Minolta Di152 Service Manual
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Minolta Di152 Service Manual

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Service Manual
[General]
Di152/Di183

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  • Page 1 Service Manual [General] Di152/Di183...
  • Page 2 INDEX (GENERAL) GENERAL MECHANICAL/ELECTRICAL...
  • Page 3 GENERAL 14413...

  • Page 4: Table Of Contents

    CONTENTS 1. SPECIFICATION ..................... G-1 2. PRECAUTIONS FOR INSTALLATION ............G-5 2-1. Installation Site ..................G-5 2-2. Power Source ..................G-5 2-3. Grounding ....................G-5 3. PRECAUTIONS FOR USE ................G-6 3-1. To ensure that the copier is used in an optimum condition ..... G-6 3-2.

  • Page 5: Specification

    30 sec. or less (23, Rated Voltage) FIRST COPY TIME 7 sec. or less (A4C, Drawer, full size mode) CONTINUOUS COPY SPEED (copies/min) Speed Size Di152 Di183 8-1/2 × 11C 8-1/2 × 11L 11 × 17L 8-1/2 × 14L 11 × 14...
  • Page 6 ZOOM RATIOS Metric Inch Full Size 100 % 100 % 200 % 200 % Enlargement 141 % 129 % Fixed 115 % 121 % 81 % 78 % Reduction 70 % 64 % 50 % 50 % Variable 50 % to 200 % (in 1 % increments) LENS Through Lens EXPOSURE LAMP...
  • Page 7 Multiple Bypass (MB-5): option TYPE Multiple Bypass INSTALLATION Mounted on the copier COPY PAPER TYPE 50 sheets Plain Paper (60 to 90 g/m Transparencies 20 sheets Type 20 sheets Thick Paper (91 to 157 g/m Postcards 20 sheets Recycled Paper (60 to 90 g/m 50 sheets Maximum (Width ×...
  • Page 8 Job Tray (JS-202): option TYPE Multiple Bypass INSTALLATION Mounted on the copier CAPACITY Exit Tray Job Tray of the machine 1Stacking height up 150 sheets (A4C/L) to 22 mm Plain Paper (60 to 90 g/m 75 sheets 100 sheets (A4C/L) (except A4C/L) 50 sheets (except A4C/L)

  • Page 9: Precautions For Installation

    PRECAUTIONS FOR INSTALLATION 2-1. Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. •...

  • Page 10: Precautions For Use

    PRECAUTIONS FOR USE 3-1. To ensure that the copier is used in an optimum condition • Never place a heavy object on the copier or subject the copier to shocks. • Insert the power plug all the way into the outlet. •...

  • Page 11: Handling Of Consumables

    HANDLING OF CONSUMABLES Before using any consumables, always read the label on its container carefully. • Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place.

  • Page 12: Other Precautions

    OTHER PRECAUTIONS Use the following precautions when performing service jobs for a copier that uses a laser. • When a service job needs to be performed in the laser beam path, such as when working around the printerhead or PC Drum, be sure first to unplug the power cord of the copier from the outlet.

  • Page 13: System Options

    SYSTEM OPTIONS 4021O009AA 1144M172AC 4021O010AA 4695U011AA 4021O013AB 4021O063AA 4021O012AA 4021O014AA 1. Plug-In Counter 9. Sifting Unit OT-103 2. Original Cover OC-5 (Illustration none) 3. Automatic Document Feeder AF-10 10. Memory M16-4, M32-3 4. Multiple Bypass MB-5 (Illustration none) 5. Copy Desk 11.
  • Page 14 MECHANICAL/ ELECTRICAL 14413...
  • Page 15 CONTENTS 1. CROSS SECTIONAL VIEW ................M-1 2. COPY PROCESS .................... M-2 3. DRIVE SYSTEM ....................M-4 4. SEQUENTIAL EXPLANATION ................ M-5 5. WATCHDOG FUNCTION (CPU OVERRUN MONITOR) ........ M-6 5-1. Watchdog Function Post-Processing ............M-6 6. IMAGE STABILIZATION SYSTEM ..............M-7 7.
  • Page 16 15-1.Paper Take Up Drive Mechanism ............M-36 15-2.Paper Take-Up Mechanism ..............M-37 15-3.Paper Empty Detection Mechanism ............M-38 15-4.Paper Take Up Control ................M-38 15-5.Paper Take Up Retry Control ..............M-39 16. IMAGE TRANSFER AND PAPER SEPARATION SECTION ......M-40 17.

