Minolta Di 152 General

Service Manual

[General]

Di152/Di183

INDEX (GENERAL)

GENERAL

MECHANICAL/ELECTRICAL

GENERAL

14413

1. SPECIFICATION .............................................................................................G-1

2. PRECAUTIONS FOR INSTALLATION .................................... ........................G-5

2-1. Installation Site ........................................................................................G-5

2-2. Power Source ..........................................................................................G-5

2-3. Grounding ................................................................................................G-5

3. PRECAUTIONS FOR USE ....................... ........................... ........................... .G-6

3-1. To ensure that the copier is used in an optimum condition .....................G-6

3-2. Operating Environment ............................................................................G-6

3-3. Power Requirements ............................................................................... G- 6

3-4. Note ......................................................................................................... G-6

4. HANDLING OF CONSUMABLES ............................. ............... ........................G-7

5. OTHER PRECAUTIONS ................. ............................ ........................... .........G-8

6. SYSTEM OPTIONS .........................................................................................G-9

1. SPECIFICATION

TYPE ORIGINAL SCANNING SYSTEM PHOTOCONDUCTOR COPYING SYSTEM

RESOLUTION PAPER FEEDING SYSTEM

EXPOSURE SYS TEM DEVELOPING SYSTEM CHARGING SYSTEM

IMAGE TRANSFER SYSTEM PAPER SEPARATING SYSTEM

FUSING SYSTEM PAPER DISCHARGING SYSTEM MAX. ORIGINAL SIZE

COPY MEDIUM

Paper Source Drawer Manual Bypass

Plain Paper (60 to 90 g/m

Transparencies

Type

Dimensions

MULTIPLE COPIES WARMING-UP TIME FIRST COPY TIME

CONTINUOUS COPY SPEED (copies/min)

Size A4C

A4L A3L B4L B5C

B5L 8-1/2 × 11C 8-1/2 × 11L

11 × 17L

8-1/2 × 14L

11 × 14

Thick Paper (91 to 157 g/m

Recycled Paper (60 to 90 g/m

Maximum (Width × Length) 297 × 432 mm 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm 90 × 140 mm

Console/Desktop Type

CCD Line Sensor

Organic Photoconductor

Electrostatic Dry Powdered Image T r ansfer to Plain Paper with a Laser

600 × 600 dpi

2-way system Manual Bypass...Single

Drawer................250 Sheets

Mirror Scanning

MT-HG System

Comb Electrode (1) DC Negative Corona with Scorotron System

Roller Image Transfer

Paper Separator Fingers and Charge Neutralizing Plate

Heat Roller

Charge Neutralizing Brush

A3L, 11 × 17

Postcards

1 to 99

30 sec. or less (23, Rated Voltage)

7 sec. or less (A4C, Drawer, full size mode)

Di152 Di183

15 12

9 10 16 13 15 12

9 10 10

)

Speed

❍❍ ❍❍ ❍❍ ❍❍ ❍❍

18 14 10 12 20 15 18 14 10 12 12

G-1

ZOOM RATIOS

Metric Inch

Full Size 100 % 100 %

200 %

Fixed

Enlargement

Reduction

Variable 50 % to 200 % (in 1 % increments)

141 % 115 %

81 % 70 % 50 %

200 % 129 % 121 %

78 % 64 % 50 %

LENS EXPOSURE LAMP

POWER/CURRENT CONSUMPTION (copier only)

Exposure Lamp

(Rating)

24 V

14.4 W

POWER REQUIREMENTS : 110 V, 120 V, 127 V, 220 V to 240 V, 50/60 Hz

ENVIRONMENTAL CONDITIONS

Temperature 10 to 30 °C with a fluctuation of 10 °C or less per hour

Humidity 15 to 85 % RH with a fluctuation of 10 % RH or less per hour

Ambient Illumination 3,000 lux or less

Levelness 1° (1.75 mm/100 mm)

COPIER DIMENSION

COPIER WEIGHT

Fusing Roller Heater Lamp

::Through Lens

Fluorescent Lamp

(Rating)

900 W

::W ...590 mm (23-1/4)

D....611 mm (24)

H....487 mm (19-1/4)

39 kg (86 lb)

Max. Power

Consumption

(full system)

