Page 1 Theory of Operation SERVICE MANUAL 501/421/361 2009.03 Ver. 2.0...
Page 2: Table Of Contents
Legal restrictions on copying ..................C-1 Composition of the service manual ................. C-2 Notation of the service manual ..................C-3 bizhub 501/421/361 Main Body OUTLINE ........................1 COMPOSITION/OPERATION ..................11 * For particulars, see the contents of the main body.
Page 3 FS-522/PU-501/OT-602 OUTLINE ........................1 COMPOSITION/OPERATION ..................9 * For particulars, see the contents of FS-522/PU-501/OT-602. FS-523/RU-507 OUTLINE ........................1 COMPOSITION/OPERATION..................7 * For particulars, see the contents of FS-523/RU-507. SD-507 OUTLINE ........................1 COMPOSITION/OPERATION ..................3 * For particulars, see the contents of SD-507. MT-502 OUTLINE ........................
Page 4: Safety And Important Warning Items
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.
Page 5: Safety Warnings
[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.
Page 6 SAFETY AND IMPORTANT WARNING ITEMS [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.
Page 7 SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING 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 CE from the risk of injury.
Page 8 SAFETY AND IMPORTANT WARNING ITEMS Connection to Power Supply WARNING • Check whether 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. Power Plug and Cord WARNING •...
Page 9 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • 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.
Page 10 SAFETY AND IMPORTANT WARNING ITEMS Installation Requirements 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.
Page 11 SAFETY AND IMPORTANT WARNING ITEMS Servicing 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.
Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When taking a report of problems from a user, check each part and repair properly. A risk of product trouble, injury, and fire exists. • Check the exterior and frame for edges, burrs, and other damages.
Page 13: Handling Of Consumables
SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When replacing a lithium battery, replace it with a new lith- ium battery specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority. Improper replacement can cause explosion.
Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Consumables WARNING • Never throw the used cartridge and toner into fire. You may be burned due to dust explosion. Handling of Service Materials CAUTION • Unplug the power cord from the wall outlet. Isopropyl alcohol and acetone are highly flammable and must be handled with care.
Page 15 SAFETY AND IMPORTANT WARNING ITEMS Used Batteries Precautions Handling of batteries CAUTION • ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. •...
Page 16: Safety Information
SAFETY INFORMATION SAFETY INFORMATION IMPORTANT NOTICE The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin- istration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This copier is certified as a "Class 1"...
Page 17: Indication Of Warning On The Machine
SAFETY INFORMATION 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. Finisher FS-522 50gap0e001nb S-14...
Page 18 SAFETY INFORMATION FS-523 50gap0e002nb 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. And also, when the caution label is peeled off or soiled and cannot be seen clearly, replace it with a new caution label.
Page 19: Measures To Take In Case Of An Accident
MEASURES TO TAKE IN CASE OF AN ACCIDENT MEASURES TO TAKE IN CASE OF AN ACCIDENT 1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.
Page 20: Legal Restrictions On Copying
Legal restrictions on copying Certain types of originals must never be copied with the purpose or intent to pass copies of such originals off as the originals. The following is not a complete list, but is meant to be used as a guide to responsible copy- ing.
Page 21: Composition Of The Service Manual
Composition of the service manual This service manual consists of the following sections and chapters: <Theory of Operation section> OUTLINE: System configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating system, and explanation of the control system This section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.
Page 22: Notation Of The Service Manual
Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) IC board: Standard printer (2) bizhub 501/421/361: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...
Page 23 Classification Load symbol Ex. of signal name Description Power to drive the motor CONT Drive signal DRV1 Motor DRV2 Drive signals of two kinds Drive signals (control signals) of three kinds DRV1 DRV2 DRV3 DRV A DRV A DRV B Drive signals (control signals) of four kinds Motor, phases A and B control signals DRV B...
Page 24 Classification Load symbol Ex. of signal name Description SG, S.GND, S_GND Signal ground Ground PG, P.GND Power ground Data carrier detection Serial input SOUT Serial output Data terminal operation available Signal ground (earth) Serial com- DSR, DSET Data set ready munication Transmission request signal Consent transmission signal...
Page 25 Blank Page...
Page 26: Main Body
Theory of Operation SERVICE MANUAL 501/421/361 Main body 2009.03 Ver. 2.0...
Page 27 Revision history 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 28 CONTENTS CONTENTS bizhub 501/421/361 OUTLINE 1. SYSTEM CONFIGURATION ............1 2.
Page 29 CONTENTS Theory of Operation Ver.2.0 Mar. 2009 10.2.3 Transfer exposure lamp (TSL) control ..........29 11.
Page 30 Theory of Operation Ver.2.0 Mar. 2009 CONTENTS 16.3 Operation ..............60 16.3.1 Loop control .
Page 31 CONTENTS Theory of Operation Ver.2.0 Mar. 2009 23.2.1 Composition............. . 102 23.2.2 Operation .
Page 32: Outline
Theory of Operation Ver.2.0 Mar. 2009 1. SYSTEM CONFIGURATION OUTLINE 1. SYSTEM CONFIGURATION A. System configuration [29] [33] [34] [35] [36] [30] [31] [32] [10] [11] [12] [13] [14] [15] [28] [27] [26] [17] [25] [20] [24] [21] [23] [18] [16] [22] [16]...
Page 33 [18] Paper feed cabinet (PC-206) "6.4 Option counter" in Field Service bizhub 501/421/361 main body for details. Dehumidifier heater is set up as service part. Swedish punch kit G is for Europe only. Upgrade kit (UK-202) is needed for using i-option.
Page 34 Theory of Operation Ver.2.0 Mar. 2009 1. SYSTEM CONFIGURATION B. Configuration for optional device connection Note • Any combination other than those listed below is not available. Combinations for paper feeding Combinations for finishing Remarks DK-506/PC-206/PC-407 *1 OT-504 DK-506/PC-206/PC-407 *1 OT-504 JS-502 DK-506/PC-206/PC-407 *1...
Page 35: Product Specifications
2. PRODUCT SPECIFICATIONS Theory of Operation Ver.2.0 Mar. 2009 2. PRODUCT SPECIFICATIONS A. Type Type Desktop type Copying method Indirect electrostatic method Original stand Fixed Original alignment Left rear standard Photo conductor Sensitizing method Laser writing Paper feed trays Two trays 500 sheet x 2, 80g/m Bypass feed 150 sheet x 1, 80g/m...
Page 36 Horizontal magnifi- x 0.25 to x 4.00 (at the step of 0.1%) cation Warm-up time 60 seconds or less (bizhub 501) 30 seconds or less (bizhub 421/361) First copy out time 3.2 seconds or less (bizhub 501) 3.6 seconds or less (bizhub 421/361) Continuous copy speed 50 copies /min.
Page 37 High quality paper of 106 to 210 g/m (thick paper) Standard specified paper Plain paper: Inch: Hammermill Tidal MP (20 lbs) Metric: Konica Minolta Profi (80 g/m Recycle paper: Inch: Hammmermill Bond (20lbs), Domtar Recycled Copy (20lbs) Metric: Nautilus (80 g/m Special paper/recommended paper...
Page 38 Theory of Operation Ver.2.0 Mar. 2009 2. PRODUCT SPECIFICATIONS E. Machine data Power source Inch: AC120V 12A, 60Hz Metric: AC220-240V 7A, 50Hz Maximum power consumption 1,560 W or less (full system) Dimensions Main body 685 (W) x 823.7 (D) x 1,150 (H) mm *1 + DF-613 + PC or DK Weight...
Page 39: Unit Configuration
3. UNIT CONFIGURATION Theory of Operation Ver.2.0 Mar. 2009 3. UNIT CONFIGURATION [17] [16] [15] [14] [13] [12] [11] [10] 50gat1c002na Scanner section [10] PC or DK (option) Paper reverse/exit section [11] Paper feed section (tray 1/2) Fusing section [12] Developing section Photo conductor section [13]...
Page 40: Paper Path
Theory of Operation Ver.2.0 Mar. 2009 4. PAPER PATH 4. PAPER PATH 50gat1c003na Reverse conveyance Tray 2 paper feed ADU conveyance Tray 1 paper feed Bypass paper feed Registration conveyance LU paper feed Paper exit PC paper feed...
Page 41 4. PAPER PATH Theory of Operation Ver.2.0 Mar. 2009 Blank page...
Page 42: Composition/Operation
Theory of Operation Ver.2.0 Mar. 2009 5. OVERALL CONFIGURATION COMPOSITION/OPERATION 5. OVERALL CONFIGURATION Time chart when the power is turned ON [1] [2] [3][4] Item Scanner motor Normal rotation (M2) Reverse rotation Exposure lamp (L1) Fusing heater lamp /1 (L2) Fusing heater lamp /2 (L3) Fusing motor (M11) Drum motor (M1)
Page 43: Control Block Diagram
5. OVERALL CONFIGURATION Theory of Operation Ver.2.0 Mar. 2009 Control block diagram Operation FK, MK RS232C unit OACB Write Section PRCB DCPU FS, RU 50gat2c090nc Image bus Other buses Clock synchronous serial bus Individual signal line UART bus SATA...
Page 44: Scanner Section
Theory of Operation Ver.2.0 Mar. 2009 6. SCANNER SECTION 6. SCANNER SECTION Composition CCD unit (CCDB) Mirror unit Exposure unit Shading correction plate 50gat2c001na Drive 50gat2c002na Scanner wire /Rr Exposure unit Scanner wire /Fr Scanner motor (M2) V-mirror unit...
Page 45: Operation
6. SCANNER SECTION Theory of Operation Ver.2.0 Mar. 2009 Operation 6.3.1 Scan/exposure lamp control A. Operation when the power is turned ON A specified period of time after the power switch (SW2) is turned on, the exposure unit conducts the home posi- tion search.
Page 46 Theory of Operation Ver.2.0 Mar. 2009 6. SCANNER SECTION B. Operation when the start key is turned ON For the original read mode, the following two types are available: the platen mode and the DF mode. While in the platen mode, the exposure unit scans the original for reading. And while in the DF mode, since DF conveys the original, the exposure unit remains at the prescribed position (DF read position) to read the original.
Page 47 6. SCANNER SECTION Theory of Operation Ver.2.0 Mar. 2009 (2) When DF is used (when DF is closed) 50gat2c038na Exposure unit stand-by position Shading correction position 1 Scanner home sensor (PS30) Shading correction position 2 DF read position Exposure lamp (L1) ON...
Page 48: Original Size Detection Control
Theory of Operation Ver.2.0 Mar. 2009 6. SCANNER SECTION 6.3.2 Original size detection control A. Detection method The original size detection method varies for the DF mode and the platen mode. (1) DF mode See DF-613 Service Manual. (2) Platen mode •...
Page 49: Ae Control
6. SCANNER SECTION Theory of Operation Ver.2.0 Mar. 2009 6.3.3 AE control When AE is selected, the density level of the original is detected to adjust it to an appropriate density automati- cally. The sampling range of the original density in the AE control varies for the platen mode and the DF mode. (1) AE sampling range in the platen mode 50gat2c039na Original...
Page 50: Image Processing
Theory of Operation Ver.2.0 Mar. 2009 6. SCANNER SECTION 6.3.4 Image processing The following items are provided for the image processing. For details, See "22. IMAGE PROCESSING". • AOC (Auto offset control) • AGC (Auto gain control) • Shading correction •...
Page 51: Write Section
7. WRITE SECTION Theory of Operation Ver.2.0 Mar. 2009 7. WRITE SECTION Composition CY2 lens Index lens Collimator lens unit Cleaner Dust-proof glass Laser drive board (LDB) Index mirror CY1 lens θ lens Polygon mirror Index board (INDEXB) 50gat2c003na...
Page 52: Operation
Theory of Operation Ver.2.0 Mar. 2009 7. WRITE SECTION Operation 7.2.1 Laser beam path [10] 50gat2c041na Dust-proof glass Polygon mirror CY2 lens CY1 lens Drum Collimator lens Index board (INDEXB) Laser diode θ lens [10] Index mirror 7.2.2 Write control Image data that has been processed is converted into laser beam on the laser drive board (LDB) to be irradiated on the drum.
