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 :Action having a high possibility of suffering death or serious injury WARNING:Action having a possibility of suffering death or serious injury CAUTION :Action having a possibility of suffering a slight wound, medium trouble, and
property damage Symbols used for safety and important warning items are defined as follows:
:Precaution when using the copier. :Prohibition when using the copier. :Direction when using the copier.

General precaution

Electric hazard

High temperature

General prohibition
Do not touch with wet hand

Do not disassemble

General instruction

Unplug

Ground/Earth

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, unauthorized 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, solder 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.

*26 Weekly timer summer time setting Mode 0 minute 10 minutes 20 minutes 30 minutes 40 minutes 50 minutes 60 minutes 70 minutes 80 minutes 90 minutes 100 minutes 110 minutes 120 minutes 130 minutes 140 minutes 150 minutes 17-1 17-1 17-1 17-1
Standard+5C Standard+10C Standard+15C Standard-5C Standard-10C Standard-15C Standard+20C *29 IP scanner default resolution Mode 400dpi 600dpi 200dpi 300dpi *30 Number of punched holes Mode 2 holes (Japan) 3 holes or 2 and 3 holes (Inch area) 4 holes or 2 and 4 holes (Metric area)

19-7 19-1

22-2 22-0
*27 Density selection for scanning tab paper The higher the brightness level, the higher the density. Mode 80 (brightness level) 255(not clipped) 17-1 17-1 17-1
*31 Image density selection (toner density selection of developer) These bits set the toner density of developer by changing toner supply threshold and developing sleeve rotation speed with image density unchanged. Decrease toner density when the image is gray background or toner is scattered. Increase toner density when the image is unevenly transferred or white spots occur. Mode Standard toner density Approx. 0.75% up Approx. 0.75% down Approx. 1.5% down 23-3 23-1
*33 Maximum number of sheets with z-folding (main tray) Mode Up to 50 sheets Up to 40 sheets Up to 30 sheets Up to 20 sheets 24-5 24-1
*37 Fixing linear velocity adjustment To protect from transfer misalignment, the fixing linear velocity can be adjusted to the conveyance linear velocity. Mode 0% -0.2% -0.4% -0.6% -0.8% -1.0% -1.2% -1.4% -1.6% +0.2% +0.4% +0.6% +0.8% +1.0% +1.2% +0.4% 33-3 33-2 33-1 33-1
Note: There are three DIP switches to change the image density : 5-0/1 (toner concentration threshold), 5-2/3 (lase PWM), and 23-2/3 (toner density of developer). The priority of order of these adjustment are as follows: (1) Laser PWM (2) Toner density of developer (3) Toner concentration threshold *32 Image's gray background control at power ON If an image's gray background problem occurs while making about 100 copies after power ON (the fixing temperature is 50C or lower), set bits 0, 1, 3, 5, 6, and 7 of DIPSW27 to 1. Note: When this setting is used, be sure to set six bits to 1 all together. And never set bits 2 and 4 of DIPSW27 to 1. Di5510/Di7210 models enable to set the control time of DIPSW27-5/6 (turning-ON control of toner recycle MC during drum/developer rotation). Mode None 30 seconds 45 seconds 60 seconds 27-6 27-1

Automatically adjusting the maximum density (Dmax). This adjustment should be performed when the drum, developer, write unit, or dustproof glass is replaced. Preparation: Be sure the drum unit is set and developer is in the developing unit. Step Operation Enter the 36 mode. [Adjustment mode menu Screen] Press " 1 Process adjustment". [Process adjustment mode menu Screen] 3 Press " 2 Drum peculiarity adjustment.". [Drum peculiarity adjustment mode menu Screen] Press " 2 Auto maximum density adj.". [Auto maximum density adjustment Screen] Press the Start 5 key. The maximum density (Dmax) is adjusted automatically. Adjustment completes in about 15 seconds and an complete message is displayed. Press the RETURN key to return to the 6 Drum peculiarity adjustment mode menu Screen.
The dot diameter is adjusted automatically. Adjustment completes in about 10 seconds and a complete message is displayed. Press the RETURN key to return to
the Drum peculiarity adjustment mode menu Screen.
Reference: If any one of the following error messages appears during auto maximum density adjustment, clean the TSCB (toner control sensor board), check its installation state, and retry the auto maximum density adjustment. <1> Error 1: The Dmax sensor dirt correction has been corrected. <2>Error 2: Maximum density adjustment is not complete when the number of rotation of developing sleeve reaches the specified value. <3>Error 3: No signal is output from the Dmax sensor. No control patch is output.
Reference: If either of the following error messages appears during auto dot diameter adjustment, clean the TSCB (toner control sensor board), check its installation state, and retry the auto dot diameter adjustment. <1> Error 1: The sensor dirt correction has been corrected. <2>Error 2: Auto dot diameter adjustment has ended with an abnormal value.

4. LD1 offset adjustment

This adjusts the place at which LD1 laser starts writing. This adjustment should be performed when the drum or developer is replaced. In the case of the Di551/Di650 The adjustment is performed at line speed of 320, 280 and 185 respectively. In the case of the Di5510/Di7210 The adjustment is performed at line speed of 345, 280 and 172.5 respectively. Preparation: Be sure the drum unit is set. Auto maximum density adjustment and auto dot diameter adjustment must have been completed. Step Operation Enter the 36 mode. [Adjustment mode menu Screen] Press " 1 Process adjustment". 8

If the specification is not satisfied, press the C button while pressing the P button. [LD2 offset adjustment Screen] Enter an offset value using the numeric
keys and press the SET key. Setting range: -128 to +127 Repeat steps 6 to 10 until the specification is satisfied. Press the RETURN key to return to the
5 Press any key of LS345 , LS280 , or
Drum peculiarity adjustment mode menu Screen.

6. LD1 bias adjustment

LD1 bias adjustment is inhibited in the field.

7. LD1 bias adjustment

8. Auto gamma adjustment (1 dot)
Performs gamma adjustment (1 dot) automatically. This adjustment should be performed when the drum, developer, write unit, or dust-proof glass is replaced. Preparation: Be sure the drum unit is set. Auto maximum density adjustment, auto dot diameter adjustment, LD1 offset adjustment and, LD2 offset adjustment must have been completed. Step Operation Enter the 36 mode. [Adjustment mode menu Screen] Press " 1 Process adjustment". [Process adjustment mode menu Screen] 3 Press " 2 Drum peculiarity adjustment". [Drum peculiarity adjustment mode menu Screen] 4 Press " 8 Auto gamma adjustment (1 dot)". [Auto gamma adjustment (1 dot) Screen] Press the 5
Reference: If any one of the following error messages appears during auto gamma adjustment, clean the TSCB (toner control sensor board), check its installation state, and retry the auto gamma adjustment. <1>Error 1: The sensor dirt correction has been corrected. <2>Error 2: No signal is output from the sensor. No control patch is output. <3>Error 3: A recurrence error occurred during curve calculation.
The drum and developer operate to automatically adjust Gamma. Adjustment completes in about 10 seconds and a complete message is displayed. Press the RETURN key to return to
9. Auto gamma adjustment (2 dot)
Performs gamma adjustment (2 dot) automatically. This adjustment should be performed when the drum, developer, write unit, or dust-proof glass is replaced. Preparation: Be sure the drum unit is set. Auto maximum density adjustment, auto dot diameter adjustment, LD1 offset adjustment , LD2 offset adjustment, and auto gamma adjustment (1 dot) must have been completed. Step Operation Enter the 36 mode. [Adjustment mode menu Screen] Press " 1 Process adjustment". [Process adjustment mode menu Screen] 3 Press " 2 Drum peculiarity adjustment". [Drum peculiarity adjustment mode menu Screen] 4 Press " 9 Auto gamma adjustment (2 dot)". [Auto gamma adjustment (2 dot) Screen] Press the Start 5 key. The drum and developer operate to automatically adjust Gamma. Adjustment completes in about 10 seconds and an complete message is displayed. Press the RETURN 6 key to return to
<3>Error 3: A recurrence error occurred during curve calculation.

