Konica Minolta bizhub 200 Service Manual
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SERVICE MANUAL
The
The
This service manual is designed for copier
This service manual is designed for copier
with Firmware Ver. 4040-0100-G10-23-00X and onward.
with Firmware Ver. 4040-0100-G10-23-00X and onward.
is available only for North America.
is available only for North America.
THEORY OF OPERATION
2006.11
Ver. 2.5

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Summary of Contents for Konica Minolta bizhub 200

  • Page 1 SERVICE MANUAL THEORY OF OPERATION is available only for North America. is available only for North America. This service manual is designed for copier This service manual is designed for copier with Firmware Ver. 4040-0100-G10-23-00X and onward. with Firmware Ver. 4040-0100-G10-23-00X and onward. 2006.11 Ver.
  • Page 2: Table Of Contents

    WARNING INDICATIONS ON THE MACHINE ............S-17 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-20 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub 200/250/350 Main Unit Outline ..........................1 Composition/Operation ....................9 Duplex Unit / Switchback Unit Outline ..........................
  • Page 3 Composition/Operation ....................7 MT-501 Outline ..........................1 Composition/Operation ....................3 SD-502 Outline ..........................1 Composition/Operation ....................3...
  • Page 4: Safety And Important Warning Items

    IMPORTANT NOTICE 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: Checkpoints When Performing On-Site Service

    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 customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS Work Performed with the Product Powered On WARNING • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.
  • Page 13: Handling Of Consumables

    SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...
  • Page 15 SAFETY AND IMPORTANT WARNING ITEMS [4] Used Batteries Precautions 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. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
  • Page 16: Internal Laser Radiation

    SAFETY AND IMPORTANT WARNING ITEMS [5] Laser Safety • This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 18 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden VARO! • Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle. Puolijohdelaser Laserdiodin suurin teho 5 mW...
  • Page 19: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety labels is attached to the outside of the machine as shown below. * Only for the U.S.A. 4040P0C506DA Laser Caution Label • A laser caution label is attached to the inside of the machine as shown below. 4040P0C503DA Precautions For Handling The Laser Equipment •...
  • Page 20: Warning Indications On The Machine

    SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown 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. CAUTION 4040P0C500DA S-17...
  • Page 21 SAFETY AND IMPORTANT WARNING ITEMS High voltage 4040P0C501DA S-18...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS High voltage 4040P0C505DA CAUTION: • You may be burned or injured if you touch any area that you are advised not to touch by any caution label. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, contact our Service Office.
  • Page 23: 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 24: Composition Of The Service Manual

    Composition of the service manual This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation 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 25: 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 200/250/350: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...
  • Page 26: Main Unit

    SERVICE MANUAL THEORY OF OPERATION Main Unit 2006.07 Ver. 2.5...
  • Page 27: Revision History

    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 Theory of Operation Ver. 2.5 Jul. 2006 CONTENTS bizhub 200/250/350 Main Unit Outline System configuration....................1 Product specifications ..................... 3 Center cross section ....................6 Paper path....................... 7 Image creation process ................... 8 Composition/Operation Overall composition....................9 Timing chart at machine power up ............... 9 Control block diagram ..................
  • Page 29 Theory of Operation Ver. 2.5 Jul. 2006 10.3.1 Photo Conductor cleaning mechanism ............26 Charge Corona section ..................27 11.1 Operation......................27 11.1.1 Charge Corona ON/OFF control..............27 Developing section....................28 12.1 Composition ....................... 28 12.2 Drive ........................29 12.3 Operation......................30 12.3.1 Developing Drive control................
  • Page 30 Theory of Operation Ver. 2.5 Jul. 2006 16.2.2 Tray2 ......................49 16.3 Operation ......................50 16.3.1 Paper Feed control (Tray1)................50 16.3.2 Paper Feed control (Tray2)................50 16.3.3 Paper Feed Mechanism ................51 16.3.4 Paper Near-Empty/Paper Empty detection ..........52 16.3.5 Tray ascent operation ..................
  • Page 31 Theory of Operation Ver. 2.5 Jul. 2006 Other control ......................74 23.1 Fan control......................74 23.1.1 Construction....................74 23.1.2 Operation ....................75 23.2 Parts Operated When the Power Switch and Auxiliary Power Button are turned ON......................76 23.2.1 Parts operated when the Power Switch and Auxiliary Power Button are turned ON .....................
  • Page 32: Outline

    Theory of Operation Ver. 2.5 Jul. 2006 1. System configuration Outline System configuration 1/2 System Front View [17] [16] [15] [14] [13] [12] [10] [11] 4040T1E501AA Original Cover (OC-502) [10] Paper Feed Cabinet (PC-102) Stamp Unit (SP-501) [11] Desk (DK-501) Reverse Automatic Document Feeder [12] Finisher (FS-508)
  • Page 33 1. System configuration Theory of Operation Ver. 2.5 Jul. 2006 2/2 System Rear View [10] DK-501 PC-202 PC-102 PC-402 4040T1E502AB Machine Scanner Unit (SU-501) *1 Fax Kit (FK-503) Expanded Memory Unit (EM-303/EM-304/EM-305) *1 Fax Multi Line (ML-502) Hard Disk (HD-504) *2 Local Interface kit (EK-502) Security Kit (SC-504) Dehumidifier Heater 1C...
  • Page 34: Product Specifications

    4.8 sec. or less (bizhub 350) First Copy Time 5.3 sec. or less (bizhub 250) (Tray1, A4, full size) 5.3 sec. or less (bizhub 200) 160 m/s (bizhub 350) System Speed 140 m/s (bizhub 250, bizhub 200) 35 copies/min (bizhub 350)
  • Page 35 1200,000 prints or 5 years, whichever is earlier (bizhub 350) Machine Durability 800,000 prints or 5 years, whichever is earlier (bizhub 250) 500,000 prints or 5 years, whichever is earlier (bizhub 200) E. Machine Specifications Voltage AC 120 V, 220 - 240 V...
  • Page 36 Theory of Operation Ver. 2.5 Jul. 2006 2. Product specifications G. Built-in Controllers Type Built-in type controller RM5231 PCL5e Emulation Printer Driver PCL6 (XL Ver. 2.1) Emulation PostScript3 Emulation (3011.xx.xx) Scan Driver TWAIN driver Server Windows NT4.0 sp6 / 2000 / 2003 Windows 98SE / Me Windows 2000 / XP OS Compatibility...
  • Page 37: Center Cross Section

    3. Center cross section Theory of Operation Ver. 2.5 Jul. 2006 Center cross section [11] [10] 4040T1E503AA Scanner Section Tray1 Duplex Unit PH Unit Fusing Unit Imaging Unit (IU) Transfer Roller Unit Section [10] Toner Bottle/Toner Hopper Section Multiple Bypass Unit [11] Switchback Unit Tray2...
  • Page 38: Paper Path

    Theory of Operation Ver. 2.5 Jul. 2006 4. Paper path Paper path • Machine equipped with a DF-605, FS-508, SD-502, and PC-402 4040T2C518AA...
  • Page 39: Image Creation Process

    5. Image creation process Theory of Operation Ver. 2.5 Jul. 2006 Image creation process [1] CCD (Photoelectric Conversion) [14] Paper Exit [2] MFBS Board [13] Fusing [11] Cleaning [5] PH (Laser Exposure) [12] Erase [10] Paper Separation [4] PC Drum Charging [3] PC Drum [9] Image Transfer [6] Developing...
  • Page 40: Composition/Operation

    Theory of Operation Ver. 2.5 Jul. 2006 6. Overall composition Composition/Operation Overall composition Timing chart at machine power up Main Power Switch ON Main Motor (M1) Synchronizing Roller Clutch (CL1) Duplex Unit Transport Clutch 1 (CL6) Duplex Unit Transport Clutch 2 (CL7) IU Motor (M2) Developing Bias DC Charge Bias...
  • Page 41: Control Block Diagram

    6. Overall composition Theory of Operation Ver. 2.5 Jul. 2006 Control block diagram Controller Source Option Option Scanner Section CCD Board (CCD) Inverter Board Exposure Lamp (LA2) BCRS Board (BCRS) Scanner Motor (M12) MFBS Board (MFBS) Operation Panel HDD (Option) Printer Section Communications System Option...
  • Page 42: Scanner Section (Ir Section)

    Theory of Operation Ver. 2.5 Jul. 2006 7. Scanner section (IR section) Scanner section (IR section) Composition 4040T2C581AA 4040T2C507AA Original Size Sensor 5 (PC205) Scanner Motor (M12) Original Size Sensor 4 (PC204) Original Size Sensor 6 (PC206) Original Cover Angle Sensor (PC209) CCD Unit (CCD) Size Reset Switch...
  • Page 43: Drive