Page 53: Image Processing
7. WRITE SECTION Theory of Operation Ver.2.0 Mar. 2009 7.2.4 Image processing The following items are provided for the image processing. For details, See "22.2 Image processing in the write section". • Rotation/elongation • • Frequency conversion...
Page 54: Photo Conductor Section
Theory of Operation Ver.2.0 Mar. 2009 8. PHOTO CONDUCTOR SECTION 8. PHOTO CONDUCTOR SECTION Composition Drum claw IDC sensor (IDCS) PGC sensor Drum 50gat2c004na...
Page 55: Drive
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver.2.0 Mar. 2009 Drive 8.2.1 Drum drive 50gat2c005na Drum motor (M1) Drum drive shaft 8.2.2 Drum claw drive 50gat2c006na Drum claw Drum claw solenoid (SD2)
Page 56: Operation
Theory of Operation Ver.2.0 Mar. 2009 8. PHOTO CONDUCTOR SECTION Operation 8.3.1 Image creation control When the print start signal turns ON [1], various motors turn ON to place each unit in the operating condition. At the same time, the erase lamp (EL) turns ON to neutralize the drum and the charging corona charges the drum. A specified period of time after the print start signal turns ON, the developing bias turns ON [2] and then a high voltage is impressed [3] on the guide plate.
Page 57: Drum Claw Control
8. PHOTO CONDUCTOR SECTION Theory of Operation Ver.2.0 Mar. 2009 8.3.2 Drum claw control A. Purpose Two drum claws are employed to prevent paper from winding up around the drum (winding-up jam). The contact and severance of the drum claws to and from the drum are made by the ON/OFF of the drum claw solenoid (SD2).
Page 58: Charging Section
Theory of Operation Ver.2.0 Mar. 2009 9. CHARGING SECTION 9. CHARGING SECTION Composition Charging control plate Erase lamp (EL) Charging wire 50gat2c007na Operation 9.2.1 Charging control A. Charging wire The high voltage unit (HV) pressurizes 24V DC to impress a minus (–) DC voltage on the charging wire for dis- charge.
Page 59: Transfer/Separation Section
10. TRANSFER/SEPARATION SECTION Theory of Operation Ver.2.0 Mar. 2009 10. TRANSFER/SEPARATION SECTION 10.1 Composition Transfer wire Plunging prevention plate Transfer exposure lamp (TSL) Separation wire 50gat2c008na...
Page 60: Operation
Theory of Operation Ver.2.0 Mar. 2009 10. TRANSFER/SEPARATION SECTION 10.2 Operation 10.2.1 Transfer guide control A. Purpose To prevent the transfer guide plate from getting stained, a minus (–) DC voltage is impressed from the high volt- age unit (HV). Voltage impressed: –500 V B.
Page 61: Developing Unit
11. DEVELOPING UNIT Theory of Operation Ver.2.0 Mar. 2009 11. DEVELOPING UNIT 11.1 Composition Developer restriction blade Developing roller Agitator screw Agitator plate TCR sensor (TCRS) 50gat2c009na...
Page 62: Drive
Theory of Operation Ver.2.0 Mar. 2009 11. DEVELOPING UNIT 11.2 Drive 50gat2c010na Drum Agitator screw Developing roller Developing unit Developing motor (M3) Agitator plate...
Page 63: Operation
11. DEVELOPING UNIT Theory of Operation Ver.2.0 Mar. 2009 11.3 Operation 11.3.1 Developer conveyance Developer in the developing unit is supplied by the agitator plate [4] to the developing roller [2]. The thickness of developer attaching to the developing roller is restricted by the developer restriction blade [5]. After completion of transfer to the drum [1], developer remaining on the developing roller is sent back to the agitator screws [3].
Page 64: Developing Bias
Theory of Operation Ver.2.0 Mar. 2009 11. DEVELOPING UNIT 11.3.2 Developing bias A. Purpose To make toner get easily attached to the drum while in developing, a developing bias is impressed onto the developing roller [1]. 50gat2c044na Developing roller Developing bias shaft Main pole position adjusting plate Developing bias contact B.
Page 65: Developing Suction Control
11. DEVELOPING UNIT Theory of Operation Ver.2.0 Mar. 2009 11.3.3 Developing suction control A. Purpose To prevent the splash of toner from the developing roller, the duct [4] is provided at 2 places of the developing unit [1]. Toner guided into the duct is sucked in by the developing suction fan (FM6) [3] to be collected by the suction filter /A [2].
Page 66: Toner Supply Section
Theory of Operation Ver.2.0 Mar. 2009 12. TONER SUPPLY SECTION 12. TONER SUPPLY SECTION 12.1 Composition Toner bottle position Toner supply motor Toner bottle sensor (PS4) Toner remaining sensor sensor (PS28) (M4) (PZS) Toner hopper Toner bottle motor (M10) Toner bottle 50gat2c011na...
Page 67: Drive
12. TONER SUPPLY SECTION Theory of Operation Ver.2.0 Mar. 2009 12.2 Drive 50gat2e003na Toner agitator plate Toner supply motor (M4) Toner conveyance screw Toner bottle motor (M10) Toner solenoid (SD5)
Page 68: Operation
Theory of Operation Ver.2.0 Mar. 2009 12. TONER SUPPLY SECTION 12.3 Operation 12.3.1 Toner level detection control A. Toner level detection control Toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When toner remaining in the hopper is found below the prescribed amount, a toner supply signal is issued to the printer control board (PRCB).
Page 69: Toner Conveyance Control
12. TONER SUPPLY SECTION Theory of Operation Ver.2.0 Mar. 2009 12.3.4 Toner conveyance control A. Purpose To convey toner in the toner bottle to the toner hopper. B. Operation The exit [1] of the toner bottle is normally closed. However, by setting the bottle to the toner supply section, the accordion section is pushed and compressed to let the exit open.
Page 70: Cleaning/Toner Recycle Section
Theory of Operation Ver.2.0 Mar. 2009 13. CLEANING/TONER RECYCLE SECTION 13. CLEANING/TONER RECYCLE SECTION 13.1 Composition Collection screw Scraper Collection paddle Drum Neutralizing sheet Cleaning blade 50gat2c013nb...
Page 71: Drive
13. CLEANING/TONER RECYCLE SECTION Theory of Operation Ver.2.0 Mar. 2009 13.2 Drive 50gat2c014na Drum motor (M1) Developer agitation drive Cleaning/recycle section drive...
Page 72: Operation
Theory of Operation Ver.2.0 Mar. 2009 13. CLEANING/TONER RECYCLE SECTION 13.3 Operation 13.3.1 Cleaning operation Toner scraped by the cleaning blade [4] is neutralized by the neutralizing sheet [2], then collected by the collec- tion paddle [1], and finally guided to the collection screw [5]. At this time, toner remaining on the collection pad- dle is scraped by the scraper [6].
Page 73: Paper Feed Section (Tray 1/2)
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) 14.1 Composition 14.1.1 Tray 1 Pick-up roller Feed roller Lift plate Separation roller Tray 1 50gat2c015na 14.1.2 Tray 2 Vertical conveyance roller Pick-up roller Feed roller Lift plate...
Page 74: Drive
Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) 14.2 Drive 14.2.1 Paper feed drive [13] [12] [11] [10] 50gat2c016na Feed motor (M9) Feed roller /2 Feed clutch /1 (CL4) Separation roller /2 Feed roller /1 [10] Pick-up roller /2 Separation roller /1 [11]...
Page 75: Operation
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver.2.0 Mar. 2009 14.3 Operation 14.3.1 Up/down control A. Up drive operation The lift drive shaft [3] is rotated by the paper lift motors /1 (M7) [6] and /2 (M8) [7]. The lift drive shaft is provided with the lift arm [1] and the lift plate [2] is pushed up when the lift drive shaft rotates.
Page 76: Paper Size Detection Control
Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) 14.3.2 Paper size detection control A. Paper size detection mechanism (1) Size detection in the main scan direction The side guide plate [12] is provided with the size detection actuator [7]. And interlocked with the side guide plate, this actuator sticks out to the rear side of the tray.
Page 77 14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver.2.0 Mar. 2009 B. Paper size detection table Paper size Paper size boards /1 (PSB/1), /2 (PSB/2) Paper size sensor Paper size sensor /Rr1 (PS10), /Rr2 /Fr1 (PS11), /Fr2 SW101 SW102 SW103 SW104 (PS16)
Page 78: Paper Feed Control
Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) 14.3.3 Paper feed control A. Pick-up mechanism The pick-up roller [4] is brought up and down mechanically by the lever [6] provided on the rear side of the paper feed unit.
Page 79 14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver.2.0 Mar. 2009 B. Pick-up control (1) Tray 1 pick-up control When the print start signal turn ON [1], the feed motor (M9) and the feed clutch /1 (CL4) also turn ON. In this way, the driving force of M9 is transmitted to the pick-up roller and the feed roller to pick up [2] the 1st sheet of paper.
Page 80 Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) C. Separation mechanism The separation roller [5] is pressed against the feed roller [8] by the operating pressure generated by the pres- sure [2] of the spring [4] and the torque of the torque limiter [3]. This operating pressure of the feed roller, sepa- ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
Page 81: Paper Empty Control
14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver.2.0 Mar. 2009 14.3.4 Paper empty control The paper empty of the tray is detected by the paper empty sensors /1 (PS5) [3] and /2 (PS12) [4]. And to prompt the supply of paper before paper in the tray runs out completely, the paper near-empty sensors /1 (PS9) [7] and /2 (PS15) [8] are equipped.
Page 82: Paper Remaining Detection Mechanism
Theory of Operation Ver.2.0 Mar. 2009 14. PAPER FEED SECTION (Tray 1/2) 14.3.5 Paper remaining detection mechanism The front cover [4] of the tray is provided with the paper remaining display window [3], and the paper remaining in the tray can be checked through this window. The inside of the paper remaining display window is provided with the display lever [2] which is interlocked with the up/down position of the lift plate [1].
Page 83: Bypass Section
15. BYPASS SECTION Theory of Operation Ver.2.0 Mar. 2009 15. BYPASS SECTION 15.1 Composition Pick-up solenoid /BP (SD1) Feed roller Separation roller Lift plate 50gat2c019na...
Page 84: Drive
Theory of Operation Ver.2.0 Mar. 2009 15. BYPASS SECTION 15.2 Drive 15.2.1 Paper feed drive 50gat2c018na Feed clutch /BP (CL6) Separation roller Feed roller Feed motor (M9) 15.2.2 Tray lift drive 50gat2c020na Feed clutch /BP (CL6) Lift plate Pick-up solenoid /BP (SD1) Spring...
Page 85: Operation
15. BYPASS SECTION Theory of Operation Ver.2.0 Mar. 2009 15.3 Operation 15.3.1 Up/down control A. Up drive operation The lift plate [4] is of the construction in which it is pushed up by the spring [5] provided on the lower section. However, while in the stand-by condition, it is hold down by the cam [3] provided on the lift drive shaft [6].
Page 86: Paper Size Detection Control
Theory of Operation Ver.2.0 Mar. 2009 15. BYPASS SECTION 15.3.2 Paper size detection control A. Size detection in the main scan direction According to the position of the guide plate connected to the paper size VR/BP (VR1), the paper size is detected in the main scan direction.
Page 87: Paper Feed Control
15. BYPASS SECTION Theory of Operation Ver.2.0 Mar. 2009 15.3.3 Paper feed control A. Pick-up control When the feed motor (M9) is turned ON by the print start signal [1], the pick-up solenoid /BP (SD1) and the ver- tical conveyance clutch (CL3) also turn ON a specified period of time after that. When SD1 turns ON, the lift plate goes up [2] and paper comes into contact with the feed roller.
Page 88: Paper Empty Control
Theory of Operation Ver.2.0 Mar. 2009 15. BYPASS SECTION B. Separation mechanism The separation roller [7] is pressed against the feed roller [1] by the operating pressure generated by the pres- sure [4] of the spring [5] and the torque of the torque limiter [6]. This operating pressure of the feed roller, sepa- ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.
Page 89: Registration Section
16. REGISTRATION SECTION Theory of Operation Ver.2.0 Mar. 2009 16. REGISTRATION SECTION 16.1 Composition Registration roller Loop roller 50gat2c021na...
Page 90: Drive
