Option Service Manual

Option
Service Manual

ZK2
ZK-2

Copyright
2002 MINOLTA CO., LTD.

Use of this manual should be strictly supervised to

avoid disclosure of confidential information.

Issued for Di551/Di650 and Other Models.

MINOLTA Co.,Ltd.

7663-4380-11 02050600
ZK-2TOC.fm Page 1 Wednesday, June 12, 2002 12:13 PM
SAFETY AND IMPORTANT WARNING ITEMS
Refer to the Di551/Di650 service manual on pageS-1
CONTENTS
CONTENTS
1. OUTLINE
PRODUCT SPECIFICATIONS..................................1-1
CENTER CROSS-SECTION DIAGRAM...................1-3
DRIVE SYSTEM DIAGRAM......................................1-4
[1] Conveyance Drive Section.........................1-4
[2] Punch Section ............................................1-5
[3] Punch Scraps Conveyance Section...........1-5
[4] 1st Folding Stopper Section .......................1-6
[5] 2nd Folding Stopper Section......................1-6
PUNCHING PROCESS.............................................1-7
[1] Switching Mechanism of Gate/L.................1-8
[2] Standby Position of Punch Unit..................1-9
[3] Formation of a Registration Loop...............1-9
[4] Conveyance .............................................1-10
[5] Adjustment of Punching position..............1-10
[6] Punch .......................................................1-11
Z-FOLDING PROCESS...........................................1-12
[1] Switching Mechanisms of Gate/L and
Gate/U......................................................1-13
[2] Positioning of 1st and 2nd Folding
Stoppers...................................................1-14
[3] 1st Folding................................................1-15
[4] 2nd Folding...............................................1-16
2. UNIT EXPLANATION
EXTERNAL SECTION...............................................2-1
[1] Composition ...............................................2-1
[2] Mechanism.................................................2-1
[3] Interlock Control .........................................2-3
CONVEYANCE SECTION.........................................2-4
[1] Composition ...............................................2-4
[2] Mechanism.................................................2-5
[3] Conveyance Control...................................2-6
PUNCH SECTION.....................................................2-8
[1] Composition ...............................................2-8
[2] Mechanism.................................................2-8
[3] Punch Control.............................................2-9
PUNCH SCRAPS CONVEYANCE SECTION.........2-11
[1] Composition .............................................2-11
[2] Mechanism...............................................2-11
[3] Punch Scraps Conveyance Control .........2-12
Z-FOLDING SECTION ............................................2-13
[1] Composition .............................................2-13
[2] Mechanism...............................................2-13
[3] 1st Folding Position Setting Control .........2-14
[4] 2nd Folding Position Setting Control ........2-15
ZK-2TOC.fm Page 2 Wednesday, June 12, 2002 12:13 PM

CONTENTS

3. DISASSEMBLY/ASSEMBLY
EXTERNAL SECTION.............................................. 3-1
[1] Removing the ZK....................................... 3-1
PUNCH SECTION.................................................... 3-2
[1] Replacing the Punch unit........................... 3-2
[2] Replacing the Punch Clutch (MC1) ........... 3-3
PUNCH SCRAPS CONVEYANCE SECTION.......... 3-4
[1] Replacing the Punch Scraps Conveyance
Motor (M7)................................................. 3-4
Z-FOLDING SECTION ............................................. 3-5
[1] Removing and Installing the Z-folding /
Conveyance Unit ...................................... 3-5
A-KIT (FNS SIDE)..................................................... 3-7
[1] Removing the Fun unit ............................. 3-7

