Konica Minolta DI5510, COVER INSERTER B DI5510/DI7210, C-404 DI5510/DI7210, FN-115 DI5510/DI7210, FN-10 User Manual
...
7662-4396-11
SERVICE MANUAL
FIELD SERVICE
Di551/Di650
Di5510/Di7210
Di5510: Europe and North America only.
2004.01
Ver. 1.0
There are using both Official Options name and Popular Options name
in the Di551/Di650/Di5510/Di7210 Service Manual and Option Service
Manual.
EDH-4, EDH-7 : RADF
FN-112, FN-6, FN-121,
FN-10, FN-113, FN-122 : FNS
OT-104 : SF
C-403, C-404 : LT & LCT
Cover Inserter B, Cover Inserter E : PI
PK-2, PK-5 : PK
ZK-2, ZK-3 : PZ
In-System Writer : ISW
KONICA BUSINESS TECHNOLOGIES
CORPORATION COPYRIGHT ©2003
CONTENTS
CONTENTS
SAFETY AND IMPORTANT WARNING
ITEMS
IMPORTANT NOTICE
. . . . . . . . . . . . . . . . . . S-1
. . . . .S-1
DESCRIPTION ITEMS FOR DANGER,
WARNING AND CAUTION . . . . .S-1
SAFETY WARNINGS
SAFETY INFORMATION
IMPORTANT INFORMATION
SAFETY CIRCUITS
INDICATION OF WARNING ON THE MACHINE
. . . . . . . . . . . . . . . . . . .S-2
. . . . . . . . . . . . . . .S-10
. . . . . . . . . . . S-10
. . . . . . . . . . . . . . . . . . S-11
. . .S-13
1. ADJUSTMENT
HOW TO USE THIS SECTION .................................1-1
[1] Scope and Precautions ..............................1-1
ADJUSTMENTS MADE WHEN REPLACING
PARTS.......................................................................1-1
LIST OF ADJUSTMENT ITEMS................................1-2
LCD ADJUSTMENT ..................................................1-4
[1] LCD Control Panel Adjustment ..................1-4
[2] LCD Panel Contrast/Key Sound
Adjustment .................................................1-4
SETTINGS AND ADJUSTMENTS MADE WITH THE
P FUNCTION.............................................................1-4
[1] Checking and Printing the P Function ........1-4
[2] Setting up the P Function ...........................1-4
MODE CHANGING MENU........................................1-5
[1] Mode Selection...........................................1-5
[2] Display Transition of 36 Modes ..................1-6
[3] Display Transition of 25 Modes ..................1-7
[4] Display Transition of Key Operation
Modes.........................................................1-7
25 MODE ...................................................................1-8
[1] Setting the 25 Mode ...................................1-8
[2] List of Adjustment Items for 25 Mode.........1-9
[3] Setting Software DIP Switches.................1-11
[4] Setting the Paper Size..............................1-24
[5] PM Count Resetting .................................1-25
[6] Setting the PM Cycle................................1-26
[7] Collecting Data .........................................1-26
[8] Copy Count by Parts to be Replaced
(Fixed Parts).............................................1-42
[9] Copy Count by Parts to be Replaced
(Optional Parts) ........................................1-47
[10] Setting Passwords....................................1-48
[11] Setting the Telephone Number and/or
Fax Number of the Service Center...........1-49
[12] Setting the Serial Number ........................1-50
[13] Displaying the ROM Version ....................1-50
[14] ISW Setting ..............................................1-51
[15] Setting Date..............................................1-51
36 MODE .................................................................1-52
[1] Setting Method .........................................1-52
[2] High Voltage Adjustment..........................1-52
[3] Charging Grid Voltage Adjustment...........1-53
[4] Drum Peculiarity Adjustment ....................1-54
[5] Drum Peculiarity Adjustment (Manual) .....1-60
[6] User Paper Setting ...................................1-60
[7]
Recall Standard Data (Process Adjustment)
[8] Tray Adjustment .......................................1-61
[9] Magnification Adjustment .........................1-62
[10] Timing Adjustment....................................1-65
[11] RADF Adjustment.....................................1-70
[12] Centring Adjustment .................................1-72
[13] Distortion adjustment (Copier)..................1-75
[14] Non-image area erase check ...................1-75
[15]
Recall standard data (Image adjustment)
[16] Running Test Mode ..................................1-77
3 DIS./ASSEMBLY2 ISW 3 DIS./ASSEMBLY1 ADJUSTMENT3 DIS./ASSEMBLY3 SERVICE3 DIS./ASSEMBLY
4 ELECTRIC PARTS LIST
...1-61
..1-76
CONTENTS
3 DIS./ASSEMBLY1 ADJUSTMENT3 DIS./ASSEMBLY2 ISW3 DIS./ASSEMBLY3 SERVICE3 DIS./ASSEMBLY
4 ELECTRIC PARTS LIST
[17] Test pattern output mode ........................ 1-77
[18] Test pattern density setting ..................... 1-84
[19] Finisher adjustment ................................. 1-84
[20] List Output Mode ..................................... 1-91
47 MODE ................................................................ 1-92
[1] 47 Mode / Multi Mode Setting Method..... 1-92
[2] Adjustment Data Display ......................... 1-94
[3] Hard Disk Check...................................... 1-94
[4] Input checklist.......................................... 1-95
[5] Output checklist..................................... 1-103
