Konica Minolta C-403 DI5510/DI7210, FN-6 DI5510/DI7210, OT-104, COVER INSERTER B DI5510/DI7210, FN-112 DI5510/DI7210 User Manual

...

OPTION SERVICE MANUAL

C-403/C-404

7663-4396-11

Cover Inserter B/E EDH-4/EDH-7 FN-115/FN-7 FN-112/FN-6 FN-121/FN-10 FN-113/FN-122 OT-104 PK-2 PK-5 ZK-2/ZK-3

2004.01 Ver. 1.0

SERVICE MANUAL

C-403/C-404

2004.01 Ver. 1.0

CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS

Refer to the Di551/Di650/Di5510/Di7210 service

manual on page .................................................... S-1

1. OUTLINE

C-403/C-404 PRODUCT SPECIFICATIONS ............1-1

CENTER CROSS-SECTIONAL DRAWING ..............1-2

DRIVE SYSTEM DRAWING......................................1-3

[1] Paper feed drive section.............................1-3

[2] Stacked paper up/down wire drive section .1-4

2. UNIT EXPLANATION

PAPER FEED SECTION...........................................2-1

[1] Composition ...............................................2-1

[2] Mechanisms ...............................................2-1

[3] First paper feed control ..............................2-2

[4] Up/down plate drive control........................2-4

[5] Remaining paper detection/No paper

detection control .........................................2-5

3. DISASSEMBLY/ASSEMBLY

PAPER FEED SECTION...........................................3-1

[1] Cleaning the Paper Dust Removing Brush.3-1 [2] Cleaning the LT feed PS (PS106)/

LT first paper feed PS(PS107) ...................3-1

[3] Removing and Reinstalling the

Paper Feed Roller Unit...............................3-2

[4] Replacing the Paper Feed Roller Rubber/

Feed Roller Rubber ....................................3-2

[5] Replacing the Double Feed

Prevention Roller Rubber ...........................3-3

[6] Replacing the LT feed MC (MC101)/

LT first paper feed MC (MC102).................3-5

[7] Replacing the C-403 Up/Down Wires.........3-6

[8] Replacing the C-404 Up/Down Wires.......3-10

2 UNIT EXPLANATION 1 OUTLINE3 DIS./ASSEMBLY

1 OUTLINE2 UNIT EXPLANATION3 DIS./ASSEMBLY

Blank page

OUTLINE

1 OUTLINE

Blank page

C-403/C-404 PRODUCT SPECIFICATIONS

C-403/C-404

[1] Type

Type:

Side mount type large volume paper feed tray

[2] Functions

Standard size paper :

C-403

• Metric area A4 / B5 / 8.5 x 11 Wide paper (314mm x 223mm max.)

• Inch area

8.5 x 11 / A4 Wide paper (314mm x 223mm max.)

C-404

• Metric area A3 / B4 / A4 / A4R / F4 11 x 17 / 8.5 x 14 / 8.5 x 11 / 8.5 x 11R Wide paper (314mm x 459mm max.)

• Inch area 11 x 17 / 8.5 x 14 / 8.5 x 11 / 8.5 x 11R A3 / B4 / A4 / A4R / F4 Wide paper (314mm x 459mm max.)

Maximum quantity:

4000 sheets (80 g/m

or 20lbs)

[4] Maintenance

Maintenance:

Same as the main body

Machine life:

Same as the main body

[5] Operating Environment

Temperature:

10°C to 30°C (50°F to 86°F)

Humidity:

10% to 80%RH

Note: The information herein may be subject to

change for improvement without notice.

1 OUTLINE

[3] Machine Data

Power source

24V DC/5V (supplied from the main body), AC27.3V

Max. power consumption

C-403 Max. 82W C-404 Max. 100 W

Weight

C-403 Approx. 30 kg C-404 Approx. 42 kg

Machine dimensions

C-403 430(W) x 639(D) x 690(H) mm C-404 670(W) x 639(D) x 695(H) mm

1-1

C-403/C-404

CENTER CROSS-SECTIONAL DRAWING

1 OUTLINE

Feed roller

Conveyance roller

Paper feed roller

Top cover

Up/down wire (the other side wire as well)