4. ADJUSTMENT
ADJUSTMENT.......................................................... 4-1
[1] Position the switches................................. 4-1
[2] Confirming the ROM version ..................... 4-1
[3] Finisher ROM version up........................... 4-1
[4] Adjustments made when replacing parts... 4-1
[5] Setting the software DIP switches............. 4-1
[6] Punch unit Punch Vertical position
adjustment................................................. 4-2
[7] Punch unit Punch horizontal position
adjustment................................................. 4-2
[8] Punch resist loop adjustment .................... 4-3
[9] Z-folding position adjustment..................... 4-3
[10] Z-folding adjustment value ........................ 4-4
[11] Adjusting the Paper-Path Switching
Solenoid ................................................... 4-5
[12] Adjusting the Tension of the Punch
Shift Timing Belt ........................................ 4-7
[13] Adjusting the 1st Folding Skew ................. 4-8
[14] Adjusting the Position of the 2nd
Folding Stopper ....................................... 4-10
[15] Adjusting the 2nd Folding Skew 2nd
Stopper Assembly ................................... 4-11
[16] Sensitivity adjustment for the paper
edgs sensor............................................. 4-12

5. SERVICE
SERVICE SCHEDULE ............................................. 5-1
[1] Maintenance Items .................................... 5-1
[2] Periodic Inspection Items .......................... 5-1
[3] Replacement parts list............................... 5-1

6. ELECTRIC PARTS LIST

PARTS LAYOUT DRAWING.................................... 6-1
CONNECTOR LAYOUT DRAWING......................... 6-2
CODE LIST.............................................................. 6-3
[1] Jam Code List............................................ 6-3
[2] Error Code List .......................................... 6-5
TIMING CHART........................................................ 6-6
ZK-2TOC.fm Page 3 Wednesday, June 12, 2002 12:13 PM

INDICATION OF WARNING ON THE MACHINE

Caution labels shown below are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns
and electric shock.

ZK-2

FNS

Unplug the machine before removing

panels.
D brancher lÕappareil avant de
retirer les panneaux arri res.
Desenchufe la m‡quina antes de
quitar los paneles.
Desconecte a unidade da tomada
antes de remover os pain is.
Unplug the machine before removing
panels.
D brancher lÕappareil avant de
retirer les panneaux arri res.
Vor Abnahme der Schutzverkleidung
Netzstecker ziehen.
Desenchufe la m‡quina antes de
quitar los paneles.
Scollegare la macchina prima di
rimuovere i pannelli.

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, replace the label.
ZK-2TOC.fm Page 4 Wednesday, June 12, 2002 12:13 PM

ABOUT THE NORMAL WORK OF ZK-2

The following are requirements for when ZK-2 operate.
If the requirement does not become complete, the machine does not operate cor-
rectly.

1. A-Kit is installed in Finisher.

2. Finisher is a model which corresponds to ZK-2.
*Blue Mark has been put on the machine which corresponds.
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Chapter3.fm Page -1 Wednesday, June 12, 2002 12:24 PM

3 DIS./ASSEMBLY
DISASSEMBLY/ASSEMBLY
 Chapter3.fm Page 0 Wednesday, June 12, 2002 12:24 PM

ZK-2

This section explains how to disassemble and reassemble the machine.

3 DIS./ASSEMBLY

When disassembling and reassembling the machine, follow the precau-

tions given below.
1. Be sure the power cord has been unplugged from the wall outlet.
2. The disassembled parts must be reassembled following the disas-
sembly procedure in reverse unless otherwise specified.
3. Care should be taken not to lose small parts. Care should also be
taken not to install small parts in wrong places.
4. Do not operate the machine before installing all the disassembled
parts completely.
5. Removal of some screws is prohibited in this section. Never loosen
them.
Chapter3.fm Page 1 Wednesday, June 12, 2002 12:24 PM

ZK-2

EXTERNAL SECTION
[1] Removing the ZK (3) Remove the three screws securing the ZK to the
main body, draw out the ZK, and remove the two
Note: Be sure to unplug the power cords of the relay connectors (CN95 and CN96) of the ZK
main body and this machine from the wall from the main body.
outlet.
Relay connectors (CN96)
a. Procedure
(1) Loosen the two screws in the lower part of the
rear cover of the ZK, then remove the two screws
in the upper part to remove the rear cover.
(2) Open the front door of the FNS and raise the
paper reception guide lever of the ZK to retract
the paper reception guide in the ZK.