    7. Scanner section (IR section) Theory of Operation Ver. 2.5 Jul. 2006 Drive Scanner Motor Scanner Drive Cable/R Exposure Unit Mirror Unit Scanner Drive Cable/F 4040T2C566AA...
  • Page 44: Operation

    Theory of Operation Ver. 2.5 Jul. 2006 7. Scanner section (IR section) Operation 7.3.1 Scan and Exposure Lamp control A. When the Main and Auxiliary Power Switches are ON • When both the Main Power Switch and Auxiliary Power Switch are ON, the Exposure Unit remains stationary at its home position (shading position).
  • Page 45: Original Size Detection Control

    7. Scanner section (IR section) Theory of Operation Ver. 2.5 Jul. 2006 7.3.2 Original Size Detection control • The size of the original is determined through the combination of width and length detect- ing sensors turning ON or OFF. • When the optional sensors are mounted, “Original Size Detecting Option” of “System Input”...
  • Page 46 Theory of Operation Ver. 2.5 Jul. 2006 7. Scanner section (IR section) for Europe area : Option PC209 : Not to be mounted PC208 BCRS PC204 PC205 PC206 PC207 PC201 PC202 PC203 SW201 4040T2M598AA Name Connect to PC201 (Option) Original Size Sensor 1 BCRS Board CN5 PC202 Original Size Sensor 2...
  • Page 47: Write Section (Ph Section)

    8. Write section (PH section) Theory of Operation Ver. 2.5 Jul. 2006 Write section (PH section) Composition PH Unit 4040T2C519AA 4040T2C508AA SOS Sensor SOS Mirror Laser Diode G1 Lens Polygon Motor (M9) Cylindrical Lens 4040T2C520AA...
  • Page 48: Operation

    Theory of Operation Ver. 2.5 Jul. 2006 8. Write section (PH section) Operation 8.2.1 Laser exposure process 1. The laser light emitted from the semiconductor laser is reflected off the Polygon Mirror. 2. The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor.
  • Page 49: Laser Shutter Mechanism

    8. Write section (PH section) Theory of Operation Ver. 2.5 Jul. 2006 8.2.4 Laser Shutter Mechanism • A shutter is provided to prevent dust and dirt from entering the PH and a laser light, should it be inadvertently emitted, from leaking when the IU is removed from the machine.
  • Page 50 Theory of Operation Ver. 2.5 Jul. 2006 8. Write section (PH section) B. Sub scan direction • The print start position in the CD direction is determined by the Image Write Start signal (VSYNC) that is output from the MFBS Board (MFBS) and the length of the paper. •...
  • Page 51: Imaging Unit Section (Iu Section)

    9. Imaging Unit section (IU section) Theory of Operation Ver. 2.5 Jul. 2006 Imaging Unit section (IU section) Composition Imaging Unit (IU) 4040T2C501DA Photo Conductor Unit 4040T2C509AA Photo Conductor Charge Corona Photo Conductor Developing Roller 4040T2C569AA Developing Unit 4040T2C521AA ATDC (TCR) Sensor...
  • Page 52: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 9. Imaging Unit section (IU section) Drive IU Motor 4040T2C549AA...
  • Page 53: Operation

    350 100 K 400 K bizhub 250 80 K 320 K bizhub 200 65 K 260 K • The Photo Conductor Unit and developer should be replaced at the same time. 9.3.2 IU Life control A. New IU detection •...
  • Page 54 Theory of Operation Ver. 2.5 Jul. 2006 9. Imaging Unit section (IU section) B. When life is reached • The following three counters available from the Tech. Rep. mode are used to detect the life of the Photo Conductor and IU. (1) PC Life Counter •...
  • Page 55: Photo Conductor Section

    10. Photo Conductor section Theory of Operation Ver. 2.5 Jul. 2006 10. Photo Conductor section 10.1 Composition Photo Conductor 4040T2C502DA Charge Generating Layer (CGL) Charge Transport Layer (CTL) Aluminum Cylinder 4040T2C509AA 4036ma2338c0 Photo Conductor Unit 4040T2C591AA Photo Conductor...
  • Page 56: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 10. Photo Conductor section 10.2 Drive IU Motor Photo Conductor 4040T2C550AA...
  • Page 57: Photo Conductor Cleaning Mechanism

    10. Photo Conductor section Theory of Operation Ver. 2.5 Jul. 2006 10.3 Operation 10.3.1 Photo Conductor cleaning mechanism A. Main Erase operation 1. The Cleaning Blade is pressed up against the surface of the Photo Conductor, scraping residual toner off the surface. 2.
  • Page 58: Charge Corona Section

    Theory of Operation Ver. 2.5 Jul. 2006 11. Charge Corona section 11. Charge Corona section 11.1 Operation 11.1.1 Charge Corona ON/OFF control • The Comb Electrode deposits a charge evenly across the surface of the Photo Conduc- tor through a grid mesh. •...
  • Page 59: Developing Section

    12. Developing section Theory of Operation Ver. 2.5 Jul. 2006 12. Developing section 12.1 Composition Photo Conductor Unit Developing Unit 4040T2C509AA 4040T2C521AA Charge Corona Photo Conductor Developing Roller 4040T2C569AA ATDC (TCR) Sensor...
  • Page 60: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 12. Developing section 12.2 Drive IU Motor Developing Roller 4040T2C551AA...
  • Page 61: Operation

    12. Developing section Theory of Operation Ver. 2.5 Jul. 2006 12.3 Operation 12.3.1 Developing Drive control Start Key ON IU Motor (M2) Charge Bias Developing Bias (DC) Developing Bias (AC) Transfer output Print 4040T2C505AA 12.3.2 Developer flow • Toner fed off from the Toner Bottle is agitated by the three rollers and conveyed onto the Developing Roller.
  • Page 62: Developing Roller

    Theory of Operation Ver. 2.5 Jul. 2006 12. Developing section 12.3.3 Developing Roller • The Developing Roller consists of an outer sleeve roller and an inner magnet roller. • The roller conveys developer to the point of development. • The developer (carrier and toner) in the Developer Mixing Chamber is conveyed onto the point of development by the Toner Conveying Rollers and the Developing Roller.
  • Page 63: Developing Bias

    12. Developing section Theory of Operation Ver. 2.5 Jul. 2006 12.3.4 Developing bias • The developing bias voltage (Vdc) is applied to the Developing Roller so that an ade- quate amount of toner is attracted onto the surface of the Photo Conductor. •...
  • Page 64: Developer Scattering Preventive Mechanism

    Theory of Operation Ver. 2.5 Jul. 2006 12. Developing section 12.3.6 Developer Scattering Preventive Mechanism • To prevent the image and machine interior from being dirtied, the Toner Suction Fan Motor draws air so that toner particles rising up in the Developing Unit can be trapped. •...
  • Page 65: Atdc (Tcr) Sensor Control

    12. Developing section Theory of Operation Ver. 2.5 Jul. 2006 12.3.7 ATDC (TCR) Sensor control • The ATDC (TCR) Sensor is located on the underside of the Developing Unit. The sensor is a magnetic type that detects the toner-to-carrier ratio (T/C). •...
  • Page 66: Toner Supply Section

    Theory of Operation Ver. 2.5 Jul. 2006 13. Toner Supply section 13. Toner Supply section 13.1 Composition Toner Bottle Unit 4040T2C510AA 4040T2C504DA 13.2 Drive IU Motor Toner Bottle Toner Bottle Unit Sub Hopper 4040T2C552AA...
  • Page 67: Operation

    13. Toner Supply section Theory of Operation Ver. 2.5 Jul. 2006 13.3 Operation 13.3.1 Toner Replenishing/control • Toner is supplied from the Toner Bottle to Sub Hopper and from the Sub Hopper to Developing Unit according to the T/C ratio detected by the ATDC (TCR) Sensor. From Toner Bottle to Sub Hopper From Sub Hopper to IU Toner Bottle...
  • Page 68 Theory of Operation Ver. 2.5 Jul. 2006 13. Toner Supply section A. Toner replenishing mechanism • The I/U Motor provides the drive for replenishing toner from the Toner Bottle to the Sub Hopper and to the Developing Unit. • The Main Hopper Toner Solenoid and Sub Hopper Toner Solenoid function to control transmission of the drive.
  • Page 69 13. Toner Supply section Theory of Operation Ver. 2.5 Jul. 2006 B. Toner replenishing operation • Toner replenishing operation is performed through two different control modes: toner replenishing amount setting control and toner replenishing control. (1) Toner replenishing amount setting control 1.
  • Page 70 Theory of Operation Ver. 2.5 Jul. 2006 13. Toner Supply section (2) Toner replenishing control • The Sub Hopper Solenoid is energized and kept so for the period of the toner replenish- ing time (amount) established through the toner replenishing amount control. The Sub Hopper is thus energized to replenish the supply of toner to the Developing Unit.
  • Page 71 T/C recovery in progress (T/C recovery sequence start → toner bizhub 350: 210 sec empty → mixing completed) bizhub 200 / 250: 240 sec bizhub 350: 150 sec T/C recovery sequence start → Toner empty detection bizhub 200 / 250: 171.4 sec...
  • Page 72: Toner Near-Empty And Toner Empty Detection Control