Theory of Operation Ver.2.0 Mar. 2009 16. REGISTRATION SECTION 16.2 Drive 50gat2c022na Registration roller Loop roller Feed motor (M9) Tray 1 Loop clutch (CL2) Registration clutch (CL1)
Page 91: Operation
16. REGISTRATION SECTION Theory of Operation Ver.2.0 Mar. 2009 16.3 Operation 16.3.1 Loop control A. Registration path Paper fed from the tray 1 [10], the tray 2 [8], the by-pass tray [6], PC/LU [7] and ADU [4] hits against the registra- tion roller [2] through the loop roller [12].
Page 92 Theory of Operation Ver.2.0 Mar. 2009 16. REGISTRATION SECTION B. Registration operation The feed motor (M9) and the loop clutch (CL2) are turned ON by the print start signal [1]. In this way, the driving force of M9 is transmitted to the loop roller and paper conveyed from each of the paper feed sections is con- veyed to the registration roller.
Page 93: Adu Section
17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION 17.1 Composition Conveyance roller /1 Conveyance roller /2 50gat2c023na...
Page 94: Drive
Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION 17.2 Drive [1] [2] [3] [4] 50gat2c024na ADU conveyance clutch /Up (CL7) Conveyance roller /2 Conveyance roller /1 Conveyance roller /3 ADU conveyance clutch /Lw (CL8) Feed motor (M9)
Page 95: Operation
17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 17.3 Operation 17.3.1 Conveyance path Paper the one side of which has been printed is conveyed to ADU by the reverse roller [12]. The paper conveyed to ADU is also conveyed to the loop roller [6], the registration roller [7] and the drum [8] by the conveyance rollers /1 [2], /2 [3] and /3 [5] and the other side is printed.
Page 96: Conveyance Control
Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION 17.3.2 Conveyance control When printing two or more sheets of paper in the double sided print mode, the conveyance control in ADU var- ies according to the length of paper in the sub scan direction. The following 3 control methods are provided for the conveyance control.
Page 97 17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 The 1st sheet of paper in ADU is conveyed with- out interruption. 50gat2c060na The 1st sheet of paper is fed again and the image of the 1st page (the front side of the 1st sheet of paper when the original is double sided) is printed.
Page 98 Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION B. 2 sheets self-contained double sided print operation Note • A figure in the illustration (shown in the square) represents the page number. With the 1st sheet of paper fed, the image of the 2nd page (the back side of the 1st sheet of paper when the original is double sided) is printed.
Page 99 17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 The 1st sheet of paper is fed again and the image of the 1st page (the front side of the 1st sheet of paper when the original is double sided) is printed. At this time, the 3rd sheet of paper is fed and the 2nd sheet of paper is turned over at the paper reverse/exit section to be conveyed into ADU.
Page 100 Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION While the 2nd sheet of paper is being exited, the image of the 8th page (the back side of the 4th sheet of paper when the original is double sided) is printed on the 4th sheet of paper. At this time, the 3rd sheet of paper is standing by on this side of the conveyance roller /3.
Page 101 17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 C. 3 sheets self-contained double sided print operation Note • A figure in the illustration (shown in the square) represents the page number. The 1st sheet of paper is fed and the image of the 2nd page (the back side of the 1st sheet of paper when the original is double sided) is printed.
Page 102 Theory of Operation Ver.2.0 Mar. 2009 17. ADU SECTION The 3rd sheet of paper is conveyed to the paper reverse/exit section and the 2nd sheet of paper is conveyed in ADU without interruption. However, the 1st sheet of paper remains standing by at the conveyance roller /3.
Page 103 17. ADU SECTION Theory of Operation Ver.2.0 Mar. 2009 The 2nd sheet of paper is fed again and the image of the 3rd page (the front side of the 2nd sheet of paper when the original is double sided) is printed. The 4th sheet of paper is turned over to be sent to ADU with the 3rd sheet of paper standing by at the conveyance roller /3.
Page 104: Fusing Section
Theory of Operation Ver.2.0 Mar. 2009 18. FUSING SECTION 18. FUSING SECTION 18.1 Composition Fusing heater Paper exit roller Fusing web Decurler roller Fusing roller lamp /1 (L2) Fusing heater lamp /2 (L3) Fusing pressure roller Fusing claw 50gat2c025na 18.2 Drive 50gat2c026na Fusing unit drive Fusing motor (M11)
Page 105: Operation
The time of preliminary rotation varies according to the detected temperature of the drum temperature sensor and the thermistors /1 (TH1) and /2 (TH2). And the starting temperature of the preliminary rotation varies for bizhub 501 and 421/361. C. Rotation control while in the print The fusing motor (M11) that drives the fusing roller and the fusing pressure roller is turned ON by the print start signal.
Page 106: Fusing Temperature Control
While in the warm-up, the fusing heater lamps /1 (L2) and /2 (L3) turn ON. And it turns OFF at the prescribed temperature. The temperature at which the warm-up completes varies for bizhub 501 and 421/361. B. While in the print The set temperature of the fusing roller varies according to the type of paper and the paper size.
Page 107: Fusing Roller Edge Cooling Control
18. FUSING SECTION Theory of Operation Ver.2.0 Mar. 2009 D. Low power mode and sleep mode When each key is not pressed within a specified period of time after the completion of the last print, the system changes into the low power mode or the sleep mode. The starting time for operation can be set individually for the low power mode and the sleep mode.
Page 108: Envelope Conveyance Mechanism
Theory of Operation Ver.2.0 Mar. 2009 18. FUSING SECTION C. Fusing cooling path The air inside the machine is sucked in by the fusing cooling fans /Fr (FM2) [6] and /Rr (FM8) [1] to be blown against the edges of the fusing roller [3] through the ducts [2] and [5]. In this way, the edges of the fusing roller are cooled down and the surface temperature of the edges of the fusing pressure roller [4] that is in contact also goes down.
Page 109: Protection Against Abnormality
18. FUSING SECTION Theory of Operation Ver.2.0 Mar. 2009 18.3.6 Protection against abnormality When the thermistors /1 (TH1) and /2 (TH2) detects a stipulated temperature (233°C) 5 times at the prescribed intervals, this is deemed to be a high temperature abnormality and the fusing heater lamps /1 (L2) and /2 (L3) are turned OFF.
Page 110: Reverse/Exit Section
Theory of Operation Ver.2.0 Mar. 2009 19. REVERSE/EXIT SECTION 19. REVERSE/EXIT SECTION 19.1 Composition Reverse roller Exhaust fan /Fr (FM3) Exhaust fan /Rr (FM9) Reverse gate Reverse roller Reverse gate Reverse solenoid (SD3) 50gat2c027na 19.2 Drive 50gat2c028na Reverse motor (M6) Reverse gate Reverse solenoid (SD3) Reverse roller...
Page 111: Operation
19. REVERSE/EXIT SECTION Theory of Operation Ver.2.0 Mar. 2009 19.3 Operation 19.3.1 Conveyance control A. Reverse gate The reverse gate is driven by the ON/OFF of the reverse solenoid (SD3). Paper conveyed from the fusing section is switched by the reverse gate between the paper exit section and the reverse section. B.
Page 112 Theory of Operation Ver.2.0 Mar. 2009 19. REVERSE/EXIT SECTION (2) Reverse path While in the double sided print, the reverse solenoid (SD3) turns ON when the print on the back side is com- pleted, and the reverse gate [1] is switched in the direction in which the conveyance path to the reverse roller [4] is opened.
Page 113: Reverse Control
19. REVERSE/EXIT SECTION Theory of Operation Ver.2.0 Mar. 2009 19.3.2 Reverse control A. Switch-back mechanism While in the double sided print, paper that passes through the reverse gate [3] is conveyed to the outside of the main body by the reverse roller [5] and then sent back again to the inside of the main body. At this time, the paper is guided to the conveyance roller /1 [1] side, not to the reverse gate side from the metal frame form of the conveyance path.
Page 114 Theory of Operation Ver.2.0 Mar. 2009 19. REVERSE/EXIT SECTION B. Reverse control While in the double sided print, when the fusing exit sensor (PS3) detects the leading edge of paper of which the printing of the back side has been completed and turns ON [1], the reverse solenoid (SD3) turns ON to switch the reverse gate a specified period of time after the registration clutch (CL1) turns ON for back side printing.
Page 115: Interface Section
20. INTERFACE SECTION Theory of Operation Ver.2.0 Mar. 2009 20. INTERFACE SECTION 20.1 Composition Serial port (RS-232C) CF card slot RJ45 Ethernet connector USB port /1 (USB TypeA) USB port /2 (USB TypeA) USB port /4 (USB TypeB) Service port USB port /3 (USB TypeA) a0r5t2c001ca 20.2 Specifications...
Page 116: Image Stabilization Control
Theory of Operation Ver.2.0 Mar. 2009 21. IMAGE STABILIZATION CONTROL 21. IMAGE STABILIZATION CONTROL 21.1 Outline This machine employs various image stabilization controls to realize the top quality print image at all times. The operation of the image stabilization control varies between while in the power switch (SW2) ON and while in the print.
Page 117 Make uniform the surface temperature of the fusing roller and the fusing pressure roller. (2) Execution timing When the detected temperature of the thermistors /1 (TH1) and /2 (TH2) gets to the stipulated temperature. Note • The stipulated temperature at which the fusing preliminary rotation is made varies for bizhub 501 and 421/361.
Page 118 Theory of Operation Ver.2.0 Mar. 2009 21. IMAGE STABILIZATION CONTROL E. Environmental decision control (1) Purpose To detect the environmental temperature and humidity to maintain the image quality, feedback is made to vari- ous controls. (2) Method A temperature sensor and a humidity sensor are equipped inside the machine. (3) Execution timing When the power switch (SW2) is turned ON, and only when it has been left unused for more than 8 hours after the SW2 was turned OFF last time and the fusing temperature is considered below the stipulated temperature,...
Page 119: Image Stabilization Control Flow While In The Print And The Idle
21. IMAGE STABILIZATION CONTROL Theory of Operation Ver.2.0 Mar. 2009 21.2.2 Image stabilization control flow while in the print and the idle The following shows the image stabilization control flow while in the print and the idle. Print start signal ON Every 20 prints Start of print A.
Page 120 Theory of Operation Ver.2.0 Mar. 2009 21. IMAGE STABILIZATION CONTROL (2) Method • Create a dot pattern patch between images of which more than 20 prints have been run off. The laser PWM at this time is maximum. • Read this dot pattern patch with the IDC sensor (IDCS) and calculate the difference between the sensor output and the specified value.
Page 121: Image Processing
22. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2009 22. IMAGE PROCESSING 22.1 Image processing in the scanner section A. Shading correction B. AE control C. Area discrimination D. Brightness/density conversion E. Filter/magnification F. Density gamma (conversion) G. Half tone processing (error diffusion) H.
Page 122: Shading Correction
Theory of Operation Ver.2.0 Mar. 2009 22. IMAGE PROCESSING 22.1.1 Shading correction This is the measure to obtain an even distribution from light of the CCD sensor. The following corrections are made at the prescribed timing. White correction The output voltage of each pixel of the CCD sensor when the white reference plate is exposed to the exposure lamp is stored as the maximum output of the pixel.
Page 123: Ae Control
22. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2009 22.1.2 AE control Through the AE control, a density suitable for the original density is automatically selected and the copy is made properly. A. Sampling area (1) While in the platen mode 50gat2c092na Original 10 mm...
