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SERVICE MANUAL

2008.06

Ver. 8.0

THEORY OF OPERATION

This service manual is designed for machine with

firmware card ver. J8 and onward.

This service manual is designed for machine with

firmware card ver. J8 and onward.

i

THEORY OF OPERATION TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1

IMPORTANT NOTICE ................................................................................................S-1

DESCRIPTIONITEMS FOR DANGER, WARNING AND CAUTION.........................S-1

SAFETY WARNINGS .................................................................................................S-2

WARNING INDICATIONS ONTHE MACHINE ........................................................S-18

MEASURES TO TAKE INCASE OF ANACCIDENT ....................................................S-21

Composition of the service manual ................................................................................. C-1

Notation of the service manual ....................................................................................... C-2

bizhub C650/C550/C451 Main body

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................. 19

DF-611/610

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 7

LU-301

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 3

ZU-603

Outline ............................................................................................................................ 1

Construction/Operation ................................................................................................... 9

FS-517/518/608

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 9

PI-503

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 3

PK-512/513

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 5

ii

FS-519/PK-510/OT-602

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 9

MT-502

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 3

SD-505

Outline ............................................................................................................................ 1

Composition/Operation ................................................................................................... 3

JS-504

Outline ............................................................................................................................ 1

Construction and operation ............................................................................................ 5

SAFETY AND IMPORTANT WARNING ITEMS

S-1

Read carefully the safety and important warning items described belowto understand them

before doing service work.

Because of possible hazards to an inexperienced person servicing this product as well as

the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.

(hereafter called the KMBT) strongly recommends that all servicing be performed only by

KMBT-trained service technicians.

Changes may have been made to this product to improve its performance after this Service

Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that

the information contained in this service manual is complete and accurate.

The user of this service manual must assume all risks of personal injury and/or damage to

the product while servicing the product for which this service manual is intended.

Therefore, this service manual must be carefully read before doing service work both in the

course of technical training and even after that, for performing maintenance and control of

the product properly.

Keep this service manual also for future service.

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 product, the relevant works (disassembling, reassembling, adjustment,

repair, maintenance, etc.) need to be conducted with utmost care.

Symbols used for safety and important warning items are defined as follows:

SAFETY AND IMPORTANT WARNING ITEMS

IMPORTANT NOTICE

DESCRIPTION ITEMS FOR DANGER,

WARNING AND CAUTION

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

:Precaution when servicing the

product. General

precaution

Electric hazard High temperature

:Prohibition when servicing the

product. General

prohibition

Do not touch

with wet hand

Do not

disassemble

:Direction when servicing the

product. General

instruction

UnplugGround/Earth

SAFETY AND IMPORTANT WARNING ITEMS

S-2

[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA

BUSINESS TECHNOLOGIES, INC.

KONICA MINOLTA brand products are renowned for their high reliability. This reliability is

achieved through high-quality design and a solid service network.

Product 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 beloware not exhaustive, but they illustrate the reason-

ing behind this policy.

SAFETY WARNINGS

Prohibited Actions

DANGER

• 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.

• Making any modification to the product unless instructed

by KMBT

• Using parts not specified by KMBT

SAFETY AND IMPORTANT WARNING ITEMS

S-3

[2] POWER PLUG SELECTION

In some countries or areas, the power plug provided with the product may not fit wall outlet

used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)

to attach appropriate power plug or power cord set in order to connect the product to the

supply.

Power Cord Set or Power Plug

WARNING

•Usepower supply cord set which meets the following

criteria:

- provided with a plug having configuration intended for

the connection to wall outlet appropriate for the prod-

uct's rated voltage and current, and

- the plug has pin/terminal(s) for grounding, and

- provided with three-conductor cable having enough cur-

rent capacity, and

- the cord set meets regulatory requirements for the area.

Use of inadequate cord set leads to fire or electric shock.

• Attach power plug which meets the following criteria:

- having configuration intended for the connection to wall

outlet appropriate for the product's rated voltage and

current, and

- the plug has pin/terminal(s) for grounding, and

- meets regulatory requirements for the area.

Use of inadequate cord set leads to the product connect-

ing to inadequate power supply (voltage, current capacity,

grounding), and may result in fire or electric shock.

• Conductors in the power cable must be connected to ter-

minals of the plug according to the following order:

•Black or Brown:L (line)

•White or Light Blue:N(neutral)

•Green/Yellow:PE (earth)

Wrong connection may cancel safeguards within the

product, and results in fire or electric shock.

kw

SAFETY AND IMPORTANT WARNING ITEMS

S-4

[3] CHECKPOINTS WHENPERFORMING ON-SITE SERVICE

KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all

applicable safety standards are met, in order to protect the customer and customer engi-

neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical

equipment may be subject to parts wear and eventual failure. In order to maintain safety

and reliability, the CE must perform regular safety checks.