10. Cartridge set mode

Note1: To check another multi number in the same code, press the P button after completing step 8. And enter another multi number. A newly entered number is written over the previously entered number. Note2: To return to the normal 47 mode, press the STOP button while holding down the P button after completing step 8.
[2] Adjustment Data Display
Displaying a list of machine adjustment values (factory-set values and current values). No adjustment (data value change) can be made in this mode. Step 1 Operation Enter the 47 mode. [I/O check Screen] Enter 94 with numeric keys. Make sure 94 is displayed in the message display field. Press the Start button. [Adjustment data display Screen] 4 Press the or button to display a desired adjustment item. 5 Press the
(1) When the total capacity of the hard disk is checked: The total capacity of the hard disk is displayed after "OUT:" in the message display field. (2) When the remaining capacity of the hard disk is checked: The remaining capacity of the hard disk is displayed after "OUT:" in the message display field. 5 (3) When bad sectors on the hard disk are checked and recovered: "NOW" is displayed after "OUT:" in the message display field and bad sector check and recovery start. Several minutes later, "OK" is displayed in the case of normal termination, "NG" is displayed in the case of abnormal termination. When "NG" is displayed, retry bad sector check and recovery. If "NG" is displayed again, replace the hard disk.

key to return to the I/

O check mode screen.

[3] Hard Disk Check

This adjustment is to be performed when checking the total capacity and remaining capacity of the optional hard disk and when error codes related to the hard disk occur. Step Operation Enter the 47 mode. Enter 99 with numeric keys. (1) Checking the total capacity of the hard disk: Press the P button and enter 1 with a numeric key. Make sure 99-01 is displayed in the message display field. (2) Checking the remaining capacity of the hard disk: Press the P button and enter 2 with a numeric key. Make sure 99-02 is displayed in the message display field. (3) Checking and recovering bad sectors on the hard disk: Press the P button and enter 3 with a numeric key. Make sure 99-03 is displayed in the message display field. 4 Press the START button.

Note1: Once the bad sector check and recovery procedure start, it can not be canceled. (The STOP button and mode change key are ineffective.) Note2: The hard disk is weak against vibration and shock. When moving the copy machine, be sure to remove the hard disk in advance.

[4] Input checklist

ClassiCode fication

Symbol TLD VR301 TH1

Multi mode
PS3 PS9 PS15 PS21 PS33 PS108 PS4 PS10 PS16 PS22 PS102 PS103 PS104 PS105 PS5 PS6 PS11 PS12 PS17 PS18 PS31 PS32 VR1

VR2 VR3 VR5

Remaining toner detection signal ADF original size VR signal 0 to 255 Fixer upper roller temperature detection signal Fixer upper roller temperature C Humidity sensor signal Dmax MONI signal Dmax signal 0 to 255 signal Machine inside temperature signal Tray 1 no paper detection signal Tray 2 no paper detection signal Tray 3 no paper detection signal Tray 4 no paper detection signal By-pass feed tray no paper detection signal LCT no paper detection signal Tray 1 remaining paper detection signal Tray 2 remaining paper detection signal Tray 3 remaining paper detection signal Tray 4 remaining paper detection signal LCT remaining paper detection signal 1 LCT remaining paper detection signal 2 ON OFF LCT remaining paper detection signal 3 LCT remaining paper detection signal 4 Tray 1 paper size detection signal 1(Di551/Di650 only) Tray 1 paper size detection signal 2(Di551/Di650 only) Tray 2 paper size detection signal 1(Di551/Di650 only) Tray 2 paper size detection signal 2(Di551/Di650 only) Tray 3 paper size detection signal 1 Tray 3 paper size detection signal 2 By-pass feed tray paper size detection signal 1 By-pass feed tray paper size detection signal 2 Tray 1 paper size detection VR signal (Di551/Di650 only) Tray 2 paper size detection VR signal (Di551/Di650 only) 0 to 255 Tray 3 paper size detection VR signal By-pass feed tray paper size detection VR signal Tray 1 paper size signal (Di551/Di650 only) 0:11x17,1:A3,2:B4,3:8.5x14,4:A4R,5:8.5x11 R,6:B5R,7:8.5x11,8:5.5x8.5R,9:A4,10:A5R1 Tray 2 paper size signal 1:B5,12:A5,13:B6R,14:5.5x8.5,15:B6,16:Sp (Di551/Di650 only) esial,17:F4(8.125x13.25),18:F4(8x13),19:F4 Tray 3 paper size signal (8.25x13),20:F4(8.5x13) By-pass feed tray paper size signal
Display and Signal Source H L In Empty

Paper feed

Analog signal
Symbol PS2 PS8 PS14 PS34 PS35 PS109 PS101

Multi mode 6 7

Name Tray 1 upper limit detection signal Tray 2 upper limit detection signal Tray 3 upper limit detection signal By-pass feed tray upper limit detection signal By-pass feed tray lower limit detection signal LCT upper limit detection signal LCT lower limit detection signal Tray 1 tray set detection signal Tray 2 tray set detection signal Tray 3 tray set detection signal Tray 1 horizontal conveyance set detection signal Tray1 pre-registration detection signal Tray2 pre-registration detection signal Tray3 pre-registration detection signal LCT pre-registration detection signal Tray 1 vertical conveyance detection signal (in the case of the Di551/Di650) Tray 1 horizontal conveyance PS/L detection signal (in the case of the Di5510/Di7210) Tray 2 vertical conveyance detection signal Tray 3 vertical conveyance detection signal Tray 1 horizontal conveyance PS/R detection signal (in the case of the Di5510/Di7210) Tray 1 horizontal conveyance PS/L detection signal (in the case of the Di5510/Di7210) LCT paper feed detection signal Transfer paper leading edge detection signal Loop detection signal Second paper feed detection signal Fixing exit detection signal Main body paper exit detection signal Paper reverse detection signal Reversed paper exit detection signal Vertical conveyance door open/close detection signal Front door open/close detection signal (left front door) Front door open/close detection signal (right front door) Front door open/close detection SW signal LCT top cover open/close detection signal LCT jam access cover open/close detection signal Toner supply door open/close detection signal

ON OFF ON OFF ON OFF ON

FN112/6/ 121/ 10

Other than start
Symbol PS732 PS719 MS701 SW704 PS731 SW703 M715

Multi mode 61

Name Clincher HP/R detection signal Sub tray full detection signal FNS interlock MS detection signal Staple/F SW detection signal Stapler HP/F detection signal Cartridge/F detection signal Clincher /F detection signal Clincher HP/F detection signal Paper exit motor lock detection signal FNS connection signal Folding knife HP detection signal Stopper HP detection signal Alignment/L HP detection signal Folding exit detection signal Folding passage detection signal Folding full detection signal
Display and Signal Source H L OFF ON ON OFF

OFF ON

FN-112/ 6/121/ 10
M733 M707 FNS PS722 PS723 PS724 PS725 PS726 PS729
Other than controlled speed

Controlled speed

Not Connected connected

ON Full With Paper

MPS8 M203 PS4 PS2 MS PS6 MS2 PS201 PS206 PS3 PS7 PS5 -
Other than full No Paper edge PS (leading/trailing/side edge sensor 1) Paper

FN-6/10

Folding conveyance motor lock detection signal Exit PS Paper edge PS (side edge sensor 2) Paper edge PS (side edge sensor 3) Paper edge PS (side edge sensor 4) PI conveyance motor Punch shift HP 2nd stopper HP Front door MS Paper scraps box detection Z-folding conveyance motor locking detection PZ punch 2/3 holes and 2/4 holes derection signal PI passage /U detection signal PI passage /L detection signal 1st stopper HP Paper scraps full detection Punch HP Fan motor locking detection Fold connecting detection Gate HP detection signal
Other than controlled Controlled speed speed

No Paper

With Paper
Other than Controlled controlled speed speed
ON OFF ON 3/4 holes ON OFF ON Lock Not connected
OFF ON OFF 2holes OFF ON OFF Other than lock Connected
Symbol PS1 PS202 PS203 PS205 PS204

