Konica Minolta DF-502 Service Manual
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Konica Minolta DF-502 Service Manual

Konica Minolta DF-502 Service Manual

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SERVICE MANUAL
THEORY OF OPERATION
DF-502
2005.04
Ver. 1.0

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Summary of Contents for Konica Minolta DF-502

  • Page 1 SERVICE MANUAL THEORY OF OPERATION DF-502 2005.04 Ver. 1.0...
  • Page 3 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.

  • Page 5: Table Of Contents

    Theory of Operation Ver. 1.0 Apr. 2005 CONTENTS Outline Product specification ....................1 Composition/Operation Automatic Document Feeder (DF-502) ..............3 Construction ......................3 Operation ......................4 2.2.1 Document Take-Up and Feed ............... 4 2.2.2 Document Transport..................5 Electrical Parts Layout ..................6 Document Separating Mechanism................

  • Page 6: Theory Of Operation Ver. 1.0 Apr

    Theory of Operation Ver. 1.0 Apr. 2005 Blank page...

  • Page 7: Product Specification

    Theory of Operation Ver. 1.0 Apr. 2005 1. Product specification Outline Product specification Name Automatic Document Feeder Installation Inserted in top portion of the copier Modes Standard = 1-sided original Mixed Original = 1-sided original Document Loading Left-hand side, face up Types and Sizes of Document Standard Mixed Original...
  • Page 8 1. Product specification Theory of Operation Ver. 1.0 Apr. 2005 Blank page...

  • Page 9: Composition/Operation

    Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502) Composition/Operation Automatic Document Feeder (DF-502) Construction 4688M502AA Main Motor Registration Rollers Pick-Up Roller Take-Up Roller Exit Rollers Take-Up Clutch...

  • Page 10: Operation

    2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005 Operation 2.2.1 Document Take-Up and Feed • The document is taken up as the Pick-Up Roller and Take-Up Roller turn. • The Pick-Up Roller transports the document up to the Take-Up Roller.

  • Page 11: Document Transport

    Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502) 2.2.2 Document Transport • The document taken up is transported to the document scanning position of the copier by the Registration Rollers. • The Registration Rollers are turned by a gear train and belts which are driven by the Main Motor.

  • Page 12: Electrical Parts Layout

    2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005 Electrical Parts Layout PC12 PC11 PC10 4688M505CA Symbol Name Symbol Name Interface Board Paper Exit Sensor Main Motor Length Size Detection Sensor 1 Paper Take-Up Clutch Length Size Detection Sensor 2...

  • Page 13: Document Separating Mechanism

    Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502) Document Separating Mechanism • The coefficient of friction between the Take-Up Roller and Separation Roller is effectively used to prevent double feed of paper. Since the friction coefficient on the top side of the paper is equal to that...

  • Page 14: Document Exit Mechanism

    2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005 Document Exit Mechanism • The document is fed out of the ADF by the Exit Roller. • The Exit Roller is driven by gears and a belt which are driven by the Main Motor.

  • Page 15: Document Size Detection Mechanism

    Theory of Operation Ver. 1.0 Apr. 2005 2. Automatic Document Feeder (DF-502) Document Size Detection Mechanism • The document size is determined by means of two different systems of document width detection and document length detection. ✽ Document Width Detection •...
  • Page 16 2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2005 Blank page...
  • Page 17 SERVICE MANUAL FIELD SERVICE DF-502 2005.04 Ver. 1.0...
  • Page 19 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 21 Field Service Ver. 1.0 Apr. 2005 CONTENTS General Product specification ....................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Pick-up Roller/Take-up Roller................ 3 2.1.2 Separation Roller ..................5 2.1.3 Cleaning of the Registration Roller/Rolls ............6 2.1.4 Cleaning of the Exit Roller/Rolls ..............
  • Page 22 Field Service Ver. 1.0 Apr. 2005 7.1.2 Switch ......................22 7.1.3 Solenoid...................... 22 7.1.4 Clutch......................22 7.1.5 Motor......................23 Jam Display......................24 Misfeed Display ....................24 8.1.1 Display Resetting Procedure ..............24 Sensor layout...................... 25 Solution ......................26 8.3.1 Initial Check Items ..................26 8.3.2 Misfeed at the Document Take-up Section ..........