Page 124: Area Discrimination
Theory of Operation Ver.2.0 Mar. 2009 22. IMAGE PROCESSING 22.1.3 Area discrimination To make a copy of the original under the correct condition (to make a correct filter processing), check the read section to see if it is a character or a dot picture, and use the results at the image processing unit at the later stage.
Page 125: Filter/Magnification
22. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2009 22.1.5 Filter/magnification A. Filter processing An appropriate filter processing is made according to the type of an original and the magnification selected. (1) Character : Make the shading of an original conspicuous. (2) Dot section : Suppress moire.
Page 126 Theory of Operation Ver.2.0 Mar. 2009 22. IMAGE PROCESSING (2) Main scan magnification processing while in reduction As shown in drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to D5, the positions of the data read when reduced are R1 to R5.
Page 127: Scanner Gamma Correction
22. IMAGE PROCESSING Theory of Operation Ver.2.0 Mar. 2009 22.1.6 Scanner gamma correction To the data obtained after the filter/magnification processing, select a density curve corresponding to the density button selected on the operation panel. An appropriate density curve is provided for each of the character/pic- ture/character and the picture/thin character modes.
Page 128: Image Processing In The Write Section
Theory of Operation Ver.2.0 Mar. 2009 22. IMAGE PROCESSING 22.2 Image processing in the write section A. Rotation/elongation B. Frequency conversion C. PWM A. Rotation/elongation Rotate the image in the direction of 90 degrees and 180 degrees as necessary. When outputting images from the memory, expand the compressed data to restore them to their original state. B.
Page 129: Others
23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 23. OTHERS 23.1 Fan control 23.1.1 Composition [10] [11] 50gat2c029nb Exhaust fan /Rr (FM9) Fusing cooling fan /Fr (FM2) Exhaust fan /Fr (FM3) Fusing cooling fan /Rr (FM8) CPU cooling fan (FM11) Power supply cooling fan (FM1) Conveyance suction fan (FM5) [10]...
Page 130 Theory of Operation Ver.2.0 Mar. 2009 23. OTHERS 23.1.2 Operation A. Power supply cooling fan (FM1) control (1) Purpose Cool down the DC power supply (DCPS) and the high voltage unit (HV2) with suction air. (2) ON timing • It turns ON a specified period of time after the drum motor (M1) turns ON. •...
Page 131 23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 D. Drum cooling fan (FM4) control (1) Purpose Cool around the drum and the toner bottle with suction air. (2) ON timing • After completion of the print, it turns ON a specified period of time after the drum motor (M1) turns OFF. •...
Page 132 Theory of Operation Ver.2.0 Mar. 2009 23. OTHERS G. Developing cooling fan (FM7) (1) Purpose Take in fresh air to cool down the developing motor (M3). (2) ON timing • After completion of the print, it turns ON a specified period of time after M3 turns OFF. •...
Page 133: Counter Control
23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 23.2 Counter control 23.2.1 Composition CN1000 CN35 CN36 CN939 OACB PRCB CN30 PWB1 CN936 CN64 LCDB 50gat2c030nb Coin vendor /2 Copy Vender...
Page 134 Key counter (KCT), optional • Counting the designated number of prints allows no fur- ther copy operation (can be removed). For data collected, See "10.6 Counter" in Field service bizhub 501/421/361 Main body. (See P.199) 50gat2c031nb CN936 (KCT connecting connector) Total counter (TCT)
Page 135 23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 B. Coin vendor/2 (Parallel) The following shows the specifications of the connecting connector. Connector Pin No. Signal name Description Output timing Type of signal M1 signal Output from the start L output while in the Open collec- key being turned ON print operation...
Page 136: Parts That Operate When The Power Switch Is Turned On
Theory of Operation Ver.2.0 Mar. 2009 23. OTHERS 23.3 Parts that operate when the power switch is turned ON 23.3.1 Parts that operate when the main power switch (SW1) is turned ON A. Composition PWB4 PWB1 DCPS 5VDC 12VDC DCPS OACB section 24VDC...
Page 137: Parts That Operate When The Power Switch (Sw2) Is Turned On
23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 23.3.2 Parts that operate when the power switch (SW2) is turned ON A. Composition PWB4 PWB1 OACB 24VDC DCPS section L2, L3 AC drive section DCPS 50gat2c033nb B. Operation Turning ON the power switch (SW2) transmits an ON signal of SW2 to the overall control board (OACB) through the operation board /1 (PWB1).
Page 138: Authentication Unit
The system supports the communications protocol in compliance with Type A, Type B, and Felica (Type C) of ISO14443. • Only Felica and Type A cards can be used for bizhub 501/421/361 machines. • Simply placing the IC card on the authentication unit will let the unit read the data from the card.
Page 139 23. OTHERS Theory of Operation Ver.2.0 Mar. 2009 Blank page...
Page 140 SERVICE MANUAL Theory of Operation DF-613 2008.05 Ver. 1.0...
Page 141 Revision history 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 142 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS DF-613 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................4 In 1-sided mode ....................4 In 2-sided mode ....................4 COMPOSITION/OPERATION COMPOSITION .......................5 DRIVE........................6 OPERATION......................7 Document pick-up mechanism................7 5.1.1 Pick-up operation ..................7 Document feed/conveyance mechanism ..............8 Raised/lowered position detecting mechanism...........12 5.3.1 DF 15°...
Page 143 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 144: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Reverse Automatic Document Feeder Paper Feed Paper Feed from top of stack Type Turnover Switch back system Paper Exit Straight exit system Installation Screw cramp to the main unit Document Alignment Center Document Loading...
Page 145 1. PRODUCT SPECIFICATIONS Theory of Operation Ver.1.0 May. 2008 D. Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Feed failure, damage to the original, or drive failure Original that is stapled or clipped. due to clip clogging Book original Feed failure, damage to the original, or drive failure...
Page 146 Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS F. Mixed original feed chart For Metric Reference original (original with a maximum width) — — — — — — Other originals — — — — — — — — — —...
Page 147: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH In 1-sided mode 16eat1c001na [1] Exit [3] Feed (Scanning the 1st side) [2] Conveyance and turnover In 2-sided mode 16eat1c002na [1] Exit [3] Feed (Scanning the 1st side) Conveyance and turnover (Scanning the 2nd [2] Conveyance and switchback side) Conveyance...
Page 148: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Document feed section Switchback section Document exit section Conveyance section 16eat2c001na...
Page 149: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE 16eat2c002na [1] Original Feed Motor (M1) [2] Original Conveyance Motor (M2)
Page 150: Operation
Theory of Operation Ver.1.0 May. 2008 5. OPERATION OPERATION Document pick-up mechanism • The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation Roller, and this section is driven by the Original Feed Motor (M1). 5.1.1 Pick-up operation •...
Page 151: Document Feed/Conveyance Mechanism
5. OPERATION Theory of Operation Ver.1.0 May. 2008 Document feed/conveyance mechanism • When the original reaches the Registration Sensor, the Original Feed Motor (M1) [5] starts rotating forward and, at the same time that the Pickup Roller goes up, drive is then supplied to the Registration Roller [3].
Page 152 Theory of Operation Ver.1.0 May. 2008 5. OPERATION A. Operation flow in the 1-sided mode 16eat2c005na [1] Exit [3] Scanning the 1st side [2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8) 1. When the Start key is pressed, the Original Feed Motor (M1) starts rotating backward, causing the Pick-Up Roller to lower and start a paper take-up sequence.
Page 153 5. OPERATION Theory of Operation Ver.1.0 May. 2008 B. Operation flow in the 2-sided mode 1. When the Start key is pressed, the Original Feed Motor (M1) starts turning backward, causing the Pick-Up Roller to lower and start feeding the 1st page of the document. A specified period of time after the leading edge of the original turns ON the Original Detection Sensor (PS8) [4], the scanning of the 1st side of the original starts.
Page 154 Theory of Operation Ver.1.0 May. 2008 5. OPERATION 4. To ensure that pages of the document are in the proper order, the page is turned over [3] again before being ejected [1] into the Exit Tray. 16eat2c008na [1] Exit [3] Turnover [2] Scanning the 2nd side...
Page 155: Raised/Lowered Position Detecting Mechanism
5. OPERATION Theory of Operation Ver.1.0 May. 2008 Raised/lowered position detecting mechanism 5.3.1 DF 15° open/close detection mechanism • When DF is closed down to about 15° or less, the Original Cover Angle Detection Lever of the main body is pressed down to turn ON the APS Timing Sensor (PS31). 5.3.2 DF open/close detection mechanism •...
Page 156 SERVICE MANUAL Theory of Operation PC-206 501/421/361 2008.05 Ver. 1.0...
Page 157 Revision history 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 158 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS PC-206 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper Feed Section ....................5 5.1.1 Paper feed mechanism..................5 5.1.2 Paper lifting motion..................6 Tray Section ......................7 5.2.1 Paper size detection ..................7 5.2.2 Paper level indicator mechanism..............8...
Page 159 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 160: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center B. Paper type Paper Type Same as the main body.
Page 161: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH 4061t1c001na [1] Convey to the main body [3] Tray 4 paper feed [2] Vertical conveyance through PC [4] Tray 3 paper feed...
Page 162: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Tray 3 Paper Feed Section Tray 4 4061t2c001na...
Page 163: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE 4061t2c002na [1] Vertical Conveyance Motor /3 (M120) [3] Vertical Conveyance Motor /4 (M121) [2] Paper Feed Motor /4 (M123) [4] Paper Feed Motor /3 (M122)
Page 164: Operations
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS OPERATIONS Paper Feed Section 5.1.1 Paper feed mechanism • The Paper Feed Motor (M122, M123) drives the Pick-up Roller [8] and Feed Roller [6] to take up and feed a sheet of paper into the main body. •...
Page 165: Paper Lifting Motion
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.1.2 Paper lifting motion • When the Tray is slid into the main body and the Tray Set Sensor /3, /4 (PS112, PS121) is activated, the Paper Lift Motor /3, /4 (M124, M125) starts rotating to raise the Lifting Plate [3].
Page 166: Tray Section
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS Tray Section 5.2.1 Paper size detection • Moving the Sub Scan Direction Restriction Plate of the Tray rotates the Circular Plate [1] provided on the bottom of the Tray. • The length of paper in the sub scan direction is detected by the Paper Size Detection Switch [8] provided on the Paper Size Detect Boards /3 and /4 (PSDB3, PSDB49) [7] that is driven by the Lever interlocked with the Circular Plate.
Page 167: Paper Level Indicator Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.2.2 Paper level indicator mechanism • All Trays are universal paper size tray. • There is a window in the front cover of the Tray that serves as the Paper Level Indicator [3] showing the amount of paper that is still available for use.
Page 168 SERVICE MANUAL Theory of Operation PC-407 501/421/361 2008.05 Ver. 1.0...