Multi mode 15

Name Paper edge PS (side edge sensor 5) Passage PS No sheet /U detection signal Sheet setting /U detection signal Tray lower limit/U detection signal Tray upper limit/U detection signal PI start /stop detection signal PI punch SW detection signal PI mode SW detection signal PI interlock MS detection signal No sheet /L detection signal Sheet setting /L detection signal Tray lower limit /L detection signal Tray upper limit /L detection signal Sheet size/ L detection signal PI connection signal Punch HP detection signal Punch scraps full detection signal Punch scraps box detection signal Paper edge PS (side edge sensor 1) Paper edge PS (side edge sensor 2) Paper edge PS (side edge sensor 3) Paper edge PS (side edge sensor 4) Paper edge PS (side edge sensor 5) Punch shift HP PK-5 detection Sub-tray paper exit Tray upper limit Tray lower limit FIN entrance passage Stacker conveyance passage Paper exit 1 Staple paper exit upper limit Alignment plate/upper HP OFF ON Paper exit belt HP Paper exit 2 Stapler movement HP Paper exit opening Entrance paper detection Stapler rotation HP Tray no paper detection Roller shift HP

1. Tool

Screwdriver (Phillips) 4
Tray 1/2/3 centring adjustment (Di551/Di650) Tray 3/4 centring adjustment (Di5510/ Di7210)

Guide plate Guide plate

Caution: Disable the mis-centering correction function by setting the dip switch 12-3 and confirm it (Enter 1 to set to ON). Confirm it using the internal pattern No.16
Screws Screws Standard value of mis-centring: within 3mm
Tray 1/2 centring adjustment (Di5510/Di7210)

Guide plate

Within 3mm

Centre of image

Centre of paper

Screws Screws

7272fs1052
LCT tray centring adjustment
Guide plate/front Guide plate/rear
Adjustment method Step Operation Raise the up/down plate. Open the top cover. Remove five screws to detach the side cover (right).

Screws

Center positioning bracket

Right side cover

Loosen two screws on the upper part of LCT to slide the guide plates (front/rear) the same amount in the same direction. Secure the guide plates by tightening two screws firmly. Loosen three screws to slide the centre positioning brackets the same amount in the same direction as you did for the guide plates (front/rear) in the step 4. Secure the centre positioning brackets by tightening three screws firmly. Put the LCT back into the original position and make a copy to check the result. Perform steps 1-8 repeatedly until miscentering is included in the automatic adjustment range (3mm).
Centre positioning bracket
Caution: Disable the mis-centering correction function by setting the dip switch 12-3 (Enter 1 to set ON) and confirm it. Confirm it using the test pattern No.16.
Setting the LCT Rear Guide (C-404 only)
Standard value of mis-centring: within 3mm Screws Rear guide Within 3mm Centre of image

Rear guide

Adjustment method Step 3 Operation Open the top cover. Press SW100 (LT tray down switch) to lower the up/down plate to the bottom. Loosen two screws at the top of the rear guide and one screw at the bottom. Set paper on the up/down plate, align the trailing edge of paper with the lower end of the rear guide, then fasten the lower screw. Fasten the two upper screws temporarily and move the up/down plate to the highest position. Set paper on the up/down plate, align the trailing edge of paper with the upper end of the rear guide, then tighten the two upper screws finally.
Reference: LCT tray size setting can be performed in the key operation mode by setting DIPSW21-1 to 1 in the 25 mode.

[2] Skew adjustment (Main body)
1. 2. Tool Screwdriver (Phillips) Adjustment method
[3] Adjusting the LCT Paper Feed Roller Pressure (C-404 only)
Caution: This adjustment is required when no paper feed occurs. Tool Screwdriver (Phillips) Adjustment method

Screw Spring

Second paper feed section

Piled plate

Step Step 5 Operation Make a copy to measure for skew. Loosen the five screws securing the second paper feed unit. Rock the second paper feed unit to adjust using the mark as a guide. Retighten the five screws. Make adjustments by repeating steps 2 to 4 until the skew becomes within the specified range. 5 6
Operation Open the top cover. Remove the spring. Install a weight plate above the paper feed rollers using the two screws. Make a copy to check whether paper is fed properly. If paper is not fed properly, add another weight plate and repeat steps 5 and 6. Install the spring.
Specified range:Paper skew 5% or less (Paper skew in the paper feed direction)
Caution: Four weight plates come standard with the LCT, and can be installed up to six.
[4] Paper up/down plate horizontal adjustment (LCT only)
Caution: Up/down plate horizontal adjustment must be carried out when a paper feed jam occurs frequently or after replacement of the up/down wires of a tray. Tool Screwdriver (Phillips) LCT up/down plate horizontal adjustment of C403

Up/down plate

Up/down pulley Adjusting screws Side cover (right)
Open the jam access door, then remove six screws to detach the front cover.

Jam access door

Up/down pulley
Screws Side cover (right) Screws
3. Step Operation Remove three screws to detach the clutch replacement cover.
Clutch replacement Screws cover
LCT up/down plate horizontal adjustment of C404
Adjustment screw Mark Up/down plate Screws

Adjustment screws

Remove twelve screws to detach the rear cover.
Adjustment method Step 1 Operation Lift the up/down plate up. Open the top cover. Loosen the two screws and adjust the position using an adjustment screw and the mark so that the front and rear of the up/down plate are at same height. Fasten two screws securely

Screws Screws Rear cover

Loosen two screws and adjust the position for each up/down pulley using an adjustment screw so that the front and rear of the up/down plate are at the same height. Fasten two screws securely for each up/ down pulley to fix its position. Install the rear cover, clutch replacement cover, front cover, and side cover (right).
[5] Skew adjustment (LCT only)
Caution: Skew adjustment is required when the paper supplied from the current tray is different from the paper supplied from other trays in the way it is skewed. However, this adjustment has little effect because skew of paper supplied from all trays is corrected in the second paper feed unit. Tool Screwdriver (Phillips) LCT skew adjustment Adjustment method (when all printed sheets are skewed) Step 1 Operation Print a test pattern (No.16) in the continuous copy mode to check for skew. Open the jam access door of the LCT and adjust the installation position of the positioning bracket on the bottom plate.

Image control E46-01 abnormality
Write section ICB (image control board) power connector

E46-02

ICB (image control board) Expansion memory

E46-03

E46-05 E46-06 E46-08

E46-12

Warning Cause Code Image control E46-13 During image read, image data comabnormality pression from the scanner to the memory is not completed within the specified time. Image data decompression from the scanner to the page memory is not completed within the specified time. SVV is not detected within the specified time. Classification E46-14 During image read, image data decompression from the memory to the printer is not completed within the specified time. Image data output from the page memory to the printer is not completed within the specified time. PVV is not detected within the specified time. During image write, improper processing was performed. For example, the decompression device was accessed although there was no resource. During image read, improper processing was performed. For example, the compression device was accessed although there was no resource. During image processing, a filter coefficient could not be generated properly. During access to the memory device, a software error was detected. Decompression from the memory to the page memory is not completed within the specified time. Compression from the page memory to the memory is not completed within the specified time. Decompression from the memory to the page memory is not completed within the specified time. Compressed data transfer between memories is not completed within the specified time. During image read, SVV is not turned OFF within the specified time and therefore preparation for next page scanning cannot be started.
Machine response If copy operation is being performed, the machine stops after paper ejection. RL1 (main) is turned OFF.
Estimated abnormal parts PRCB (printer control board) ICB (image control board)

E46-15

ICB (image control board) ICB program

E46-16 Main body

E46-17

E46-19 E46-21

PRCB (printer control board) ICB (image control board) ICB program

E46-23

ICB (image control board)
Warning Cause Code Image control E46-24 Shading correction error (GA error) abnormality Classification E46-25
If copy operation is being performed, the machine stops after AOC/AGC error The light blocking cover and lens paper ejection. cover are removed from the scanner RL1 (main) is turned OFF. section. The A/D converter board connector is disconnected. The power cable of A/D converter board is disconnected. The IC protector on the A/D converter board is blown out. The exposure lamp intensity is excessive. The exposure lamp does not light.

