Minolta Di 152, Di 183 Service Manual Main Service

Service Manual

[Field Service]

Di152/Di183

FrameMaker Ver.5.5(PC) Di152/Di183

01.08.06

INDEX (FIELD SERVICE)

SAFETY PRECA UTIONS FOR
INSPECTION AND SERVICE

DIS/REASSEMBLY,
ADJUSTMENT

SWITCHES ON PWBs,
TECH. REP. SETTINGS

TROUBLESHOOTING

FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

1. 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.

Indicates a potentially hazardous situation which, if not avoided,

WARNING

CAUTION

• The following graphic symbols are used to give instructions that need to be observed.

Used to call the service technician’s attention to what is graphically represented
inside the marking (including a warning).

Used to prohibit the service technician’s from doing what is graphically repre­sented inside the marking.

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.

Used to instruct the service technician’s to do what is graphically represented
inside the marking.

1-1. Warning

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 O perator’s 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.

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3. Do not throw toner or the toner bottle into a fir.

• Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner
expelled from the fire may cause burns.

4. Use the specified parts.

• For replacement parts, always use the genuine parts specified in the manufac­turer’s 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 manufacturer’s 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.

5. 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.

6. 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.

7. 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.

8. 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 c ooled down before replacing them or any surround­ing parts.

9. 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.

10. 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.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

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11. Restore all parts and harnesses to their original positions.

• To promote safety and prevent product damage, make sure the harnes ses 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.

1-2. Caution

CAUTION

1. Precautions for Service Jobs.

• A toothed washer and spring washer, if used or iginally, must be reinstalled.
Omitting them may result in contact failure wh ich 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 remove d. The use of folded paper or some other object
may damage the interlock switc h mechanism, poss ibly resulting in an electric
shock, injury or blindness.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

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 s ervice 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 manufac­turer’s 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 user’s premises or attempt to try to discharge one.

5. Precautions for the Laser Beam. (Only for Products Employing a Laser)

• Removing the cover marked with the 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 unavoidab le , 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.”

6. Precautions for storage the toner or imaging cartridge.

• Be sure to keep the toner or imaging cartridge out of the reach of children. Lick­ing the imaging cartridge or ingesting its contents is harmful to your health.

1-3. Other Precautions

• When handling circuit boards, observe the “HANDLING of PWBs”.

• 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.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

1-4. Used Batteries Precautions

ALL Areas

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 manufacturer’s instructions.

Germany

Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

France

Il y a danger d’explosion s’il y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du même type ou d’un type équivalent recom­mandé par le constructeur.
Mettre au rebut les batteries usagées conformément aux instructions du fabricant.

Denmark

Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandøren.

Finland, Sweden

Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.

CAUTION

VORSICHT!

ATTENTION

ADVARSEL!

VAROlTUS

VARNING
Explosionsfara vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat­tillverkaren.
Kassera använt batteri enligt fabrikantens instruktion.

Norway

Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

ADVARSEL

P-5

FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

1-5. Precautions for Service

• When performing inspection and service procedures, observe the following precautions

to prevent mishandling of the machine and its parts.

✽

Depending on the model, some of the precautions given in the following do not apply.

1. Precautions Before Service

• When the user is using a word processor or personal computer from a wall outlet of the

same line, take necessary steps to prevent the circuit breaker from opening due to over­loads.

• Never disturb the LAN by breaking or making a network connection, altering termination,

installing or removing networking hardware or software, or shutting down networked
devices without the knowledge and express permission of the network administrator or
the shop supervisor.

2. How to Use this Book
< DIS/REASSEMB LY, ADJUSTMENT >

• To reassemble the product, reverse the order of disassembly unless otherwise specified.
< TROUBLESHOOTING >

• If a component on a PWB or any other functional unit including a motor is defective, the

text only instructs you to replace the whole PWB or functional unit and does not give trou­bleshooting procedures applicable within the defective unit.

• All troubleshooting procedures contained herein assume that there are no breaks in the

harnesses and cords and all connectors are plugged into the right positions.

• The procedures preclude possible malfunctions due to noise and other external causes.

3. Precautions for Service

• Check the area surrounding the service site for any signs of damage, wear or need of

repair.

• Keep all disassembled parts in good order and keep tools under control so that none will

be lost or damaged.

• After completing a service job, perform a safety check. Make sure that all parts, wiring

and screws are returned to their original positions.

• Do not pull out the toner hopper while the toner bottle is turning. This could result in a

damaged 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.

• Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sen-

sors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit
containing these sensors is to be cleaned, first remove the sensors from the unit.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

4. Precautions for Dis/Reassembly

• Be sure to unplug the copier from the outlet before attempting to service the copier.

• The basic rule is not to operate the copier anytime during disassembly. If it is absolutely

necessary to run the copier with its covers removed, use care not to allow y our clothing to
be caught in revolving parts such as the timing belt and gears.

• Before attempting to replace parts and unplug connectors, make sure that the power

cord of the copier has been unplugged from the wall outlet.

• Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the

Interlock Switch with the covers left open or removed.

• While the product is energized, do not unplug or plug connectors into the circuit boards

or harnesses.

• Never use flammable sprays near the copier .

• A used battery should be disposed of according to the local regulations and never be dis-

carded casually or left unattended at the user’s premises.

• When reassembling parts, make sure that the correct screws (size, type) and toothed

washer are used in the correct places.

5. Precautions for Circuit Inspection

• Never create a closed circuit across connector pins except those specified in the text and

on the printed circuit.

• When creating a closed circuit and measuring a voltage across connector pins specified

in the text, be sure to use the GND wire.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

6. Handling of PWBs
< During Transportation/St orage >

• During transportation or when in storage, new P.W. Boards must not be indiscriminately

removed from their protective conductive bags.

• Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem-

perature.

• When it becomes absolutely necessary to remove a Board from its conductive bag or

case, always place it on its conductive mat in an area as free as possible from static elec­tricity.

• Do not touch the pins of the ICs with your bare hands.

• Protect the PWBs from any external force so that they are not bent or damaged.
< During Inspection/Replacement >

• Avoid checking the IC directly with a multimeter; use connectors on the Board.

• Never create a closed circuit across IC pins with a m etal tool.

• Before unplugging connectors from the P.W . Boards, make sure that the power cord has

been unplugged from the outlet.

• When removing a Board from its conductive bag or conductive case, do not touch the

pins of the ICs or the printed pattern. Place it in position by holding only the edges of the
Board.

• When touching the PWB, wear a wrist strap and connect its cord to a securely grounded

place whenever possible. If you cannot wear a wrist strap, touch a metal part to dis­charge static electricity before touching the PWB.

• Note that replacement of a PWB may call for readjustments or resetting of particular

items.

7. Handling of Other Parts

• The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy

disk, magnetic card, or CRT tube.

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03

01.04.23

8. Handling of the PC Drum

✽

Only for Products Not Employing an Imaging Cartridge.

< During Transportation/St orage >

• Use the specified carton whenever moving or storing the PC Drum.

• The storage temperature is in the range between –20°C and +40°C.

• In summer, avoid leaving the PC Drum in a car for a long time.
< Handling >

• Ensure that the correct PC Drum is used.

• Whenever the PC Drum has been removed from the copier , store it in i ts carton or protect

it with a Drum Cloth.

• The PC Drum exhibits greatest light fatigue after being exposed to strong light over an

extended period of time. Never, therefore, expose it to direct sunlight.

• Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger-

prints, and other foreign matter.

• Do not scratch the surface of the PC Drum.

• Do not apply chemicals to the surface of the PC Drum.

• Do not attempt to wipe clean the surface of the PC Drum.
If, however, the surface is contaminated with fingerprints, clean it using the following proce-

dure.

A. Place the PC Drum into one half of its carton.

1076D001

1076D002

B. Gently wipe the residual toner off the surface of the

PC Drum with a dry, Dust-Free Cotton Pad.

• Turn the PC Drum so that the area of its surface on
which the line of toner left by the Cleaning Blade is
present is facing straight up. Wipe the surface in one
continuous movement from the rear edge of the PC
Drum to the front edge and off the surface of the PC
Drum.

• Turn the PC Drum slightly and wipe the newly
exposed surface area with a CLEAN face of the
Dust-Free Cotton Pad. Repeat this procedure until
the entire surface of the PC Drum has been thor­oughly cleaned.

✽

At this time, always use a CLEAN face of the dry
Dust-Free Cotton Pad until no toner is e vident on the
face of the Pad after wiping.

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C. Soak a small amount of either ethyl alcohol or iso-

propyl alcohol into a clean, unused Dust-Free Cot­ton Pad which has been folded over into quarters.
Now, wipe the surface of the PC Drum in one con­tinuous movement from its rear edge to its front
edge and off its surface one to two t imes.

✽

Never move the Pad back and forth.