  • Page 23: Product Specification

    Field Service Ver. 1.0 Apr. 2005 1. Product specification General Product specification Name Automatic Document Feeder Installation Inserted in top portion of the copier Modes Standard = 1-sided original Mixed Original = 1-sided original Document Loading Left-hand side, face up Types and Sizes of Document Standard Mixed Original...
  • Page 24 1. Product specification Field Service Ver. 1.0 Apr. 2005 Blank page...

  • Page 25: Maintenance

    Field Service Ver. 1.0 Apr. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Pick-up Roller/Take-up Roller A. Cleaning Procedure 1. Open the Upper Door. 2. Using a soft cloth dampened with alcohol, wipe the Take-up Roller clean of dirt.
  • Page 26 2. Periodical check Field Service Ver. 1.0 Apr. 2005 B. Replacing Procedure 1. Open the Upper Door. 2. Open the Document Take-up Section Cover. ☞ 9 3. Snap off two C-clips. 4. Remove two Bearings and the Pick- up Roller/Take-up Roller Assy. 4688D019AA 5.

  • Page 27: Separation Roller

    Field Service Ver. 1.0 Apr. 2005 2. Periodical check 2.1.2 Separation Roller A. Replacing Procedure 1. Open the Upper Door. 2. Remove two screws and the Separa- tor Section Protective Cover. 4688D023AA 3. Unhook one spring and remove the Separation Roller Assy. 4688D024AA 4.

  • Page 28: Cleaning Of The Registration Roller/Rolls

    2. Periodical check Field Service Ver. 1.0 Apr. 2005 2.1.3 Cleaning of the Registration Roller/Rolls 1. Raise the Automatic Document Feeder. 2. Using a soft cloth dampened with alcohol, wipe the Registration Rolls clean of dirt. 4688D027AB 3. Remove the Rear Cover. 4.

  • Page 29: Cleaning Of The Exit Roller/Rolls

    Field Service Ver. 1.0 Apr. 2005 2. Periodical check 2.1.4 Cleaning of the Exit Roller/Rolls 1. Remove the Rear Cover. 2. Remove the Document Feeding Tray. ☞ 9 3. Using a soft cloth dampened with alcohol, wipe the Exit Roller/Rolls clean of dirt.

  • Page 30: Other

    3. Other Field Service Ver. 1.0 Apr. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 31: Disassembly/Assembly Procedure

    Field Service Ver. 1.0 Apr. 2005 3. Other Disassembly/Assembly procedure 3.2.1 Exterior Parts 4688D034AB Part Name Removal Procedure Open the Upper Door. → Remove two screws. → Remove the Document Take-up Section Cover Document Take-up Section Cover. Open the Upper Door. → Remove one screw and unhook six tabs. Rear Cover →...

  • Page 32: Interface Board (Pwb/Af)

    3. Other Field Service Ver. 1.0 Apr. 2005 3.2.2 Interface Board (PWB/AF) PWB/AF 4688D036AA 1. Open the Upper Door. 2. Remove the Rear Cover. ☞ 9 3. Unplug all connectors from the Inter- face Board. 4. Remove two screws and the Inter- face Board.

  • Page 33: Adjustment/Setting

    Field Service Ver. 1.0 Apr. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. A.

  • Page 34: Service Mode

    5. Service Mode Field Service Ver. 1.0 Apr. 2005 Service Mode Service Mode function setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the Service mode. 5.1.1 Procedure 1.

  • Page 35: Setting In The Service Mode

    Field Service Ver. 1.0 Apr. 2005 5. Service Mode Setting in the Service Mode 5.2.1 ADJUST A. ADF SUB ZOOM Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different parts by varying the scanning zoom ratio in the sub scanning direction when the Automatic Document Feeder is used.
  • Page 36 5. Service Mode Field Service Ver. 1.0 Apr. 2005 B. ADF MAIN REGIST Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the main scanning direction when the Automatic Docu- ment Feeder is used.
  • Page 37 Field Service Ver. 1.0 Apr. 2005 5. Service Mode C. ADF SUB REGIST1 Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the sub scanning direction when the Automatic Document Feeder is used.

  • Page 38: Function

    5. Service Mode Field Service Ver. 1.0 Apr. 2005 5.2.2 FUNCTION A. ADF FEED TEST Purpose/Use • To check for correct paper passage of the paper take-up and transport system in the Automatic (Duplexing) Document Feeder alone as a single unit. •...