PS801 PUNCH HP SENSOR

CN504-1 CN504-2 CN504-3 CN504-4 CN504-5 CN504-6 CN504-7

PAPER EDGE SENSOR

CN504-1 CN504-2 CN504-3
PUNCH SCRAPS BOX SET SENSOR

CN531-3 CN531-2 CN531-1

CN531-1 CN531-2 CN531-3

CN502-1 CN502-2 CN502-3

PUNCH SCRAPS FULL SENSOR
Crimp 50-1 Faston Connector Relay connector

P P P P

CN69-1 24V CN69-2 24V CN69-3 M802 DRVA CN69-4 M802 DRVA CN69-5 M802 DRVB CN69-6 M802 DRVB
CN158-3 CN158-9 CN158-1 CN158-5 CN158-7 CN158-11

PUNCH SHIFT MOTOR

CN67-1 PS803 5V H CN67-2 PS803 IN CN67-3 PS803 SG

CN505-1 CN505-2 CN505-3

PS803 PUNCH SHIFT HP SENSOR
[6] ZK-2 Overall Wiring Diagram

FRONT DOOR MS

+V:24V RT10 +V:24V RT13
CN 2- 1 24V1 CN 2- 2 24V2

CN 4- 5 S-HP1-IN

CN36- 4/10

-V:P.G RT11 -V:P.G RT12

CN 2- 3 P.G

BK CN 2- 4 P.G

CN 4- 6 S-HP2-IN

CN36- 5/9

CN 4- 3 5V CN 4- 4 PSS-IN CN 4- 14 GND
PGC5 CN36- 7/7 CN36- 6/8 CN36- 2/12 PGC6

CN 4- 11 EXT-PS

CN36-1/13
CN 4- 2 5V CN 4- 12 M6 EN
CN36- 8/6 CN36- 9/5 CN36- 3/11

CN 4- 9 P-FULL-IN

CN 1- 1 5V R B CN 1- 3 S.G
CN 4- 1 5V CN 4- 10 BOX-IN CN 4- 13 GND

CN 4- 7 P-HP1-IN

P P P P P P P P P P P P
CN 9- 7 F-TXD-OUT CN 9- 2 SGND CN 9- 9 P-REQ-OUT CN 9- 4 SGND CN 9- 11 F-ACK-IN CN 9- 6 SGND CN 9- 1 F-RXD-IN CN 9- 8 SGND CN 9- 3 F-REQ-IN CN 9- 10 SGND CN 9- 5 P-ACK-OUT CN 9- 12 SGND CN 9- 13 CN95- 1 CN95- 2 CN95- 3 CN95- 4 CN95- 5 CN95- 6 CN95- 7 CN95- 8 CN95- 9 CN95-10 CN95-11 CN95-12 CN10- 1 M-RXD-IN CN10- 2 SGND CN10- 3 M-REQ-IN CN10- 4 SGND CN10- 5 M-ACK-OUT CN10- 6 SGND CN10- 7 M-TXD-OUT CN10- 8 SGND CN10- 9 P-REQ-OUT CN10- 10 SGND CN10- 11 M-ACK-IN CN10- 12 SGND
CN90-12 CN90-11 CN90-10 CN90- 9 CN90- 8 CN90- 7 CN90- 6 CN90- 5 CN90- 4 CN90- 3 CN90- 2 CN90- 1

PGC1 PGC2

CN96- 1 CN96- 2 CN96- 3 CN96- 4 CN96- 5 CN96- 6

O R B BK BK BK

CN91- 1 24VDC CN91- 2 5VDC CN91- 3 SGND CN91- 4 PGND CN91- 5 PGND CN91- 6 PGND

5VDC PS1 SGND

FT24 FT23

464-1 464-2 464-3

467-3-4 467-2-5 467-1-6
406-3 5V2 406-2 HP_PS_F 406-1 S.GND

465-1 465-2 465-3

467-6-1 467-5-2 467-4-3
406-6 5V2 406-5 HP_PS_R 406-4 S.GND
414-1 S.GND 414-2 F_TXD 414-3 F_RXD 414-4 F_RESET 414-5 5V 414-6 VPP 414-7 MD 414-8 S.GND

130 131

132 133
408-6 MC24V 408-7 TSL_DR H
413-1 5V 413-2 CLK 413-3 RXD 413-4 TXD 413-5 S.GND 413-6 S.GND

351-1 -2 -3 -4 -5 -6 -7

188-7-1 188-6-2 188-5-3 188-4-4 188-3-5 188-2-6:TEST 188-1-7:TEST
211-7 24V1 211-6 GND 211-5 POLM_CONT 211-4 POLM_CLK 211-3 POLM_LOCK 211-2 N.C. 211-1 N.C.

TSL M10

408-4 SEP_CLR_M B 408-5 SEP_CLR_M A

134 135

136 137

469-1 469-2

460-2-6 460-3-5

141 142

460-1-7 H2 H1
215-1 24V2 215-2 24V2 215-3 A 215-4 /A 215-5 B 215-6 /B

144 145

146 147
CONVEYANCE SUCTION FAN FM3
435-3-1 435-2-2 435-1-3 436-6-1 436-5-2 436-4-3 461-1-3 461-2-2 461-3-1
408-1 ASUC_FAN 408-2 ASUC_EM 408-3 P.GND
230-1 24V2 230-2 24V2 230-3 A 230-4 /A 230-5 B 230-6 /B

151 152

202-A13 S_IN1 202-A12 GND 202-A11 S_OUT1 202-A10 GND 202-A9 /CTS1 202-A8 /RTS1 202-A7 /DSR1 202-A6 /DTR1 202-A5 SHUTDOWN 202-A4 GND 202-A3 GND 202-A2 (24VRL_CNT) 202-A1 (SC_MEM) 202-B13 /PVV 202-B12 /TONVV 202-B11 /B_VV 202-B10 /SVV 202-B9 BPSIZE_VR_0 202-B8 EE_VV 202-B7 RESET 202-B6 AC_OFF 202-B5 SW_SIG 202-B4 DDF_VV 202-B3 GND 202-B2 REM/2 202-B1 REM/3

699-4 699-2 699-1 699-3

KEY COUNTER (OPTION)
450-1 450-2 450-3 436-3-4 436-2-5 436-1-6
402-A18 P.GND 402-A17 ADUFANEM 402-A16 ADUCFAN_D
35-1 MC24V_3 35-2 KEYC_SET 35-3 GND 35-4 KEYC_DRV 35-5 GND
402-A15 5V2 402-A14 ADUREV_PS 402-A13 S.GND
229-1 GND 229-2 MAINEXIT_PS 229-3 5V 229-4 FIXFAN_D 229-5 FIXFAN3_EM 229-6 GND L L 229-7 FIXFAN_D 229-8 FIXFAN2_EM 229-9 GND
344-9-1 344-8-2 344-7-3 344-6-4 344-5-5 344-4-6
310-3 310-2 310-1 342-3-1 342-2-2 342-1-3
PAPER EXIT SENSOR FM6 PAPER EXIT FAN/F FM7
344-3-7 344-2-8 344-1-9 343-3-1 343-2-2 343-1-3

COIN VENDOR (OPTION)

402-B18 NC 402-B17 5V2 402-B16 REV_PS 402-B15 S.GND

456-1 456-2 456-3

B A 13 13
L L H 402-B5 5V2 402-B4 ADUEX_PS 402-B3 S.GND

457-2-1 457-1-2

229-13 WRFAN_D 229-14 WRFAN_EM 229-15 WRFAN_HL 229-16 S.GND H 229-17 MC24V_2 229-18 WEBSD_DRV H 402-B2 LOCK_SD 402-B1 MC24V L H L P P
13x-1 VBUS 13x-2 D13x-3 D+ 13x-4 GND 38

FT45 CHARGER

CN323-1 FT47
320-1 320-2 320-3 320-4 320-5 320-6 320-7 320-8 320-9 320-10 320-11 320-12 320-13 320-14 TRANSFER FT48
CN110-B1 TG -B2 CLAMP -B3 ACLAMP -B4 BCLAMP 100-1 5V1 100-2 5V1 100-3 SG 100-4 SG 104-1 5V1 104-2 5V1 104-3 12V1 105-1 S.GND 105-2 S.GND 105-3 S.GND FOR KRDS 139-1 DCD 139-2 RXD 139-3 TXD 139-4 DTR 139-5 S.GND 139-6 DSR 139-7 RTS 139-8 CTS 139-9 RI