1. Power Supply

Connection to Power Supply

WARNING

• Check that mains voltage is as specified.

Connection to wrong voltage supply may result in fire or

electric shock.

• Connect power plug directly into wall outlet having same

configuration as the plug.

Use of an adapter leads to the product connecting to

inadequate power supply (voltage, current capacity,

grounding), and may result in fire or electric shock.

If proper wall outlet is not available, advice the customer

to contact qualified electrician for the installation.

•Plug the power cord into the dedicated wall outlet with a

capacity greater than the maximum power consumption.

If excessive current flows in the wall outlet, fire may

result.

• If two or more power cords can be plugged into the wall

outlet, the total load must not exceed the rating of the wall

outlet.

If excessive current flows in the wall outlet, fire may

result.

• Make sure the power cord is plugged in the wall outlet

securely.

Contact problems may lead to increased resistance,

overheating, and the risk of fire.

•Checkwhether the product is grounded properly.

If current leakage occurs in an ungrounded product, you

may suffer electric shock while operating the product.

Connect power plug to grounded wall outlet.

kw

SAFETY AND IMPORTANT WARNING ITEMS

S-5

Power Plug and Cord

WARNING

• When using the power cord set (inlet type) that came with

this product, make sure the connector is securely inserted

in the inlet of the product.

When securing measure is provided, secure the cord with

the fixture properly.

If the power cord (inlet type) is not connected to the prod-

uct securely, a contact problem may lead to increased

resistance, overheating, and risk of fire.

• Check whether the power cord is not stepped on or

pinched by a table and so on.

Overheating may occur there, leading to a risk of fire.

• Check whether the power cord is damaged. Check

whether the sheath is damaged.

If the power plug, cord, or sheath is damaged, replace

with a newpower cord (with plug and connector on each

end) specified by KMBT. Using the damaged power cord

may result in fire or electric shock.

• Do not bundle or tie the power cord.

Overheating may occur there, leading to a risk of fire.

• Check whether dust is collected around the power plug

and wall outlet.

Using the power plug and wall outlet without removing

dust may result in fire.

• Do not insert the power plug into the wall outlet with a wet

hand.

The risk of electric shock exists.

• When unplugging the power cord, grasp the plug, not the

cable.

The cable may be broken, leading to a risk of fire and

electric shock.

SAFETY AND IMPORTANT WARNING ITEMS

S-6

2. Installation Requirements

Wiring

WARNING

•Never use multi-plug adapters to plug multiple power cords

in the same outlet.

If used, the risk of fire exists.

• When an extension cord is required, use a specified one.

Current that can flowin the extension cord is limited, so

using a too long extension cord may result in fire.

Do not use an extension cable reel with the cable taken

up. Fire may result.

Prohibited Installation Places

WARNING

• Do not place the product near flammable materials or vola-

tile materials that may catch fire.

A risk of fire exists.

• Do not place the product in a place exposed to water such

as rain.

A risk of fire and electric shock exists.

When not Using the Product for a long time

WARNING

• When the product is not used over an extended period of

time (holidays, etc.), switch it off and unplug the power

cord.

Dust collected around the power plug and outlet may

cause fire.

SAFETY AND IMPORTANT WARNING ITEMS

S-7

Ventilation

CAUTION

• The product generates ozone gas during operation, but it

will not be harmful to the human body.

If a bad smell of ozone is present in the following cases,

ventilate the room.

a. When the product is used in a poorly ventilated room

b. When taking a lot of copies

c. When using multiple products at the same time

Stability

CAUTION

•Besure to lock the caster stoppers.

In the case of an earthquake and so on, the product may

slide, leading to a injury.

Inspection before Servicing

CAUTION

• Before conducting an inspection, read all relevant docu-

mentation (service manual, technical notices, etc.) and

proceed with the inspection following the prescribed pro-

cedure in safety clothes, using only the prescribed tools.

Do not make any adjustment not described in the docu-

mentation.

If the prescribed procedure or tool is not used, the prod-

uct may break and a risk of injury or fire exists.

• Before conducting an inspection, be sure to disconnect

the power plugs from the product and options.

When the power plug is inserted in the wall outlet, some

units are still powered even if the POWER switch is

turned OFF. A risk of electric shock exists.

• The area around the fixing unit is hot.

Yo umay get burnt.