Konica Minolta DF-606 User manual

SERVICE MANUAL
2005.06
Ver. 1.0
DF-606
Field Service

Revision history
After publication of this service manual, the parts and mechanism may be subject to change for improve-
ment 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.
Revision mark:
• To indicate clearly a section revised, show to the left of the revised section.
A number within represents the number of times the revision has been made.
• To indicate clearly a section revised, show in the lower outside section of the corresponding
page.
A number within represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
• When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
• When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
1
1
1
1
2005/06 1.0 — Issue of the first edition
Date Service manual Ver. Revision mark Descriptions of revision

DF-606
CONTENTS
i
Field Service Ver1.0 Jun.2005
CONTENTS
DF-606
OUTLINE
1. PRODUCT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE
2. PERIODIC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Maintenance procedure of the paper feed section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Replacing the pick-up roller/paper feed roller/paper feed assist roller . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 Replacing the separation roller/torque limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.3 Cleaning the pick-up roller unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.4 Cleaning the cleaning pad/registration roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.5 Cleaning the front separation rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.6 Cleaning the paper feed section sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Maintenance procedure of the conveyance section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Cleaning the conveyance section sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Maintenance procedure of the read section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.1 Cleaning the read section sensor/mirror for the sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Maintenance procedure of the paper exit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Cleaning the mirror on the driven roller assembly/
paper exit section sensor/mirror for the sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Items not allowed to be disassembled and adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 List of parts to be disassembled and assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Removal procedure of parts to be disassembled and assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.1 Removing/reinstalling the DF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.2 Removing/reinstalling the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENT/SETTING
4. MECHANICAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 DF paper skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 DF hinge pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Adjustment to prevent false detection by the original count sensor (PS310),
original size sensors /Rt (PS302) and /Lt (PS303) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DF-606
CONTENTS
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Field Service Ver1.0 Jun.2005
Blank page

DF-606
1. PRODUCT SPECIFICATIONS
1
Field Service Ver1.0 Jun.2005
OUTLINE
1. PRODUCT SPECIFICATIONS
A. Type
B. Functions
C. Original
Name Double sided original auto feeder
Type Sheet-through type original auto feeder
Original size Metric: A3, B4, A4, A4R, B5, B5R, A5, A5R, B6R, 11 x 17, 8.5 x 11,
8.5 x 13
Inch: 11 x 17, 8.5 x 14, 8.5 x 11, 8.5 x 11R, 5.5 x 8.5, 5.5 x 8.5R, A3,
B4, A4, B5, B5R, A5, A5R, B6R
Taiwan spec: A3, A4, A4R, A5, A5R, 8K, 16K, 16KR
Maximum original size: 297 x 431.8 mm
Minimum original size: 128 x 139.7 mm
Original stacking capacity 100 sheets, max. (80g/m2or 20 lbs)
Original read speed (A4
size)
Single sided copy mode: 92 sheets/min.
Double sided copy mode: 65 sheets/min.
Original feed layout Set with the front side up, at center as standard
Original image read position Dedicated slit glass section
Resolution 600 dpi
Type of paper High-quality paper of 50 to 130 g/m2
In the case of the single sided original mode, however, high-quality paper of
131 to 200 g/m2is also available.
Amount of curling Up to 10 mm with 5 originals overlapped one another
a Amount of curling: up to 10 mm
[1] Original
Originals other than those
that paper feed and
throughput can be guaran-
teed
With the following originals, no severe problems are found such as frequent jams
and major damage to the originals, although it is not possible to obtain a numeric
value indicating reliability that can be specified in product guarantee terms:
Recycled paper, straw paper, heat sensitive paper, originals fed in the mixing
of perforated original mode, high-quality paper of 35 to 50 g/m
2
, irregular-
sized originals (such as CF originals), coated paper, originals with a rough
surface (such as letterhead), folded originals (Z-folded or folded in two)
15sat1c001na
[1]
a