Double feed prevention roller

Up/down plate

1-2

DRIVE SYSTEM DRAWING

C-403/C-404

[1] Paper feed drive section

LT First paper feed SD (SD100)

FRONT

1 OUTLINE

Feed roller

Paper feed roller

Conveyance roller

FRONT

LT First paper feed MC (MC 102)

Double feed prevention roller

LT paper feed motor (M101)

LT feed drive MC (MC101)

Paper feed roller

Feed roller

1-3

C-403/C-404

[2] Stacked paper up/down wire drive section

1 OUTLINE

a. C-403

Up/down plate

FRONT

LT up/down motor (M100)

Up/down shaft

1-4

C-403/C-404

b. C-404

1 OUTLINE

Up/down plate

LT up/down motor (M100)

FRONT

Up/down shaft

1-5

1 OUTLINE

Blank page

UNIT EXPLANATION

2 UNIT EXPLANATION

Blank page

PAPER FEED SECTION

[1] Composition

LT feed MC (MC101)

LT paper feed motor (M101)

LT first paper feed MC (MC102)

LT first paper feed SD (SD100)

Paper dust removing brush

Conveyance roller

C-403/C-404

LT feed PS (PS106)

LT first paper feed PS (PS107)

2 UNIT EXPLANATION

Up/down wire (the other side wire as well)

LT up/down motor (M100)

Remaining paper detection gear

[2] Mechanisms

Mechanism Method

Paper lifting *1 Wire drive

Paper feed Paper feed roller

No paper detection

Remaining paper detection *2

Paper conveyance Roller conveyance

*1 Paper lifting

a.Up/down plate lifting drive operation

The up/down plate is lifted with the up/down wires. When the top cover closes, LT up/down motor (M100) rotates and the up/down plate connected to the up/down wires rises.

b.Up/down plate down drive operation

The up/down plate automatically lowers by 120 mm when the top cover is opened. Subsequently, it is lowered by 120 mm each time LT tray down drive switch (SW100) is pressed.

Photo sensor (PS108) +actuator

Remaining paper detection gear+ photo sensor (PS102, PS103, PS104, PS105)

Up/down plate

LT tray down drive switch (SW 100)

*2 Remaining paper detection

The LCT is equipped with a remaining paper detection gear which rotates together with LT up/ down motor (M100) driving the up/down plate. The remaining paper detection gear has an actuator to turn ON/OFF LT remaining paper detection PS1 (PS102), LT remaining paper detection PS2 (PS103), LT remaining paper detection PS3 (PS104), and LT remaining paper detection PS4 (PS105).

2-1

C-403/C-404

2 UNIT EXPLANATION

Each sensor is turned ON/OFF according to the rotating position of the remaining paper detection gear and since this is linked with the up/down position of the up/down plate, the remaining paper quantity in the LCT can be determined by monitoring the ON/OFF of each sensor. The remaining paper quantity detected with the four sensors is displayed on the main body display.

a. C-403

LT remaining paper

LT up/down motor (M100)

detection PS1 (PS102)

Actuator

LT remaining paper detection PS2 (PS103)

LT remaining paper detection PS3 (PS104)

Gear for M100

Remaining

LT remaining paper

detection PS4 (PS105) paper detection gear

b. C-404

LT remaining paper detection PS2 (PS103)

LT remaining paper detection PS1 (PS102)

LT remaining paper detection PS3 (PS104)

[3] First paper feed control

UPOP_PS

S_GND

CONV_PS

S_GND

PR_PS

SIDOP_PS

24V

CONT

24V

CONT

24V

CONT

24V

LCTM_CONT

LCTM_CLK

LCTM_F/R LCTM_EM

GND

P_GND

MS101

LT DB

HTR101

MAIN BODY

24V

PGND

SGND

IO_DTXD IO_UCLK

LCT_LATCH

IO_DCLK

ERR_OUT4

IO_URXD

ACK4

REQ4

The first paper is fed by the paper feed roller and the feed roller driven by M101(LT paper feed) via MC101(LT feed MC). The paper feed roller and feed roller touche the paper when SD100 (LT first feed) is ON, feeding the paper to the conveyance roller. Then, SD100 (LT first paper feed) turns OFF to release the paper feed roller and feed roller from the paper. The conveyance roller is also driven by M101, by turning ON MC102 (LT first feed MC), paper is fed to the main body. The related signals are: PS100 (LT top cover open/close detection), PS106 (LT feed), PS107 (LT first feed), and PS110 (LT jam access door open/close detection).