  • Page 17: Cross Sectional View

    CROSS SECTIONAL VIEW 4021M001AA 1. IR Section 4. Paper Take-Up/Feed Section 2. Fusing Unit 5. PH Section 3. Imaging Unit...

  • Page 18: Copy Process

    COPY PROCESS 4021M065CB 1. PC Drum • Used as the medium on which a visible developed image of the original is formed. 2. Drum Charging • A uniform negative DC charge is deposited across the entire surface of the PC Drum. 3.
  • Page 19 9. Bypass Paper Feed • Feeds paper from the Manual Bypass Tray, one piece at a time. • The optional Multiple Bypass Tray (MB-5), when mounted on the machine, permits con- tinuous paper feeding. 10. Image Transfer • A DC positive charge is applied to the Image Transfer Roller to transfer the visible image on the surface of the PC Drum onto the paper.Paper Separation.

  • Page 20: Drive System

    DRIVE SYSTEM Paper Exit Roller Gear Transport Roller Gear Fusing Roller Gear PC Drum Synchronizing Roller Clutch Paper Take-Up Roller Gear 4021M003AA 1. Scanner Motor M5 2. Main Motor M1...

  • Page 21: Sequential Explanation

    SEQUENTIAL EXPLANATION...

  • Page 22: Watchdog Function (Cpu Overrun Monitor

    WATCHDOG FUNCTION (CPU OVERRUN MONITOR) • The watchdog function, or CPU overrun monitor function, monitors whether any of the CPUs mounted in the copier overruns. • If the function detects that a CPU overruns, the copier automatically resets the CPU, thereby restarting the logic circuit and mechanism.

  • Page 23: Image Stabilization System

    IMAGE STABILIZATION SYSTEM The following image stabilization controls are provided to ensure stabilized copy image. Purpose Means Control The Vg/Vb control voltage is varied to bring Vg/Vb to an appropriate level according to the following settings. • Tech. Rep. Choice: ID Adjustment To stabilize image density.

  • Page 24: Imaging Unit (I/U

    IMAGING UNIT (I/U) • The IU integrates the PC Drum, Developing Unit, PC Drum Charge Corona, and the PC Drum Cleaning Mechanism, all in one body. PC Drum PC Drum Cleaning Mechanism 4021M006AB PC Drum Charge Corona Developing Unit 4021M007AB...

  • Page 25: Imaging Unit (Iu) Drive Mechanism

    7-1. Imaging Unit (IU) Drive Mechanism • The IU is driven by the Main Motor. 4021M008AB Main Motor M1 Forward Backward Elevtrical Component Control Signal Wiring Diagram Rotation Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7...

  • Page 26: Pc Drum Section

    PC DRUM SECTION • The PC Drum consists of layers of semiconductive materials placed on an aluminum alloy base, on which an electrostatic latent image is formed. PC Drum (PC Drum Cross-Section) Charge Transport Layer Charge Generation Layer 1167M007AA Aluminum Base 1139M007AA 8-1.

  • Page 27: Grounding Of The Pc Drum

    8-2. Grounding of the PC Drum • The potential on the surface of the PC Drum exposed to the light is grounded to the frame. PC Drum Frame Ground Plate 4021M010AA M-11...

  • Page 28: Pc Drum Charging Section

    PC DRUM CHARGING SECTION • The PC Drum Charge Corona has a scorotron grid to deposit a charge evenly across the surface of the PC Drum. • The corona unit has a comb electrode that discharges only toward the grid mesh, thus minimizing the amount of ozone produced.

  • Page 29: Image Reading Section

    10. IMAGE READING SECTION 4021M012AB 1. Scanner /Motor M5 4. Scanner 2. CCD Board PWB-J 5. 2nd/3rd Mirrors Carriage 3. Size Reset Switch S10 6. Scanner Home Position Sensor PC6 M-13...

  • Page 30: 10-1.Image Processing Process

    10-1. Image Processing Process 1. Photoelectric Conversion • Light reflected off the original is read by the CCD Sensor which converts the data to a corresponding analog signal. 2. Analog-to-Digital Conversion • The analog signal output from the CCD Sensor is converted to a corresponding 8-bit dig- ital signal.