1076D003

D. Using the SAME face of the Pad, repeat the proce-

dure explained in the latter half of step 3 until the
entire surface of the PC Drum has been wiped.
Always OVERLA P the areas when wiping. Two
complete turns of the PC Drum would be appropri­ate for cleaning.

1076D004

NOTES

• Even when the PC Drum is only locally dirtied, wipe the entire surface.

• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under
interior illumination.

• If dirt remains after cleaning, repeat the entire procedure from the beginning one more
time.

9. Handling of the Imaging Cartridge

✽

Only for Products Employing an Imaging Cartridge.

< During Transportation/St orage >

• The storage temperature is in the range between –20°C and +40°C.

• In summer, avoid leaving the Imaging Cartridge in a car for a long time.

< Handling >

• Store the Imaging Cartridge in a place that is not exposed to direct sunlight.

< Precautionary Information on the PC Drum Inside the Imaging Cartr idge >

• Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger­prints, and other foreign matter.

• Do not scratch the surface of the PC Drum.

• Do not attempt to wipe clean the surface of the PC Drum.

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FrameMaker Ver5.5E(PC) Di152/Di183 DIS/REASSEMBLY, ADJUSTMENT

01.09.03

DIS/REASSEMBLY,

ADJUSTMENT

10230

FrameMaker Ver5.5E(PC) Di152/Di183 DIS/REASSEMBLY, ADJUSTMENT

01.09.03

CONTENTS

1. SAFETY INFORMATION ............. ................................................ ....................D-1

1-1. LASER SAFETY ............................................................ ..........................D-1

1-2. INTERNAL LASER RADIATION ..............................................................D-1

1-3. LASER SAFETY LABEL ................. ................................................ .........D-4

1-4. LASER CAUTION LABEL .................................... ......................... ...........D-4

1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ...............D-4

2. SERVICE INSTRUCTIONS .............................................................................D-5

2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS ............. .......D-5

2-2. PARTS WHICH MUST NOT BE TOUCHED .................................... .......D-6

(1) Red Painted Screws ...................................... ..................................D-6

(2) Variable Resistors on Board ................................................... .........D-6

3. DISASSEMBLY/REASSEMBLY ...................................................................... D-7

3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION

AND REMOVAL PROCEDURES ............................................................D-7

3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL

COMPONENTS .......................................................................................D-9

(1) Removal of the Master Board ..........................................................D-10

(2) Removal of the Control Board .........................................................D-11

(3) Removal of the High Voltage Unit ...................................................D-11

(4) Removal of the DC Power Supply . ..................................................D-13

3-3. MAINTENANCE SCHEDULE .................................................................. D-16

3-4. PAPER TAKE-UP/TRANSPORT SECTION ............................................D-18

(1) Removal of the Paper Separator Roll Assy and

Paper Take-Up Roll .........................................................................D-18

(2) Cleaning of the Paper Separator Roll ..............................................D-18

(3) Cleaning of the Paper Take-Up Roll ................................................D-18

(4) Cleaning of the Right and Left Synchronizing Rollers .....................D-19

(5) Removal of the Paper Dust Remover Assy .....................................D-19

(6) Cleaning of the Paper Dust Remover ..............................................D-20

(7) Cleaning of the Bypass Transport Roller .........................................D-20

3-5. OPTICAL SECTION ...................................................... ..........................D-21

(1) Cleaning of the Original Glass and ADF Glass ...............................D-21

(2) Cleaning of Mirrors ..........................................................................D-21

(3) Cleaning of the Lens ...................................................... ....... .. .. .... .. .D-21

(4) Cleaning of the CCD Sensor ...........................................................D-22

(5) Cleaning of the Scanner Rails/Bushings .........................................D-22

(6) Removal of the CCD Unit ................................................................D-23

(7) Removal of the Scanner, Exposure Lamp, and Inverter Board .......D-23

(8) Removal of the Scanner Drive Cables ............................................D-25

(9) Winding of the Scanner Drive Cables ..............................................D-27

3-6. PH ............................................................................................................ D-29

(1) Removal of the PH Unit ...................................................................D-29

(2) Cleaning of the PH Window .............................................................D-29

3-7. Imaging Unit (IU) ......................................................................................D-30

(1) Removal of the IU ............................................................................D-30

(2) Disassembly of the IU ......................................................................D-30

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FrameMaker Ver5.5E(PC) Di152/Di183 DIS/REASSEMBLY, ADJUSTMENT

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(3) Application of Toner .........................................................................D-34