PS100

PS106

PS107

PS110

MC101

MC102

SD100

MS102

M101

Actuator

Remaining paper detection gear

Gear for M100

LT remaining paper

detection PS4 (PS105)

2-2

C-403/C-404

1. Operation

a. First paper feed timing

(1) Start of first paper feed

At predefined interval after the START button is pressed.

(2) Start of second and subsequent papers

When PS106 (LT feed) is turned OFF by the preceding paper.

(3) OFF timing

When the main body M7 (paper exit) turns OFF.

b. Interlock

The power supply line of M101 (LT paper feed) is equipped with MS101 (LT interlock/1) and MS102 (LT interlock/2). When the top cover is opened, MS101 turns OFF, and when the jam access door is opened MS102 turns OFF, thereby cutting off the power supply to M101. Furthermore, the top cover is equipped with PS100 (LT top cover open/close detection) and the jam access door is equipped with PS110 (LT jam access door open/close detection) and when either of these doors is opened during paper feed, the M101 drive signal is turned OFF to stop the paper feed operation.

c. Internal heater

The LCT is equipped with HTR101 (LT internal heater) to protect the paper from humidity. HTR101 is directly controlled by the main body PRCB (printer control board) rather than by the LTDB (LT drive board).

2. Signals

a. Input signals

(1) UPOP_PS (PS100 to LTDB)

Top cover open/close detection signal [L]: Cover opened [H]: Cover closed

(2) CONV_PS (PS106 to LTDB)

Conveyance roller exit paper detection signal [L]: Paper detected [H]: Paper not detected

(3) PR_PS (PS107 to LTDB)

Conveyance roller entrance (pre-registration position) paper detection signal [L]: Paper detected [H]: Paper not detected

(4) SIDOP_PS (PS110 to LTDB)

Jam access door open/close detection signal [L]: Door opened [H]: Door closed

(5) LCTM_EM (M101 to LTDB)

M101 rotation error detection signal [L]: M101 rotating [H]: M101 not rotating

(6) IO_DTXD (MAIN BODY to LTDB)

Serial data to transmit main body PRCB (printer control board) operating status to LTDB

(7) LCT_LATCH (MAIN BODY to LTDB)

IO_DTXD signal latch signal

(8) IO_DCLK (MAIN BODY to LTDB)

IO_DTXD signal clock signal

(9) ERR_OUT4 (MAIN BODY to LTDB)

Signal to notify LTDB (LT drive board) when there is error in the main body

(10) ACK4 (MAIN BODY to LTDB)

Serial data transmission enable signal from LCT to main body PRCB (printer control board)

2 UNIT EXPLANATION

2-3

C-403/C-404

2 UNIT EXPLANATION

b. Output signals

(1) CONT (LTDB to MC101)

MC101 (LT feed MC) ON/OFF drive signal [L]: MC101 ON [H]: MC101 OFF

(2) CONT (LTDB to MC102)

MC102 (LT first paper feed MC) ON/OFF drive signal [L]: MC102 ON [H]: MC102 OFF

(3) CONT (LTDB to SD100)

SD100 ( LT first paper feed) ON/OFF drive signal [L]: SD100 ON [H]: SD100 OFF

(4) LCTM_CONT (LTDB to M101)

M101 (LT paper feed) ON/OFF control signal [L]: M101 ON [H]: M101 OFF

(5) IO_URXD (LTDB to MAIN BODY)

Serial data to transmit the LTDB (LT drive board) operating status to main body PRCB

(6) IO_UCLK (LTDB to MAIN BODY)

IO_URXD signal clock signal

(7) REQ4 (LTDB to MAIN BODY)

Serial data send request signal from LCT to main body PRCB

(8) LCTM_CLK (M101 to LTDB)

M101 (LT paper feed) rotational speed control clock signal

(9) LCTM_F/R (M101 to LTDB)

M101 (LT paper feed) rotational direction indication signal This machine always indicates [H]: normal rotation.