    Theory of Operation Ver. 2.5 Jul. 2006 13. Toner Supply section 13.3.2 Toner Near-Empty and Toner Empty detection control • The Sub Hopper Empty Switch provided in the Sub Hopper detects a toner empty condi- tion. • A toner near empty condition is detected when the Toner Bottle is rotated 30 complete turns continuously.
  • Page 73: Transfer Corona Section

    14. Transfer Corona section Theory of Operation Ver. 2.5 Jul. 2006 14. Transfer Corona section 14.1 Composition 4040T2C530AA 4040T2C511AA Synchronizing Roller Clutch (CL1) Synchronizing Roller Image Transfer Roller 4040T2C505DA...
  • Page 74: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 14. Transfer Corona section 14.2 Drive Synchronizing Roller Clutch (CL1) Main Motor (M1) Synchronizing Roller 4040T2C553AA 14.3 Operation 14.3.1 Transfer Mechanism • A charge is applied to the Image Transfer Roller to transfer the toner image formed on the surface of the Photo Conductor onto the paper.
  • Page 75: Charge Neutralization And Separation Of Paper

    14. Transfer Corona section Theory of Operation Ver. 2.5 Jul. 2006 14.3.3 Charge neutralization and separation of paper A. Charge Neutralizing Plate • To neutralize any charge potential left in the paper which has undergone the image trans- fer stage, there is the Charge Neutralizing Plate fitted to the guide plate after the Transfer Roller.
  • Page 76: Toner Collecting Section

    Theory of Operation Ver. 2.5 Jul. 2006 15. Toner Collecting section 15. Toner Collecting section 15.1 Composition Toner Conveying Roller 1 Recycling Duct 4040T2C512AA 4040T2C556AA 15.2 Drive IU Motor Toner Conveying Roller 2 Toner Conveying Roller 1 4040T2C555AA...
  • Page 77: Operation

    15. Toner Collecting section Theory of Operation Ver. 2.5 Jul. 2006 15.3 Operation 15.3.1 Toner recycling mechanism • The Cleaning Blade pressed up against the surface of the Photo Conductor scrapes residual toner off the surface. The toner is then conveyed by the Toner Conveying Rollers 1/2 to the Recycling Duct and eventually back to the Developer Mixing Chamber.
  • Page 78: Paper Feed Section

    Theory of Operation Ver. 2.5 Jul. 2006 16. Paper feed section 16. Paper feed section 16.1 Composition 16.1.1 Tray1 Tray 1 Feed Roller Tray1 Pick-up Roller Tray1 separation roller 4040T2C572AA 4040T2C513AA Tray1 Paper Near-Empty Sensor (PC8) Tray1 Paper Lift Motor (M7) 1st Drawer Paper Feed Clutch (CL3) Tray1 Set Sensor (PC7) Tray1 Paper Lift Sensor (PC6)
  • Page 79: Tray2

    16. Paper feed section Theory of Operation Ver. 2.5 Jul. 2006 16.1.2 Tray2 Tray2 Feed Roller Tray2 Pick-up Roller Tray2 separation roller 4040T2C573AA 4040T2C514AA Tray2 Paper Near-Empty Vertical Conveyance Clutch Tray2 Paper Lift Motor (M8) Sensor (PC14) (CL2) Tray2 Set Sensor Vertical Conveyance Sensor (PC13) (PC2)
  • Page 80: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 16. Paper feed section 16.2 Drive 16.2.1 Tray1 Main Motor (M1) 1st Drawer Paper Feed Clutch (CL3) Tray1 Feed Roller Tray1 Paper Lift Motor (M7) Tray1 separation roller Tray1 Paper Near-Empty Tray1 Paper Empty Sensor (PC8) Sensor (PC9) Tray1 Pick-up Roller...
  • Page 81: Operation

    16. Paper feed section Theory of Operation Ver. 2.5 Jul. 2006 16.3 Operation 16.3.1 Paper Feed control (Tray1) Main Motor (M1) Paper Exit Sensor (PC4) Synchronizing Roller Sensor (PC1) Synchronizing Roller Clutch (CL1) 1st Drawer Paper Feed Clutch (CL3) IU Motor (M2) 4040T2E599AA 16.3.2 Paper Feed control (Tray2)
  • Page 82: Paper Feed Mechanism

    Theory of Operation Ver. 2.5 Jul. 2006 16. Paper feed section 16.3.3 Paper Feed Mechanism • The Paper Feed Motor drives the Pick-up Roller and Paper Take-up Roller to take up and feed a sheet of paper into the main unit. •...
  • Page 83: Paper Near-Empty/Paper Empty Detection

    16. Paper feed section Theory of Operation Ver. 2.5 Jul. 2006 16.3.4 Paper Near-Empty/Paper Empty detection • When the Paper Empty Sensor is blocked/unblocked, a corresponding warning display is given on the control panel. 16.3.5 Tray ascent operation • When the drawer is slid into the main unit and the Set Sensor is activated, the Lift Motor starts rotating to raise the Paper Lifting Plate.
  • Page 84: Paper Size Detection

    Theory of Operation Ver. 2.5 Jul. 2006 16. Paper feed section 16.3.6 Paper size detection • When the Trailing Edge Stop of the drawer is moved, the circular plate located on the bot- tom of the drawer turns, allowing the four switches to detect the paper length. •...
  • Page 85: On/Off Positions Of Paper Size Detecting Switches/Sensors And Corresponding Paper Size Detected

    16. Paper feed section Theory of Operation Ver. 2.5 Jul. 2006 16.3.7 ON/OFF positions of Paper Size Detecting Switches/Sensors and Corre- sponding Paper Size Detected FD Paper Size Board 1 (PWB-I1) Tray1 CD Paper Tray1 CD Paper FD Paper Size Board 2 (PWB-I2) Size Sensor1 Size Sensor2 Paper Size...
  • Page 86: Paper Level Indicator Mechanism

    Theory of Operation Ver. 2.5 Jul. 2006 16. Paper feed section 16.3.8 Paper level indicator mechanism • There is a window in the front cover of the drawer for indicating the paper supply level. • When the Paper Lifting Plate goes up, a red lever appears in the window. The lower the level of the paper stack, the more the red portion is visible.
  • Page 87: Bypass Section

    17. Bypass section Theory of Operation Ver. 2.5 Jul. 2006 17. Bypass section 17.1 Composition Bypass FD Paper Size Sensor/1 (PC19) Bypass FD Paper Size Sensor/2 (PC20) 4040T2C515AA 4037T2C535AA Bypass FD Paper Size Sensor/3 (PC21) Bypass FD Paper Size Sensor/4 (PC22) Bypass Paper Empty Sensor (PC18) Bypass Pick-Up Solenoid (SL3) Bypass Feed Roller...
  • Page 88: Drive

    Theory of Operation Ver. 2.5 Jul. 2006 17. Bypass section 17.2 Drive Main Motor (M1) Bypass Paper Feed Clutch (CL5) Bypass Pick-Up Solenoid (SL3) Bypass Feed Roller Bypass Separation Roller 4040T2C562AA 17.3 Operation 17.3.1 Bypass Paper Feed control Main Motor (M1) Synchronizing Roller Sensor (PC1) Vertical Conveyance Sensor (PC2) Synchronizing Roller Clutch (CL1)
  • Page 89: Paper Empty Detection

    17. Bypass section Theory of Operation Ver. 2.5 Jul. 2006 17.3.2 Paper Empty detection • The Bypass Paper Empty Sensor detects a paper empty condition in the Bypass Sec- tion. Bypass Paper Empty Sensor (PC18) 4036ma2530c0...
  • Page 90: Bypass Paper Lifting Motion Control

    Theory of Operation Ver. 2.5 Jul. 2006 17. Bypass section 17.3.3 Bypass Paper Lifting Motion Control • At the start of a Bypass paper take-up sequence, the Bypass Paper Pick-up Solenoid is energized to raise the Paper Lifting Plate so that the sheet of paper can be taken up. When the print cycle is completed, the Bypass Paper Pick-up Solenoid is energized again to return the Paper Lifting Plate to the standby position.
  • Page 91: Paper Size Detection

    17. Bypass section Theory of Operation Ver. 2.5 Jul. 2006 17.3.4 Paper size detection • The size of the paper loaded in the Bypass Section is detected by the combination of ON or OFF positions of the four Bypass FD Paper Size Sensors and the Bypass Paper Size Detection Unit.
  • Page 92: Synchronizing Roller/Conveyance Section