110 V: 970 W 120 V: 1090 W 127 V: 1180 W 220 V: 990 W 230 V: 1050 W 240 V: 1120 W

Max. Current Consumption

(full system) 110 V: 8.9 A

120 V: 9.1 A 127 V: 9.3 A 220 V: 4.5 A 230 V: 4.6 A 240 V: 4.7 A

G-2

Multiple Bypass (MB-5): option

TYPE INSTALLATION

COPY PAPER TYPE

Plain Paper (60 to 90 g/m

Transparencies 20 sheets

Type

Thick Paper (91 to 157 g/m

Recycled Paper (60 to 90 g/m

Dimensions

Size

Maximum (Width × Length) 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm

A3L, B4L, FLS, A4L, A4C, B5L, B5C, A5C ,11 × 17, 11 × 14, 8-1/2 × 14, 8-1/2 × 11L, 8-1/2 × 11C, 8-1/2 × 5-1/2

DOCUMENT ALIGNMENT CAPACITY POWER REQUIREMENTS MAX. POWER CONSUMPTION DIMENSIONS

WEIGHT OPERATING ENVIRONMENT

::Multiple Bypass

Mounted on the copier

)

50 sheets

20 sheets

Postcards 20 sheets

)

Center

: :

50 sheets (80 g/m

DC24 V, DC5 V (supplied from copier)

9 W or less

W...245 mm (9-3/4)

)

50 sheets

D....435 mm (17-1/4)

H....137 mm (5-1/2)

2.7 kg (6 lb)

Same as copier

G-3

Job Tray (JS-202): option

TYPE INSTALLATION

::Multiple Bypass

Mounted on the copier

CAPACITY

Exit Tray

of the machine

1Stacking height up

Plain Paper (60 to 90 g/m

150 sheets (A4C/L)

75 sheets

)

(except A4C/L)

to 22 mm 100 sheets (A4C/L) 50 sheets (except A4C/L)

Transparencies

Type

Thick Paper (91 to 157 g/m

)

20 sheets 10 sheets

Postcards

Stacking height up to

Recycled Paper (60 to 90 g/m

150 sheets (A4C/L)

75 sheets

)

(except A4C/L)

22 mm 100 sheets (A4C/L) 50 sheets (except A4C/L)

Dimensions

Maximum (Width × Length) 297 × 432 mm

Minimum (Width × Length) 90 × 140 mm 140 × 140 mm

Exit Tray by Application Mode

Application Mode

Exit Tray

of the machine

Job Tray

Fax and Copier Copier Fax

Printer and Copier Copier Printer

Fax, Copier and Printer Copier Fax and Printer

Job Tray

POWER REQUIREMENTS : DC24 V, DC5 V (supplied from copier)

Shifting Unit (OT-103): option

TYPE INSTALLATION POWER REQUIREMENTS

Multiple Bypass

Mounted on the copier

DC24 V, DC5 V (supplied from copier)

G-4

2. PRECAUTIONS FOR INSTALLATION

2-1. Installation Site

To ensure safety and utmost performance of the copier, the copier should NOT be used in a place:

• Where it will be subjected to extremely high or low temperature or humidity.

• Where it will be subjected to sudden fluctuations in either temperature or humidity.

• Which is exposed to direct sunlight.

• Which is in the direct air stream of an air conditioner, heater, or ventilator.

• Which has poor ventilation or is dusty.

• Which does not have a stable, level floor or where it will receive undue vibration.

• Which is near any kind of heating device.

• Which is near volatile flammables (thinner, gasoline, etc.).

• Where it may be splashed with water.

• Which puts the operator in the direct stream of exhaust from the copier.

• Where ammonia gas might be generated.

2-2. Power Source

• If any other electrical equipment is sourced from the same power outlet, make sure that the capacity of the outlet is not exceeded.

• Use a power source with little voltage fluctuation.

• Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the copier.

• Ensure that the copier does not ride on the power cord or communication cable of other electrical equipment, and that it does not become wedged into or underneath the mechanism.

• Make the following checks at frequent intervals:

✽

Is the power plug abnormally hot?

✽

Are there any cracks or scrapes in the cord?

✽

Has the power plug been inserted fully into the outlet?

✽

Does something, including the copier itself, ride on the power cord?

Use an outlet with a capacity of 110 to 127 V, 15 A or more. 220 to 240 V, 10 A or more.