1. PRODUCT SPECIFICATIONS
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DF-606
Note
• The information herein may be subject to change for improvement without notice.
D. Maintenance
E. Machine data
F. Operating environment
Originals not allowed to be
fed
The following originals are not allowed to be used:
OHP film, blueprint master, label paper, offset master, bonded original,
high-quality paper of less than 35 g/m2or more than 201 g/m2
Combination of mixed origi-
nals
Combinations of the same and different size originals is available. The following
table shows the available combination of mixed originals.
Maintenance Same as the main body.
Machine service life Same as the main body.
Power source 24V/5.1V DC (supplied from the main body)
Maximum power consumption 210W or less
Dimensions 650 (W) x 570 (D) x 170 (H) mm
Weight Approx. 22kg
Temperature 10 to 30°C
Humidity 10 to 80% RH (with no condensation)
Reference original (original with a maximum width)
A3 A4 B4 B5 A4R A5 B5R A5R B6R
Other
origi-
nals
A3 U{———————
A4 {U———————
B4 ~~U{—————
B5 ~~{U—————
A4R ~~~~U{———
A5 ~~~~{U———
B5R X X ~~~~U——
A5R X X X X X X X U—
B6R X X X X X X X ~U
U: Single size {: Same size ~: Different size X: Mixing not allowed
—: Cannot be set

DF-606
2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
MAINTENANCE
2. PERIODIC CHECK
2.1 Maintenance procedure of the paper feed section
Note
• Be sure to unplug the power cord of the main body from the power outlet.
2.1.1 Replacing the pick-up roller/paper feed roller/paper feed assist roller
A. Periodically replaced parts/cycle
• Pick-up roller: Every 4,500,000 prints (once for every 800,000 prints for actual replacement cycle)
• Paper feed roller: Every 4,500,000 prints (once for every 800,000 prints for actual replacement cycle)
• Paper feed assist roller: Every 4,500,000 prints (once for every 800,000 prints for actual replacement cycle)
B. Procedure
1. Open the open/close cover [1].
2. Remove the screw [2] and then remove the sen-
sor cover [3] in the arrow-marked direction [4].
[2] [3]
[1]
[4]
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DF-606
3. Remove the spring [1].
4. Remove the C-clips [2] and [3], and slide the bear-
ing [4] and the one-way clutch [5] to the outside
respectively.
5. Slide the pick-up roller unit [1] and release it from
the coupling [2] to remove it.
Note
• When installing the pick-up roller unit, be sure
to check to see if the projection [3] of the
pick-up roller unit is engaged with the original
registration sensor [4]. When it is not engaged
correctly, paper may not be fed correctly.
• When installing the pick-up roller unit, be sure
to check to see if the curved section [5] of the
pick-up roller unit comes above the curved
section [6] of the stay. If it is below the curved
section, paper may not be fed correctly.
[2] [5] [1]
[4] [3]
15saf2c002na
15saf2c003na
[1] [2]
[5]
[6][3]
[4]

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2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
6. Position the pick-up roller unit so that the one-way
clutch [1] comes to the lower left side of it. And
then remove the one-way clutch.
Note
• When installing the one-way clutch [1], be
sure to check to see if the arrow mark of the
one-way clutch points in the direction oppo-
site to the paper feed roller [3]. When the one-
way clutch is installed in the reverse direc-
tion, paper may not be fed correctly.
7. Remove the belt [4].
8. Remove the C-clip [5] and then remove the bear-
ing [6].
9. Pull out the shaft [8] of the pick-up roller [7] in the
arrow-marked direction [9] and then remove the
pick-up roller.
Note
• A washer is inserted between the pick-up
roller [7] and the bearing [10]. Be careful that
the washer does not get lost.
• When installing the pick-up roller [7], be sure
to check to see if the arrow mark [11] of the
pick-up roller points in the direction of the
gear [12]. When the pick-up roller is installed
in the reverse direction, paper may not be fed
correctly.
[12][9] [10] [8] [7] [6]
[1] [4] [3] [5]
[11]
[2]
15saf2c004na