    Theory of Operation Ver. 2.5 Jul. 2006 18. Synchronizing Roller/Conveyance section 18. Synchronizing Roller/Conveyance section 18.1 Composition Synchronizing Roller 4040T2C539AA 4040T2C516AA 18.2 Drive Main Motor (M1) Synchronizing Roller Clutch (CL1) Synchronizing Roller 4040T2C559AA...
  • Page 93: Operation

    18. Synchronizing Roller/Conveyance section Theory of Operation Ver. 2.5 Jul. 2006 18.3 Operation • A loop is formed in the paper between the Transport Roller and Registration Roller during the paper transportation to correct skewed paper feeding. The amount of the paper loop can be adjusted using “Loop Adjust”...
  • Page 94: Fusing Section

    Theory of Operation Ver. 2.5 Jul. 2006 19. Fusing section 19. Fusing section 19.1 Composition Fusing Unit 4040T2C540AA 4040T2C517AA Heating Roller Fusing Roller Heater Lamp (H1) Pressure Roller Fusing Roller Thermistor (TH1) Fusing Roller Sub Thermistor (TH2) 4040T2C541AA Fusing Roller Sub Heater Lamp (H2) Fusing Roller Sub Fusing Roller Thermostat (TS1) Thermistor (TH2)
  • Page 95: Drive

    19. Fusing section Theory of Operation Ver. 2.5 Jul. 2006 19.2 Drive Pressure Roller Heating Roller Main Motor (M1) 4040T2C560AA...
  • Page 96: Operation

    Theory of Operation Ver. 2.5 Jul. 2006 19. Fusing section 19.3 Operation 19.3.1 Fusing Roller drive control • Drive of the Fusing Unit is controlled by the Main Motor. • The Main Motor drives the Heating Roller and the Pressure Roller is driven by the Heat- ing Roller.
  • Page 97 19. Fusing section Theory of Operation Ver. 2.5 Jul. 2006 for Europe area (bizhub 350) Warm-up Completed Start Key ON Main Power Switch ON 14 sec 4040T2M603AA : Fusing Roller Thermistor (TH1) : Fusing Roller Sub Thermistor (TH2) During the warm-up cycle In standby state (Mode3) Heating Roller temperature: 165 °C Heating Roller temperature: 165 °C...
  • Page 98 Theory of Operation Ver. 2.5 Jul. 2006 19. Fusing section A. Warm-up Fusing Roller Thermistor Fusing Roller Sub Thermistor (TH1) (TH2) Warm-up completion 165 °C 160 °C temperature B. During a copy cycle (for US and Canada area) • To achieve the intended level of fusing performance, the set temperature of each roller is varied according to the paper type.
  • Page 99: Protection Against Abnormal Conditions

    19. Fusing section Theory of Operation Ver. 2.5 Jul. 2006 E. In standby (for Europe area) Fusing Roller Thermistor Fusing Roller Sub Thermistor (TH1) (TH2) Mode1: 190 °C Standby temperature Mode2: 190 °C -> 165 °C Mode3: 165 °C 19.3.3 Protection against abnormal conditions •...
  • Page 100 Theory of Operation Ver. 2.5 Jul. 2006 19. Fusing section Abnormality protection 4 Inter Lock SW Abnormality protection 1 Sub SW TR_A TR_B Hardware Protect Hardware Protect Heater Remote FUSE Zero Cross Abnormality protection 2 PWB-A MFB Board HEATER Main Unit Abnormality protection 3 Main SW 4040T2C548AA...
  • Page 101: Paper Exit Section

    20. Paper exit section Theory of Operation Ver. 2.5 Jul. 2006 20. Paper exit section 20.0.1 Composition 4040T2C584AA 4040T2C517AA 20.1 Drive Exit Roller Main Motor 4040T2C561AA...
  • Page 102: Image Stabilization Control

    Theory of Operation Ver. 2.5 Jul. 2006 21. Image stabilization control 21. Image stabilization control 21.1 Overview • The image stabilization control is provided to ensure that the image quality is consistent, as caused by fluctuating environmental conditions and degraded durability. •...
  • Page 103: Image Processing

    22. Image processing Theory of Operation Ver. 2.5 Jul. 2006 22. Image processing 22.1 Scanner section image processing block diagram 1. Photoelectric Conversion MFBS Board 2. Analog-to-Digital Conversion 3. Image Processing Zoom, MTF correction, ABC processing 4. Binarization 5. White Masking 6.
  • Page 104: Write Section Image Processing Block Diagram 1

    Theory of Operation Ver. 2.5 Jul. 2006 22. Image processing 22.2 Write section image processing block diagram 1 MFBS Board From SDRAM or Expanded Memory Unit 1. File Management 2. Decoding 3. Reduction (for fax) 4. Rotate/Edit 5. Resolution Conversion (for fax) 6.
  • Page 105: Other Control

    23. Other control Theory of Operation Ver. 2.5 Jul. 2006 23. Other control 23.1 Fan control 23.1.1 Construction Cooling Fan Motor (M5) Toner Suction Fan Motor (M11) Fusing Unit Cooling Fan Motor (M10) IU Cooling Fan Motor (M6) Power Supply Cooling Fan Motor (M4) 4040T2C585AA...
  • Page 106: Operation

    Theory of Operation Ver. 2.5 Jul. 2006 23. Other control 23.1.2 Operation A. Function Motor Name Control Conditions Power Supply Cooling Fan • It exhausts the accumulated heat inside the unit in order to prevent Motor (M4) temperature from increasing at DC power supply part. •...
  • Page 107: Parts Operated When The Power Switch And Auxiliary Power Button Are

    23. Other control Theory of Operation Ver. 2.5 Jul. 2006 23.2 Parts Operated When the Power Switch and Auxiliary Power Button are turned ON 23.2.1 Parts operated when the Power Switch and Auxiliary Power Button are turned ON • When the Auxiliary Power Button is turned ON, the Control Board detects it and sends a control signal to the DC Power Supply.
  • Page 108: Counter Control

    Theory of Operation Ver. 2.5 Jul. 2006 23. Other control 23.3 Counter control 23.3.1 Construction Key Counter Total Counter (option) PWB-A Electronic Counter MFBS 4040T2C590AA Name Function • Shows the cumulative number of copies made in all copy modes Total Counter •...
  • Page 109 23. Other control Theory of Operation Ver. 2.5 Jul. 2006 Blank Page...
  • Page 110 SERVICE MANUAL THEORY OF OPERATION Duplex Unit/ Switchback Unit 2005.08 Ver. 1.0...
  • Page 111 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 112 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS Duplex Unit / Switchback Unit Outline System configuration....................1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Drive ........................4 Switchback Drive ....................4 Transport/Duplex Paper Feed Drive..............4 Operation ........................ 5 Paper Transport Path Switching Mechanism ............
  • Page 113 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 114: Outline

    Theory of Operation Ver. 1.0 Aug. 2005 1. System configuration Outline System configuration A. Type (1) Duplex Unit Name Duplex Unit Type Switchback and Circulating Duplex Unit Installation Mounted on the right side door of main unit Document Alignment Center B.
  • Page 115: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Feed Path Switchback to Main Unit Paper is fed into the main unit again 4346T1C501AA...
  • Page 116: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition Switchback Unit Section Duplex Unit Section 4346T2C501AA...
  • Page 117: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive Switchback Drive Switchback Motor (M3) Paper Exit Roller (Switchback Unit) 4346T2C528AA Transport/Duplex Paper Feed Drive Duplex Unit transport Drive Section 4346T2C503AA...
  • Page 118: Operation

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operation Operation Paper Transport Path Switching Mechanism 5.1.1 Transport path switching operation • The Switchback Solenoid of the Switchback Unit drives the Exit/Switchback Selecting Gate to select the paper path either toward the exit section or the switchback section. •...
  • Page 119: Switchback Mechanism

    5. Operation Theory of Operation Ver. 1.0 Aug. 2005 Switchback mechanism 5.2.1 Switchback operation • The Switchback Unit Sensor is deactivated as the trailing edge of the paper moves past it. After a given period of time, the paper is brought to a temporary stop. As the Switch- back Motor turns backward, the paper undergoes a switchback operation and is fed to the Duplex Unit with its trailing edge first.
  • Page 120: Switchback Motor Control

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operation 5.2.2 Switchback Motor Control • The Duplex Unit is driven through the Duplex Unit Transport Clutches from the Main Motor. • When Duplex Unit Transport Clutch 1 (CL6) is energized, Duplex Unit Transport Roller 1 is driven.
  • Page 121: Transport Control