2-3. Grounding

• Always ground the copier to prevent receiving electrical shocks in the case of electrical leakage.

• Connect the ground wire to the ground terminal of the outlet or a grounding contact which complies with the local electrical standards.

• Never connect the ground wire to a gas pipe, the ground wire for a telephone, lightning arrester, or a water pipe for fear of fire and electrical shock.

G-5

3. PRECAUTIONS FOR USE

3-1. To ensure that the copier is used in an optimum condition

• Never place a heavy object on the copier or subject the copier to shocks.

• Insert the power plug all the way into the outlet.

• Do not attempt to remove any panel or cover which is secured while the copier is making copies.

• Do not turn OFF the copier while it is making copies.

• Provide good ventilation when making a large number of copies continuously.

• Never use flammable sprays near the copier.

• If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and unplug it.

• Do not turn ON the power switch at the same time when you plug the power cord into the outlet.

• When unplugging the power cord, do not pull on the cord; hold the plug and pull it out.

• Do not bring any magnetized object near the copier.

• Do not place a vase or vessel containing water on the copier.

• Be sure to turn OFF the power switch at the end of the workday or upon power failure.

• Use care not to drop paper clips, staples, or other small pieces of metal into the copier.

3-2. Operating Environment

The operating environmental requirements of the copier are as follows.

• Temperature: 10 to 30 °C

• Humidity: 15 to 85 % RH

• Rate of temperature change: 10 °C/h

• Rate of humidity change: 10 % RH/h

3-3. Power Requirements

The power source voltage requirements are as follows.

• Voltage fluctuation: AC110 to 127 V/220 to 240 V ± 10 %

(copying performance assured)

• Frequency fluctuation: 50/60 Hz ± 0.3 %

+10 %/-15 % (paper feeding performance assured)

3-4. Note

• It is prohibited to copy paper and hard currencies, government securities, and municipal bonds (even when they are stamped as “Sample”).

• For fear of infringement of copyright, it is also prohibited to copy copyrighted works, including books, music, works of art, maps, drawings, motion pictures, and photos except when the copy is to be used only personally.

G-6

4. HANDLING OF CONSUMABLES

Before using any consumables, always read the label on its container carefully.

• Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place.

• Keep consumables out of the reach of children.

• Do not touch the PC Drum with bare hands.

• The same sized paper is of two kinds, short grain and long grain. Short grain paper should only be fed through the copier crosswise, long grain paper should only be fed lengthwise.

• If your hands become soiled with toner, wash them with soap and water.

• Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be collected.

• Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.).

• Do not store consumables in a place which:

✽

Is hot and humid.

✽

Is subject to direct sunlight.

✽

Has an open flame nearby.

G-7

5. OTHER PRECAUTIONS

Use the following precautions when performing service jobs for a copier that uses a laser.

• When a service job needs to be performed in the laser beam path, such as when working around the printerhead or PC Drum, be sure first to unplug the power cord of the copier from the outlet.

• If the job requires that the power cord be left plugged in, observe the following precautions.

1. Take off your watch, ring and any other reflective object and wear laser protective gog-

gles.

2. Keep users away from the job site.

3. Do not bring a highly reflective tool into the laser beam path during the service job.

G-8

6. SYSTEM OPTIONS

4021O009AA

1144M172AC

4021O010AA

4695U011AA

4021O013AB

4021O063AA

4021O012AA

1. Plug-In Counter

2. Original Cover OC-5

3. Automatic Document Feeder AF-10

4. Multiple Bypass MB-5

5. Copy Desk

6. Paper Feed Cabinet PF-120

7. Data Terminal DT- 201

8. Job Tray JS-202 (Illustration none)

4021O014AA

9. Sifting Unit OT-103 (Illustration none)

10. Memory M16-4, M32-3 (Illustration none)

11. Mechanical Counter CNT1 (Illustration none)

G-9

MECHANICAL/

ELECTRICAL

14413

1. CROSS SECTIONAL VIEW ............................................................................M-1

2. COPY PROCESS ............................................................................................M-2

3. DRIVE SYSTEM ..............................................................................................M-4

4. SEQUENTIAL EXPLANATION ................. ........................... ............................M-5

5. WATCHDOG FUNCTION (CPU OVERRUN MONITOR) ................................M-6

5-1. Watchdog Function Post-Processing . ......................................................M-6