(4) Replacement of the ATDC Sensor ..................................................D-35

3-8. IMAGE TRANSFER SECTION ................................................................D-36

(1) Removal of the Image Transfer Roller Assy ....................................D-36

(2) Cleaning of the Pre-Image Transfer Lower Guide Plate ..................D-36

(3) Cleaning of the Charge Neutralizing Pla te ............ ......................... .D-36

3-9. FUSING SECTION ..................................................................................D-37

(1) Removal of the Fusing Unit .............................................................D-37

(2) Disassembly of the Fusing Unit ....................................................... D-37

3-10.MULTIPLE BYPASS (MB-5): OPTION ....................................................D-42

(1) Removal of the Separator Roll Assy ................................................D-42

(2) Removal of the Paper Take-Up Roll ................................................D-42

(3) Cleaning of the Separator Roll/Paper Take-Up Roll ........................D-45

(4) Cleaning of the Paper Take-Up Roll ................................................D-45

3-11.JOB TRAY (JS-202): OPTION ................................................................D-46

(1) Removal of the Main Board .............................................................D-46

(2) Paper Detecting Board .................................................................... D-48

3-12.SHIFTING UNIT (OT-103): OPTION ....................................................... D -49

(1) Removal of the Main Board .............................................................D-49

4. ADJUSTMENT .................................................................................................D-51

4-1. ADJUSTMENT JIGS AND TOOLS USED ...............................................D-51

4-2. TIMING BELT TENSION ADJUSTMENT ............................................. ...D-51

4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, AND

ADJUST MODE ...................................... ................................................ .D-52

(1) Function Mode .................................................................................D-52

(2) Tech. Rep. Choice Mode .................................................................D-52

(3) Adjust Mode .......................................................................... .... .... ...D-52

4-4. ELECTRICAL/IMAGE ADJUSTMENT ..................... ................................D-53

(1) Edge Erase Adjustment (Leading, Trailing, and Top/Bottom

Edges) .............................................................................................D-53

(2) Loop Length Adjustment (1st and 2nd Trays, Bypass Tray) ...........D-54

(3) Printer CD Registration Adjustment .................................................D-55

(4) Printer FD Registration Adjustment .................................................D-56

(5) Scanner CD Registration Adjustment ..............................................D-57

(6) Scanner FD Registration Adjustment ..............................................D-58

(7) Scanner CD Zoom Adjustment ........................................................D-59

(8) Scanner FD Zoom Adjustment ...................................... ........... .... ...D-60

(9) ATDC Sensor Automatic Adjustment (F8) .......................................D-61

(10) Manual Bypass Registration Adjustment .... .....................................D-62

(11) Multiple By pa ss Registrati o n Ad j u stment (MB-5) : O p ti o n ........ .. ......D-6 3

4-5. OTHER ADJUSTMENTS ....................................................... ..................D-64

(1) Adjustment of the Position of the Scanner and

2nd/3rd Mirrors Carriage .................................................................D-64

(2) CCD Unit Position Adjustment .......... ......................... ......................D-65

(3) Adjustment of the Gap between the Doctor Blade and

Sleeve Roller (Db Adjustment) ........................................................D-66

4-6. MISCELLANEOUS .................................................................................. D-68

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FrameMaker Ver5.5E(PC) Di152/Di183 DIS/REASSEMBLY, ADJUSTMENT

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(1) Remounting the EEPROM (U29) .....................................................D-68

(2) Installation of the Plug-In Counter Socket (Option) .........................D-69

(3) Installation of the Mechanical Counter (Option) ..............................D-70

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FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

1. SAFETY INFORMATION

1-1. LASER SAFETY

• This is a digital machine certified as a class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.

1-2. INTERNAL LASER RADIATION

Semiconductor laser

Maximum average radiation power(*) 26.4 µW

Wavelength 770-795 nm

*:Laser Aperture of the Print Head Unit

• This product employs a Class 3b laser diode that emits an invisible laser beam. The laser
diode and the scanning polygon mirror are incorporated in the print head unit.

• The print head unit is NOT A FIELD SERVICE ITEM. Therefore, the print head unit
should not be opened under any circumstances.

This figure Shows the view inside the Right Door
with the Imaging Unit removed.

D-1

Laser Aperture of
the Print Head Unit

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

the U.S.A., Canada
(CDRH Regulation)

• This machine is certified as a Class I Laser product under Radiation Performance Stan­dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory
for Laser products marketed in the United States and is reported to the Center for
Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.