  • Page 31: 10-2.Exposure Components Section

    10-2. Exposure Components Section 4021M013AA 1. Auxiliary Reflector When a book or other bound original is copied, the paper in the area near the binding generally fails to come flush against the glass, so that the copy of these areas is gener- ally too dark.

  • Page 32: 10-3.Scanner And Mirrors Carriage Movement Mechanism

    10-3. Scanner and Mirrors Carriage Movement Mechanism Scanner Movement Mechanism • The Scanner is driven by the Scanner Motor. 2nd/3rd Mirrors Carriage Movement Mechanism • The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner, thereby keeping constant the optical path length between the original and the CCD Board.

  • Page 33: 10-4.Scanner Motor Drive Control

    10-4. Scanner Motor Drive Control • The speed at which the Scanner is moved is controlled by varying the period of the motor drive pulse that is timed with the reference clock. High Speed Low Speed Period • The distance over which the Scanner travels is controlled by the number of motor drive pulses that correspond to each paper size and zoom ratio.

  • Page 34: Memory Storage Image Processing System

    11. MEMORY STORAGE IMAGE PROCESSING SYSTEM • Based on the image data output from the IR, a laser light is projected onto the surface of the PC Drum to form a corresponding latent image. PH Unit 4021M015AA M-18...

  • Page 35: 11-1.Laser Exposure Process

    11-1. Laser Exposure Process 1. The Start key is pressed. 2. The laser diode is forced to turn ON and the laser intensity is automatically adjusted. 3. The SOS Sensor Board is illuminated by the laser beam, which generates an SOS sig- nal.

  • Page 36: Developing Unit Section

    12. DEVELOPING UNIT SECTION The Developing Unit agitates and triboelectrically charges toner so that it sticks to the elec- trostatic latent image formed on the surface of the PC Drum, then changing the image to a visible, developed one. 4021M017AA 1.

  • Page 37: 12-1.Developing Unit Drive Mechanism

    12-1. Developing Unit Drive Mechanism The rollers are driven through a gear train from the motor. 1st Toner Conveying Roller Sleeve/Magnet Roller Main Motor M1 2nd Toner Conveying Roller 3rd Toner Conveying Roller 4021M008AB Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G...

  • Page 38: 12-3.Developing Bias

    12-2. Sleeve/Magnet Roller • The Sleeve/Magnet Roller, which consists of an outer sleeve roller and an inner magnet roller, conveys developer to the point of development. • The magnetic force of the magnet roller at the point of development is the strongest so that the developer brush stands straight up to deliver the greatest amount of toner to the point of development.

  • Page 39: Atdc Sensor Automatic Adjustment

    12-4. ATDC Sensor The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer Mixing Chamber. 2nd Toner Conveying Roller 4021M019AA ATDC Sensor UN1 ATDC Sensor Automatic Adjustment The reference value for the ATDC Sensor is automatically adjusted as detailed below using the ATDC Sensor Automatic Adjustment mode.

  • Page 40: 12-5.Toner Replenishing Mechanism

    12-5. Toner Replenishing Mechanism • Toner is supplied from the Toner Bottle to the Developer Mixing Chamber. 1. The coupling is turned by the motor, which turns the Toner Bottle. 2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering Chamber provided in the outer race of the coupling.

  • Page 41: 12-6.Toner Replenishing Control

    12-6. Toner Replenishing Control • Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio. • If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value. •...

  • Page 42: 12-7.T/C Recovery Mode

    12-7. T/C Recovery Mode The machine enters the T/C recover mode when a T/C of 10 % or less is detected. Toner is replenished for 90 sec. T/C is recovered by 1 % or more. T/C is not recovered by 1 % or more, or T/C is less than 12 %.

  • Page 43: 12-8.Toner Bottle Home Position Detection Mechanism

    12-8. Toner Bottle Home Position Detection Mechanism • The Toner Bottle is at its home position (where it remains stationary) when its Toner Sup- ply Port faces up. This position is detected by a sensor. Toner Bottle Home Position Sensor PC7 Toner Supply Port 4021M024AA Elevtrical Component...