OTHER ADJUSTMENT ........................................ 1-108
[1] Centring Adjustment.............................. 1-108
[2] Skew adjustment (Main body) ............... 1-111
[3] Adjusting the LCT Paper Feed Roller
Pressure (C-404 only) ........................... 1-111
[4] Paper up/down plate horizontal
adjustment (LCT only) ........................... 1-112
[5] Skew adjustment (LCT only) ................. 1-114
[6] Tray spring pressure adjustment........... 1-115
[7] Paper feed height (upper limit)
adjustment (LCT only) ........................... 1-117
[8] Pick-up release amount
adjustment (LCT only) ........................... 1-118
[9] RADF mounting position adjustment ..... 1-119
[10] RADF paper skew adjustment............... 1-120
[11] FNS Adjusting the magnets on the
by-pass conveyance guide plate
(FN-112/6/121/10) ................................. 1-121
[12] FNS adjusting the by-pass gate
(FN-112/6/121/10) ................................. 1-122
[13] FNS Adjusting the Shift Position
(FN-112/6/121/10) ................................. 1-124
[14] FNS Adjusting the paper exit solenoid
(FN-112/6/121/10) ................................. 1-125
[15] FNS Adjusting the mount location of the
paper exit arm (FN-112/6/121/10) ......... 1-127
[16] FNS Adjusting the mount location
of the alignment plates / U
(FN-112/6/121/10) ................................. 1-128
[17] FNS Adjusting the mount location
of the alignment plates / L (FN-6/10) ..... 1-129
[18] FNS Adjusting the stapling position
(Flat stapling) (FN-112/6/121/10) .......... 1-130
[19] FNS Adjusting the stapler vertical
positioning (FN-112/6/121/10) ............... 1-131
[20] FNS Adjusting the stapling position
(stapling-and-folding) (FN-6/10) ............ 1-133
[21] FNS Adjusting the angle of the folding
stopper (FN-6/10) .................................. 1-134
[22] FNS Adjusting the folding force
(FN-6/10) ............................................... 1-135
[23] FNS Adjusting the three-holding positions
(FN-6/10) ............................................... 1-136
[24] PK Adjusting the tilt of the punch hole position
(PK-2) .................................................... 1-137
[25] PK Adjusting the tilt of the punch hole position
(PK-5).....................................................1-138
[26] PK Adjusting the punch hole vertical position
(PK-2).....................................................1-139
[27] Sensitivity adjustment for the PK paper edge
sensor (PK-5) .........................................1-140
[28] PI Centering Adjustment (PK-2).............1-141
[29] Adjusting the tilt of PI (when PK punch
is used) (PK-2) .......................................1-142
[30] Sensitivity adjustment for the PZ paper edge
sensor (PZ) ............................................1-143
[31] FNS Stapler Driver Belt Position
Adjustment (FN-112/6/121/10)...............1-144
[32] Adjusting the PZ Paper-Path Switching
Solenoid (PZ) .........................................1-146
[33] Adjusting the Tension of the PZ Punch
Shift Timing Belt (PZ) .............................1-147
[34]
Adjusting the PZ 1st Folding Skew (PZ)
[35] Adjusting the Position of the PZ 2nd
Folding Stopper (PZ) ..............................1-149
[36] Adjusting the PZ 2nd Folding Skew 2nd
Stopper Assembly (PZ) ..........................1-150
[37] FNS Adjusting the Magnets on Conveyance
Guide Plate B (FN-115)..........................1-151
[38] FNS Adjusting the Magnets on Conveyance
Guide Plate C (FN-115) .........................1-152
[39] FNS Adjusting the Sub-tray Paper Exit Gate
(FN-115).................................................1-153
[40] FNS Adjusting the Paper-Path Switching Gate
(FN-115).................................................1-154
[41] FNS Adjusting the By-pass Gate
(FN-115).................................................1-156
[42] FNS Adjusting the Shift Position
(FN-115).................................................1-157
[43] FNS Adjusting Opening/Closing
at the Paper Exit (FN-115) .....................1-158
[44] FNS Adjusting the Paper Exit-Opening
Solenoid (FN-115)..................................1-159
[45] FNS Adjusting the Paper Exit-Opening
Lower Guide Plate (FN-115) ..................1-160
[46] FNS Adjusting the Mount Location of
the Paper Exit Arm (FN-115)..................1-161
[47] FNS Adjusting the Mount Location of
the Upper Alignment Plates (FN-115) ....1-162
[48] FNS Adjusting the Tension of the Upper
Alignment Plate Drive Timing Belt
(FN-115).................................................1-163
[49] FNS Adjusting the Stapling Position
(Flat Stapling) (FN-115) ......................... 1-163
[50] OT-104 Testing Operation .....................1-164
[51] FN-113/122 Output Check Mode ...........1-166
[52] FN-113/122 Lengthwise Position
Adjustment of Punch Hole......................1-170
[53] FN-113/122 Adjustment of Solenoids ....1-171
[54] FN-113/122 Timing Belt Tension
Adjustment .............................................1-172
....1-148
CONTENTS
[55] FN-113/122 Adjustment of the Elevator Tray
Upper Limit Sensor................................ 1-173
[56] FN-113/122 Adjustment of Elevator Tray Over