• The label shown to page D-4 indicates compliance with the CDRH regulations and must
be attached to laser products marketed in the United States.

CAUTION

Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 nm

All Areas

CAUTION

Use of controls, adjustments or performance of procedures other than those specified in
this manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 nm

Denmark

ADVARSEL

Usynlig Laserstråling ved åbning, når sikkerhedsafbrydere er ude af funktion. Undgå
udsættelse for stråling. Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene.

Halvlederlaser

Laserdiodens højeste styrke 5 mW

Bølgelængden 770-795 nm

D-2

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

Finland, Sweden

VARO!

Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä
katso säteeseen.

LOUKAN 1 LASERLAITE
KLASS 1 LASER APPARAT

VAROITUS!

Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa
käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

Puolijohdelaser

Laserdiodin suurin teho 5 mW

Aallonpituus 770-795 nm

VARNING!

Om apparaten används på annat sätt än i denna bruksanvisning specificerats, kan använ­daren utsättas för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

Halvledarlaser

Den maximala effekten för laserdioden 5 mW

Våglängden 770-795 nm

VARNING!

Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej
strålen.

Norway

ADVERSEL

Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning, kan
brukeren utsettes for unsynlig laserstråling som overskrider grensen for laser klass 1.

Halvleder laser

Maksimal effekt till laserdiode 5 mW

Bølgelengde 770-795 nm

D-3

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

1-3. LASER SAFETY LABEL

• A laser safety labels is attached to the outside of the machine as shown below.

Laser safety label

For Europe

CLASS 1 LASER PRODUCT
LASER KLASSE 1

For United States

PRODUCT

1155O764AA

4022D038CA

4002O312CA

1-4. LASER CAUTION LABEL

• A laser caution label is attached to the inside of the machine as shown below.

4022D501AA

4022D027AA

1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.

• When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC Drum, be sure first to turn the copier OFF.

• If the job requires that the copier be left ON, take off your watch and ring and wear laser
protective goggles.

• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the user’s premises.

D-4

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

2. SERVICE INSTRUCTIONS

2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS

Control Board (PWB-C)
125 V 3 A

DC Power Supply (PU1)
100 V system 125 V 15 A (F2)
200 V system 250 V 6.3 A (F2)

Thermoswitch 1 (TS1)
250 V 7.5 A/125 V 15 A

4022D028AA

D-5

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

2-2. PARTS WHICH MUST NOT BE TOUCHED

(1) Red Painted Screws

Purpose of Application of Red Paint
Red painted screws show that the assembly or unit secured can only be adjusted or set at
the factory and shall not be readjusted, set, or removed in the field.
If it becomes unavoidably necessary to disassemble any of these assemblies and units,
disassembly may be done provided that the conditions permitting reassembly are met.
Note also that when two or more screws are used on the part in question, only one repre­sentative screw may be marked with red paint.

(2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting instructions are given in
“ADJUSTMENT.”
Other Screws not Marked with Red Paint
<PH Unit>

PH Unit

<IR Unit>

Left side face

PH Unit base plate

Right side face

D-6

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

3. DISASSEMBLY/REASSEMBLY

3-1. DOORS, COVERS, AND EXTERIOR P ARTS: IDENTIFICATION

AND REMOVAL PROCEDURES

1

2

11

3

9

10

18

17

16

4

5

6

8

7

12

13

D-7

14

15

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

No. Part Name Removal Procedure

1 Original Cover Pull the Original Cover straight up.
2 Original Glass

3 Control Panel

4 Right Inside Cover

5 Front Cover

6 Front Door

71st Tray

8 Left Cover

9 Upper Cover

10 Rear Inside Cover

11 ADF Glass Remove two ADF Glass mounting screws.
12 Left Hinge Remove no. 14. → Remove three Left Hinge mounting screws.
13 Right Hinge Remove no. 14. → Remove three Right Hinge mounting screws.
14 Rear Cover Remove six Rear Cover mounting screws.

15 Rear Right Cover

Multip le B ypass

16

Cover (when the
option is mounted)

17 Right Door

18 Right Cover

Remove no. 18. → Remove two holding brackets or no. 11 and
the Original Glass.

Remove two control panel mounting screws. → Remove two
ground wire mounting screws. → Remove one flat cable and
unplug one connector.

Remove no. 5. → Remove one Right Inside Cover mounting
screw.

Remove no. 3. → Open the Front Door and remove six Front
Cover mounting screws.

Open the Front Door and remove one band mounting screw. →
Snap off one C-clip.