  • Page 44: Paper Take Up/Feed Section

    13. PAPER TAKE UP/FEED SECTION 4021M025AA 1. Paper Size Detecting Board PWB-I 4. Paper Take-Up Roll 2. Paper Size Detecting Sensor S11 5. Separator Roll 3. Paper Empty Sensor PC4 6. Paper Lifting Plate M-28...
  • Page 45 13-1. Drawer In Position Detection • When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor. The copier then knows that the drawer has been slid in position. Drawer Set Sensor PC5 4021M026AA Elevtrical Component Control Signal Activated Deactivated Wiring Diagram...

  • Page 46: 13-3.Paper Lifting Plate

    13-3. Paper Lifting Plate • The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked when the tray is slid into the unit. • The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times. Paper Lifting Plate Spring 4021M063AA...
  • Page 47 Paper Size Detecting Board Paper Size Detecting PWB-I Paper Size Sensor S11 — — — — — B4L, 8-1/2 × 14 — — — — Activated 11 × 14 — — — Activated A3L, 11 × 17 — — — A5L, 5-1/2 ×...

  • Page 48: 13-5.Paper Take Up Mechanism

    13-5. Paper Take Up Mechanism • Drive for the paper take-up sequence is transmitted via the Paper Take-Up Solenoid from a motor. Main Motor M1 Paper Take-Up Roll Paper Take-Up Solenoid SL1 4021M027AA Paper Separating Mechanism • The coefficient of friction between the Paper Take-Up Roll and Separator Roll is effec- tively used to prevent double feed of paper.

  • Page 49: 13-6.Paper Take Up Control

    13-6. Paper Take Up Control Start Key ON Main Motor M1 Paper Take-Up Solenoid SL1 Synchronizing Roller Sensor PC1 4021M515CA Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7 Elevtrical Component Control Signal Wiring Diagram PWB-A PJ5A-2 Elevtrical Component Control Signal Activated Deactivated...

  • Page 50: Manual Bypass Section

    14. MANUAL BYPASS SECTION 14-1. Paper Take Up Drive Mechanism • Drive for paper take-up from the Manual Bypass is transmitted from a motor via the Sole- noid. Main Motor M1 Manual Feed Paper Sensor PC2 Manual Bypass Solenoid SL2 4021M028AA 14-2.

  • Page 51: 14-3.Manual Feed Take Up Control

    14-3. Manual Feed Take Up Control Paper Set Start Key ON Manual Feed Paper Sensor PC2 Main Motor M1 Manual Bypass Solenoid SL2 Paper drawing-in sequence completed 4021M511CA Forward Elevtrical Component Control Signal Wiring Diagram Rotation PWB-A PJ7A-5 17-G PWB-A PJ7A-7 Elevtrical Component Control Signal Wiring Diagram...

  • Page 52: Multiple Bypass Section

    15. MULTIPLE BYPASS SECTION 4021M031AA 1. Paper Take-Up Roll 3. Multiple Bypass Paper Empty Sensor 2. Multiple Bypass Solenoid SL21 PC21 15-1. Paper Take Up Drive Mechanism • Drive for paper take-up from the Multiple Bypass is transmitted from a motor via the Sole- noid.

  • Page 53: 15-1.Paper Take Up Drive Mechanism

    15-2. Paper Take-Up Mechanism • The Paper Lifting Plate is raised to press the paper stack on the tray up against the Paper Take-Up Roll. • The Paper Lifting Plate is raised and lowered in time with a paper take-up sequence. •...

  • Page 54: 15-3.Paper Empty Detection Mechanism

    15-3. Paper Empty Detection Mechanism • The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass. <When Paper is Present> <When Paper is not Present> Multiple Bypass Paper Empty Sensor PC21 Paper 4021M034AA 4021M035AA 15-4. Paper Take Up Control Paper Set Start Key ON Multiple Bypass Paper Empty Sensor PC21...
  • Page 55 15-5. Paper Take Up Retry Control • To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo- rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given period of time after the sequence has been started. The paper take-up sequence is then performed again.

  • Page 56: Image Transfer And Paper Separation Section

    16. IMAGE TRANSFER AND PAPER SEPARATION SEC- TION Image Transfer • A positive charge is applied to the Image Transfer Roller to transfer the toner image formed on the surface of the PC Drum onto the paper. • The charge applied to the Image Transfer Roller is varied according to the following con- ditions to ensure that image transfer efficiency is stabilized.