Page 169 Revision history 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 170 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS PC-407 OUTLINE PRODUCT SPECIFICATION...................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper Feed Section ....................5 5.1.1 Paper feed mechanism..................5 Tray Section ......................6 5.2.1 Up/down mechanism..................6 5.2.2 Shift Gate drive mechanism ................7 5.2.3 Shifter drive mechanism................8 5.2.4...
Page 171 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 172: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATION OUTLINE PRODUCT SPECIFICATION A. Type Name 2500 sheets paper feed cabinet Type Front loading type LCC Installation Desk type Document Alignment Center B. Paper type Paper Type Same as the main body. Metric: A4 Paper Size Inch: 8...
Page 173: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH 4061t1c201na [1] Convey to the main body [4] From the Sub Tray to Main Tray [2] Tray paper feed [5] Sub Tray [3] Main Tray...
Page 174: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Tray Section Paper Feed Section Main Tray Sub Tray 4061t2c201na...
Page 175: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE [10] 4061t2c202na [1] Paper Lift Motor (M5) [6] Shift Gate Drive Section [2] Paper Lift Drive Section [7] Tray Lock Solenoid (SD1) [3] Shifter Drive Section [8] Paper Feed Motor (M1) [4] Shift Motor (M4) [9] Vertical Conveyance Motor (M2) [5] Shift Gate Motor (M3)
Page 176: Operations
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS OPERATIONS Paper Feed Section 5.1.1 Paper feed mechanism • The Paper Feed Motor (M1) drives the Pick-up Roller [8] and Feed Roller [6] to take up and feed a sheet of paper into the main body. •...
Page 177: Tray Section
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Tray Section 5.2.1 Up/down mechanism • The Main Tray [3] is suspended by the cables [1] at the front and rear. • As the Paper Lift Motor (M5) [5] turns forward or backward, the cables are wound to raise or lower the Main Tray.
Page 178: Shift Gate Drive Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.2.2 Shift Gate drive mechanism • If the Main Tray runs out of paper, while the Sub Tray is loaded with paper, the paper stack on the Sub Tray is moved to the Main Tray [2]. •...
Page 179: Shifter Drive Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.2.3 Shifter drive mechanism • After completion of the evacuation of the Shift Gate, starts the movement of the Shifter [2]. • The movement of paper from the Sub Tray to the Main Tray is made by the Shifter that is driven by the Shift Motor (M4) [1].
Page 180: Paper Empty Detection
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.2.4 Paper empty detection • Paper empty detection of Main Tray is performed by Main Tray Empty Board (MEB) [2]. • Paper empty detection of Sub Tray is performed by Sub Tray Empty Sensor (PS9) [3]. 4061t2c207na [1] Main Tray [3] Sub Tray Empty Sensor (PS9)
Page 181 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 182 SERVICE MANUAL Theory of Operation LU-203 2008.05 Ver. 1.0...
Page 183 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.
Page 184 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS LU-203 OUTLINE 1. PRODUCT SPECIFICATION ............1 2.
Page 185 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank page...
Page 186: Outline
11 Recommended paper Plain paper Inch: Hammermill Tidal MP (20 lbs) Metric: Konica Profi (80 g/m ), Konica Minolta Original (80 g/m Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs) Metric: Nautilus (80 g/m D. Maintenance Maintenance Same as the main body.
Page 187: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 2. PAPER PATH 16aat1c001na Lift plate Feed roller Separation roller Pick-up roller Conveyance roller...
Page 188: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION 3. COMPOSITION Paper feed section Tray section 16aat2c001na...
Page 189: Paper Feed Section
4. PAPER FEED SECTION Theory of Operation Ver.1.0 May. 2008 4. PAPER FEED SECTION Drive 4.1.1 Paper feed drive A. Front side drive 16aat2c002na Pick-up solenoid (SD151) Feed roller Conveyance roller Pick-up roller B. Rear side drive 16aat2c007na Feed motor (M150) Feed clutch (CL151) Conveyance roller...
Page 190: Operation
Theory of Operation Ver.1.0 May. 2008 4. PAPER FEED SECTION Operation 4.2.1 Paper feed control A. Pick-up mechanism (1) Drive transmission The driving force of the feed motor (M150) is transmitted to the paper feed gear /3 [4] through various gears. The paper feed gear /3 is connected with the pick-up solenoid (SD151) [1] through the claw [2].
Page 191 4. PAPER FEED SECTION Theory of Operation Ver.1.0 May. 2008 (2) Paper feed roller unit up/down mechanism On the inside of the paper feed gear /3 [2], the cam [3] is provided. While in the standby, the cam pushes the lift- up shaft [1].
Page 192: Remaining Paper Detection Control
Theory of Operation Ver.1.0 May. 2008 4. PAPER FEED SECTION 4.2.2 Remaining paper detection control As paper in the tray gets reduced, the lift plate goes up gradually. The actuator [1] provided on the rear side of LU rotates in interlock with the up/down operation of the lift plate. The actuator is provided with the remaining paper sensors /1 (PS154) [3] and /2 (PS151) [2] and the remaining paper is detected by the combination of the ON/OFF of these sensors.
Page 193: Tray Section
5. TRAY SECTION Theory of Operation Ver.1.0 May. 2008 5. TRAY SECTION Drive 5.1.1 Tray lift drive 16aat2c006na Actuator Lift plate Wire Wire Coupling Spring Parallel pin Paper lift motor (M151)
Page 194: Operation
Theory of Operation Ver.1.0 May. 2008 5. TRAY SECTION Operation 5.2.1 Tray lift control When the upper door is closed, a parallel pin for the up drive of the lift plate is pushed out to be coupled to the coupling of the paper lift motor (M151). Closing the upper door also turn ON the upper door interlock switch (MS151) to supply a 24V DC to the load of the drive system.
Page 195 5. TRAY SECTION Theory of Operation Ver.1.0 May. 2008 Blank page...
Page 196 SERVICE MANUAL Theory of Operation FS-522/PU-501/ OT-602 2008.05 Ver. 1.0...
Page 197 Revision history 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 198 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS FS-522/PU-501/OT-602 OUTLINE PRODUCT SPECIFICATIONS ................1 FS-522 ........................1 PU-501........................3 OT-602 ........................4 PAPER PATH ......................5 Exiting Paper to the Tray /1 ...................5 Exiting Paper to the Tray /2 ...................6 Exiting Paper to OT....................7 COMPOSITION/OPERATION COMPOSITION .......................9 DRIVE........................10 FS-522 ........................10...
Page 199 CONTENTS Theory of Operation Ver.1.0 May. 2008 PU-501........................30 Composition ....................... 30 Operation......................30 6.2.1 Registration mechanism ................30 6.2.2 Punch mechanism ..................31 6.2.3 Punch status detection ................31 6.2.4 Punch Scraps Box full detection mechanism..........32 OT-602 ........................33 Composition .......................
Page 200: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS FS-522 A. Type Name Multi tray finisher built into the main body Installation Installed in the main body Document Alignment Center Consumables Staples (5,000 staples/cartridge) B. Functions Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted) C.
Page 201 1. PRODUCT SPECIFICATIONS Theory of Operation Ver.1.0 May. 2008 (3) Sort Staple Type Size Weight Max. Capacity Metric: Tray /1 200 sheets A3, B4, A4, A4S, B5, B5S *2 Plain paper A4S, 8 x 11S 1000 11 x 17, 8 x 11, or less sheets...
Page 202 Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS PU-501 A. Type Type FS built-in type punching operation device Installation Screwed to the FS Metric: A3, B4, A4, A4S, B5 11 x 17, 8 x 11, 8K *1, 16K *1 Paper Size Inch: 2 holes: 11 x 17, 8...
Page 203 1. PRODUCT SPECIFICATIONS Theory of Operation Ver.1.0 May. 2008 OT-602 A. Type Type Additional Tray to FS Installation Screwed to the FS Mode Non sort, sort, group, and sort staple Number of Bins 1 bin Document Alignment Center B. Paper Type Mode Size Type...
Page 204: Paper Path
Theory of Operation Ver.1.0 May. 2008 2. PAPER PATH PAPER PATH Exiting Paper to the Tray /1 4349t1c001na [1] From the main body [3] Exiting paper to the Tray /1 [2] Convey to the Tray /1...
Page 205: Exiting Paper To The Tray /2
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 Exiting Paper to the Tray /2 4349t1c002na [1] From the main body [3] Exiting paper to the Tray /2 [2] Convey to the Tray /2...
Page 206: Exiting Paper To Ot
Theory of Operation Ver.1.0 May. 2008 2. PAPER PATH Exiting Paper to OT 4349t1c003na [1] From the main body [3] Exiting paper to OT [2] Convey to OT...
Page 207 2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 208: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Up/down Section Conveyance Section Staple Section 4349t2c001na...
Page 209: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE FS-522 4349t2c002na [1] Stapler Drive Section [5] Paper Exit Opening Drive Section [2] Exit Drive Section [6] Conveyance/Alignment Drive Section [3] Up/down Drive Section [7] Entrance Drive Section [4] Shutter Drive Section...
Page 210 Theory of Operation Ver.1.0 May. 2008 4. DRIVE PU-501 4512t2c001na [1] Punch Drive Section...
Page 211: Operations
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 OPERATIONS Conveyance Section • The Conveyance Section is divided into the entrance conveyance section [3], intermediate conveyance section [1], and the exit conveyance section [2]. It controls to convey the paper fed from the main body, stop the paper at the punching and folding positions, and drive the paper for feeding into the exit section.
Page 212: Entrance/Conveyance Section
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.1.1 Entrance/Conveyance section • A paper [5] fed from the main body is conveyed to the intermediate conveyance section. • The Entrance Motor (M3) [3] provides the drive for conveying a paper. •...
Page 213: Intermediate Conveyance Section
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.1.2 Intermediate Conveyance Section • A paper conveyed from the entrance conveyance section is brought to a stop at the punch- ing and folding position. • A paper is also conveyed to the exit conveyance section. •...
Page 214: Exit Conveyance Section
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.1.3 Exit Conveyance Section • The paper is exited onto each of the trays. • The Exit Motor (M1) [1] provides drive for the Exit Roller [3], Stacker Paddle [5], and Exit Paddle [2].
Page 215: Up/Down Section
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Up/down Section 5.2.1 Up/down mechanism • The Up/down mechanism is operated to select a specific tray, thereby feeding the paper exit onto a specific tray. 4349t2c007na [1] Tray Lift Motor (M11)
Page 216: Tray Up/Down Operation
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.2.2 Tray Up/Down operation • The Tray is moved up or down by the Tray Lift Motor (M11) that turns forward or backward to drive the front and rear belts. • The Lower Limit Sensor (PS14) [1] detects the Tray at its lower limit position. •...
Page 217: Tray Upper Limit Position Detection Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.2.3 Tray Upper Limit Position Detection Mechanism • Each of the Tray moves up or down according to the amount of paper fed onto it. • When the Upper Limit Sensor (PS15) [1] turns ON for each exit of paper, bring down once the Lift Tray until PS15 turns OFF so that the upper surface of paper on the Tray is kept at the same level at all times while in the paper exit.
Page 218 Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS A. Tray Position Detection • Tray position detection is controlled according to the number of times the Tray Position Sen- sor (PS3) [1] is activated after the Lower Limit Sensor (PS14) [2] has been activated. (1) Tray position detection operation 1.