SEPARATION

CN1-1 24V2 CN1-2 5V2 CN1-3 S.GND CN1-4 P.GND CN1-5 P.GND CN1-6 P.GND

ALIGNMENT MOTOR/L

P P P P P P P P
CN150-1 CN150-2 CN150-3 CN150-4 CN150-5 CN150-6 CN7-A1 24V CN7-A2 24V CN7-A3 M716 DRVA CN7-A4 M716 DRVA CN7-A5 M716 DRVB CN7-A6 M716 DRVB
CN8-1 24V CN8-2 24V CN8-3 M701 DRVA CN8-4 M701 DRVA CN8-5 M701 DRVB CN8-6 M701 DRVB
CN100-2 CN100-5 CN100-1 CN100-3 CN100-4 CN100-6

ALIGNMENT HP SENSOR/L

CN12-A2 5V H CN12-A8 PS704 IN CN12-B5 GND CN121-1 CN121-2 CN121-3
CN172-1 CN172-2 CN172-3 CN191-4 CN191-5 CN191-6 CN4-A9 5V CN4-A8 PS724 IN H CN4-A7 GND

FNS ENTRANCE SENSOR

FOLDING STOPPER MOTOR
CN151-2 CN151-5 CN151-4 CN151-6 CN151-3 CN151-1 CN7-A7 24V CN7-A8 24V CN7-A9 M718 DRVA CN7-A10 M718 DRVA CN7-A11 M718 DRVB CN7-A12 M718 DRVB CN190-1 CN190-2 CN190-3 CN4-A6 5V CN4-A5 PS723 IN H CN4-A4 GND CN171-1 CN171-2 CN171-3
FOLDING STOPPER HP SENSOR

PS723 M719

CN7-A13 24V L CN7-A14 M719 DRV L CN152-1 CN152-2
FOLDING KNIFE MOTOR FOLDING KNIFE HP SENOR
CN12-B12 M712 DRVB CN12-B11 M712 DRVB CN12-B10 M712 DRVA CN12-B9 M712 DRVA CN12-B8 24V CN12-B7 24V

GATE DRIVE MOTOR

L H P H L
CN153-1 CN170-1 CN170-2 CN170-3 CN4-A3 5V CN4-A2 PS722 IN L CN4-A1 GND
P L H (Old Type) H (New Type) P P P P P P P P
CN12-A4 5V L CN12-A10 PS716 IN CN12-B3 GND

CN123-1 CN123-2 CN123-3

GATE HP SENSOR
CN10-1 24V H CN10-2 M702 DRV

CN102-1 CN102-2

[3] FN-112/FN-6/FN-121/FN-10 Overall Wiring Diagram

CLINCHER HP SENSOR/R

CLINCHER HP SENSOR/F
STAPLER MOTOR/R STAPLER HP SENSOR/R CARTRIDGE SWITCH/R STAPLE SWITCH/R

(FN-112/FN-6)

STAPLER MOTOR/F STAPLER HP SENSOR/F CARTRIDGE SWITCH/F STAPLE SWITCH/F

FN-6/FN-10 ONLY

The fixing unit is very hot. To avoide getting burned, DO NOT TOUCH.

VORSICHT

Heie Oberflche!
Brandverletzungsgefahr. Bei Beseitigung von Papierstaus vorsichtig vorgehen.
The conveyance fixing unit is heavy. Use care and draw it out gently; otherwise you may be injured.
DO NOT put your hand between the main body and developing fixing unit; otherwise you may be injured.

PRECAUCION

Temperatura alta!
No tocar. Tener cuidado al remover el papel.

ATTENZIONE

Alta temperatura!
Non toccare. Agire con prudenza nel rimuovere la carta.
CAUTION You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself 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)
(FN-112/FN-6/FN-121/FN-10 Finisher)
(FN-6/FN-10 Finisher only)

(FN-6/FN-10 Finisher)

CAUTION You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself 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.
SAFETY AND IMPORTANT WARNING ITEMS In the case of the Di5510/Di7210
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. 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)

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Use care after opening the paper exit outlet. DO NOT put your hand into it; otherwise you may be injured. 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.

(FN-115 Finisher)

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<SCANNER SECTION>

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<WRITE UNIT> In the case of the Di551/Di650

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In the case of the Di5510/Di7210

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<REAR COVER>
<ZK Puncher with Z-folding>

Blank page

Di551/Di650/Di5510/Di7210 LIST OF DIFFERENCE

LIST OF DIFFERENCE FOR Di551/Di650 AND Di5510/Di7210
Classification Warm-up time Di551 5.5 minutes max.(at 20 C rated voltage) 3.4 seconds or shorter 55 copies (A4) Di650 6.5 minutes max.(at 20 C rated voltage) 3.1 seconds or shorter 65 copies (A4) Diminutes max.(at 20 C rated voltage) 3.4 seconds or shorter 55 copies (A4) Diminutes max.(at 20 C rated voltage) 3.0 seconds or shorter 72 copies (A4) Reason Change of fixing control temperature CPM change CPM change

Specification

First copy out time (A4) Continuous copy speed (A4) Consumables Developer Toner Drum
Common to Di551/Di650/Di5510/Di7210
Fixing section External Section Paper Feed Section Write Section Drive Section

Liner speed

280mm/s (standard) 185mm/s (thick paper) 33,070rpm (standard) 21,850rpm (thick paper)
320mm/s (standard) 185mm/s (thick paper) 37,795rpm (standard) 21,850rpm (thick paper)
280mm/s (standard) 172.5mm/s (thick paper) 33,070rpm (standard) 40,748rpm (thick paper)
345mm/s (standard) 172.5mm/s (thick paper) 40,748rpm (standard) 40,748rpm (thick paper)

CPM change

Polygon motor revolutions

Paper feed tray

500 copies x copies x copies x copies x copies x copies x copies x copies x copies x copies x 2
Cooling for developing section
Duct + develop- Duct + develop- Improvement in ing cooling fan ing cooling fan developing suction Common to Di551/Di5510 Common to Di650/Di7210
Fixing upper roller Fixing heater lamp /1

Common to Di551/Di5510

Common to Di650/Di7210

ADU Section

ADU drive board Transfer and separation corona unit Image control program Printer control program

Exclusively for Di551

Exclusively for Di650
Common to Di5510/Di7210 Included
ADU linear speed change Automation of cleaning operation CPM change

Control

Exclusively for Di5510

Exclusively for Di7210

1 OUTLINE

OUTLINE

MAIN BODY

OUTLINE OF SYSTEM

In the case of the Di551/Di650
Cover Inserter [Cover Inserter B] Key counter Punch kit [PK-2/5] Hard disk Expansion memory
Adapter for ZK [ZK A kit] Cover Inserter [Cover Inserter B]

Finisher [FN-112]

Paper exit tray A4LCT [C-403]

Punch kit [PK-2/5]

Adapter for ZK [ZK A kit]
Punch with Z-folding function [ZK-2] Finisher [FN-6]

A3LCT [C-404]

Finisher [FN-113]

(1) Operation with AE

First white correction Second white correction AE scanning

Exposure scanning

(2) Operation without AE
First white correction Second white correction Exposure scanning

[4] Exposure control

EXP CONT
[5] Original Read Control

24V CONT LAMP.PG

5V2 S.GND 24V1 5V2 S.GND P.GND L.PG

CCD ADB

L1 (exposure lamp) is driven by L1 INVB (L1 inverter) and is controlled by PRCB (printer control board) via SCDB (scanner drive board).
L1 (exposure lamp) is a xenon lamp driven by the inverter circuit. The xenon lamp can emit a constant light intensity and generates less heat than other lamps, so it does not require the light intensity control circuit that has been used in the existing machines, requiring no thermal protector circuit. However, since L1 is held lit when the exposure unit is stationary in the ADF mode, FM9 (scanner cooling) is installed in the read section.
a. Output signals (1) EXP_CONT (PRCB to SCDB) L1 (exposure lamp) ON/OFF control signal [L]: L1 ON [H]: L1 OFF (2) CONT (SCDB to L1 INVB) L1 (exposure lamp) ON/OFF control signal [L]: L1 ON [H]: L1 OFF

L1 INVB

12V2 12V2 GND APR ADRST PDWN GND TCK /TCK GND RCK /RCK GND LCLK1 /LCLK1 GND SCLK /SEN SDI SDO TG CLAMP GND BCLAMP GND D0 /D0 GND D1 /D1 GND D2 /D2 GND LCLK0 /LCLK0 GND 5V2 5V2 GND
GND TG TG_OUT CLAMP A_CLAMP PRD_KEEP GND +LCLK -LCLK GND -RCLK +RCLK GND GND +TCK -TCK GND GND SCLK /SEN SDI SDO GND -AD_D0 +AD_D0 GND -AD_D1 +AD_D1 GND -AD_D2 +AD_D2 GND -LVDSCLKO +LVDSCLKO GND ADRST APR LVDS_PDWN GND +5V +5V +5V +5V +5V +5V GND +12V +12V +12V GND
(2) ADF mode After lapse of the specified interval since the original's leading edge turned PS306 (original conveyance) ON.