  • Page 57: Pc Drum Cleaning Section

    17. PC DRUM CLEANING SECTION • The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum. • The spent toner is conveyed through the Recycling Duct and eventually back to the Developer Mixing Chamber. •...

  • Page 58: Main Erase Section

    18. MAIN ERASE SECTION • Any potential remaining on the surface of the PC Drum is neutralized by both light from the Main Erase and a negative voltage applied by the Charge Neutralizing Sheet. • A negative charge is applied to the Charge Neutralizing Sheet to neutralize a positive charge on the surface of the PC Drum.

  • Page 59: Fusing Unit Section

    19. FUSING UNIT SECTION • The Fusing Unit fixes permanently the developed image to the paper by applying heat and pressure to the toner and paper. 4021M041AD 1. Paper Exit Roller 6. Pressure Spring 2. Transport Roller 7. Fusing Heater Lamp H1 3.

  • Page 60: 19-1.Fusing Unit Drive Mechanism

    19-1. Fusing Unit Drive Mechanism • The Fusing Unit is driven by a motor. Main Motor M1 Left Fusing Roller Right Fusing Roller 4021M042AA 19-2. Fusing Rollers Pressure Mechanism • To ensure that there is a certain width of area of contact between the Right and Left Fus- ing Rollers, a pressure spring is used to press the Lower Fusing Roller up against the Upper Fusing Roller.

  • Page 61: 19-3.Fusing Temperature Control

    19-3. Fusing Temperature Control • The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the surface of the Fusing Roller. • The Fusing Roller surface temperature is detected by using a thermistor that translates the temperature to a corresponding electrical signal.

  • Page 62: Job Tray (Js-202): Option

    20. JOB TRAY (JS-202): Option 4021M045AC 1. Job Tray 5. Upper Home Position Sensor PC32 2. Main Board PWB-A 6. Lower Home Position Sensor PC33 3. Paper Empty Sensor PC35 7. Paper Detecting Board PWB-B 4. Full Detecting Sensor PC34 8.
  • Page 63 20-1. Tray Selecting Mechanism • Paper is fed into either the Exit Tray of the machine or the Job Tray. Either is selected according to the application mode (fax, copier, or printer). • The specific tray in which paper is fed is selected by a motor and a sensor. <When feeding paper into the Exit Tray: Copier>...

  • Page 64: 20-2.Tray-Full Detecting Mechanism

    20-2. Tray-Full Detecting Mechanism • Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the low- ered position). • A tray-full condition is detected when the sensor is blocked for a continuous given period of time (approx.

  • Page 65: Shifting Unit (Ot-103): Option

    21. SHIFTING UNIT (OT-103): Option 4021M053AB 1. Main Board PWB-A 2. Home Sensor S31 3. Shift Motor M1 M-49...

  • Page 66: 21-1.Exit Position Shifting Mechanism

    21-1. Exit Position Shifting Mechanism • Paper is fed into the Shifting Unit along a straight path or shifted from the reference straight path position. This exit position shifting mechanism allows different finishing functions offered by the machine (Non-Sort, Sort, and Group) to be effected. <Straight Feeding>...
  • Page 67 Elevtrical Forward Backward Control Signal Wiring Diagram Component Rotation Rotation PWB-A PJ2A-1 to 4 Pulse output 16-C Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PWB-A PJ3A-3 17-D M-51...

  • Page 68: Other Mechanism

    22. OTHER MECHANISM 22-1. Cooling Mechanism Power Supply Section Cooling Mechanism • A cooling fan motor draws air from the area around the Power Supply Unit to the outside to prevent the Power Supply Unit temperature from running high. • The cooling fan motor is turned at full speed when the Main Motor turns and at a speed reduction during other timings, thereby making the machine quieter without sacrificing cooling performance.

  • Page 69: Fusing Section Cooling Mechanism

    Fusing Section Cooling Mechanism • A fan motor draws air from the area around the Fusing Unit to the outside to prevent the machine interior temperature from running high. In addition, the fan motor pulls paper being transported up through suction force to help stabilize paper transport. •...
  • Page 70 Service Manual [General] Di152/Di183 Copyright 2001 MINOLTA CO., LTD. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA Co.,Ltd. 4021-7990-11 01100500...

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