Page 219 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 2. After PS14 has been activated, the Up/Down Section is subjected to an ascent motion. 3. When PS3 [1] is activated a first time after the ascent motion of the Up/Down Section has been started, it is determined that the Up/Down Section is now located at the paper exit opening for the Tray /1.
Page 220: Shutter Open/Close Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.2.4 Shutter Open/Close Mechanism • The paper exit section is provided with the Shutter [3] and this Shutter is normally in the up condition (the condition in which the Paper Exit Opening is opened). However, when the Tray goes up and down, the Paper Exit Opening is closed to prevent an accident such as hands getting caught in the Paper Exit Opening.
Page 221: Stacker Section
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Stacker section 5.3.1 Paper aligning mechanism (sub scan direction) • Sheets of paper are aligned properly and stapled together inside the stacker section before being fed out onto the corresponding tray. • In the Sort, Group, Staple, or Half Fold/Fold & Staple mode, each copy set is stored in the Stacker with the Upper Exit Roller separated from the Lower Exit Roller.
Page 222: Paper Aligning Mechanism (Main Scan Direction)
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.3.2 Paper aligning mechanism (main scan direction) • Aligning Plates are moved and the Paddle is rotated so as to align the paper at the stapling position. • The paper in the Stacker is aligned in the main scan direction by two Alignment Motors and aligning plates.
Page 223 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 B. Paper aligning sequence • In normal print and staple mode, the paper is fed into the tray at its center position. • If no stapling is involved in the Sort or Group Print mode, the aligning plate shifts 15 mm to the front or rear from the center.
Page 224: Exit Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.3.3 Exit mechanism • The paper exit roller section is provided with the Paper Holding Paddle [3] to hold the paper exited onto the Tray while in the sort mode so that the paper does not have an uneven edge. •...
Page 225 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 A. Exit Roller up/down mechanism • While in the sort mode and the staple mode, the Exit Roller /Up is pressed to the Exit Roller /Lw after the paper is stacked in the Stacker. •...
Page 226: Stapling
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS Stapling 5.4.1 Stapling mechanism • Stapling is performed by the Stapling Unit. • When the Stapling Motor [1] is rotated, the Clinch Arm [3] lowers. The Stapler [2] thereafter goes up to drive a staple in the paper. •...
Page 227: Stapling Unit Moving Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 5.4.2 Stapling Unit moving mechanism • The Stapling Unit is moved by the Stapler Movement Motor (M7) [3]. • M7 drives the belt so that the Stapling Unit is moved to the corresponding stapling position. •...
Page 228: Staple Empty Detection
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.4.4 Staple empty detection • Staple Empty Sensor [2] detect whether or not there are staples still left. • When the number of staples left in the staple cartridge becomes about 20, a staple sheet empty condition results, causing a corresponding empty message to appear on the opera- tion panel.
Page 229: Composition
6. PU-501 Theory of Operation Ver.1.0 May. 2008 PU-501 Composition 4512t2c002na Operation 6.2.1 Registration mechanism • For punch and holding operations, a loop is formed in the paper at the Registration Roller [2] to correct skew of the paper. • The Entrance Sensor (PS4) [1] detects the leading edge of the paper and the Registration Roller forms a loop in the paper.
Page 230: Punch Mechanism
Theory of Operation Ver.1.0 May. 2008 6. PU-501 6.2.2 Punch mechanism • After a given period of time after the Entrance Sensor (PS4) [3] has detected the trailing edge of the paper, the Conveyance Motor (M2) of FS is deenergized and a punch hole oper- ation is made at the trailing edge portion in each sheet of paper.
Page 231: Punch Scraps Box Full Detection Mechanism
6. PU-501 Theory of Operation Ver.1.0 May. 2008 6.2.4 Punch Scraps Box full detection mechanism • Punch scraps produced as a result of punching operation is stored in the Punch Scraps Box. • The Punch Scraps Box is provided with the Punch Scraps Full Sensor (PS1) [1]. When a punch waste is detected, the corresponding message is displayed on the operation panel.
Page 232: Composition
Theory of Operation Ver.1.0 May. 2008 7. OT-602 OT-602 Composition 4625t2c001na Operation 7.2.1 Overview • Mounting the optional OT provides a total of three trays. • The OT is attached at different positions depending on whether options SD or MT is mounted or not.
Page 233 7. OT-602 Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 234 SERVICE MANUAL Theory of Operation FS-523/RU-507 2008.05 Ver. 1.0...
Page 235 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.
Page 236 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS FS-523/RU-507 OUTLINE 1. PRODUCT SPECIFICATION ............1 FS-523 .
Page 237 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank page...
Page 238: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATION OUTLINE 1. PRODUCT SPECIFICATION FS-523 A. Type Type Multi staple finisher Installation Floor-mounted type Document alignment Center Consumables Staples B. Functions Mode Normal Non-sort, sort, group, sort-staple Punch Non-sort-punch, sort-punch, group-punch, sort-staple-punch C.
Page 239 1. PRODUCT SPECIFICATION Theory of Operation Ver.1.0 May. 2008 (2) Non-sort, sort, group Type of paper Size of paper Weight Max. capacity Exit tray Max. number of sheets stapled Plain paper Inch: 50 to 210 g/m 3000 sheets Main tray —...
Page 240 Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATION D. Stapling Staple filling method Dedicated staple cartridge (5000 staples) Staple detection Available (near empty: 20 remaining staples) Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5 x 11, 11 x 17 Inch: 8 Front: Diagonal 45°...
Page 241 1. PRODUCT SPECIFICATION Theory of Operation Ver.1.0 May. 2008 RU-507 A. Type Type Roller method relay conveyance unit B. Functions Conveyance Paper conveyance from the main body to FS C. Type of paper Paper size Same as the main body. Paper type Same as the main body.
Page 242: Paper Path
Theory of Operation Ver.1.0 May. 2008 2. PAPER PATH 2. PAPER PATH A. Non-sort mode (sub tray paper exit) 4521t1c004na Paper exit roller (main body) FS-523 Bypass gate Punch Main gate RU-507 Sub tray Note: Even when mixed with the punch mode, the paper path is the same. B.
Page 243 2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 C. Staple mode [10] [11] 4521t1c006na Paper exit roller (main body) Paper path for other than the 1st paper of the 2nd and succeeding copies. Bypass gate Paper path for the 1st paper of the 2nd and FS-523 succeeding copies Main gate...
Page 244: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION 3. COMPOSITION Conveyance Punch section Sub tray section RU-507 Main tray section Staple section 4521t2c001na...
Page 245: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 4. DRIVE FS-523 [12] [13] [14] [11] [10] 4521t2e001na Paddle motor /Lw (M9) Paper exit motor (M3) Hole punch selector motor (M14) (for inch Paddle motor /Up (M15) area) [10] Paper exit roller release motor (M13) Tray lift motor (M7) [11] Conveyance motor /Lw (M2)
Page 246 Theory of Operation Ver.1.0 May. 2008 4. DRIVE RU-507 16fat2c001na Main body - fusing motor (M11) Conveyance roller Entrance conveyance roller (FS-523) Coupling gear Belt...
Page 247: Operation
5. OPERATION Theory of Operation Ver.1.0 May. 2008 5. OPERATION RU conveyance section 5.1.1 Conveyance mechanism • The driving force from the fusing motor (M11) is transmitted through the coupling gear [2] to rotate the con- veyance roller [5]. • Paper conveyed from the paper exit roller [1] on the main body side is conveyed by the conveyance roller to the entrance roller [3] on the FS side.
Page 248: Fs Conveyance Section
Theory of Operation Ver.1.0 May. 2008 5. OPERATION FS conveyance section • The conveyance section is made up of the entrance conveyance mechanism [6] that conducts the convey- ance drive, the main route conveyance mechanism [2], the sub tray conveyance mechanism [5], the han- dling/paper exit conveyance mechanism [3], the gate mechanism [1] that switches the paper path and the roller separation mechanism [4] that conducts the pressure/release of the roller.
Page 249 5. OPERATION Theory of Operation Ver.1.0 May. 2008 5.2.1 Entrance conveyance mechanism • The driving force of the entrance conveyance motor (M1) [4] rotates the entrance roller [1] to convey [3] paper [2] into FS. 4521t2c005na Entrance roller Paper conveyance direction Paper Entrance conveyance motor (M1) A.
Page 250: Gate Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.2.2 Gate mechanism • On the conveyance path, the following 2 types of gates are provided: the bypass gate [6] and the main gate [3]. • The bypass gate is driven by the bypass gate solenoid (SD1) [5]. •...
Page 251 5. OPERATION Theory of Operation Ver.1.0 May. 2008 A. Operation • The paper conveyance path of the bypass gate [1] is switched over in the bypass route direction [2] when the bypass gate solenoid (SD1) turns OFF and switched over in the main gate direction [10] when it turns •...
Page 252: Sub Tray Conveyance Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.2.3 Sub tray conveyance mechanism • The paper conveyance to the sub tray is made while in the non-sort mode. • The conveyance motor /Up (M4) [5] drives the conveyance roller /Up [1] and the sub tray paper exit roller [2] to convey [3] paper [4] to the sub tray.
Page 253: Main Tray/Handling Tray Conveyance Mechanism
5. OPERATION Theory of Operation Ver.1.0 May. 2008 5.2.4 Main tray/handling tray conveyance mechanism • The conveyance motor /Lw (M2) [7] drives the conveyance roller /Lw [1] and the intermediate conveyance roller [9] to convey paper in the main tray direction [4]. When rotating M2 in the reverse direction, paper is switched back [10].
Page 254 Theory of Operation Ver.1.0 May. 2008 5. OPERATION A. Switch back control When the FS start signal turns ON, the conveyance motor /Lw (M2) rotates in the normal direction. And when the bypass route conveyance sensor (PS2) [3] detects the trailing edge of the 1st paper [1] of the 2nd copy that has been conveyed to the bypass route, M2 turns OFF.
Page 255 5. OPERATION Theory of Operation Ver.1.0 May. 2008 B. Handling tray conveyance operation (1) Sort mode • When the FS start signal turns ON, the paper exit motor (M3) rotates in the normal direction to convey paper to the main tray. M3 turns OFF a specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the last paper.
Page 256: Roller Separation Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.2.5 Roller separation mechanism • The intermediate conveyance roller and the paper exit roller are provided with a separation mechanism that releases the pressure from the roller. • The intermediate conveyance roller release motor (M12) [1] drives the cam [5] to pressure/release the inter- mediate conveyance roller [2].
Page 257 5. OPERATION Theory of Operation Ver.1.0 May. 2008 A. Intermediate conveyance roller separation control When printing continuously a large size paper (217 mm or larger) in the staple mode, the leading edge of the 2nd paper [4] gets to the intermediate conveyance roller [2] while in the switch back [1] of the 1st paper of the 2nd and succeeding copies.
Page 258 Theory of Operation Ver.1.0 May. 2008 5. OPERATION B. Paper exit roller separation control To stack [1] paper in the handling tray [2] while in the staple mode, FS start signal turns ON, and the paper exit roller release motor (M13) turns ON. After the pressure of the paper exit roller [3] is released and the paper exit roller is separated [4], M13 turns OFF.