    5. Operation Theory of Operation Ver. 1.0 Aug. 2005 Transport Control 5.3.1 2-sided printing method • The following two types of 2-sided printing methods are available. 2-sided printing with a single sheet of paper resident in the system: B4S (364 mm) to Ledger (431.8 mm) 2-sided printing with two sheets of paper resident in the 2-Sided Printing Methods system: Letter (215.9 mm) to B4S (364 mm)
  • Page 122 Theory of Operation Ver. 1.0 Aug. 2005 5. Operation Operation 4 • The main unit carries out the second print cycle to pro- duce the print image of the first page of the original on the other side of the 1-sided print. 4346T2C509AA Operation 5 •...
  • Page 123 5. Operation Theory of Operation Ver. 1.0 Aug. 2005 B. Operations in 2-sided printing with two sheets of paper resident in the system Operation 1 • The first sheet of paper is taken up and fed in from the main unit drawer and the main unit starts the first print cycle to produce the print image of the second page of the original.
  • Page 124 Theory of Operation Ver. 1.0 Aug. 2005 5. Operation Operation 6 • The third 1-sided print is transported to the Switchback Unit. • Immediately before the third 1-sided print is fed out by the Exit Roller of the Switchback Unit, the direction of rotation of the Exit Roller is reversed and the third 1- sided print is transported toward and into the Duplex Unit.
  • Page 125 5. Operation Theory of Operation Ver. 1.0 Aug. 2005 C. Operations in 2-sided printing with three sheets of paper resident in the system Operation 1 • The first sheet of paper is taken up and fed in from the main unit drawer and the main unit starts the first print cycle to produce the print image of the second page of the original.
  • Page 126 Theory of Operation Ver. 1.0 Aug. 2005 5. Operation Operation 4 • The third 1-sided print is transported to the Switchback Unit. • At the same time that the third 1-sided print is trans- ported, the first 1-sided print that has stood by in the Duplex Unit for the subsequent paper motion is trans- ported into the main unit.
  • Page 127 5. Operation Theory of Operation Ver. 1.0 Aug. 2005 Operation 8 • A print cycle is carried out to produce a print image of the third page of the original to the second 1-sided print. • At the same time, the fourth 1-sided print is transported toward and into the Duplex Unit.
  • Page 128 SERVICE MANUAL THEORY OF OPERATION FK-503 2005.08 Ver. 1.0...
  • Page 129 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 130 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS FK-503 Outline Product specifications ..................... 1 Circuitry Operation ....................4 Composition/Operation Summary of Board functions................... 5 MFBS Board ......................6 3.1.1 Main Controller....................6 3.1.2 Reading Controller ..................8 3.1.3 Image Data Processor ................10 3.1.4 Network Control ..................
  • Page 131 Theory of Operation Ver. 1.0 Aug. 2005 Encoding Method ....................24 Selecting Print Paper .................... 25 Printing Area....................... 25 Printing Mode ..................... 26 5.2.1 Automatic reduction mode ................26 5.2.2 Cut off mode ....................26 Print Paper Selection Mode (FAX)..............27 5.3.1 Standard mode ...................
  • Page 132: Outline

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Outline Product specifications A. Type Memory Capacity 32MB Communication mode G3/ECM Scanning resolution 8 x 3.85 line/mm (main line x feed line) 8 x 7.7 line/mm 8 x 15.4 line/mm 16 x 15.4 line/mm Data speed G3 / ECM: 2.4 Kbps - 33.6 Kbps...
  • Page 133 High speed scanning (0.55 sec/Letter fine) bizhub 350 35 ppm/A4 High speed printout bizhub 250 25 ppm/A4 Speed bizhub 200 20 ppm/A4 ECM mode (2 sec approx./Std document) High speed half tone Super fine mode Half tone transmission Auto retransmission after error...
  • Page 134 Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Function bizhub 350, 250, 200 Activity report (TX/RX) Transmission report (with document merge) Incompleted transmission report (with document merge) Serial broadcast report (with document merge) Account list Report functions One-Touch list Fax program list Bulletin Board list Confidential list...
  • Page 135: Circuitry Operation

    2. Circuitry Operation Theory of Operation Ver. 1.0 Aug. 2005 Circuitry Operation Fax Multi Line (ML-502) LINE1 Fax Board LINE1 (FK-503) TEL1 Compact Flash Operation Panel Speaker BCRS Board Sensor RAMS Inverter Board MFBS Board (INV) Exposure Lamp(LA2) Mechanical Control Board 4551T1E502AA...
  • Page 136: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions Composition/Operation Summary of Board functions Name Description This Board is a micro program control circuit that forms the nucleus of the PMC RM5231A external 32 bit RISC processor, and performs control of the control circuit of each PKG by software.
  • Page 137: Mfbs Board

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 MFBS Board • The MFBS board is a main controller that has an external 32 (internal 64) bit RISC pro- cessor, and controls circuits by software. As the primary functions, it controls the trans- mitter, reader, printer, mechanically moving parts, operation unit, and network.
  • Page 138 Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions C. Function (1) RM5231A • This is the CPU of the system. It is an external 32 (internal 64) bit RISC processor. (2) DEM LSI • It connects the CPU and the controller for controlling overall operation of the system. (3) Program memory (RAMS board section) •...
  • Page 139: Reading Controller

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 3.1.2 Reading Controller A. Overview • This controller performs reading controls that form the nucleus of the ESP3 LSI. It has a CCD output image process circuit, binary image process circuit, motor control circuit and sensor I/F circuit.
  • Page 140 Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions C. Function (1) CCD driver circuit • Necessary blocks are formed for the CCD drive with a built-in ESP3 LSI. (2) CCD output image process circuit <Analog process circuit> •...
  • Page 141: Image Data Processor

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 3.1.3 Image Data Processor A. Overview • This processor has interface blocks with the BS unit or the printer units, and the Fax communication block. It has a storage coder/decoder and a storage code memory man- ager (DEM LSI), image memory (SDRAM FILE), a printer controller (DEM LSI), a modem (V.34), and a communication controller (DEM LSI).
  • Page 142 Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions C. Function (1) Storage coder/decoder (DEM LSI) • The coder function codes image data into stored code data. The decoder function decodes stored code data into image data. (2) Image memory manager (DEM LSI) •...
  • Page 143: Network Control

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 3.1.4 Network Control A. Overview • This control unit provides for the network LAN (10BaseT/100BaseTX) interface by the PCI bus and the USB2.0 (full speed) interface that can be used for the PC printer. B.
  • Page 144: Expansion Interface

    Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions 3.1.5 Expansion Interface A. Overview • This interface block has an expansion interface for various system options. B. Block diagram DEM-LSI Extended Memory (MEM/MEMS board) Extended Memory (MEM/MEMS board) Super G3 FAX FAX board- Standard Super G3 FAX...
  • Page 145: Fax Board

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 FAX Board 3.2.1 Overview • This board comes loaded with a G3 modem for communicating Super G3 facsimile com- munications. Cascade connection of two identical fax boards easily achieves a multi- port.
  • Page 146 Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions C. Image memory backup circuit (Si3056 silicone DAA) • The silicone DAA (Direct Access Arrangement) processes almost all kinds of analog communications for blocks following the modem DSP or blocks from the analog front-end section (AFE) to the line.
  • Page 147: Rams Board

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 RAMS Board 3.3.1 Overview • This board mounts a flash memory storing the program to operate the system. • It also has a clock IC circuit, a SRAM circuit for storing different types of registration infor- mation, and a file memory backup circuit by an Ni-MH battery.
  • Page 148: Bcrs Board

    Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions BCRS Board 3.4.1 Overview • The BCRS relays between the MFBS board and the Xe lamp and S motor of the Scanner unit, the CCDS board, and the Operation Panel, and various sensors. •...
  • Page 149: Mem Board

    3. Summary of Board functions Theory of Operation Ver. 1.0 Aug. 2005 MEM Board 3.5.1 Overview • This board is used as memory for image information for expansion. • Its memory capacity is 32 MB. • Insert this board into a memory expansion slot of the MFBS board. 3.5.2 Block diagram SDRAM...
  • Page 150: Mems Board

    Theory of Operation Ver. 1.0 Aug. 2005 3. Summary of Board functions MEMS Board 3.6.1 Overview • This board is used as memory for image information for expansion. • Its memory capacity is 128 MB. • Insert this board into a memory expansion slot of the MFBS board. 3.6.2 Block Diagram MEMS...
  • Page 151: Communication Control