[4] Up/down plate drive control

LT DB

MAIN BODY

24V

PGND

SGND

IO_DTXD IO_UCLK

LCT_LATCH

IO_DCLK

ERR_OUT4

IO_URXD

ACK4

REQ4

When the top cover opens or closes, M100 (LT up/down motor) rotates forward or backward to move the up/down plate up or down. The up/ down plate descends by 120 mm each time SW100 (LT tray down drive) is pressed while the top cover is opened. The related signals are PS100 (LT top cover open/close detection), PS101 (LT lower limit detection), and PS109 (LT upper limit detection).

1. Operation

a. Up/down plate descend timing

(1) ON timing

When the top cover is opened and PS100 (LT top cover open/close detection) is turned OFF, M100 rotates backward to lower the up/down plate. When SW100 (LT tray down drive) turns ON by pressing, M100 rotates backward to move the up/down plate down.

(2) OFF timing

M100 turns OFF at predefined interval after PS100 turns OFF or SW100 turns ON. This in turn lowers the up/down plate by 120 mm.

(3) Others

The up/down plate descends by 120 mm each time SW100 is pressed until PS101 turns ON to indicate the bottom limit of the up/down plate.

UPOP_PS

S_GND

SIG

S_GND

DW_SW

UP_PS

S_GND

PS100

PS101

SW100

PS109

M100

2-4

C-403/C-404

b. Up/down plate ascend timing

(1) ON timing

When the top cover is closed and PS100 (LT top cover open/close detection) is turned ON, M100 (LT UP/DOWN) rotates forward to raise the up/ down plate.

(2) OFF timing

When the up/down plate rises and PS109 (LT upper limit detection) turns ON to indicate the detection of the topmost paper, M100 (LT UP/ DOWN) turns OFF and stops the up/down plate. The up/down plate also stops when the top cover is opened and PS100 (LT top cover open/ close detection) turns OFF.

2. Signals

a. Input signals

(1) SIG (PS101 to LTDB)

Up/down plate lower limit detection signal [L]: Up/down plate not at lower limit [H]: Up/down plate at lower limit

(2) UP_PS (PS109 to LTDB)

Up/down plate upper limit detection signal [L]: Up/down plate not at upper limit [H]: Up/down plate at upper limit

(3) DW_SW (SW100 to LTDB)

SW100 (LT tray down switch) ON/OFF detection signal [L]: SW100 ON [H]: SW100 OFF

b. Output signal

(1) D1, 2 (LTDB to M100)

M100 (LT UP/DOWN) drive signal These signals switches the direction of the drive current to control the rotation direction of M100.

[5] Remaining paper detection/No paper

detection control

LT DB

MAIN BODY

24V

PGND

SGND

IO_DTXD IO_UCLK

LCT_LATCH

IO_DCLK

ERR_OUT4

IO_URXD

ACK4

REQ4

The remaining paper quantity is detected by PS102 (LT remaining paper detection 1), PS103 (LT remaining paper detection 2), PS104 (LT remaining paper detection 3), and PS105 (LT remaining paper detection 4) and no paper detection is made by PS108 (LT no paper detection). The signals detected by these sensors are controlled by LTDB (LT drive board) and displayed on the main body display.

1. Operation

a. Remaining paper detection control

The remaining paper quantity is determined from the ON/OFF combination of sensors PS102 (LT remaining paper detection 1), PS103 (LT remaining paper detection 2), PS104 (LT remaining paper detection 3), and PS105 (LT remaining paper detection 4) which detect the rotational position of M100 (LT UP/DOWN) that is driving the up/down plate. Each sensor turns ON or OFF according to the position of the remaining paper detection gear which is linked with the rotation of M100. The remaining paper quantity is detectable at eight levels, but it is displayed on the main body display as five levels.

SIG

S_GND

SIG

S_GND

SIG

S_GND

SIG

S_GND

0_PS

S_GND

PS102

PS103

PS104

PS105

PS108

M100

2 UNIT EXPLANATION

2-5

C-403/C-404

Stacked

paper

quantity

0 to 700 OFF OFF OFF OFF 1 flashing

701 to 1200 ON OFF OFF OFF 1 on

1201 to 1700 ON ON OFF OFF 2 on

1701 to 2200 ON ON ON OFF 2 on

2201 to 2700 ON ON ON ON 3 on

2701 to 3200 OFF ON ON ON 3 on

3201 to 3700 OFF OFF ON ON 4 on

2 UNIT EXPLANATION

3701 or more OFF OFF OFF ON 4 on

Caution:The remaining paper quantity is indicated on

b. No paper detection control

When there is no more paper inside the LCT, PS108 (LT no paper detection) turns ON and a message is displayed on the main body display.