Detection Level...................................... 1-174
2. ISW
WHAT'S ISW?........................................................... 2-1
SETUP ...................................................................... 2-2
[1] ISW-compatible boards ............................. 2-2
[2] Data flow.................................................... 2-2
[3] Prepare the copier to start an ISW
transfer ...................................................... 2-2
[4] Preparing the copier to transfer ................. 2-4
[5] Relationships between processing states
and operational LEDs ................................ 2-5
[6] Rewriting procedure after an error
interruption................................................. 2-5
[7] Preparation when PZ is installed ............... 2-6
[8] Connecting to the ISW connector .............. 2-6
INTERNET ISW ........................................................ 2-8
[1] What is the Internet ISW ?......................... 2-8
[2] Operating environment.............................. 2-8
[3] Main features............................................. 2-8
[4] Initial setting............................................... 2-9
[5] Mail Remote Notification System............. 2-16
[6] Internet ISW using Web utility.................. 2-30
[7] Internet ISW by operation panel .............. 2-33
[8] Precautions for use.................................. 2-35
3. SERVICE
SERVICE SCHEDULE.............................................. 3-1
[1] Service Schedule....................................... 3-1
[2] Maintenance Items .................................... 3-2
[3] Main Body Periodic Inspection Items....... 3-10
[4] RADF [EDH-4/7] ...................................... 3-12
[5] FNS [FN-112/6] ....................................... 3-12
[6] FNS [FN-115] .......................................... 3-13
[7] LCT [C-403/404] ...................................... 3-13
[8] PI [Cover Inserter B/E]............................. 3-14
[9] PZ [ZK-2/3] .............................................. 3-14
[10] Periodic replacement parts list................. 3-15
[11] Optional replacement parts list ................ 3-18
COPY MATERIALS ................................................ 3-19
[1] Single unit supply .................................... 3-19
SERVICE MATERIAL LIST..................................... 3-20
4. ELECTRIC PARTS LIST
PARTS LAYOUT DRAWING.....................................4-1
[1] Di551/Di650/Di5510/Di7210 Parts Layout
Drawing ......................................................4-1
[2] EDH-4/7 Parts Layout Drawing ................4-12
[3] C-403/404 Parts Layout Drawing .............4-13
[4] FN-112/6/121/10 Parts Layout Drawing ...4-14
[5] Cover Inserter B/E Parts Layout
Drawing ....................................................4-17
[6] PK-2/5 Parts Layout Drawing ...................4-18
[7] ZK-2/3 Parts Layout Drawing ...................... 4-19
[8] FN-115 Parts Layout Drawing ..................4-20
[9] OT-104 Parts Layout Drawing..................4-22
CONNECTOR LAYOUT DRAWING........................4-23
[1] Di551/Di650/Di5510/Di7210
Connector Layout Drawing.......................4-23
[2] C-403/404 Connector Layout Drawing .....4-30
[3] FN-112/6/121/10 Connector Layout
Drawing ....................................................4-30
[4] Cover Inserter B/E Connector Layout
Drawing ....................................................4-31
[5] PK-2/5 Connector Layout Drawing ...........4-31
[6] ZK-2/3 Connector Layout Drawing .............. 4-32
[7] FN-115 Connector Layout Drawing............. 4-33
[8] OT-104 Connector Layout Drawing............. 4-33
JAM CODE LIST......................................................4-34
ERROR CODE LIST................................................4-50
TIMING CHART.......................................................4-69
[1] Di650 Timing Chart (1) .............................4-69
[2] Di650 Timing Chart (2) .............................4-70
[3] Di7210 Timing Chart (1) ...........................4-71
[4] Di7210 Timing Chart (2) ...........................4-72
[5] EDH-4/EDH-7 Timing Chart (1)................4-73
[6] EDH-4/EDH-7 Timing Chart (2)................4-74
[7] C-403/C-404 Time Chart ..........................4-75
[8] FN-112/FN-6/FN-121/FN-10
TIming Chart (1) .......................................4-76
[9] FN-112/FN-6/FN-121/FN-10
Timing Chart (2) .......................................4-77
[10] FN-112/FN-6/FN-121/FN-10
Timing Chart (3) .......................................4-78
[11] FN-112/FN-6/FN-121/FN-10
Timing Chart (4) .......................................4-79
[12] Cover Inserter B/Cover Inserter E
Timing Chart ............................................4-80
[13] PK-2 Timing Chart ...................................4-81
[14] PK-5 Timing Chart ...................................4-82
[15] ZK-2/ZK-3 Timing Chart ...........................4-83
[16] FN-115 Timing Chart (1) ..........................4-84
[17] FN-115 Timing Chart (2) ..........................4-85
[18] OT-104 Timing Chart ...............................4-86
[19] FN-113/FN-122 Timing Chart (1) ............4-87
[20] FN-113/FN-122 Timing Chart (2) ............4-88