    4. Communication Control Theory of Operation Ver. 1.0 Aug. 2005 Communication Control • Communication control of this system follows ITU-T (previously known as CCITT) recom- mended T.30 binary procedure (G3/ECM; error collection mode). • Communication mode will be selected automatically with the type of phone line (PSTN) and the ID signal from a remote terminal.
  • Page 152 Theory of Operation Ver. 1.0 Aug. 2005 4. Communication Control <Post-control> Source Terminal Sh Sh PPS- Flags "1" Image Data Line Disconnect Recipient Terminal Sh Sh ALT Flags Flags Line Disconnect 4551T2C503AA...
  • Page 153 4. Communication Control Theory of Operation Ver. 1.0 Aug. 2005 4.1.1 V.34 Mode Communication Procedure • V3.4 mode does not always select the transmission speed of 36.6 Kbit/s. An optimal transmission speed will be selected according to the sequences described in the item 3 and 4 below in order to establish communication.
  • Page 154: Communication Mode

    Theory of Operation Ver. 1.0 Aug. 2005 4. Communication Control Communication Mode 4.2.1 Priority • This system has two communication modes: ECM and G3. Communication will be estab- lished with an appropriate mode determined by the capability of the remote terminal. The priority of the communication modes is as follows: Communication Priority...
  • Page 155: Encoding Method

    4. Communication Control Theory of Operation Ver. 1.0 Aug. 2005 Encoding Method • There are 4 encoding methods available to this system: JBIG, MMR, MR, MH. An opti- mal method will be selected according to the capabilities and image quality of both termi- nals.
  • Page 156: Selecting Print Paper

    Theory of Operation Ver. 1.0 Aug. 2005 5. Selecting Print Paper Selecting Print Paper Printing Area • The figure below shows the printable area on the paper. • The minimum margins are 4 mm. 4551T2C504AA...
  • Page 157: Printing Mode

    5. Selecting Print Paper Theory of Operation Ver. 1.0 Aug. 2005 Printing Mode • There are 2 printing modes available to this system. The soft switch (MODE 007) toggles these modes. They are valid only for printing received documents. 5.2.1 Automatic reduction mode •...
  • Page 158: Print Paper Selection Mode (Fax)

    Theory of Operation Ver. 1.0 Aug. 2005 5. Selecting Print Paper Print Paper Selection Mode (FAX) • This system has the following modes for selecting print paper. The soft switch (MODE 008) toggles these modes. • They are valid only for printing received documents. 5.3.1 Standard mode •...
  • Page 159: Fixed Width Mode

    5. Selecting Print Paper Theory of Operation Ver. 1.0 Aug. 2005 5.3.3 Fixed width mode • This mode selects print paper whose width is the same as a received document. Example: Metric area Available sizes of print paper: A4 Lengthwise and A3 Lengthwise Size of received document B4 Lengthwise Printing mode...
  • Page 160 Theory of Operation Ver. 1.0 Aug. 2005 5. Selecting Print Paper The following table summarizes the effective print length for print paper which this system can use: Print paper size Effective print size Print paper size Remark Sub scanning Main scanning Sub scanning Main scanning length...
  • Page 161: Print Paper Size Selections (When Receiving)

    5. Selecting Print Paper Theory of Operation Ver. 1.0 Aug. 2005 5.3.4 Print paper size selections (when receiving) • This system automatically selects and prints on the most suitable print paper for the received document from the available print paper cassettes. <Print paper selection when factory set>...
  • Page 162: Paper Detection

    Theory of Operation Ver. 1.0 Aug. 2005 5. Selecting Print Paper 5.3.5 Paper detection <Method to declare print paper size to facsimile of other party when print paper has run out> <Method to declare print paper size to facsimile of other party when print paper has run out>...
  • Page 163: List Of Reports

    6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 List of Reports Report name Auto print Manual print TRANSMISSION REPORT – Transmission SERIAL BROADCAST REPORT – management TRANSMISSION REPORT (for incompleted TX) – ACTIVITY REPORT (TX) Statistical management ACTIVITY REPORT (RX) Memory MEMORY CLEAR REPORT...
  • Page 164: Activity Report (Tx)

    Theory of Operation Ver. 1.0 Aug. 2005 6. List of Reports Activity Report (TX) ACTIVITY REPORT ( TX ) (FRI) MAY 28 2003 15:16 ACCOUNT NAME SIZE DOCUMENT# TIME SENT DURATION DESTINATION MODE PAGE RESULT 6500000-000 MAR 28 14:04 22" 2134 6500000-002 MAR 28 14:12...
  • Page 165: Activity Report (Rx)

    6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 Activity Report (RX) ACTIVITY REPORT ( RX ) (FRI) MAY 28 2003 15:16 DOCUMENT# TIME RCVED DURATION DESTINATION MODE PAGE RESULT ACCOUNT NAME 5534567-003 MAY 28 14:09, 1" ifax@abc.dd.com 5534567-004 MAY 28 14:12 1"...
  • Page 166: Protocol Trace

    Theory of Operation Ver. 1.0 Aug. 2005 6. List of Reports Protocol Trace • Each communication processes information on a protocol trace. • If you wish to print it, go to the maintenance mode to press <Utility>. 6.3.1 G3 Protocol Trace 27F51E5E FF 13 22 00 00 49 0C D2 27F51F08...
  • Page 167: Network Protocol Trace

    6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 Network Protocol Trace 27F51E5E FF 13 22 00 00 49 0C D2 27F51F08 FF 03 20 00 00 49 40 00 00 00 00 C8 C8 ..34 7D 02 00 DA 80 7E 04 86 10 89 20 19 50 7C 20 ..
  • Page 168: Service Call Report

    Theory of Operation Ver. 1.0 Aug. 2005 6. List of Reports Service Call Report P. 1 SERVICE CALL REPORT REPORT CONTENTS : DATE CALLED USER INFO TEL1 : TEL2 : TX CONDITION TRANS. METHOD : DATA SERVICE DST. : G3 : E-MAIL MAINTENANCE : OFF ADDRESS : SERVICE FAX # : CONTACT # :...
  • Page 169 6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 B. USER AND TERMINAL INFORMATION • This report has various information on users and terminals of your facsimile system. (1) Phone number <Details> • USER INFO TEL1 • USER INFO TEL2 •...
  • Page 170 Theory of Operation Ver. 1.0 Aug. 2005 6. List of Reports (7) MACHINE CONFIGURATION <Details> • MEMORY (0 MB or 32 MB or 64 MB or 128 MB) • PC PRT (ON or OFF) • PRINTER TYPE (PCL or PS) •...
  • Page 171 6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 C. Counter information (COUNTER INFO) <Details> Count Timing Counter Type Counting Method Paper Paper Others Feed Ejec The total number of printed pages TOTAL (large size (A3) paper is counted two) LARGE SIZE The number of printed pages produced TOTAL...
  • Page 172 Theory of Operation Ver. 1.0 Aug. 2005 6. List of Reports Count Timing Counter Type Counting Method Paper Paper Others Feed Ejec Per Paper size The number of used sheets PAPER Per Special COUNTER The number of used sheets paper setting SERVICE The number CALL...
  • Page 173 6. List of Reports Theory of Operation Ver. 1.0 Aug. 2005 (2) Printer <Details> • EDGE ERASE LEAD • EDGE ERASE TRAIL • EDGE ERASE (R/L) • TRAIL ERASE (DUP) • LOOP ADJ. (1ST) • LOOP ADJ. (2ND) • LOOP ADJ. (3RD) •...
  • Page 174 SERVICE MANUAL THEORY OF OPERATION DF-605 2005.08 Ver. 1.0...
  • Page 175 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 176: Content

    Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS DF-605 Outline Product specifications ..................... 1 Paper Feed 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 ..................
  • Page 177 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 178 Theory of Operation Ver. 1.0 Aug. 2005 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 179: Product Specifications

    1. Product specifications Theory of Operation Ver. 1.0 Aug. 2005 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 180 Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications F. Mixed original feed chart For Metric Max. Original 297 mm 257 mm 210 mm 182 mm 148 mm Size Mixed Original Size 297 mm 257 mm 210 mm 182 mm 148 mm 123 mm For Inch...
  • Page 181: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Feed Path In 1-sided mode 3: Exit 2: Transport and turnover 1: Feed (scanning the 1st side) 4344T1C501AA In 2-sided mode 2: Transport and switchback 6: Exit 4: Transport and switchback 1: Feed (scanning the 1st side) 3: Transport and turnover (scanning the 2nd side) 5: Transport...
  • Page 182: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition Document feed section Conveyance section Switchback section Document exit section 4344T2C501AA...
  • Page 183: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive Paper Feed Motor (M1-ADF) 4344T2C502AA Transport Motor (M2-ADF)
  • Page 184: Operation

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operation Operation Document pick-up mechanism • The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separa- tion Roller, and this section is driven by the Paper Feed Motor. 5.1.1 Pick-up operation •...
  • Page 185: Document Feed/Transport Mechanism

