product is energized, do not unplug or plug connectors into the circuit boards
or harnesses.
The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy
disk, magnetic card, or CRT tube.
An air gun and vacuum cleaner generates a strong electrostatic charge that can destroy
the ATDC sensor and other sensors. Before cleaning a component with one of these
devices, be sure to remove all the sensors. Otherwise, use a blower brush and cloth
when cleaning parts.
When handling circuit boards with MOS ICs, observe the INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs (applicable only to the products using MOS ICs).
The PC Drum is a very delicate component. Observe the precautions given in HANDLING OF THE PC DRUM because mishandling may result in serious image problems.
Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.
After completing a service job, perform a safety check. Make sure that all parts, wiring
and screws are returned to their original positions.
Check the area surrounding the service site for any signs of damage, wear or need of
repair.
Do not pull out the toner hopper while the toner bottle is turning. This could result in a
damaged hopper motor or locking mechanism.
If the product is to be run with the front door open, make sure that the toner hopper is in
the locked position.

P-5

Used Batteries Precautions

ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturers instructions.
Germany
VORSICHT!
Explosionsgefahr bei unsachgemen Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen hnlichen typ.
Entsorgung gebrauchter batterien nach Angaben des Herstellers.
France
ATTENTION
Ily a danger dexplosion sily a remplacement incorrec de la batterie.
Remplacer uniquement avec une batterie du meme type ou dun type quivalent recommande par le constructueur.
Mettre au rebut les batteries usages conformment aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering Udskiftning m kun ske med batteri af samme fabrikat og type.
Levr det brugte batteri tilbage til leverandren.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
Sweden
VARNING
Explosionsfara vid felaktigt batteribyte.
Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren.
Kassera anvnt batteri enligt fabrikantens instruktion.
Finland
VAROlTUS
Paristo voi rjht, los se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit Kytetty paristo
valmistajan ohjeiden mukaisesti.

P-6

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%ODQNSDJH

1.

SPECIFICATIONS

Type

: Switchback and Circulating Duplex Unit

Installation

: Mounted on the right side door of copier

Type of Copy Paper

: Plain paper

Paper Sizes

: A5L to A3Wide or 5-1/2 8-1/2L to 11 17L

Paper Weight

: 64 to 90 g/m2 or 17 to 24 lbs.

Registration

: Center

Power Requirements

: DC24 V 10 %, DC5.1 V 5% (supplied from copier)

Max. Power Consumption

: 17 W

Dimensions

: Width ... 139 mm or 5-1/2 in

Depth ... 440 mm or 17-1/4 in
Height ... 365 mm or 14-1/4 in

Weight

: 3.1 kg or 6-3/4 lbs.

Environmental Requirements

: Same as copier

2.

PARTS IDENTIFICATION

Duplex Unit Door

4657M001AA

M-1

3.

CROSS-SECTIONAL VIEW

4657M002AA

1. Duplex Unit Transport Roll 2

2. Duplex Unit Transport Roller 2
3. Duplex Unit Transport Roll 3

4. Duplex Unit Transport Roller 3

5. Duplex Unit Transport Roll 1
6. Duplex Unit Transport Roller 1

M-2

4.

DRIVE SYSTEM

Duplex Unit Transport

Drive Mechanism

Switchback Drive
Mechanism

4657M003AA

5.

ELECTRICAL COMPONENTS LAYOUT

M1

PI2
PWB-A
PI1

M2
PC1
4657M004AB

Symbol

Name

PWB-A Duplex Control Board

M1
Switchback Motor
M2
Duplex Unit Transport Motor

Symbol

Name

PC1
PI1

Duplex Unit Transport Sensor 2

Duplex Unit Transport Sensor 1
(in PWB-A)
Duplex Unit Door Set Sensor (in PWB-A)

PI2

M-3

6.

MECHANICAL OPERATIONS

6-1.
(1)

Switchback Mechanism
Switchback Operation

The Paper Exit Roller of the copier is used to subject the 1-sided copy to a switchback
sequence so that the 1-sided copy is to be transported through the Duplex Unit.
Feeding the Paper into Duplex Unit

Paper Exit Roller

Paper Exit Sensor PC10

(2)

4657M005AB

Paper Exit Roller Drive Coupling Mechanism

When the Duplex Unit is mounted, the tip of the Duplex Unit Lever raises the Idle Lever to
cut off the drive from the copier (Fusing Rollers) and the Paper Exit Roller is driven by the
Switchback Motor.
Switchback Motor
M1

Idle Lever
Duplex Unit
Lever

Paper Exit Roller

4657M526AA

(3)

4657M514AA

Switchback Motor Control

Rotation of the Switchback Motor is controlled by the signals output from pins 1 to 4 of
PJ2A on the Duplex Control Board.