Page 259: Conveyance Operation
5. OPERATION Theory of Operation Ver.1.0 May. 2008 5.2.6 Conveyance operation A. Continuous copy in the staple mode (in case of A4S, 3 originals, and 2 copies) The 1st paper [2], the 2nd paper [3] and the 3rd paper [4] of the 1st copy are conveyed to the handling tray [1].
Page 260 Theory of Operation Ver.1.0 May. 2008 5. OPERATION After completion of the stapling operation of the paper [1] of the 1st copy, the paper exit roller [2] is pres- sured to exit the paper of the 1st copy. At this time, the moment the paper of the 1st copy is exited, the 1st and the 2nd sheets of paper [3] of the 2nd copy are also conveyed in the main tray direction.
Page 261: Main Tray Section
5. OPERATION Theory of Operation Ver.1.0 May. 2008 Main tray section 5.3.1 Main tray up/down mechanism • The up/down of the main tray is made by the normal/reverse rotation of the tray lift motor (M7) [2]. 4521t2c018na Main tray upper limit LED (LED19) Main tray upper limit sensor (PS19) Tray lift motor (M7) Main tray reset sensor (PS8)
Page 262: Main Tray Shift Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.3.2 Main tray shift mechanism • While in the sort/group mode, the shift motor (M8) [4] is driven to shift the main tray [5] 30 mm in the main scan direction through the shift plate [3]. •...
Page 263: Punch Section
5. OPERATION Theory of Operation Ver.1.0 May. 2008 Punch section 5.4.1 Punch mechanism • For the punch, a hole is punched on the rear side of paper for each paper. • The driving force from the punch motor (M11) [5] is transmitted to the eccentric cam [6] by the punch clutch (CL1) [4].
Page 264: Punch Hole Switchover Mechanism (For Inch Area)
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.4.2 Punch hole switchover mechanism (for inch area) • The hole punch selector motor (M14) [5] and the hole punch position switch (SW4) [4] are employed to move the lock holder [2] as necessary to select the hole positions (2 or 3 holes [1][6]). 4521t2e002na 2 holes Hole punch selector motor (M14)
Page 265: Staple Section
5. OPERATION Theory of Operation Ver.1.0 May. 2008 Staple section 5.5.1 Alignment mechanism • While in the staple mode, paper is conveyed to the handling tray for alignment operation. • The alignment in the main scan direction is made by the movement of the alignment plate, and the align- ment in the sub scan direction is made by the rotation of the paddle.
Page 266 Theory of Operation Ver.1.0 May. 2008 5. OPERATION B. Paddle • The paddle /Up [3] and /Lw [6] hit paper against the stopper to conduct the alignment in the sub scan direction. • The drive of the paddle /Up is made by the paddle motor /Up (M15) [5] and the paddle solenoid (SD3) [4]. •...
Page 267: Stapler Movement Mechanism
5. OPERATION Theory of Operation Ver.1.0 May. 2008 5.5.2 Stapler movement mechanism • The movement/rotation of the staplers /Fr [4] and /Rr [1] are made by the stapler moving motor (M6) [3]. • The home position is detected by the stapler home sensor (PS14) [2] and the position is decided according to the drive amount of M6.
Page 268: Stapling Mechanism
Theory of Operation Ver.1.0 May. 2008 5. OPERATION 5.5.3 Stapling mechanism • The stapling operation is made by the stapler. • When the stapler motors /Rr (M16) and /Fr (M17) [1] are driven, the clinch arm [3] goes down to drive the staple blade [2] and hit in a staple.
Page 269: Staple Sheet Empty Control
5. OPERATION Theory of Operation Ver.1.0 May. 2008 5.5.4 Staple sheet empty control A. Detection mechanism • The detection of the staple sheet [6] is made by the staple empty sensors /Rr (PS20) and /Fr (PS23) [4]. • The detection of the staple ready is made by the staple ready sensors /Rr (PS21) and /Fr (PS24) [2]. 4521t2c025na No staple condition Staple empty sensors /Rr, /Fr (PS20, PS23)
Page 270 SERVICE MANUAL Theory of Operation SD-507 501/421/361 2008.05 Ver. 1.0...
Page 271 Revision history 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 272 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS SD-507 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 Half-fold section ....................4 Saddle Stitching Section ..................4 OPERATIONS ......................5 Paper Conveyance mechanism ................5 Conveyance roller pressure/release ..............6 5.2.1 Pressure/release mechanism................6 5.2.2 Operation.......................7 Stapling mechanism....................8...
Page 273 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 274: Product Specifications
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type FS built-in saddle-stitching device Installation Screwed to the FS Document Alignment Center Center parallel two points Stapling Function No. of sheets to be stapled together: 2 to 15 Consumables Staples (2000 staples/cartridge) B.
Page 275: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH 4511t1c001na...
Page 276: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Saddle-Stitching Section Half-Fold Section 4511t2c001na...
Page 277: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE Half-fold section 4511t2c013na [1] Folding Roller [3] Half-folding Blade [2] Folding Motor (M10) Saddle Stitching Section 4511t2c003na [1] Conveyance Roller /Up [3] Exit Open/Close Motor (M9) [2] Conveyance Motor (M8)
Page 278: Operations
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS OPERATIONS Paper Conveyance mechanism • Paper is conveyed by the Exit Rollers of FS and Conveyance Roller /Up [5], /Lw [2]. • The Conveyance Motor (M8) [3] provides the drive for the Conveyance Roller /Lw [2]. •...
Page 279: Conveyance Roller Pressure/Release
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Conveyance roller pressure/release 5.2.1 Pressure/release mechanism • The Conveyance Roller /Up [1] is moved away from, or pressed up against, the Conveyance Roller /Lw [2], when the paper is fed out as a bundle of papers. •...
Page 280: Operation
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.2.2 Operation 1. The Conveyance Roller /Up [5] is moved up or down by the cams which are driven by the Exit Open/Close Motor (M9) [6]. 2. When a bundle papers moves past the Conveyance Roller /Up and /Lw, the motor is energized to press the Conveyance Roller /Up up against the Conveyance Roller /Lw, thereby feeding a bundle papers out into the tray.
Page 281: Stapling Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Stapling mechanism • The Staple units [2] position are fixed. • Since the unit are for center stapling only, it is made up of the upper clincher portion [1] and the lower stapling portion. A bundle papers moves through the space between the upper and lower portions of the staplers.
Page 282: Staple Guide
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS Staple guide • The Staple Guide is used to guide the leading edge of the first sheet of paper when the first sheet of paper is stored, thereby preventing the leading edge from contacting the Stapling Unit and jamming.
Page 283: Half-Folding Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Half-folding mechanism • The Entrance Sensor (PS4) [2] of FS detects the trailing edge of the paper. • The paper feed amount is determined for each paper size as counted from the timing when the trailing edge is detected.
Page 284: Operation
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS 5.5.1 Operation • When the Folding Motor (M10) is energized for one cycle of operation, the Conveyance Guides /Lw [2] are retracted to the right and left and the Half-folding Blade [3] makes one up-and-down reciprocating motion.
Page 285: Paper Guide
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Paper guide • When a bundle papers is fed onto the tray, the Paper Guide supports the leading edge of the paper of a large size so as to prevent it from pushing the trailing edge of the paper that has previously been fed out.
Page 286: Tray Paper Detection
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS Tray paper detection • When paper is fed onto the tray, it pushes the actuator, which causes the Tray Empty Sensor (PS21) [1] to detect the paper. 4511t2c012na [1] Tray Empty Sensor (PS21)
Page 287 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 288 SERVICE MANUAL Theory of Operation MT-502 501/421/361 2008.05 Ver. 1.0...
Page 289 Revision history 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 290 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS MT-502 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper conveyance mechanism ................5 Paper path selection mechanism ................6 Paper detection .....................7...
Page 291 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 292: Outline
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type 4 bins Mailbin (available only for printing from PC) Installation Screwed to the FS Number of Bins 4 bins Number of Sheets 125 sheets (80 g/m Stored per Bin Storable Paper Plain Paper (56 to 90 g/m...
Page 293: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH 4510t1c001na...
Page 294: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION 4510t2c001nb...
Page 295: Drive
4. DRIVE Theory of Operation Ver.1.0 May. 2008 DRIVE 4510t2c003na [1] Conveyance Roller [3] Conveyance Motor (M1) [2] Exit Roller...
Page 296: Operations
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS OPERATIONS Paper conveyance mechanism • When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS-522) and toward the Mailbin. • Drive for the Conveyance Rollers [2] of the Mailbin is transmitted from the Conveyance Motor (M1) [1] by way of a belt.
Page 297: Paper Path Selection Mechanism
5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Paper path selection mechanism • The Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [1] are energized or deenergized to direct paper fed from the Finisher into a specific tray. • There are SD1, SD2, SD3 provided that will be energized or deenergized to operate the cor- responding Gate [2], thereby selecting a specific paper path into a specific tray.
Page 298: Paper Detection
Theory of Operation Ver.1.0 May. 2008 5. OPERATIONS Paper detection • The Paper Detection Sensor /1, /2, /3, /4 (PS1, PS2, PS3, PS4) [2] detects any sheet of paper that is fed into the tray, causing the LED to light up blue steadily to inform the user that a sheet of paper has been fed into the tray.
Page 299 5. OPERATIONS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 300 SERVICE MANUAL Theory of Operation JS-502 501/421/361 2008.05 Ver. 1.0...
Page 301 Revision history 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 302 Theory of Operation Ver.1.0 May. 2008 CONTENTS CONTENTS JS-502 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 OPERATIONS ......................4 Job Tray Conveyance/Exit..................4...
Page 303 CONTENTS Theory of Operation Ver.1.0 May. 2008 Blank Page...
Page 304: Product Specifications
Theory of Operation Ver.1.0 May. 2008 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Job Separator Type Expansion tray Installation Installed in the main body Document Alignment Center B. Paper type Exit Tray Size Type Capacity Inch: 11 x 17, 8 x 14, 250 sheets Plain Paper (56 to 90 g/m...
Page 305: Paper Path
2. PAPER PATH Theory of Operation Ver.1.0 May. 2008 PAPER PATH 4347t1c001na [1] Conveyance from the main body...
Page 306: Composition/Operation
Theory of Operation Ver.1.0 May. 2008 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Job Separator section Switchback Unit section 4347t2c001na...
Page 307: Operations
4. OPERATIONS Theory of Operation Ver.1.0 May. 2008 OPERATIONS Job Tray Conveyance/Exit • The Switchback Unit functions to convey paper through, and feed it out from, the Job Tray. • The paper sensor section of the Job Tray is mounted to the Switchback Unit, thereby detect- ing paper.
Page 308 © 2008 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to avoid CCA0R5-M-TE2 disclosure of confidential information.