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Original read control is performed by ADB (A/D converter board) and CCD sensor installed in ADB.
The light reflected by the exposed original is input to the CCD sensor through the lens. The analog voltage corresponding to the quantity of the input light is A/D-converted in the ADB (A/D converter board), being output to the ICB (image control board). a. Original read The original read timing is as follows: (1) Platen mode After lapse of the specified interval since the exposure unit turned PS61 (scanner HP) OFF.

[6] APS Control

APC CONT COVER SIG APS.1 SIG APS.2 SIG APS.3 SIG S.GND APS TIM 5V S.GND APS.1 APS 5V S.GND APS.2 APS 5V S.GND APS.3 APS 5V S.GND SIZE PS L 5V S.GND SIZE PS S 5V A.GND SIZE ANA 3.3V
Relationships between sensors and paper sizes are as follows:

Sensor

Paper size
PS63 PS64 PS65 PS309 PS310 VR301
APS TIMING SIZE PS L SIZE PS S SIZE ANA
B5R B5 B4 A4R A4 A3 8.5 x 11R

24V1 5V2 S.GND P.GND

The APS method used in the platen mode is different from that used in the ADF mode. The signal read by the APS sensor or RADF's original size detection sensor is processed by ICB (image control board) via SCDB (scanner drive board).

8.5 x 11 8.5 x 14 11x 17

ON OFF b. APS detection timing The APS detection timing differs between the platen mode and DF mode. (1) ADF mode When the RADF mode is selected or an original is set on the RADF original feed tray, APS detection takes place using PS309 (original size/2), PS310 (original size/1), and VR301 (original size). (2) Platen mode When the RADF is closed and PS51 (APS timing) turns ON, L1 (exposure lamp) turns ON and the CCD detects the reflected light to detect the original size in the main scanning direction. Since RADF is still open at this time, the black level of the sky shot (outside the original) and the white level of the original (inside the original) are detected according to whether an original is present. At this time, the original size in the subscanning direction is detected using PS63 to PS65 (APS/1 to APS/3). When the RADF is closed completely and PS311 (ADF open/close) turns ON, CCD reads the white level of the platen cover and the black level in the original. Among the two original sizes detected as discussed above, the larger size is determined as the original size in the main scanning direction.
a. APS detection (1) ADF mode The paper size is detected according to the combination of ON/OFF states of PS309 (original size/2) and PS310 (original size/1) of the RADF's original feed tray and the resistance value of VR301 (original paper size). (2) Platen mode The paper size is detected according to the combination of ON/OFF states of PS63 (APS/1), PS64 (APS/2), and PS65 (APS/3) and the signal read by the CCD sensor. PS63 to PS65 are used to detect the original size in the sub-scanning direction and the CCD sensor is used to detect the original size in the main scanning direction.

a. Image processing The following processing is performed by the ICB (image control board): (1) AOC (Automatic Offset Control) The IC on the ADB (A/D converter board) automatically adjusts the analog offset voltage of the CCD sensor output so that it is at the lower limit of the A/D converter level. (2) AGC (Automatic Gain Control) During shading correction, the white reference plate is read to adjust the analog amplification factor of the CCD sensor output so that the read level is at the upper limit of the A/D converter level. (3) Shading correction <Timing> When SW2 (sub power) is ON At job start (4) Brightness/density conversion (5) AE processing (6) Text/dot pattern judgment (7) Filtering (8) Magnification change processing (9) Copy gamma correction (10) Skew correction (11) Error diffusion processing (12) Data compression/expansion processing (13) Write density control b. Write The ICB (image control board) sends image data on a pixel basis to LDB (laser driver board) according to the control signals from the PRCB (printer control board). LDB causes the laser light to be emitted for a period corresponding to the image data. This laser light is radiated onto the drum surface. (1) MPC (Maximum Power Control) ICB (image control board) informs LDB (laser driver board) of the maximum output value and sets that value for the laser beam emission. LDB store this value and maintain the laser beam level using the APC (Auto Power Control). <MPC timing> When SW2 (sub power switch) is turned ON
(2) APC (Automatic Power Control) After MPC is set, the ICB (image control board) outputs an APC start instruction to LDB (laser driver board) at the following timing: <APC timing> LDB (laser driver board) automatically monitor the laser drive current one line at a time, and controls it so that the light intensity remains the MPC value. (3) Write timing a) Main scanning direction Using INDEX signal (/IND) from INDXSB (index sensor board), the laser write reference position is determined for each scan in the drum rotation direction, and the image is written onto the copy paper according to the copy paper position detected by PS70 (paper mis-centering). b) sub scanning direction Specified interval after PS44 (registration) detects the leading edge of the copy paper.
a. Input signals (1) /IND (INDXSB to ICB) This is an index signal used to detect deviation of main scanning. (2) /INDPR (INDXSB to ICB) This signal monitors the INDXSB (index sensor board) power supply. [H]: Abnormal [L]: Normal (3) /ALM1 (LDB to ICB) This signal indicates the state of the laser 1 drive current. [H]: Normal [L]: Abnormal (4) LPR5V (LDB to ICB) This signal monitors the LDB (laser driver board) power supply. [H]: Normal [L]: Abnormal (5) /ALM2 (LDB to ICB) This signal indicates the state of the laser 2 drive current. [H]: Normal [L]: Abnormal

The purpose of Dmax control is to adjust the maximum density to the reference level for each machine.
a. Dmax control (1) Method Several latent images are created at the maximum laser power, images are developed with the rotational speed of the developing sleeve varied, then each density is read by the Dmax sensor (PD1) on TCSB (toner control sensor board). The developing sleeve speed detected when the density has reached the reference level is recorded as the optimum sleeve speed, allowing developing to be performed at this sleeve speed. (2) Timing a) When the fixing temperature is lower than 50C at SW2 (sub power) ON b) Every 10,000 prints, upon completion of the last job.
a. Input signals (1) DM_SIG_EX (TCSB to PRCB) Output voltage of Dmax detection sensor (PC1) on TCSB (toner control sensor board) Reference voltage: 2.5 V (2) DM_MONI_EX (TCSB to PRCB) This signal monitors the light reflected by the drum surface (without toner). The voltage applied to the Dmax detection LED is corrected by TNLED_REF so that the output voltage becomes 1.9 V (calibration). Reference voltage: 1.9 V <Timing> Before Dmax correction (3) DRUM_JSIG_EX (TCSB to PRCB) This signal detects a jam caused by paper wrapping around the drum. A jam is detected when the voltage becomes 4.0 V or more. (4) TEMP, 3.3V2 (TCSB to PRCB) Drum temperature detection signal b. Output signals (1) DMLED CONT (PRCB to TCSB) Dmax LED ON/OFF control signal [L]: LED ON [H]: LED OFF (2) TNLED_REF (PRCB to TCSB) Power supply line for PD1 LED on TCSB. The voltage is adjusted so that the Dmax MONI signal becomes 1.9 V. (3) DJLED_CONT (PRCB to TCSB) JAM LED ON/OFF control signal [L]: LED ON [H]: LED OFF
[6] Gradation Correction Control
12V A.GND G SIG EX LED CONT TNLED REF 5V P.GND DRUM CONT DRUM CLK CW/CCW DRUM EM
Gradation correction control is performed by TCSB (toner control sensor board), M2 (drum), M3 (developing), and so on under the control of PRCB (printer control board).
(2) Timing a) When the fixing temperature is lower than 50C at SW2 (sub power) ON b) Every 5,000 prints, upon competion of the last job.
The gradation characteristics of the toner density versus exposure amount at the image forming section (drum area) are detected to obtain a linear relation between the image density on a document and the copying image density. (1) Method Exposure is performed with the laser PWM varied in several steps, and development is performed at the sleeve speed obtained by Dmax correction. Next, each density is read by the sensor (PD2) on TCSB (toner control sensor board) to detect the gradation characteristics of image density. The gradation characteristics obtained here are used as the values for correcting the laser exposure amount. Gradation correction control must be performed in two ways: 1-dot PWM (for normal mode) and 2-dot PWM (for photo mode). 2-G-6