  • Page 39: Mechanical Adjustment

    Field Service Ver. 1.0 Apr. 2005 6. Mechanical adjustment Mechanical adjustment ADF Height Adjustment 1. Turn one screw so that the spacer contacts the glass at the scale posi- tion of the copier. Turn the screw clockwise to raise the ADF.

  • Page 40: Adf Leading Edge Skew Adjustment

    6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2005 ADF Leading Edge Skew Adjustment NOTE • This adjustment is to be made when a tilted image occurs. 1. Prepare the test chart that comes with the ADF (option). 4035D513AA 2. Load the test chart in the ADF and make five 1-sided copies.
  • Page 41 Field Service Ver. 1.0 Apr. 2005 6. Mechanical adjustment 5. If the deviation is as shown on the left, move the graduations of the ADF to the front. 4688U001AB 4688U206AA 6. If the deviation is as shown on the left, move the graduations of the ADF to the rear.
  • Page 42 6. Mechanical adjustment Field Service Ver. 1.0 Apr. 2005 Blank page...

  • Page 43: Troubleshooting

    Field Service Ver. 1.0 Apr. 2005 7. Introduction Troubleshooting Introduction • Information required for troubleshooting and steps that must be performed are described in this chapter. Electrical Components Check Procedure • If a paper misfeed or malfunction occurs, perform the following operations to check the condition of the electrical components.

  • Page 44: Switch

    7. Introduction Field Service Ver. 1.0 Apr. 2005 7.1.2 Switch Step Check Result Action Replace the switch. Does the input signal (NO) of the control board change from L Replace the control to H when the switch is activated? board. Not Use 4025T523AB 7.1.3...

  • Page 45: Motor

    Field Service Ver. 1.0 Apr. 2005 7. Introduction 7.1.5 Motor Step Check Result Action Replace the control Does the LOCK signal switch to H when the machine goes into board. Replace the standby? motor. Replace the motor. Does the REM signal of the master board change from H to L Replace the control when the motor is turned on? board.

  • Page 46: Jam Display

    8. Jam Display Field Service Ver. 1.0 Apr. 2005 Jam Display Misfeed Display • When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives a corresponding message. C4506P298CA Display Message Misfeed/Paper Location Ref. Page ☞ Document take-up section OPEN DOC.

  • Page 47: Sensor Layout

    Field Service Ver. 1.0 Apr. 2005 8. Jam Display Sensor layout 4688T501AB Registration Sensor (PC3/AF) Paper Exit Sensor (PC5/AF) Separator Sensor (PC4/AF)

  • Page 48: Solution

    8. Jam Display Field Service Ver. 1.0 Apr. 2005 Solution 8.3.1 Initial Check Items • When a paper misfeed occurs, first perform the following initial checks. Check Item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper stor- age procedures.

  • Page 49: Misfeed At The Document Take-Up Section

    Separator Sensor (PC4/AF) WIRING DIAGRAM Ref. Location Step Operations Page Control signal (Electrical Components) Initial checks – – – ☞ M1/AF operation check – D-6 (DF-502) ☞ PC4/AF sensor check PWB/AF CN2/AF-9 (ON) I-4 (DF-502) Replace PWB/AF – – –...

  • Page 50: Misfeed At The Document Transport Section

    Registration Sensor (PC3/AF) WIRING DIAGRAM Ref. Location Step Operations Page Control signal (Electrical Components) Initial checks – – – ☞ M1/AF operation check – D-6 (DF-502) ☞ PC3/AF sensor check PWB/AF CN2/AF-6 (ON) H-4 (DF-502) Replace PWB/AF – – –...

  • Page 51: Misfeed At The Document Exit Section

    Paper Exit Sensor (PC5/AF) WIRING DIAGRAM Ref. Location Step Operations Page Control signal (Electrical Components) Initial checks – – – ☞ M1/AF operation check – D-6 (DF-502) ☞ PC5/AF sensor check PWB/AF CN2/AF-12 (ON) H-6 (DF-502) Replace PWB/AF – – –...
  • Page 52 8. Jam Display Field Service Ver. 1.0 Apr. 2005 Blank page...

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