M-4

6-2.
(1)

Transport and Duplex Paper Take-Up Mechanism

Transport and Duplex Paper Take-Up Operation

Drive for the Duplex Unit is provided by the Duplex Unit Transport Motor.
Duplex Unit Transport Roller 1

Duplex Unit
Transport Roller 2

Duplex Control Board PWB-A

Duplex Unit Transport

Motor M2
Duplex Unit Transport Roller 3

4657M007AB

(2)

Duplex Unit Transport Motor Control

Rotation of the Duplex Unit Transport Motor is controlled by the signals output from pins 1
to 4 of PJ3A on the Duplex Control Board.

M-5

6-3.

2-Sided Copying Method

The following two types of 2-sided copying methods are available.

2-Sided Copying Methods

2-sided copying with a single sheet of paper resident

in the system
2-sided copying with two sheets of paper resident in
the system (FD length 215.9 mm or less)

(1)

Operations in 2-sided copying with a single sheet of paper resident in the system

Operation 1
Paper Exit
The first sheet of paper is taken up and fed in from the
Roller
copier drawer and the copier starts the first copy cycle to
produce the copy image of the second page of the original.

4657M521AA

Operation 2
Immediately before the 1-sided copy leaves the Paper Exit
Roller, the direction of rotation of the Paper Exit Roller is
reversed and the 1-sided copy is transported toward and
into the Duplex Unit.

4657M522AA

Operation 3
The 1-sided copy moves through the Duplex Unit and is
directly subject to the second copy cycle without being
stopped.
2

4657M523AA

M-6

Operation 4
The copier carries out the second copy cycle to produce
the copy image of the first page of the original on the other
side of the 1-sided copy.

4657M524AA

Operation 5
While feeding the first 2-sided copy out of itself, the copier
carries out the first copy cycle for the second sheet of
paper to produce the copy image of the fourth page of the
original.

2
1

4657M525AA

Steps 2 through 5 are repeated.

witchback Motor
1

ON
OFF

uplex Unit
ransport Motor M2

ON
OFF

Forward Backward
Rotation Rotation

Forward
Rotation

anual Feed Paper ON

ake-Up Clutch CL3 OFF
xit Sensor PC10

H
L

ynchronizing Roller
ensor PC17

H
L

uplex Unit Transport H

ensor 2 PC1
L
4657M513CA

M-7

(2)

Operations in 2-sided copying with two sheets of paper resident in the system

Operation 1
The first sheet of paper is taken up and fed in from the
copier drawer and the copier starts the first copy cycle to
produce the copy image of the second page of the original.

Paper Exit
Roller
2

4657M515AA

Operation 2
Immediately before the first 1-sided copy leaves the Paper
Exit Roller, the direction of rotation of the Paper Exit Roller
is reversed and the first 1-sided copy is transported toward
and into the Duplex Unit.
At the same time, the second sheet of paper is taken up
and fed into the copier.

4657M516AA

Operation 3
The copier carries out the first copy cycle for the second
sheet of paper to produce the copy image of the fourth
page of the original.
At the same time, the first 1-sided copy is transported
through the Duplex Unit.

4
2

4657M517AA

Operation 4
The copier produces the copy image of the first page of the
original on the first 1-sided copy that has been fed through
the Duplex Unit.
At the same time, the second sheet of paper is subjected
to a switchback sequence at the exit section and fed into
the Duplex Unit. It is then fed through the Duplex Unit without being stopped and into the copier again.

4657M518AA

Operation 5
While feeding the first sheet of paper out, the copier carries
out a copy cycle for the second sheet of paper to produce
the copy image of the third page of the original.

2
1

4657M519AA

M-8

Operation 6
While feeding the second sheet of paper out, the copier
takes up and feeds the third sheet of paper to produce the
copy image of the sixth page of the original on the third
sheet of paper.

4
2

4657M520AA

Steps 2 through 6 are repeated.

M-9

Blank page

DIS/REASSEMBLY,
ADJUSTMENT

Blank page

1.
1-1.

DISASSEMBLY
Maintenance Schedule

To ensure good copies and an extended service life of the Duplex Unit, it is recommended that the maintenance jobs described in this schedule be carried out.
Maintenance
Tools
Schedule Cycle Used for Parts No. QTY Reference
Page
Clean Replace Cleaning

PM Parts
Duplex Unit Transport Roller 1, 2

Duplex Unit Transport Roll 1, 2

Cloth,
alcohol

D-1

D-1

Cleaning (indicated by in the above schedule) should be performed when a paper

transport failure occurs.
The above information is subject to change without notice.