PS102 PS103 PS104 PS105

the control panel with four horizontal bars. Stacked paper quantity differs depending on the thickness of the paper.

Remaining paper quantity display

2. Signals

a. Input signals

(1) SIG (PS102 to LTDB)

Remaining paper detection gear rotational position detection signal [L]: PS102 OFF [H]: PS102 ON

(2) SIG (PS103 to LTDB)

Remaining paper detection gear rotational position detection signal [L]: PS103 OFF [H]: PS103 ON

(3) SIG (PS104 to LTDB)

Remaining paper detection gear rotational position detection signal [L]: PS104 OFF [H]: PS104 ON

(4) SIG (PS105 to LTDB)

Remaining paper detection gear rotational position detection signal [L]: PS105 OFF [H]: PS105 ON

(5) 0_PS (PS108 to LTDB)

LCT no paper detection signal [L]: No paper [H]: Paper present

2-6

DISASSEMBLY/ASSEMBLY

3 DIS./ASSEMBLY

This section explains how to disassemble and reassemble the machine. When disassembling and reassembling the machine, follow the precautions given below.

1. Be sure the power cord has been unplugged from the wall outlet.

3 DIS./ASSEMBLY

2. The disassembled parts must be reassembled following the disassembly procedure in reverse unless otherwise specified.

3. Care should be taken not to lose small parts. Care should also be taken not to install small parts in wrong places.

4. Do not operate the machine before installing all the disassembled parts completely.

5. Removal of some screws is prohibited in this section. Never loosen them.

PAPER FEED SECTION

C-403/C-404

[1] Cleaning the Paper Dust Removing

Brush

Caution:If LT is connected to the main

body, make sure that main body power plug is disconnected from the power outlet.

a. Procedure

(1) Open the top cover. (2) Remove six screws to detach the paper feed

cover B.

To p cover

Screws

[2] Cleaning the LT feed PS (PS106)/LT

first paper feed PS (PS107)

Caution:If LT is connected to the main

body, make sure that main body power plug is disconnected from the power outlet.

a. Procedure

(1) Looking into the paper exit side of the LCT from

below, and clean sensors through the cavity for LT feed PS (PS106) and the cavity for LT first paper feed (PS107) using a blower brush.

Cavity for PS106

Cavity for PS107

Paper exit side

3 DIS./ASSEMBLY

Paper feed cover B

(3) Insert a flat bladed screwdriver in the cavities (in

two locations) for paper dust removing brush to release the locking lugs, then remove the paper dust removing brush.

Paper dust removing brush

Cavity

Locking lugs

(4) Clean the paper dust removing brush using a

blower brush.

(5) Reinstall the above parts following the removal

steps in reverse.

3-1

C-403/C-404

[3] Removing and Reinstalling the Paper

Feed Roller Unit

Caution:If LT is connected to the main

body, make sure that main body power plug is disconnected from the power outlet.

a. Procedure

(1) Open the top cover. (2) Remove the spring from the paper feed roller

unit.

Top cover

Spring

Remove this.

Paper feed roller unit

3 DIS./ASSEMBLY

[4] Replacing the Paper Feed Roller Rub-

ber/Feed Roller Rubber

Caution:If LT is connected to the main

body, make sure that main body power plug is disconnected from the power outlet.

a. Procedure

(1) Remove the paper feed roller unit. (2) Remove the bearing and paper feed reference

actuator.

Paper feed reference actuator

Paper feed roller unit

(3) After removing two stop rings, remove the two

bearings outward to remove the paper feed roller unit.

Paper feed roller unit

Bearing

Stop ring

Bearing

Stop ring

Bearing

(3) Remove two stop rings. (4) Remove two bearings outward to detach the

roller section from the roller fitting.

Roller fitting

Stop rings

Bearing

(4) Reinstall the above parts following the removal

steps in reverse.