OVERALL WIRING DIAGRAM................................4-89
[1] EDH-4/EDH-7 Overall Wiring Diagram.....4-89
[2] C-403/C-404 Overall Wiring Diagram.......4-90
3 DIS./ASSEMBLY1 ADJUSTMENT3 DIS./ASSEMBLY2 ISW3 DIS./ASSEMBLY3 SERVICE3 DIS./ASSEMBLY
4 ELECTRIC PARTS LIST
CONTENTS
3 DIS./ASSEMBLY1 ADJUSTMENT3 DIS./ASSEMBLY2 ISW3 DIS./ASSEMBLY3 SERVICE3 DIS./ASSEMBLY
[3] Cover Inserter B/Cover Inserter E
Overall Wiring Diagram ........................... 4-91
[4] PK-2 Overall Wiring Diagram .................. 4-92
[5] PK-5 Overall Wiring Diagram .................. 4-93
[6] ZK-2 Overall Wiring Diagram................... 4-94
[7] FN-115 Overall Wiring Diagram .............. 4-95
[8] OT-104 Overall Wiring Diagram .............. 4-96
[9]
FN-113/FN-122 Overall Wiring Diagram
APPENDIX
[1] Di551/Di650 Overall Wiring Diagram......... A-1
[2] Di5510/Di7210 Overall Wiring Diagram..... A-2
[3] FN-112/FN-6/FN-121/FN-10
Overall Wiring Diagram ............................. A-3
..... 4-97
4 ELECTRIC PARTS LIST
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY AND IMPORTANT WARNING ITEMS
Read carefully the Safety and Important Warning Items described below to understand them before doing ser-
vice work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this copier as well as the risk of damage to
the copier, Konica Minolta Business Technologies, INC. (hereafter called the KMBT) strongly recommends that
all servicing be performed only by KMBT-trained service technicians.
Changes may have been made to this copier to improve its performance after this Service Manual was printed.
Accordingly, KMBT does not warrant, either explicitly or implicitly, that the information contained in this Service
Manual is complete and accurate.
The user of this Service Manual must assume all risks of personal injury and/or damage to the copier while ser-
vicing the copier for which this Service Manual is intended.
Therefore, this Service Manual must be carefully read before doing service work both in the course of technical
training and even after that, for performing maintenance and control of the copier properly.
Keep this Service Manual also for future service.
DESCRIPTION ITEMS FOR DANGER, WARNING AND
CAUTION
In this Service Manual, each of three expressions “ DANGER”, “ WARNING”, and “ CAUTION” is defined
as follows together with a symbol mark to be used in a limited meaning.
When servicing the copier, the relevant works (disassembling, reassembling, adjustment, repair, maintenance,
etc.) need to be conducted with utmost care.
DANGER
WARNING
CAUTION
Symbols used for safety and important warning items are defined as follows:
:Precaution when using the copier.
:Action having a high possibility of suffering death or serious injury
:Action having a possibility of suffering death or serious injury
:Action having a possibility of suffering a slight wound, medium trouble, and
property damage
General precaution Electric hazard High temperature
:Prohibition when using the copier.
:Direction when using the copier.
General prohibition Do not touch with wet hand Do not disassemble
General instruction
S-1
Unplug
Ground/Earth
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY
KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Konica Minolta brand copiers are renowned for their high reliability. This reliability is achieved through high-quality design
and a solid service network.
Copier design is a highly complicated and delicate process 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 reason, unau-
thorized modifications involve a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reasoning behind this policy.
DANGER : PROHIBITED ACTIONS
• Using any cables or power cord not specified by KMBT.
• Using any fuse or thermostat not specified by KMBT. Safety will not be
assured, leading to a risk of fire and injury.
• Disabling fuse functions or bridging fuse terminals with wire, metal clips, sol-
der or similar object.
• Disabling relay functions (such as wedging paper between relay contacts)
• Disabling safety functions (interlocks, safety circuits, etc.) Safety will not be
assured, leading to a risk of fire and injury.
• Making any modification to the copier unless instructed by KMBT
• Using parts not specified by KMBT
S-2
SAFETY AND IMPORTANT WARNING ITEMS
[2] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
Konica Minolta brand copiers are extensively tested before shipping, to ensure that all applicable safety standards are met,
in order to protect the customer and customer engineer (hereafter called the CE) 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,
the CE must perform regular safety checks.
1.Power Supply
WARNING: Wall Outlet
• Check that mains voltage is as specified. Plug the power cord into the dedi-
cated wall outlet with a capacity greater than the maximum power consump-
tion.
If excessive current flows in the wall outlet, fire may result.
• If two or more power cords can be plugged into the wall outlet, the total load
must not exceed the rating of the wall outlet.
If excessive current flows in the wall outlet, fire may result.
kw
WARNING: Power Plug and Cord
• Make sure the power cord is plugged in the wall outlet securely.