2. PERIODIC CHECK
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DF-606
10. Remove the C-clip [1] and then remove the bear-
ing [2].
11. Slide the gear [3] in the arrow-marked direction [4]
and then remove the pin [6] from the shaft [5].
12. Pull out the shaft [5] in the arrow-marked direction
[7] and remove the paper feed auxiliary roller [8].
Note
• Be careful that the pin [6] does not get lost.
• When installing the gear [3], be sure to check
to see if the detent [9] points to the paper
feed auxiliary roller [8].
• When installing the paper feed auxiliary roller
[8], be sure to check to see if the arrow mark
[10] of the paper feed auxiliary roller points in
the direction opposite to the gear [3]. When
the paper feed auxiliary roller is installed in
the reverse direction, paper may not be fed
correctly.
13. Remove the bearing [1].
14. Remove the C-clip [2] and then remove the gear
[3].
Note
• A pin [4] is inserted in the inside of the gear
[3]. Be careful that it does not get lost.
• When installing the gear [3], be sure to set the
pin [4] into the hole [5] of the detent.
15. Pull the pin [4] out of the shaft [6] and then remove
the spacer [7] and the bearing [8].
[5]
[2] [3][6]
[7]
[8] [10]
[9] [3]
[1] [4][5]
15saf2c005na
[2] [3] [4]
[1]
[3]
[5]
[6] [7] [8]
15saf2c006na

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2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
16. Remove the C-clip [1] and then remove the bear-
ing [2].
17. Slide the gear [3] in the arrow-marked direction
[4], and then pull the pin [6] out of the shaft [5].
Note
• Be careful that the pin [6] does not get lost.
• When installing the gear [3], be sure to set the
pin [6] to the hole [7] of the detent.
18. Remove 2 C-clips [8].
19. Pull out the shaft [5] and then remove the paper
feed roller [9].
Note
• When installing the paper feed roller [9], be
sure to check to see if the arrow mark [10] of
the paper feed roller points in the direction
opposite to the gear [3]. When the paper feed
roller is installed in the reverse direction,
paper may not be fed correctly.
20. Reinstall the above parts following the removal
steps in reverse.
[6]
[9] [5]
[3][8]
[10]
[2] [5][1] [7][4]
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2. PERIODIC CHECK
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DF-606
2.1.2 Replacing the separation roller/torque limiter
A. Periodically replaced parts/cycle
• Separation roller: Every 2,000,000 prints (once for every 400,000 prints for actual replacement cycle)
• Torque limiter: Every 4,500,000 prints (once for every 800,000 prints for actual replacement cycle)
B. Procedure
1. Remove the pick-up roller unit. (See "2.1.1
Replacing the pick-up roller/paper feed roller/
paper feed assist roller.")
2. Remove 2 screws [1] and then remove the assist
roller assembly [2].
[1] [2]
15saf2c008na

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2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
3. Remove the C-clip [1] and then remove the gear
[2].
4. Slide 2 bearings [3] and remove the separation
roller unit [4].
5. Remove the bearing [1].
6. Remove the C-clip [2] and then remove the sepa-
ration roller [3].
Note
• When installing the separation roller, be sure
to set the cross cut [4] of the separation roller
to the projection [6] of the torque limiter [5].
[3] [2]
[4] [1]
15saf2c013na
[1][2][5] [3]
[4][6][5]
15saf2c014na

2. PERIODIC CHECK
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DF-606
7. Remove the torque limiter [1].
Note
• Be careful that the detent pin [2] of the torque
limiter does not get lost.
• When installing the torque limiter, be sure to
set the pin to the detent hole [3].
8. Reinstall the above parts following the removal
steps in reverse.
2.1.3 Cleaning the pick-up roller unit
A. Periodic cleaning cycle
• Pick-up roller: Every 500,000 prints
• Paper feed roller: Every 500,000 prints
• Paper feed assist roller: Every 500,000 prints
B. Procedure
1. Remove the pick-up roller unit. (See "2.1.1
Replacing the pick-up roller/paper feed roller/
paper feed assist roller.")
2. Clean the pick-up roller [1], the paper feed roller
[2] and the paper feed auxiliary roller [3] with a
drum cleaner and a cleaning pad.
3. Reinstall the above parts following the removal
steps in reverse.
[1]
[2] [3]
15saf2c015na
[2]
[1] [3]
15saf2c016na