3-2

C-403/C-404

(5) Remove the bearing from the opposite side of the

coupling, then remove the paper feed roller from the shaft.

(6) Remove the stop ring to pull the feed roller from

the shaft.

(7) Remove the rubber from each roller.

Coupling

Feed roller

Paint mark

Paper feed roller

Bearing

Paper feed roller rubber

Shaft

Stop ring

Feed roller rubber

(8) Reinstall the above parts following the removal

steps in reverse. Caution1: Make sure rollers and rubber por-

tions are oriented properly when reinstalling them.

Caution2: Make sure the one-way clutch direc-

tion is correct.

Caution3: Check whether grease or the like is

present on each roller.

[5] Replacing the Double Feed Preven-

tion Roller Rubber

Caution:If LT is connected to the main

body, make sure that main body power plug is disconnected from the power outlet.

a. Procedure

Caution: With the power held on, press the LT

tray down switch (SW100) to move the up/down plate down to the bottom in

advance. (1) Remove the paper feed roller unit. (2) Remove two screws to detach the double feed

prevention roller unit cover.

Double feed

Double feed prevention roller

prevention roller unit cover

Screws

3 DIS./ASSEMBLY

3-3

C-403/C-404

(3) Remove two screws to detach the double feed

prevention roller unit.

(5) Remove the double feed prevention roller rubber

from the double feed prevention roller.

Caution: When reinstalling the double feed pre-

vention roller unit, tighten the screws on the rear side first.

Double feed prevention roller unit

Screws

(6) Reinstall the double feed prevention roller in the

Paint mark

Double feed prevention roller

Shaft

Double feed prevention roller rubber

reverse order of the removal procedure.

3 DIS./ASSEMBLY

(4) Remove two stop rings, fit the shaft into the D-cut

in the fitting, and remove the double feed prevention roller together with the shaft.

Caution1: Make sure the double feed preven-

tion roller rubber is oriented properly when reinstalling it.

Caution2: Check whether scratch or the like is

Double feed prevention roller

visible on the pet cover for the drive gear.

Caution3: Check whether grease or the like is

present on double feed prevention roller.

D-cut

Stop ring

3-4

C-403/C-404

[6] Replacing the LT feed MC (MC101)/LT

first paper feed MC (MC102)

a. Procedure

(1) Open the top cover. (2) Remove the spring from the paper feed roller

unit.

(3) Remove two screws to detach the top cover.

Top cover

Screws

(4) Remove three screws to detach the clutch

replacement cover.

(5) Disconnect two relay connectors (CN765,

CN766) of the clutches.

(6) Remove the stop ring to detach each clutch.

LT first paper feed MC (MC102)

LT feed MC (MC101)

Stop ring

Relay connector (CN766)

Relay connector (CN765)

(7) Reinstall the above parts following the removal

steps in reverse.

Caution: When installing each MC, make sure

that the stopper of each clutch is on

the predefined position.

3 DIS./ASSEMBLY

Clutch replacement cover

Screws

3-5

C-403/C-404

[7] Replacing the C-403 Up/Down Wires

Caution: With the power held on, press the LT

tray down switch (SW100) to move the up/down plate down to the bottom in advance.

a. Procedure

(1) Open the top cover. (2) Remove the clutch replacement cover. (3) Remove five screws to detach the right side

cover.

3 DIS./ASSEMBLY

Right side cover

Screws

(5) Remove twelve screws to detach the rear cover.

Screw

Screws

Rear cover

(6) Remove the five relay connectors (CN749,

CN780, CN781, CN782, CN783) to disconnect the wiring harness from the up/down motor

mounting assembly. (7) Remove the E-ring to detach the up/down gear. (8) Pull the pin from the shaft. (9) Remove the E-ring to detach the bearing. (10) Remove three screws to detach the up/down

motor assembly.

(4) After opening the jam access door, remove six

screws to detach the front cover.

Caution: When removing the front cover, close

the jam access door after removing the screws.

Jam access door

Screws

Right side cover

Screws

Relay connector

Up/down motor mounting assembly

Shaft

(CN749)

Screw

Bearing

E-ring

Relay connector (CN780)

Relay connector (CN781)

Relay connector (CN782)

Relay connector (CN783)

Screw

Up/down gear

E-ring

3-6

+ 400 hidden pages