3 DIS./ASSEMBLY
Relay connectors (CN95)

Paper reception guide lever

(4) Remove the two screws (front side) fixing the ZK

and the FNS, and remove two screws (rear side)
fixing the positioning plate.
(5) Pull the lever of the FNS installation stay to
release the fixing the ZK and the FNS, and
detach the ZK by lifting.
(6) Remove the two relay connectors of the FNS
from the ZK.
(7) Reinstall the above parts following the removal
Screws steps in reverse.

Screws(loosen)
Rear cover

3-1
 Chapter3.fm Page 2 Wednesday, June 12, 2002 12:24 PM

ZK-2

PUNCH SECTION
[1] Replacing the Punch unit a. Procedure
(1) Remove the sensor mounting stay by removing
Note: Be sure to unplug the power cords of the a screw.
main body and this machine from the wall
outlet.
Note: The following screws should not be
removed. If you do, punching cannot be
done as designed.

Punch unit
3 DIS./ASSEMBLY

Retaining ring
that should not
Screws that should be removed
not be removed
Paper mounting stay
Screw

(2) Cut the wiring harness band and disconnect the

relay connector (CN39) upward.
(3) Remove the punch unit by removing four screws.

Punch unit
Wiring harness band
Screws that should not be removed

Retaining ring that should

not be removed

OK

NG
Screws

Relay connector (CN39)

Screws that should not be removed (4) Reinstall the above parts following the removal
steps in reverse.
Note: When reinstalling, harnes the band in
same direction. (see the figure is step (3))

3-2
Chapter3.fm Page 3 Wednesday, June 12, 2002 12:24 PM

ZK-2

[2] Replacing the Punch Clutch (MC1) (4) Remove the punch clutch by removing the
retaining ring.
Note: Be sure to unplug the power cords of the
main body and this machine from the wall
outlet. Stopper
Note: The punch unit gear rotates only in the
direction of the arrow.
Never turn it in the direction opposite to
the arrow direction. If you do so, the MC1
(punch clutch) will break.

Caution: Never turn the gear in the

direction opposite to the arrow
direction. Punch clutch

3 DIS./ASSEMBLY
Retaining ring

(5) Reinstall the above parts following the removal

steps in reverse.

Note1: Fasten all the three wiring harness

a. Procedure
(1) Remove the punch unit. See "[1] Replacing the
Punch unit."
(2) Remove the punch motor unit by removing two
screws.
(3) Cut the three wiring harness bands and discon-
nect the punch clutch relay connector (CN52).
bands with the tightening part oriented
as shown in the illustration. See the fig-
ure in step (3).
Note2: When installing the punch motor unit,
push the punch motor gear against the
punch clutch gear. After installing the
punch motor unit, check for backlash.
Note3: When installing the punch clutch, take
care of the position of the stopper.

4 3
1. Wiring harness bands
2. Relay connector (CN52)
3. Screw
4. Punch motor unit

3-3
 Chapter3.fm Page 4 Wednesday, June 12, 2002 12:24 PM

ZK-2

PUNCH SCRAPS CONVEYANCE SECTION

[1] Replacing the Punch Scraps Convey- (3) Remove the punch scraps conveyance motor
ance Motor (M7) from the bracket by removing the two screws.

Note: Be sure to unplug the power cords of the Screws

main body and this machine from the wall
outlet.

a. Procedure
(1) Disconnect the relay connector (CN47)
(2) Remove the punch scraps conveyance motor
unit by removing the two screw.

Punch scraps conveyance motor

3 DIS./ASSEMBLY

(4) Apply grease (Plus guard No.2) to the worm gear

of the new punch scraps conveyance worm gear.
(5) Reinstall the above parts following the removal
steps in reverse.
Note: When installing the M7 (with a bracket),
provide backlash.
Installing the M7 too closely to the right
end will reduce backlash to zero.