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2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
2.1.4 Cleaning the cleaning pad/registration roller
A. Periodic cleaning cycle
• Cleaning pad: Every 500,000 prints
• Registration roller: Every 500,000 prints
B. Procedure
1. Open the open/close cover [1].
2. Remove the screw [2] and take off the cleaning
pad [3].
3. Clean the registration roller [4] with drum cleaner
and a cleaning pad.
4. Clean the cleaning section [2] of the cleaning pad
[1] with a blower brush.
5. Reinstall the above parts following the removal
steps in reverse.
[1]
[2] [4][3]
15saf2c017na
[2]
[1]
15saf2c018na

2. PERIODIC CHECK
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DF-606
2.1.5 Cleaning the front separation rubber
A. Periodic cleaning cycle
• Front separation rubber: Every 500,000 prints
B. Procedure
1. Remove the pick-up roller unit. (See "2.1.1
Replacing the pick-up roller/paper feed roller/
paper feed assist roller.")
2. Clean the front separation rubber [1] with a drum
cleaner and a cleaning pad provided as a service
material.
3. Reinstall the above parts following the removal
steps in reverse.
[1]
15saf2c019na

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2. PERIODIC CHECK
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2.1.6 Cleaning the paper feed section sensor
A. Periodic cleaning cycle
• Original count sensor (PS310): Every 500,000 prints
• Original size sensor /Lt (PS303): Every 500,000 prints
• Original size sensor /Rt (PS302): Every 500,000 prints
B. Procedure
1. Close the DF.
2. Use a blower brush to clean the original count
sensor (PS310) [1], the original size sensor /Lt
(PS303) [2] and the original size sensor /Rt
(PS302) [3].
[2][1] [3]
15saf2c020na

2. PERIODIC CHECK
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DF-606
2.2 Maintenance procedure of the conveyance section
2.2.1 Cleaning the conveyance section sensor
A. Periodic cleaning cycle
• Original registration sensor (PS306): Every 500,000 prints
B. Procedure
1. Open the open/close cover.
2. Use a blower brush to clean the original registra-
tion sensor (PS306) [1] and the original registration
mirror [2].
[1][2]
15saf2c021na

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2. PERIODIC CHECK
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Field Service Ver1.0 Jun.2005
2.3 Maintenance procedure of the read section
2.3.1 Cleaning the read section sensor/mirror for the sensor
A. Periodic cleaning cycle
• Original conveyance sensor (PS308): Every 500,000 prints
• Original skew sensor /Rr (PS311): Every 500,000 prints
• Original skew sensor /Fr (PS312): Every 500,000 prints
B. Procedure
1. Open the DF.
2. Open the platen guide [1].
3. Remove 2 screws [2] and then remove the driven
roller assembly [3].
4. Remove 4 screws [4] and then remove the con-
veyance guide [5].
5. Use a blower brush to clean 3 mirrors [2] of the
conveyance guide [1].
[3][5] [2][4]
[1][4] [2]
15saf2c022na
[1]
[2] 15saf2c023na

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DF-606
6. Close the platen guide and then close the DF.
7. Open the open/close cover [1].
8. Open the conveyance guide [2].
9. Use a blower brush to clean the original skew
sensor /Rr (PS311) [1], the original conveyance
sensor (PS308) [2] and the original skew sensor /
Fr (PS312) [3].
10. Reinstall the above parts following the removal
steps in reverse.
[1] [2]
15saf2c024na
[1] [2] [3]
15saf2c025na