Contact problems may lead to increased resistance, overheating, and the
risk of fire.
• Check whether the power cord is damaged. Check whether the sheath is
damaged.
If the power plug, cord, or sheath is damaged, replace with a new power
cord (with plugs on both ends) specified by KMBT. Using the damaged
power cord may result in fire or electric shock.
• When using the power cord (inlet type) that came with this copier, be sure to
observe the following precautions:
a. Make sure the copier-side power plug is securely inserted in the socket
on the rear panel of the copier.
Secure the cord with a fixture properly.
b. If the power cord or sheath is damaged, replace with a new power cord
(with plugs on both ends) specified by KMBT.
If the power cord (inlet type) is not connected to the copier securely, a
contact problem may lead to increased resistance, overheating, and risk
of fire.
• Check whether the power cord is not stepped on or pinched by a table and
so on.
Overheating may occur there, leading to a risk of fire.
S-3
SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Power Plug and Cord
• Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
• Check whether dust is collected around the power plug and wall outlet.
Using the power plug and wall outlet without removing dust may result in
fire.
• Do not insert the power plug into the wall outlet with a wet hand.
The risk of electric shock exists.
• When unplugging the power cord, grasp the plug, not the cable.
The cable may be broken, leading to a risk of fire and electric shock.
WARNING: Wiring
• Never use multi-plug adapters to plug multiple power cords in the same out-
let.
If used, the risk of fire exists.
• When an extension cord is required, use a specified one.
Current that can flow in the extension cord is limited, so using a too long
extension cord may result in fire.
Do not use an extension cable reel with the cable taken up. Fire may
result.
WARNING: Ground Lead
• Check whether the copier is grounded properly.
If current leakage occurs in an ungrounded copier, you may suffer electric
shock while operating the copier. Connect the ground lead to one of the
following points:
a. Ground terminal of wall outlet
b. Ground terminal for which Class D work has been done
S-4
SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Ground Lead
• Pay attention to the point to which the ground lead is connected.
Connecting the ground lead to an improper point such as the points listed
below results in a risk of explosion and electric shock:
a. Gas pipe (A risk of explosion or fire exists.)
b. Lightning rod (A risk of electric shock or fire exists.)
c. Telephone line ground (A risk of electric shock or fire exists in the case
of lightning.)
d. Water pipe or faucet (It may include a plastic portion.)
2.Installation Requirements
WARNING: Prohibited Installation Place
• Do not place the copier near flammable materials such as curtains or volatile
materials that may catch fire.
A risk of fire exists.
• Do not place the copier in a place exposed to water such as rain water.
A risk of fire and electric shock exists.
WARNING: Nonoperational Handling
• When the copier is not used over an extended period of time (holidays, etc.),
switch it off and unplug the power cord.
Dust collected around the power plug and outlet may cause fire.
CAUTION: Temperature and Humidity
• Do not place the copier in a place exposed to direct sunlight or near a heat
source such as a heater.
A risk of degradation in copier performance or deformation exists.
Do not place the copier in a place exposed to cool wind.
Recommended temperature and humidity are as follows:
Temperature: 10
Humidity: 10% to 80% (no dew condensation)
Avoid other environments as much as possible.
°C
to 30
°C
CAUTION: Ventilation
• Do not place the copier in a place where there is much dust, cigarette
smoke, or ammonia gas.
Place the copier in a well ventilated place to prevent machine problems
and image faults.
S-5
SAFETY AND IMPORTANT WARNING ITEMS
CAUTION: Ventilation
• The copier generates ozone gas during operation, but it is not sufficient to be
harmful to the human body.
If a bad smell of ozone is present in the following cases, ventilate the
room.
a. When the copier is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple copiers at the same time
CAUTION: Vibration
• When installing the copier, read the Installation Guide thoroughly. Be sure to
install the copier in a level and sturdy place.
Constant vibration will cause problems.
• Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the copier may slide, leading to a
injury.
CAUTION: Inspection before Servicing
• Before conducting an inspection, read all relevant documentation (service
manual, technical notices, etc.) and proceed with the inspection following the
prescribed procedure in safety clothes, using only the prescribed tools. Do
not make any adjustment not described in the documentation.
If the prescribed procedure or tool is not used, the copier may break and a
risk of injury or fire exists.
• Before conducting an inspection, be sure to disconnect the power plugs from
the copier and options.
When the power plug is inserted in the wall outlet, some units are still pow-
ered even if the POWER switch is turned OFF. A risk of electric shock
exists.
• The area around the fixing unit is hot.
You may get burnt.
DANGER: Work Performed with the Copier Powered
• Take every care when making adjustments or performing an operation check
with the copier powered.
If you make adjustments or perform an operation check with the external
cover detached, you may touch live or high-voltage parts or you may be
caught in moving gears or the timing belt, leading to a risk of injury.
S-6
SAFETY AND IMPORTANT WARNING ITEMS
DANGER: Work Performed with the Copier Powered
• Take every care when servicing with the external cover detached.
High-voltage exists around the drum unit. A risk of electric shock exists.