5V3 TIUP_PS SGND

a. PRCB input signals (1) T1UP_PS (PS2 to PRCB) Paper upper limit detection signal (tray 1) [L]: Not detected. [H]: Detected. (2) T1RM_PS (PS4 to PRCB) Remaining paper detection signal (tray 1) [L]: Not detected. [H]: Detected. (3) T2UP_PS (PS8 to PRCB) Paper upper limit detection signal (tray 2) [L]: Not detected. [H]: Detected. (4) T2RM_PS (PS10 to PRCB) Remaining paper detection signal (tray 2) [L]: Not detected. [H]: Detected. b. PRCB output signals (1) T1RISEM_24V (PRCB to M16) M16 ON/OFF control signal (tray 1) (2) T2RISEM_24 (PRCB to M17) M17 ON/OFF control signal (tray 2)
[5] Paper Size Detection Control
5V3 T1SIZE_S_PS SGND 5V3 T1SIZE_L_PS SGND 3.3V2 T1SIZE_VR AGND

PS5 PS6 VR1 Tray 2

5V3 T2SIZE_S_PS SGND 5V3 T2SIZE_L_PS SGND 3.3V2 T2SIZE_VR AGND

PS11 PS12 VR2

5V2 S.GND
The paper size in tray 1/2 is detected using PS5/ 6/11/12 (paper size/1-1/2-1/1-2/2-2), and VR1/2 (paper size/1/2). Based on the detection signals, the PRCB (printer control board) judges the paper size.
The length of paper is detected using PS5/6/11/ 12 (paper size/1-1/2-1/1-2/2-2). Variable resistors (VR1/2) interlocked with the guide position are installed at the bottom of the tray to detect the width of paper. The relationships between the sensors and paper sizes (lengths) are as follows: Paper size Sensor PS5/11 PS6/12 8.5 x 11 or less OFF OFF A4R to B5R ON OFF F4 or larger ON ON
a. PRCB input signals (1) T1SIZE_S_PS (PS5 to PRCB) Paper size detection signal (tray 1) [L]: Paper does not exist. [H]: Paper exists. (2) T1SIZE_L_PS (PS6 to PRCB) Paper size detection signal (tray 1) [L]: Paper does not exist. [H]: Paper exists. (3) T2SIZE_L_PS (PS11 to PRCB) Paper size detection signal (tray 2) [L]: Paper does not exist. [H]: Paper exists. (4) T2SIZE_S_PS (PS12 to PRCB) Paper size detection signal (tray 2) [L]: Paper does not exist. [H]: Paper exists. (5) T1SIZE_VR (VR1 to PRCB) Paper width detection signal (tray 1) (6) T2SIZE_VR (VR2 to PRCB) Paper width detection signal (tray 2)
[6] No paper detection control

Fixing heater lamps Two halogen lamps are used for the fixing upper roller and one halogen lamp is used for the fixing lower roller to reduce the warm-up time and ensure reliable fixing. Cleaning Cleaning web is used to clean the fixing upper roller. The web SD (SD2) in the main body turns ON/OFF to drive the cleaning web wind-up shaft via the ratchet mechanism and gears, thus supplying cleaning web from the cleaning web unwinding shaft. SD2 is controlled according to the copy count, and cleaning web supplied about 0.025 to 0.05 mm/copy. Cleaning web containing silicon oil is pressed against the fixing roller (upper) by the pressure roller.
Decurler The paper guided by the reverse/exit selection gate is decurled while it passes between the decurler roller and restriction shafts. The decurler roller is driven by the fixing roller (upper) via gears.
Fixing roller (upper) Decurler roller Restriction shafts
Pressure roller Cleaning web unwinding shaft Web SD (SD2)
Jam detection When a jam occurs in the fixing exit section, the paper exit guide plate (lower) is pressed down, causing the fixing exit PS (PS30) to detect a jam via the jam detection plate and actuator.

Actuator

Exit guide plate (lower)

Jam detection plate

[3] M16 (Web Drive) Control
24VDC PGND 5VDC SGND 5V2 FIXEXIT_PS S.GND MC24V_2 WEBSC_DRV
a. PRCB input signal (1) FIXEXIT_PS (PS30 to PRCB) Detection signal of passage of paper at fixing unit exit [L]: Detected. [H]: Not detected. b. PRCB output signal (1) WEBSC_DRV (PRCB to SD2) SD2 (web) drive control signal [L]: SD2 ON [H]: SD2 OFF

PS30 SD2

SD2 (web) is controlled by PRCB (printer control board). The related signal is PS30 (fixing exit).
When PS30 is turned ON by passage of paper, SD2 is controlled by PRCB (printer control board) according to the fixing web counter value. The fixing web counter value is incremented together with the total counter in exit section of the main body. The relationship between the fixing web counter values and SD2 (web) is as follows: Fixing web counter value

Developer

a. Procedure (1) Draw out the drum unit from the main body. (See "DRUM UNIT.") (2) Remove the developing unit from the drum unit. (3) Release the hook of the developing unit cover and remove it upward.
Developing unit cover Developing unit stopper roller
Hooks (Same as on the opposite side)
(8) Rotate the developing gear counterclockwise to check that the developer bristles along the entire length of the developing sleeve.
Developing sleeve Developing unit stopper roller
[4] Cleaning the Developing Unit Bias shaft
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out the drum unit from the main body. (See "DRUM UNIT.") (2) Remove the developing unit from the drum unit. (3) Wipe the dirt on the developing unit bias shaft with waste.
(9) Install the developing unit cover, then install the developing unit in the drum unit. Caution: After installing the developing unit in the drum unit, make sure the developing unit stopper roller is in contact with the developing unit stopper plate (allocation of DSD).
Developing sleeve Developing unit bias shaft
[1] Replacing and Cleaning the Toner Cartridge
a. Procedure (1) Open the toner supply door and pull the toner supply unit forward.

Toner supply door

Toner supply unit
(2) Remove the toner cartridge. (3) After removing the toner cartridge, clean the area around the toner cartridge insertion hole with a waste.

Cartridge insertion hole

[1] Removing and Reinstalling the Cleaning Blade
Caution: Be sure the power cord has been unplugged from the wall outlet. Caution1: Be sure to replace the following parts at the same time: Cleaning blade Toner guide roller (TGR) Caution2: Do not touch the edges of the cleaning blade with bare hands. Caution3: When reinstalling the cleaning blade, apply setting powder to the entire surface of the drum and cleaning blade regardless of whether the drum and cleaning blade are new or old. Caution4: When you have applied setting powder to the drum, perform the following before installing the drum unit on the main body: 1) To ensure accurate toner concentration, wipe scattered setting powder off the sensor and Dmax/JAM sensor on the toner control sensor board with a rag moistened with alcohol. 2) With the charging corona unit and developing unit removed, turn the drum once (to prevent setting powder from scattering onto the charging corona unit, and to prevent image defects). Procedure Remove the drum unit. (See "DRUM UNIT.") Remove the charging corona unit. (See "CHARGING CORONA UNIT.") Remove the developing unit. (See "DEVELOPING UNIT.") Remove two screws to remove the cleaner cover.

(9) Reinstall the above parts following the removal steps in reverse. 3-I-3
PAPER FEED UNITS OF TRAYS 1 AND 2 (Di551/Di650)
[1] Removing and Reinstalling the Paper Feed Unit
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out paper feed tray 1 or 2. (2) Loosen the securing shaft screw, and remove one screw. (3) Disconnect the relay connector (CN814, 834) and remove the paper feed unit by lifting.
Relay connector (CN814, 834) Securing shaft screw Paper feed unit Screw
[2] Removing and Reinstalling the Paper Feed Trays 1 and 2
Warning: When removing the tray, stand in a proper position so that you do not hurt your back and waist. If the tray contains paper, remove all paper before removing the tray. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out paper feed tray 1 or 2. (2) Remove the paper feed unit. (3) Remove four screws and remove tray 1 or 2 by lifting.