1-2.

Removal of the Duplex Unit

1. Remove the wiring cover and disconnect two connectors.

4657D001AA

2. Open the Duplex Unit Door.

3. Remove two shoulder screws and the Duplex Unit.

4657D002AA

1-3.

Cleaning of Duplex Unit Transport Roller 1 and 2 and Duplex

Unit Transport Roll 1 and 2
1. Open the Duplex Unit Door.
2. Wipe the surfaces of Duplex Unit Transport Roller
1 and 2 and Duplex Unit Transport Roll 1 and 2
clean with a soft cloth dampened with alcohol.

4657D003AA

D-1

2.
2-1.

ADJUSTMENT
Changing the Cable Tension Strength (Replacement of the
Spring)
1. Open the Upper Right Door of the copier.
NOTE
Do not jerk the Upper Right Door open, as a malfunction could result. Be sure to hold onto the door
with both hands and open it gently.

4657D503AA

2. Remove two screws and the Exit Cover of the

copier.

4657D006AA

3. Remove the spring and, instead, install the spring

furnished with the Duplex Unit in position.
NOTE
When the Duplex Unit is mounted, the Right Door of
the copier can jerk open by its own weight as it is
opened, damaging the copier. Be sure to replace the
spring to change the tension strength of the cable.
4657D007AA

D-2

2-2.

Reference Position Adjustment

1. Press the Utility key and touch Meter Count.
2. Press the following keys in this order to show the
Tech. Rep. mode screen: Stop 0 0 Stop
0 1.
3. Touch Machine Adjust.

k4659P004CA

4. Touch PRT Area.

4659P005CA

5. Touch Dup. Left Margin.

6. Touch 1st.
NOTE
Use the same procedures that follow for 2nd, 3rd,
and 4th.

4657D201AA copy

Feeding
Direction

7. Press the Start key to produce a test print.

8. Measure dimension A on the second side to see if
it falls within the specifications.
Specifications: 3.0 1.0 mm

4657D502AA

9. Using
or
key, input the difference
between the measured value of dimension A and
the specifications.
10. Produce another test print and make a check
again.

D-3

Blank page

MISFEED DETECTION

Blank page

1.

MISFEED DETECTION

1-1.

Location of Misfeed Detecting Sensors

Duplex Unit Transport

Sensor 1 PI1
Synchronizing Roller Sensor
PC17
Duplex Unit Transport
Sensor 2 PI2

4657T501AA

1-2.

Misfeed Detection Timing

The following lists the types of misfeed detection and detection timings for different misfeed locations.
The symbol L (for the leading edge) and T (for the trailing edge) given in ( ) indicate
the particular edge of the paper detected by the sensor.
Type

Detection Start

Detection

Paper left

Power Switch ON

Duplex Unit Transport Sensor 1

ON

Paper take-up failure

Manual Feed Paper Take-Up

Clutch ON

Synchronizing Roller Sensor (L)

Misfeed during
transport through unit

Duplex Unit Transport Sensor 1 Duplex Unit Transport Sensor 2

(L)
(L)

T-1

Blank page

ADU (AD-231)

Page 58
December, 2002

Konica Business Technologies

Models 8020/8031
1st Edition

REF.
NO.

PART NUMBER

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

65FA37010
111T50020
111T50030
111T50040
111T50050
25TU75420
111T50060
111T50070
111T77470
111T50080
111T50090
111T80090
111X-9360
111T85030
111T50100
111T50110
111T12420
111T50120
111T50130
111T50140
111T12430
111T50150
111T50160
111T50170
111T47680
111T47690
111T47700
111T47550

DESCRIPTION

Guide
Roller
Roller
Member
Torsion Spring
Bushing
Torsion Spring
Actuator
Gear
Ring
Seal
Motor
PWB Assembly
Photosensor
Shoulder Screw
Tension Spring
Cover
Torsion Spring
Guide
Roller
Cover
Pressure Spring
Lever
Cover Assembly
Stopper
Cover
Cover
Frame Assembly
HARDWARE

Models 8020/8031
1st Edition

Konica Business Technologies

REF.
LTR.

PART
NUMBER

a
b
c
d
e
f
g

00Z253061
25TU03720
00Z253081
00Z163081
00Z283061
111T00020
11YA00370

Page 59
December, 2002