WARNING: Safety Checkpoints
• Check the exterior and frame for edges, burrs, and other damages.
The user or CE may be injured.
• Do not allow any metal parts such as clips, staples, and screws to fall into the
copier.
They can short internal circuits and cause electric shock or fire.
• Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or fire.
• When disconnecting connectors, grasp the connector, not the cable.
(Specifically, connectors of the AC line and high-voltage parts)
Current can leak, leading to a risk of electric shock or fire.
• Carefully remove all toner remnants and dust from electrical parts and elec-
trode units such as a charging corona unit.
Current can leak, leading to a risk of copier trouble or fire.
• Check high-voltage cables and sheaths for any damage.
Current can leak, leading to a risk of electric shock or fire.
• Check electrode units such as a charging corona unit for deterioration and
sign of leakage.
Current can leak, leading to a risk of trouble or fire.
• Before disassembling or adjusting the write unit incorporating a laser, make
sure that the power cord has been disconnected.
The laser light can enter your eye, leading to a risk of loss of eyesight.
• Do not remove the cover of the write unit. Do not supply power with the write
unit shifted from the specified mounting position.
The laser light can enter your eye, leading to a risk of loss of eyesight.
• When replacing a lithium battery, replace it with a new lithium battery speci-
fied in the Parts Guide Manual. Dispose of the used lithium battery using the
method specified by local authority.
Improper replacement can cause explosion.
S-7
SAFETY AND IMPORTANT WARNING ITEMS
WARNING: Safety Checkpoints
• After replacing a part to which AC voltage is applied (e.g., optical lamp and
fixing lamp), be sure to check the installation state.
A risk of fire exists.
• Check the interlock switch and actuator for loosening and check whether the
interlock functions properly.
If the interlock does not function, you may receive an electric shock or be
injured when you insert your hand in the copier (e.g., for clearing paper
jam).
• Make sure the wiring cannot come into contact with sharp edges, burrs, or
other pointed parts.
Current can leak, leading to a risk of electric shock or fire.
• Make sure that all screws, components, wiring, connectors, etc. that were
removed for safety check and maintenance have been reinstalled in the orig-
inal location. (Pay special attention to forgotten connectors, pinched cables,
forgotten screws, etc.)
A risk of copier trouble, electric shock, and fire exists.
DANGER: HANDLING OF SERVICE MATERIALS
• Toner and developer are not harmful substances, but care must be taken not
to breathe excessive amounts or let the substances come into contact with
eyes, etc. It may be stimulative.
If the substances get in the eye, rinse with plenty of water immediately.
When symptoms are noticeable, consult a physician.
• Never throw the used cartridge and toner into fire.
You may be burned due to dust explosion.
S-8
SAFETY AND IMPORTANT WARNING ITEMS
DANGER : HANDLING OF SERVICE MATERIALS
• Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (acetone-based) are
highly flammable and must be handled with care. A risk of fire exists.
• Do not replace the cover or turn the copier ON before any solvent remnants
on the cleaned parts have fully evaporated.
A risk of fire exists.
• 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.
A risk of fire exists.
• When using any solvent, ventilate the room well.
Breathing large quantities of organic solvents can lead to discomfort.
[3] 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 KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded through direct on-site checks, in
accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations given in “Serious Accident Report/
Follow-up Procedures”.
[4] CONCLUSION
1. Safety of users and customer engineers depends highly on accurate maintenance and administration. Therefore,
safety can be maintained by the appropriate daily service work conducted by the customer engineer.
2. 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.
S-9
SAFETY AND IMPORTANT WARNING ITEMS
SAFETY INFORMATION
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 mandatory for products mar-
keted 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 completely confined within
protective housings and external covers, the laser beam cannot escape during any phase of normal user opera-
tion.
S-10
SAFETY CIRCUITS
SAFETY AND IMPORTANT WARNING ITEMS
This machine is provided with the following safety circuits
to prevent machine faults from resulting in serious acci-
dents.
[1] Overall protection circuit
[2] L2 and L3 (fixing heater lamps) overheating
prevention circuit
These safety circuits are described below to provide the
service engineer with a renewed awareness of them in
order to prevent servicing errors that may impair their
functions.
[1] Overall Protection Circuit
CBR1
NF
CBR2
1. Protection by CBR1 and CBR2 (circuit
breakers)
CBR1 and CBR2 interrupt the AC line instanta-
neously when an excessive current flows due to a
short in the AC line.
CAUTION:
The CBR1 and CBR2 functions must not
be deactivated under any circumstances.
[2] Protection by L2, L3 and L4 (fixing
heater lamps) overheating prevention
circuit
DCPS
RL1
PRCB
RL1
TH2
Control
section
AC driver
section
TH1
1. Protection by software
The output voltage from TH1 (fixing temperature
sensor 1) is read by the CPU. If this voltage is
abnormal, L2 (fixing heater lamp 1), L3 (fixing
heater lamp 2), L4 (fixing heater lamp 3) and RL1
(main relay) are turned OFF.