Tray 1,2

[3] Removing and Reinstalling the Paper Feed Roller and Feed Roller Rubber
a. Procedure (1) Remove the paper feed unit. (2) Remove the two stop rings and slide the two bearings outward. (3) Release the feed roller axis from the holder slit to detach the paper feed roller unit.
[4] Removing and Reinstalling the Double Feed Prevention Roller Rubber
a. (1) (2) (3) Procedure Remove the paper feed unit. Remove the paper feed roller unit. Remove the stop ring to detach the double feed prevention roller. (4) Remove the double feed prevention roller rubber from the roller.

Paint mark

Stop ring Double feed prevention roller

Bearing

Double feed prevention roller rubber
Paper feed roller unit Bearing Stop ring
(4) Remove the two stop rings from the paper feed roller unit to detach the paper feed roller and feed roller. (5) Remove the rubber from each roller.

Paper feed roller rubber

(5) Reinstall the above parts following the removal steps in reverse. Caution1: When reinstalling the double feed prevention roller, pay attention to their orientation. Caution2: Check that no grease or the like remains on the double feed prevention roller.
Feed roller Feed roller rubber Stop rings
(6) Reinstall the above parts following the removal steps in reverse. Caution1: When reinstalling the rollers, pay attention to their orientation. Caution2: Check that no grease or the like remains on each roller. 3-J-2
[5] Replacing the Pre-registration and Feed Clutches (MCs)
a. Procedure (1) Remove the paper feed unit. (2) Remove the four connectors (CN810, 811, 830, 831). (3) Remove the stop ring to detach the pre-registration MC/1/2 (MC4/6) and feed MC/1/2 (MC3/5).

The contents here shall be in accordance with the "[1] Removing and Reinstalling the Paper Feed Unit" of PAPER FEED UNITS OF TRAY 1 and 2 (Di551/Di650).

LCT cover /L Screws

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(4) Remove five screws to detach the tray 1 by lifting.
[3] Removing and Reinstalling the Paper Feed Tray 2
Warning: When removing the tray, stand in a proper position so that you do not hurt your back and waist. If the tray contains paper, remove all paper before removing the tray. Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Draw out paper feed tray 2. (2) Remove the paper feed unit. (3) Remove five screws and remove the LCT cover /R.

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LCT cover /R

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(4) Remove five screws to detach the tray 2 by lifting.
[4] Removing and Reinstalling the Paper Feed Roller and Feed Roller Rubber

Slit Stop ring

(4) Remove the two stop rings from the paper feed roller unit to detach the paper feed roller and feed roller.

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(5) Remove the rubber from each roller.
[5] Removing and Reinstalling the Double Feed Prevention Roller Rubber
The contents here shall be in accordance with the "[4] Removing and Reinstalling the Double Feed Prevention Roller Rubber" of PAPER FEED UNITS OF TRAY 1 AND 2 (Di551/Di650).

Feed roller rubber

Feed roller Arrow mark

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(6) Reinstall the above parts following the removal steps in reverse. Caution1: When reinstalling the rollers, pay attention to their orientation. Caution2: Check that no grease or the like remains on each roller.

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[6] Replacing the Pre-registration and Feed Clutches (MCs)
The contents here shall be in accordance with the "[5] Replacing the Pre-registration and Feed Clutches (MCs)" of PAPER FEED UNITS OF TRAY 1 and 2 (Di551/Di650).
[7] Replacing the Horizontal Conveyance MC/L and /R
a. Procedure (1) Remove the vertical conveyance section. (See "VERTICAL CONVEYNACE SECTION") (2) Draw out the horizontal conveyance section and tray 2. (3) Remove two relay connectors (CN902, 903). (4) Remove a screw to detach the sensor mounting plate. (5) Remove a stop ring for each, detach the horizontal conveyance MC/L (MC15) and horizontal conveyance MC/R (MC16).

Shaft Screws (2) Paper feed roller rubber Paper feed roller Gear

Screw Bearing

Paper feed roller assembly Screws (2) By-pass feed tray Connector (CN214)

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(4) Remove the stop ring from the paper feed roller assembly to pull out the shaft and remove the paper feed roller rubber from the paper feed roller.
Paper feed roller Paper feed roller rubber
(5) Reinstall the above parts following the removal steps in reverse. Caution1: Check that the orientation of the roller is correct when installing. Caution2: Check that no grease or the like remains on the roller. 3-L-1
[3] Replacing the Double Feed Prevention Roller Rubber
a. Procedure (1) Remove the by-pass feed tray and place the tray upside down. (2) Remove two screws to remove the bottom plate assembly. (3) Remove the spring.
Screws (2) Bottom plate assembly
(6) Reinstall the above parts following the removal steps in reverse. Caution1: Check that the orientation of the double feed prevention roller is correct when installing. Caution2: Check that no grease or the like remains on the double feed prevention roller. Caution3: There are three spring holes. Insert the spring in the middle hole.

Spring hole

(4) Remove the double feed prevention roller assembly from the by-pass feed tray unit. (5) Remove the stop ring to pull out the shaft and remove the double feed prevention roller rubber from the double feed prevention roller.
Paint mark Double feed prevention roller rubber
Double feed prevention roller
Double feed prevention roller assembly Stop ring
[1] Removing and Reinstalling the Vertical Conveyance Section
Caution: Be sure the power cord has been unplugged from the wall outlet. a. Procedure (1) Remove all right side covers. (See "EXTERNAL SECTION.") (2) Disconnect the connector (CN880). (3) Remove eleven screws to remove the vertical conveyance section.
[2] Removing and Reinstalling the Vertical Conveyance MC (MC11, MC12)
Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure Remove the vertical conveyance section. Remove the gear lock to remove the two gears and two spacer axes. Disconnect the two connectors (CN881, CN882) to remove the wiring harness from the harness guide. Remove each MC.

Faston terminal Screw

Positioning jig (00M8-1-00) Thermostat/U (TS1)

Thermostat/U (TS1) Screw

a) Set the distance "a" between the thermostat/ U and fixing upper roller so that it is equal to the thickness (B) of the positioning jig.
Faston terminals (2) Thermostat/U (TS1)
Fixing upper roller Standard value of a: 3.75 0.25mm

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b) When making the adjustment, make sure that the thermostat/U does not ride on the positioning jig (C).
[14] Removing and Reinstalling the Thermostat/L (TS2)
Caution: This is an important safety part. (P/N : SP00-0010) Be sure to observe the following cautions and steps when removing or reinstalling. Caution1: After reinstalling the thermostat/L, make sure that its wires do not touch the fixing lower roller. Caution2: When reinstalling the thermostat/L, adjust its position using the positioning jig (56AEJG011) and secure it with screws. Be sure to apply screw lock agent to the screws. This adjustment should be made in a pressured state. a. Removal procedure (1) Remove the fixing lower roller. (2) Close the fixing cover (top). (3) Remove the two Faston terminals of the thermostat/L through the fixing entrance side.

(C) (B) (A)

(3) Apply screw lock agent to the screw securing the thermostat/U. (4) Reverse the removal procedure to install other parts.

Faston

(4) Open the fixing cover (top). (5) Remove two screws to remove the thermostat/L.

Screws Thermostat/L

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b. Reinstallation procedure (1) Set a part (a) thermostat/L positioning jig (56AEJG011) between the thermostat/L and the fixing lower roller, and secure the thermostat/L with two screws so that the distance between the thermostat/L and roller is equal to the thickness of the jig.
Screws Positioning jig (56AEJG011)
b) After setting the distance b, remove the thermostat/L positioning jig, and make sure that the part (b) thermostat/L positioning jig cannot be inserted in a space between the fixing lower roller and the thermostat/L.

Part (a)

Thermostat/L (TS2) Faston terminal

Part (b)

(2) Apply screw lock agent to the two screws securing the thermostat/L. (3) Reverse the removal procedure to reinstall other parts.
a) Set the distance "b" between the thermostat/ L and the fixing lower roller so that it is equal to the thickness of the positioning jig.
Fixing lower roller Thermostat/L (TS2) Standard value of a: 1.75 0.25mm

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