    5. Operation Theory of Operation Ver. 1.0 Aug. 2005 Document feed/transport mechanism • When the document reaches the Registration Sensor, the Feed Roller starts turning for- ward and, at the same time that the Pickup Roller goes up, drive is then supplied to the Registration Roller.
  • Page 186 Theory of Operation Ver. 1.0 Aug. 2005 5. Operation A. Operation flow in the 1-sided mode Original Detection Sensor Exit Scanning the 1st side Exit/Turnover Sensor 4344T2C506AA 1. When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start a paper take-up sequence.
  • Page 187 5. Operation Theory of Operation Ver. 1.0 Aug. 2005 B. Operation flow in the 2-sided mode 1. When the Start key is pressed, the Paper Feed Motor starts turning backward, causing the Pick-Up Roller to lower and start feeding the 1st page of the document. The scanning of the 1st side is started after the lapse of a given period of time after the Original Detection Sensor has been activated by the leading edge of the 1st page.
  • Page 188 Theory of Operation Ver. 1.0 Aug. 2005 5. Operation 4. To ensure that pages of the document are in the proper order, the page is turned over again before being ejected into the Exit Tray. Turnover Exit Scanning the 2nd side 4344T2C505AA...
  • Page 189: Raised/Lowered Position Detecting Mechanism

    5. Operation Theory of Operation Ver. 1.0 Aug. 2005 Raised/lowered position detecting mechanism 5.3.1 Document size detection • The 15 degree Open Detection Mechanism enables the main unit to detect the document size when the DF is used as the Original Cover of the main unit, there is the Lever Actu- ator provided in the DF body that blocks or unblocks a sensor to initiate a reconfirmation of the original size as read by the original size detection sensors.
  • Page 190 SERVICE MANUAL THEORY OF OPERATION PC-102/PC-202 2005.08 Ver. 1.0...
  • Page 191 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 192 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS PC-102/PC-202 Outline Product specifications ..................... 1 Type ........................1 Paper type ......................1 Machine specifications..................1 Operating environment ..................1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Drive system ......................4 Operations.......................
  • Page 193 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 194: Product Specifications

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Outline Product specifications Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center Paper type Paper Type Plain paper 56 to 90 g/m (15 to 24 lb) Paper Size...
  • Page 195: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Feed Path Paper fed from the 3rd Tray Transport to the main unit Main Vertical transport through PC PC-102/202 PC-202 only Paper fed from the 4th Tray 4061t1c001aa...
  • Page 196: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition Cassette Section Paper Feed Section PC-102/202 Only PC-202 4061t2c001aa...
  • Page 197: Drive System

    4. Drive system Theory of Operation Ver. 1.0 Aug. 2005 Drive system <PC-102> Tray3 Transport Roller Motor (M120-PF) Tray3 Paper Feed Motor (M122-PF) 4348M005AA Tray3 Transport Roller Motor (M120-PF) <PC-202> Tray3 Paper Feed Motor (M122-PF) Tray4 Transport Roller Motor (M121-PF) Tray4 Paper Feed Motor (M123-PF) 4348M002AB...
  • Page 198: Operations

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Operations Paper Feed Section 5.1.1 Vertical transport drive mechanism • The Paper Feed Motor drives the Pick-up Roller and Paper Take-up Roller to take up and feed a sheet of paper into the main unit. •...
  • Page 199: Paper Lifting Motion

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.1.2 Paper lifting motion • When the drawer is slid into the main unit and the Set Sensor is activated, the Lift-up Motor starts rotating to raise the Paper Lifting Plate. •...
  • Page 200: Cassette Section

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Cassette Section 5.2.1 Paper size detection • When the Trailing Edge Stop of the drawer is moved, the circular plate located on the bottom of the drawer turns, allowing the four FD Paper Size Sensors on the FD Paper Size Detection Board.
  • Page 201: Paper Level Indicator Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.2.2 Paper level indicator mechanism • All drawers now use the universal paper size tray for greater functionality. • There is a window in the front cover of the drawer that serves as the Paper Level Indica- tor showing the amount of paper that is still available for use.
  • Page 202 SERVICE MANUAL THEORY OF OPERATION PC-402 2005.08 Ver. 1.0...
  • Page 203 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 204 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS PC-402 Outline Product specification ....................1 Type ........................1 Paper type ......................1 Machine specifications..................1 Operating environment ..................1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Drive ........................4 Operations.......................
  • Page 205 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 206: Product Specification

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specification Outline Product specification Type Name Large Capacity Tray Type Front loading type LCT Installation Desk type Document Alignment Center Paper type Paper Type Plain paper 56 to 90 g/m (15 to 24 lb) Paper Size A4, 8-1/2 ×...
  • Page 207: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Feed Path Transport to the main unit Main Unit PC-402 Paper fed from the LCC Tray Main Tray 4061t1c101aa Sub Tray From the Sub Tray to Main Tray...
  • Page 208: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition Tray Section Paper Feed Section 4061t2c102aa Sub Tray Main Tray...
  • Page 209: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive Tray Lock Solenoid (SL1-LCT) Paper Feed Motor (M1-LCT) Transport Roller Motor (M2-LCT) Elevator Motor (M5-LCT) 4061t2c101aa Shift Gate Motor (M3-LCT) Shift Motor (M4-LCT)
  • Page 210: Operations

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Operations Paper Feed Section 5.1.1 Paper Feed drive mechanism • The Paper Feed Motor drives the Pick-up Roller and Paper Take-up Roller to take up and feed a sheet of paper into the main unit. •...
  • Page 211: Tray Section

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Tray Section 5.2.1 Elevator tray mechanism • The Main Tray is suspended by the cables at the front and rear. • As the Elevator Motor turns forward or backward, the cables are wound to raise or lower the tray.
  • Page 212: Shift Gate Drive Mechanism

    Theory of Operation Ver. 1.0 Aug. 2005 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. •...
  • Page 213: Paper Empty Detection

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.2.4 Paper empty detection • Paper empty detection of Main Tray is performed by Paper Empty Board. • Paper empty detection of Sub Tray is performed by Shift Tray Paper Empty Sensor. Main Tray Sub Tray 4348M623AA...
  • Page 214 SERVICE MANUAL THEORY OF OPERATION JS-502 2005.08 Ver. 1.0...
  • Page 215 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 216 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS JS-502 Outline System configuration....................1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Operations....................... 4 Job Separator Transport/Exit ................4...
  • Page 217 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 218: System Configuration

    Theory of Operation Ver. 1.0 Aug. 2005 1. System configuration Outline System configuration A. Type Name Job Separator Type Expansion drawer Installation Installed in the copier Document Alignment Center B. Paper type Exit Tray Size Type Capacity 250 sheets Plain Paper (56 to 90 g/m , 15 to 24 lb) OHP transparencies A6S to A3...
  • Page 219: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Feed Path Transport from the main unit 4689T2C501AB...
  • Page 220: Composition/Operation

    Theory of Operation Ver.1.0 Aug. 2005 3. Composition Composition/Operation Composition Job Separator section Switchback Unit section 4689T2C502AA...
  • Page 221: Operations

    4. Operations Theory of Operation Ver.1.0 Aug. 2005 Operations Job Separator Transport/Exit • The Switchback Unit functions to transport paper through, and feed it out from, the Job Separator. • The paper sensor section of the Job Separator is mounted to the Switchback Unit, thereby detecting paper.
  • Page 222 SERVICE MANUAL THEORY OF OPERATION FS-508/PU-501/ OT-601 2005.08 Ver. 1.0...
  • Page 223 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 224 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS FS-508/PU-501/OT-601 Outline Product specifications ..................... 1 FS-508 ........................1 PU-501 ......................... 3 OT-601 ........................4 Paper Feed Path ..................... 5 Feeding Paper to the 1st Exit Tray ................ 5 Feeding Paper to the 2nd Exit Tray............... 5 Feeding Paper to the 2nd Exit Tray (When OT-601 is Mounted)......
  • Page 225 Theory of Operation Ver. 1.0 Aug. 2005 Operation......................24 6.2.1 Skew correction mechanism ............... 24 6.2.2 Punch mechanism ..................25 6.2.3 Punch status detection ................25 6.2.4 Punch Trash Box full detection mechanism ..........26 Output Tray (OT-601)..................... 27 Composition ....................... 27 Operation......................
  • Page 226: Product Specifications