CAUTION:
Do not change the gap between the roller
and TH1. When replacing TH1, check the
specified mounting dimensions. The RL1
function must not be deactivated under
any circumstances.
TS2
TS1
L2
L3
L4
S-11
SAFETY AND IMPORTANT WARNING ITEMS
2. Protection by the hardware circuit
The output voltages from TH1 and TH2 (fixing
temperature sensors) are compared with the abnor-
mality judgment reference value in the comparator
circuit. If the output voltage from TH1 or TH2
exceeds the reference value, L2 (fixing heater lamp
1), L3 (fixing heater lamp 2), L4 (fixing heater
lamp 3) and RL1 (main relay) are turned OFF in
hardware means.
CAUTION:
Periodically check the TH2 face contacting the roller, and replace TH2 if any
abnormality is detected.
Since TH1 (fixing temperature sensor)
face does not contact the roller, check the
distance from the roller and the sensor
orientation if any abnormality is detected.
The RL1 function must not be deactivated
under any circumstances.
3. Protection by TS1 (thermostat/U) and TS2
(thermostat/L)
When the temperature of the fixing roller (upper/
lower) exceeds the specified value, TSs are turned
OFF, thus interrupting the power to L2 (fixing
heater lamp/1), L3 (fixing heater lamp/2), and L4
(fixing heater lamp/3) directly.
CAUTION:
Do not use any other electrical conductor
in place of TS1 and TS2. Do not change
the distance between the roller and TS
(thermostat).
S-12
SAFETY AND IMPORTANT WARNING ITEMS
INDICATION OF WARNING ON THE MACHINE
Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric
shock.
CAUTION
DO NOT INSERT
your finger into the
two RADF hinge
portions;
otherwise you may
be injured.
WARNING
This area generates
high voltage. If touched,
electrical shock may
occur. DO NOT TOUCH.
CAUTION
ATTENTION
VORSICHT
PRECAUCION
ATTENZIONE
CAUTION
DO NOT put your hand between
the main body and developing
fixing unit; otherwise you may
be injured.
CAUTION
High temperature!
Do not touch. Use care
when clearing paper.
ATTENTION
Temp rature lev e!
Risque de br lure. Soyez
prudent en retirant la
feuille coinc e.
VORSICHT
Hei§e OberflŠche!
Brandverletzungsgefahr.
Bei Beseitigung von
Papierstaus vorsichtig
vorgehen.
PRECAUCION
ÁTemperatura alta!
No tocar. Tener cuidado al
remover el papel.
ATTENZIONE
Alta temperatura!
Non toccare. Agire con
prudenza nel rimuovere la
carta.
CAUTION
The fixing unit is
very hot. To avoide
getting burned, DO
NOT TOUCH.
CAUTION
ATTENTION
VORSICHT
PRECAUCION
ATTENZIONE
CAUTION
The conveyance fixing
unit is heavy. Use care
and draw it out gently;
otherwise you may be
injured.
CAUTION
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-13
SAFETY AND IMPORTANT WARNING ITEMS
In the case of the Di551/Di650
(Finisher with
Cover Inserter B/E only)
CAUTION
(FN-112/FN-6/FN-121/FN-10 Finisher)
(FN-6/FN-10 Finisher only)
(FN-6/FN-10 Finisher)
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-14
In the case of the Di5510/Di7210
DO NOT put your hand
between the main
body and tray;
otherwise you may be
injured.
SAFETY AND IMPORTANT WARNING ITEMS
The shift tray moves to and fro while
printing. DO NOT put your hand in
between the tray and tray supporting part;
otherwise you may be injured.
Also, DO NOT put your hand in the paper
exit outlet while the tray is moving;
otherwise you may be injured.
(OT-104 Shift tray)
DO NOT put your hand
between the main
body and tray;
otherwise you may be
injured.
(Main body tray 1 and 2)
(Main body tray 3 and 4)
7272sf006
CAUTION
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-15
SAFETY AND IMPORTANT WARNING ITEMS
To avoid injury, DO
NOT put your hand
on top of the
printed sheets.
Be sure to hold
both sides of the
printed sheets
when removing
them, and DO NOT
leave your hand on
the printed sheets
while the primary
(main) tray goes up.
Use care after opening the
paper exit outlet.
DO NOT put your hand into
it; otherwise you may be
injured.
(FN-115 Finisher)
7272sf007
CAUTION
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-16
<SCANNER SECTION>
<WRITE UNIT>
In the case of the Di551/Di650
SAFETY AND IMPORTANT WARNING ITEMS
7272sf004
In the case of the Di5510/Di7210
7272sf005
7272sf001
S-17
SAFETY AND IMPORTANT WARNING ITEMS
<REAR COVER>
CAUTION
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-18
WARNING
SAFETY AND IMPORTANT WARNING ITEMS
<ZK Puncher with Z-folding>
CAUTION
You may be burned or injured if you touch any area that you are advised by any caution label to keep your-
self away from.
Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot
be read, contact our Service Office.
S-19
Blank page
1
ADJUSTMENT
1 ADJUSTMENT
1 ADJUSTMENT
Blank page
HOW TO USE THIS SECTION
HOW TO USE THIS
SECTION
[1] Scope and Precautions
This section provides detailed information about
adjustment items and procedures. Before addressing
customer complaints, perform the following checks.