This manual is also suitable for:

Bizhub 421 Bizhub 361

Konica Minolta Bizhub 501 Service Manual

Theory of Operation Total

Table of Contents

1 System Configuration

Bizhub 501/421/361 Main Body

Table of Contents

Pc-206

23 Others

1 Product Specifications

2 Paper Path

Df-613

3 Composition

4 Drive

Table of Contents

Pc-407

5 Operation

1 Product Specifications

2 Paper Path

3 Composition

4 Drive

5 Operations

Outline/Composition/Operation

2 Paper Path

3 Composition

4 Drive

5 Operations

Table of Contents

Lu-203

Outline

1 Product Specification

2 Paper Path

Composition/Operation

3 Composition

4 Paper Feed Section

5 Tray Section

Outline/Composition/Operation

1 Product Specifications

2 Paper Path

Composition/Operation

3 Composition

4 Drive

Table of Contents

Fs-522/Pu-501/Ot-602

5 Operations

1 Product Specification

2 Paper Path

Composition/Operation

3 Composition

4 Drive

5 Operation

Table of Contents

1 Product Specifications

2 Paper Path

3 Composition

4 Drive

Fs-523/Ru-507

Mt-502

Sd-507

Quick Links

Chapters

Related Manuals for Konica Minolta Bizhub 501

Summary of Contents for Konica Minolta Bizhub 501