Slide out the 1st Tray. → Remove the fixing brackets on the right
and left.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
five Left Cover mounting screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
no. 8. → Remove two screws and two Upper Cover mounting
screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
no. 8. → Remove no. 9. → Remove no. 4. → Remove two Rear
Inside Cover mounting screws.

Remove no. 14. → Remove one Rear Right Cover moun ting
screw.

Remove two Multiple Bypass Cover mounting screws.

Remove no. 14. → Remove no. 15. → Remove three Right Door
mounting screws.

Remove no. 3. → Remove no. 5. → Remove no. 14. → Remove
four Right Cover mount ing screws.

D-8

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL

COMPONENTS

• When removing a circuit board or other electrical component, refer to “PRECAUTIONS
FOR HANDLING THE PWBs” and follow the corresponding removal proc edures.

• The removal procedures given in the following omit the removal of connectors and
screws securing the circuit board support or circuit board.

• Where it is absolutely necessary to touch the ICs and other electrical components on the
board, be sure to ground your body.

PWB-A
Job Tray (JS-202): Option
Shifting Unit (OT-103): Option

PWB-R1

PWB-J

PWB-C

PU3

PU2

PWB-A

PWB-I

HV1

4022D029AA

PWB-R2

PU1

PWB-B
Job Tray (JS-202): Option

D-9

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

Symbol Part Name Removal Procedure
PWB-A Master Board
PWB-C Control Board

PWB-I

PWB-J CCD Board
PWB-R1 Fusing Board Remove the Fusing Unit. → PWB-R1
PWB-R2
PU1 DC Power Supply

PU2 Inverter Board

PU3 Control Panel

HV1 High Voltage Unit

Job Tray (JS-202): Option

Symbol Part Name Removal Procedure
PWB-A Main Boar d
PWB-B Paper Detecting Board☞ D-48

Paper Size Detecting
Board

Pre-Image Transfer
Board

☞

D-10

☞

D-11

Remove the Rear Cover. → Remove t he PWB Assy. →
Remove two screws and the PWB-I Assy. → PWB-I

☞

D-23

✽

Remove the CCD Unit as a unit.

Open the Right Door. → PWB-R2

☞

D-13

☞

D-23

Remove two control panel mounting screws. → Remove
two ground wire mounting screws. → Remove one flat
cable and unplug one connector. → PU3

☞

D-11

☞

D-46

Shifting Unit (OT-103): Option

Symbol Part Name Removal Procedure
PWB-A Main Boar d

(1) Removal of the Master Board

1. Remove the Rear Cover.

2. Remove 12 screws and the PWB Cover Assy.

☞

D-49

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FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

3. Unplug all connectors (but PJ20) from the Master
Board.

4. Remove f our screws and the Master Board.

(2) Removal of the Control Board

1. Remove the Rear Cover.

2. Remove the PWB Cover Assy.

3. Unplug all connectors from the Control Board.

4. Remove six screws and the Control Board.

(3) Removal of the High Voltage Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Upper Cover, Right
Inside Cover, and Rear Inside Cover.

2. Remove the PWB Cover Assy.

3. Unplug all connectors from the Master Board (except for PJ20) and from the Control
Board.

4. Remove the harness from seven wiring saddles and two edge covers.

D-11

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

5. Unplug three connectors from the High Voltage
Unit and remove the harness from one wiring
saddle.

6. Remove the harness from one wiring saddle.

7. Remove ten screws and the PWB Assy.

8. Remove the harness from one wiring saddle of
the High Voltage Unit cover.

D-12

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

9. Remove nine screws and the High Voltage Unit
cover.

10. Unplug two connectors from the High Voltage
Unit.

11. Remove two screws and the High Voltage Unit.

(4) Removal of the DC Power Supply

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover.

2. Unplug two connectors of the Hopper Assy.

3. Remove two Hopper mounting screws on the
right.

4. Remove two Hopper mounting screws on the left
and the Hopper Assy.

5. Remove three screws and the Power Supply
Right Cover.

D-13

FrameMaker Ver.5.5E(PC) DIS/REASSEMBLY, ADJUSTMENT FOR Di152/Di183

01.09.03

6. Remove f our screws and the Power Supply Left
Cover.

7. Unplug one connector and remove the harness
from one edge cover.

8. Unplug one connector and remove the harness
from one wiring saddle.

9. Unplug one connector and remove the harness
from one wiring saddle.

10. Unplug three connectors and remove the harness
from two wiring saddles.

D-14