1. Check whether the power supply voltage meets
the specifications.
2. Check whether the power supply is properly
grounded.
3. Check whether this machine shares the power
supply with any other machine that draws large
current intermittently (e.g., elevator and air conditioner that produce electrical noise).
4. Check whether the installation environment is
good.
a. High temperature / High humidity, direct sun-
light, ventilation, etc.
b. Level of installed location
5. Check whether original has a problem that may
cause defective images.
6. Check whether the selected density value is correct.
7. Check whether the platen glass, slit glass, etc. is
soiled.
8. Check whether correct paper is used for copying.
9. Check whether copying materials and parts
(e.g., developer, drum, and cleaning blade) are
replenished and replaced when they reach the
end of their useful life.
10. Check whether toner remains.
When servicing the machine, observe the following
precautions:
ADJUSTMENTS MADE
WHEN REPLACING
PARTS
Adjustments (including checks) and settings are not
only required when a customer complaint about the
copy image quality is received, but also after replacing
or reassembling parts.
[How to Read Tables]
Components of the tables used in this section are as
follows:
1. Mode
Adjustment mode to be selected.
[P]: P mode
[25]: 25 mode
[36]: 36 mode
[47]: 47 mode
2. Code
Code and copy quantity setting button used in
each mode.
3. Page
Page in the "ADJUSTMENT" section.
4. Circled numbers
2
1
Indicate that adjustments (including
checks) must be made in order of precedence.
(Circle without numeric character):
Indicates that adjustments (including
checks) can be made independently.
1 ADJUSTMENT
11. Only either side of the AC line is shut off when the
SW1 (main power) of this machine is turned off.
Always unplug the power cord before starting
service work. If it is necessary to service the
machine with the power on, take care not to be
caught in the scanning gear of the exposure unit.
12. Special care should be taken when handling the
fixing unit because it operates at extremely high
temperatures.
13. The developing unit has a strong magnetic field.
Keep watches and measuring equipment away
from it.
14. Take care not to damage the drum with tools and
so on.
15. Do not touch IC pins with bare hands.
1-1
LIST OF ADJUSTMENT ITEMS
LIST OF ADJUSTMENT ITEMS
1 ADJUSTMENT
Item No.
Process
1
Adjustment
2
3
4
5
6
7
8
9
Image
10
Adjustment
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32 Finisher
Adjust-
33 Folding stopper adjustment 1-85
ment
34 Cover sheet tray size adjustment 1-86
Classification by Adjustment
High voltage
adjustment
Drum Peculiarity Adjustment
Tray Adjustment
Magnification
Adjustment
Timing Adjustment
RADF Adjustment
Centering
Adjustment
Warp Adjustment (Copier)
Stitch and fold stopper adjustment 1-85
Charging grid manual
adjustment
Blade setting mode
Auto maximum density
adjustment
Auto dot diameter
adjustment
LD1 offset adjustment
LD2 offset adjustment
Auto gamma adjustment (1dot)
Auto gamma adjustment (2dot)
Cartridge set mode
Printer vertical magnification adjustment
Printer horizontal magnification adjustment
Scanner (platen) vertical
adjustment
Scanner (RADF) vertical
adjustment
Printer leading edge timing adjustment
Printer registration loop
adjustment
Printer pre-registration
adjustment
Printer leading edge timing adjustment
Scanner (platen) leading
edge timing adjustment
Scanner (RADF) leading
edge timing adjustment
Scanner (RADF) registration loop adjustment
RADF density adjustment
RADF original size
adjustment
RADF incline offset
adjustment
Printer centering adjustment
Scanner (platen) centering adjustment
Scanner (RADF) centering adjustment
Scanner (platen) warp
(main scan)
Scanner (platen) warp
(sub-scan)
Scanner (RADF) warp
(main scan)
Scanner (RADF) warp
(sub-scan)
Adjustment Item
36
Mode
1-53
1-54
1-55
1-55
1-56
1-57
1-58
1-59
1-59
1-61
1-62
1-63
1-63
1-64
1-66
1-67
1-68
1-68
1-69
1-69
1-70
1-71
1-71
1-72
1-73
1-73
1-74
1-75
1-75
1-75
1-75
Page
Drum
Developer
Write unit
Dust-proof glass
Each tray unit
By-pass paper feed unit
Tray up/down wire
Registration roller
Registration unit
Registration clutch
Mis-centering detection sensor
ADU unit
CCD unit
Fixing unit
Memory board
RADF
LCT
FNS
Stapler unitPIPK (PK-2)
1
3
421
5 3 2 2
6 4 3
7 5 4
8 653
9 7
2 1
1
4
6
OO O
OO O
OOO
O OOO O
OOO
O
O
O
O
O
O
O
O
O
OO
OO
O
O
O
OO
(O)
OO
O
O
OO
OO
OO
(O)
OO
OO
OO
OO
OO
OO
OO
OO
PK (PK-5)
PZ
1-2
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