6. IMAGE STABILIZATION SYSTEM ..................................................................M-7

7. IMAGING UNIT (I/U) ........................................................................................M-8

7-1. Imaging Unit (IU) Drive Mechanism .........................................................M-9

8. PC DRUM SECTION .......................................................................................M-10

8-1. PC Drum Drive Mechanism ..................................................................... M-10

8-2. Grounding of the PC Drum ................. .... .... .. .... ......... .... .. .... ......... .... .... .. .M-11

9. PC DRUM CHARGING SECTION ...................................................................M-12

10. IMAGE READING SECTION ...........................................................................M-13

10-1.Image Processi ng Pr o cess ............. ....................................... ..................M-14

10-2.Exposure Components Section ...............................................................M-15

10-3.Scanner and Mirrors Carriage Movement Mechanism ............................ M-16

(1) Scanner Movement Mechanism ......................................................M-16

(2) 2nd/3rd Mirrors Carriage Movement Mechanism ............................M-16

10-4.Scanner Motor Drive Control ...................................................................M-17

11. MEMORY STORAGE IMAGE PROCESSING SYST EM .................................M-18

11-1.Laser Exposure Process .........................................................................M-19

12. DEVELOPING UNIT SECTION .............................. ............................ .............M-20

12-1.Developing Unit Drive Mechanism ..........................................................M-21

12-2.Sleeve/Magnet Roller ..............................................................................M-22

12-3.Developing Bi a s ..................... ........................................ ..........................M-22

12-4.ATDC Sensor ................................... ........................... ............... .............M-23

(1) ATDC Sensor Automatic Adjustment ..............................................M-23

12-5.Toner Replenishing Mechanism ..............................................................M-24

12-6.Toner Replenishing Control .....................................................................M-25

12-7.T/C Recovery Mode .................................................................................M-26

12-8.Toner Bottle Home Position Detection Mechanism .................................M-27

13. PAPER TAKE UP/FEED SECTION .................................................................M-28

13-1.Drawer In Position Detection ...................................................................M-29

13-2.Paper Empty Detection Mechanism ........................................................M-29

13-3.Paper Lifting Plate ...................................................................................M-30

13-4.Universal Tray Paper Size Detection Mechanism ...................................M-30

13-5.Paper Take Up Mechanism .....................................................................M-32

(1) Paper Separating Mechanism ......................................................... M-32

13-6.Paper Take Up Control ............................................................................M-33

(1) Paper Take Up Retry Control ..........................................................M-33

14. MANUAL BYPASS SECTION .........................................................................M-34

14-1.Paper Take Up Drive Mechanism ............................................................M-34

14-2.Paper Detection Mechanism ...................................................................M-34

14-3.Manual Feed Take Up Control ........................................................... .... .M-35

15. MULTIPLE BYPASS SECTION .......................................................................M-36

15-1.Paper Take Up Drive Mechanism ............................................................M-36

15-2.Paper Take-Up Mechanism .....................................................................M-37

15-3.Paper Empty Detection Mechanism ........................................................M-38

15-4.Paper Take Up Control ............................................................................M-38

15-5.Paper Take Up Retry Control ..................................................................M-39

16. IMAGE TRANSFER AND PAPER SEPARATION SECTION ..........................M-40

17. PC DRUM CLEANING SECTION ....................................................................M-41

18. MAIN ERASE SECTION .................................................................................. M-42

19. FUSING UNIT SECTION .................................................................................M-43

19-1.Fusing Unit Drive Mechanism ..................................................................M-44

19-2.Fusing Rollers Pressure Mechanism .......................................................M-44

19-3.Fusing Temperature Control ....................................................................M-45

19-4.CPM Control ............................................................................................M-45

20. JOB TRAY (JS-202): Option ............................................................................M-46

20-1.Tray Selecting Mechanism ......................................................................M-47

20-2.Tray-Full Detecting Mechanism ...............................................................M-48

20-3.Job Tray Paper Detecting Mechanism ....................................................M-48

21. SHIFTING UNIT (OT-103): Option ..................................................................M-49

21-1.Exit Position Shifting Mechanism ............................................................M-50

22. OTHER MECHANISM ................................ ........................... ..........................M-52

22-1.Cooling Mechanism . . ...............................................................................M-52

(1) Power Supply Section Cooling Mechanism .....................................M-52

(2) Fusing Section Cooling Mechanism ................................................M-53

1. CROSS SECTIONAL VIEW

1. IR Section

2. Fusing Unit

3. Imaging Unit

4. Paper Take-Up/Feed Section

5. PH Section

4021M001AA

M-1

2. COPY PROCESS

4021M065CB

1. PC Drum

• Used as the medium on which a visible developed image of the original is formed.