1. Relay connector (CN47)

2. Screws
3. Punch scraps conveyance motor unit

3-4
Chapter3.fm Page 5 Wednesday, June 12, 2002 12:24 PM

ZK-2

Z-FOLDING SECTION
[1] Removing and Installing the Z-fold- (3) Pull out the z-folding/conveyance unit.
ing/Conveyance Unit (4) Disconnect three connectors (CN30, CN32,
CN36) at the arm joint section.
Note: Be sure to unplug the power cords of the (5) Remove two screws to remove the arm.
main body and this machine from the wall
outlet. Note: The arm should be held by the hand when
Note1: Take care of the z-folding/conveyance removal, since it falls.
unit dropping since it is heavy.
Note2: The following screws should not be or 1
removed. If you do z-folding cannot be
done as designed.

3 DIS./ASSEMBLY
2

6
3

4
Screws that should Screws that should 5
not be removed not be removed
1. Z-folding/conveyance unit
a. Procedure 2. Screw
(1) Remove the ZK from the main body and FNS. 3. Connector (CN30)
(2) Remove four screws to remove the top cover. 4. Connector (CN36)
5. Arm
Screw 6. Connector (CN32)
Top cover
(6) Return the z-folding/conveyance unit to the
basis.

Screw

3-5
 Chapter3.fm Page 6 Wednesday, June 12, 2002 12:24 PM

ZK-2

(7) Remove two screws to remove the FNS jointing

plate.
(8) Remove four screws to remove the z-folding/
conveyance unit with the rails pulling out to the
front.

1 2

1
3 DIS./ASSEMBLY

3
1

3 3

1. Screw
2. FNS jointing plate
3. Rail holder

(9) Install the above parts following the removal

steps in reverse.
Note: Put the z-folding/conveyance unit on four
rail holders certainly when installing. (For
fall prevention)

3-6
Chapter3.fm Page 7 Wednesday, June 12, 2002 12:24 PM

ZK-2

A- KIT (FNS SIDE)

[1] Removing the Fun unit
Note: Be sure to unplug the power cords of the
main body and this machine from the wall
outlet.
Note: Be careful when detaching the stacker
unit. If you remove the stopper, and in
succession pull out the stacker unit, the
FNS may fall due to the weight of the
stacker unit. This may cause injury.
a. Procedure
(1) Remove six screws and rear cover of the finisher. Stacker unit
(2) Remove the wire bundle connectors for the fan
unit (2 places). Screw holding the rail stopper

3 DIS./ASSEMBLY
connector 2 Support preventing the falling of the FNS

(6) Remove two screws and Fun unit.

Screws

connector 1

(3) Open the front door.

(4) Remove five screws to detach the stacker unit
cover.
(5) Remove two screws, and further pull stacker unit
out.
Fun unit
Note: Place something under the drawn stacker
unit to prevent the FNS from falling due to (7) Remove the Sensor stopper plate.
the weight of the unit. Sensor stopper plate
Guide

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3 DIS./ASSEMBLY
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Time(sec)
Symbol 0 1 2 3 4 5 6
Item
- Ejection signal from main body
68ms loop 68ms loop 68ms loop
- Paper edge sensor(leading and trailing edge)

Registration motor 790mm/s

M1
370mm/s

Conveyance motor 790mm/s

M6
370mm/s
Release
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M5
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M4 Punch motor
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M7 Punch scraps conveyance motor
SD1 Gate SD/L
SD2 Gate SD/U

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 Option Service Manual
Option
Service Manual

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Copyright
2002 MINOLTA CO., LTD.

Use of this manual should be strictly supervised to

avoid disclosure of confidential information.

Issued for Di551/Di650 and Other Models.

MINOLTA Co.,Ltd.

7663-4380-11 02050600