2. Drum Charging

• A uniform negative DC charge is deposited across the entire surface of the PC Drum.

3. Photoelectric Conversion

• CCD converts the image data represented by light reflected off the original to a corresponding electrical signal which, in turn, is output to IR image-processing section.

4. IR Image-Processing

• The electrical signal is converted to an 8-bit digital image signal (A/D conversion) which, in turn, goes through appropriate correction before being output to the PH Image Processing.

5. PH Image Processing

• After going through corrections, the digital image signal is converted to a corresponding electrical signal (D/A conversion) that controls the intensity of the light from the laser diode.

6. Laser Exposure

• The laser beam strikes the surface of the PC Drum, forming an electrostatic latent image.

7. Developing

• Toner negatively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image.

• An AC/DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original.

8. Paper Feed

• Paper is fed from the drawer.

M-2

9. Bypass Paper Feed

• Feeds paper from the Manual Bypass Tray, one piece at a time.

• The optional Multiple Bypass T ray (MB-5), when mounted on the machine, permits continuous paper feeding.

10. Image Transfer

• A DC positive charge is applied to the Image Transfer Roller to transfer the visible image on the surface of the PC Drum onto the paper.Paper Separation.

11. Paper Separation

• The PC Drum Paper Separator Fingers remove paper from the surfa ce of the PC Drum.

• The Charge Neutralizing Plate neutralizes any charge left on the paper.

12. Cleaning

• Residual toner on the surface of the PC Drum is scraped off.

• The toner is then recycled back to the Developing Unit.

13. Main Erase

• Light is directed to the surface of the PC Drum to neutralize any surface potential remaining there after cleaning.

14. Paper Transport

• The paper is fed to the Fusing Unit.

15.Fusing

• The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Right and Left Fusing Rollers.

16. Paper Exit

• The paper is fed out onto the Exit Tray.

• When the optional Job Tray (JS-202) is mounted, the specific tray into which paper is f ed is selected according to the application mode.

• The optional Shifting Unit (OT-103), when mounted, permits different finishing functions set on the machine (Non-Sort, and Sort) .

M-3

3. DRIVE SYSTEM

Paper Exit Roller Gear

Transport Roller Gear

Fusing Roller Gear

1. Scanner Motor M5

2. Main Motor M1

PC Drum

Synchronizing Roller Clutch

Paper Take-Up Roller Gear

4021M003AA

M-4

4. SEQUENTIAL EXPLANATION

4021M510CA

Power Switch ON Start Key ON

Polygon Motor M2

Predrive

150 ˚C Warm-up completed

Exposure Lamp LA2

Main Motor M1

Paper Take-Up Solenoid SL1

Synchronizing Roller Sensor PC1

Synchronizing Roller Clutch CL1

Developing Bias (VB) DC

Developing Bias (VB) AC

Image Transfer Bias (+)

Image Transfer Bias (–)

Exit Paper Sensor PC3

M-5

Full speed

Speed reduction

Power Supply Cooling

Fan Motor M4

Fusing Cooling Fan

Motor M3

+ 49 hidden pages

Minolta Di 152 General

GENERAL

CONTENTS

1. SPECIFICATION

2. PRECAUTIONS FOR INSTALLATION

2-1. Installation Site

2-2. Power Source

2-3. Grounding

3. PRECAUTIONS FOR USE

3-1. To ensure that the copier is used in an optimum condition

3-2. Operating Environment

3-3. Power Requirements

3-4. Note

4. HANDLING OF CONSUMABLES

5. OTHER PRECAUTIONS

6. SYSTEM OPTIONS

CONTENTS

1. CROSS SECTIONAL VIEW

2. COPY PROCESS

3. DRIVE SYSTEM

4. SEQUENTIAL EXPLANATION