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Outline Product specifications FS-508 A. Type Name Multi staple finisher built into the copier Installation Installed in the copier Document Alignment Center Consumables Staples B. Functions Modes Non sort, sort, group, sort stable, and punch (when PU-501 is mounted) C.
  • Page 227 1. Product specifications Theory of Operation Ver. 1.0 Aug. 2005 (3) Sort Staple Type Size Weight Max. Capacity A6S to A3 Exit 200 sheets 5.5 to 11 x 17 Tray1 Max. A4S, 8.5 x 11S 1000 297 mm x 431.8 mm 56 to 90g/m or less sheets...
  • Page 228 Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications PU-501 A. Type Name Punch Unit PU-501 Installation Built into the Finisher B5S/B5 to A3 Paper Size 8.5 x 11S, 8.5 x 11, 8.5 x 14S, 11 x 17 Paper Type Plain Paper (60 to 163 g/m , 16 to 43.5 lb) Punch Hole...
  • Page 229 1. Product specifications Theory of Operation Ver. 1.0 Aug. 2005 OT-601 A. Type Name Output Tray OT-601 Installation Fixed to the Finisher Mode Non sort, sort, group, and sort stable Number of Bins 1 bin Document Alignment Center B. Paper Type Mode Size Type...
  • Page 230: Paper Feed Path

    Theory of Operation Ver. 1.0 Aug. 2005 2. Paper Feed Path Paper Feed Path Feeding Paper to the 1st Exit Tray Transporting paper to the 1st Exit Tray Feeding paper to the 1st Exit Tray Transporting paper from the main unit 4349T1C502AA Feeding Paper to the 2nd Exit Tray Transporting paper to the 2nd Exit Tray...
  • Page 231: Feeding Paper To The 2Nd Exit Tray

    2. Paper Feed Path Theory of Operation Ver. 1.0 Aug. 2005 Feeding Paper to the 2nd Exit Tray (When OT-601 is Mounted) Feeding paper to the 2nd Exit Tray Transporting paper to the 2nd Exit Tray Transporting paper from the main unit 4349T1C501AA...
  • Page 232: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition Elevator Section Transport Section 4349T2C501AA Staple Section...
  • Page 233: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive FS-508 Horizontal Transport Drive Section Elevator Drive Section PU-501 4349T2C502AA...
  • Page 234: Operations

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Operations Transport Section • The Transport Section is divided into the entrance transport section, intermediate trans- port section, and the exit transport section. It controls to transport the paper fed from the main unit, stop the paper at the punching and creasing positions, and drive the paper for feeding into the exit section.
  • Page 235: Entrance/Transport Section

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.1.1 Entrance/Transport section • The paper fed from the main unit is transported to the intermediate transport section. • The Entrance Motor (M3-FN) provides the drive for transporting the paper. • When the Entrance Motor (M3-FN) is energized, the Entrance Roller and Registration Roller are driven to rotate.
  • Page 236: Exit Transport Section

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.1.3 Exit Transport Section • The paper is transported onto each of the exit trays. • The Exit Motor provides drive for the Exit Roller, Storage Paddle, and Exit Paddle. Exit Open/Close Motor (M6-FN) Storage Paddle Exit Roller Exit Paddle...
  • Page 237: Elevator Section

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Elevator Section 5.2.1 Elevator mechanism • The elevator mechanism is operated to select a specific exit port, thereby feeding the paper out onto a specific exit tray. Elevator Motor (M11-FN) 4349T2C508AA 5.2.2 Elevator Tray Ascent/Descent •...
  • Page 238: Tray Position Detection Mechanism

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.2.3 Tray Position Detection Mechanism • The tray moves up or down according to the amount of paper fed onto it. • If the Elevator Tray Upper Limit Sensor is activated when a sheet of paper is fed onto the tray, the Elevator Tray is temporarily lowered until the Elevator Tray Upper Limit Sensor is deactivated and then the tray is raised to a level, at which the Elevator Tray.
  • Page 239 5. Operations Theory of Operation Ver. 1.0 Aug. 2005 A. Tray Position Detection • Tray position detection is controlled according to the number of times the Elevator Tray Home Position Sensor is activated after the Elevator Tray Lower Limit Sensor has been activated.
  • Page 240 Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Elevator Tray Home Position Sensor (PC3-FN) 4349T2C514AA 4. When the Elevator Tray Home Position Sensor (PC3-FN) is activated a second time after the ascent motion of the Elevator Tray has been started, it is determined that the Elevator Tray is now located at the exit port for the 2nd Exit Tray.
  • Page 241: Shutter Open/Close Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.2.4 Shutter Open/Close Mechanism • There is a shutter provided at the exit area of the finisher. The Shutter is normally in the raised position and the exit port is open. When the trays are moving, however, the Shut- ter is closed to ensure operator safety.
  • Page 242: Paper Aligning Section

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Paper aligning section 5.3.1 Paper aligning mechanism (sub scan direction) • Sheets of paper are aligned properly and stapled together inside the transport section before being fed out onto the corresponding exit tray. •...
  • Page 243: Paper Aligning Mechanism (Main Scan Direction)

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 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 sta- pling position. • The paper in the Storage Tray is aligned in the main scan direction by two Alignment Motors and aligning plates.
  • Page 244: Exit Mechanism

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.3.3 Exit mechanism • There is a paper holding paddle provided at the Exit Roller for preventing the copy set/ stack on the exit tray from being pushed by a new copy set/stack that is being fed out. •...
  • Page 245 5. Operations Theory of Operation Ver. 1.0 Aug. 2005 A. Upper exit roller up/down motion mechanism • The Exit Open/Close Motor moves the Upper Exit Roller away from the Lower Exit Roller or presses the Upper Exit Roller up against the Lower Exit Roller. •...
  • Page 246: Stapling

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Stapling 5.4.1 Stapling mechanism • Stapling is performed by the Stapling Unit. • When the Stapling Motor is rotated, the Clinch Arm lowers. The Stapler thereafter goes up to drive a staple in the paper. •...
  • Page 247: Stapling Unit Moving Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 5.4.2 Stapling Unit moving mechanism • The Stapling Unit is moved by the Stapling Unit Moving Motor. • The Stapling Unit Moving Motor drives the belt so that the Stapling Unit is moved to the corresponding stapling position.
  • Page 248: Staple Sheet Empty Detection

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.4.4 Staple sheet empty detection • Staple Empty Detection Sensor 1, 2 detect whether or not there is a staple sheet 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 con- trol panel.
  • Page 249: Punch Kit (Pk-6)

    6. Punch Kit (PK-6) Theory of Operation Ver. 1.0 Aug. 2005 Punch Kit (PK-6) Composition 4349T2C532AA Operation 6.2.1 Skew correction mechanism • For punch and center crease operations, a loop is formed in the paper at the Registration Roller to correct skew. •...
  • Page 250: Punch Mechanism

    Theory of Operation Ver. 1.0 Aug. 2005 6. Punch Kit (PK-6) 6.2.2 Punch mechanism • After a given period of time after the Entrance Sensor has detected the trailing edge of the paper, the Punch Motor is deenergized and a punch hole operation is made at the trailing edge portion in each sheet of paper.
  • Page 251: Punch Trash Box Full Detection Mechanism

    6. Punch Kit (PK-6) Theory of Operation Ver. 1.0 Aug. 2005 6.2.4 Punch Trash Box full detection mechanism • Punch trash produced as a result of punching operation is stored in the Punch Trash Box. • The Punch Trash Box is provided with the Punch Trash Full (PC1-PK). When a punch waste is detected, the corresponding message is displayed on the control panel.
  • Page 252: Output Tray (Ot-601)

    Theory of Operation Ver. 1.0 Aug. 2005 7. Output Tray (OT-601) Output Tray (OT-601) Composition 4349T2C531AA Operation 7.2.1 Overview • Mounting the optional Output Tray (OT-601) provides a total of three exit trays. • The Output Tray is attached at different positions depending on whether options SD-502/ MT-501 are mounted or not.
  • Page 253 7. Output Tray (OT-601) Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 254 SERVICE MANUAL THEORY OF OPERATION MT-501 2005.08 Ver. 1.0...
  • Page 255 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 256 Theory of Operation Ver.1.0 Aug. 2005 CONTENTS MT-501 Outline Product specifications ..................... 1 Paper Path....................... 2 Composition/Operation Composition ......................3 Drive ........................4 Operations....................... 5 Paper transport mechanism.................. 5 Paper path selection mechanism................6 Paper detection..................... 7...
  • Page 257 Theory of Operation Ver.1.0 Aug. 2005 Blank Page...
  • Page 258: Product Specifications

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Outline Product specifications A. Type Name Mailbin Kit Installation Install at the top section of the Finisher Elevator Tray. Number of Bins 4 bins Number of Sheets 125 sheets (80 g/m , 52.75 lb) Stored per Bin Storable Paper...
  • Page 259: Paper Path

    2. Paper Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Path 4510T2C501AA...
  • Page 260: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition 4510T2C506AA...
  • Page 261: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive Transport Motor (M1-MK) Transport Rollers Exit Rollers 4510T2C502AA...
  • Page 262: Operations

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Operations Paper transport mechanism • When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS- 508) and toward the Mailbin. • Drive for the Transport Rollers of the Mailbin is transmitted from the Transport Motor (M1-MK) by way of a belt.
  • Page 263: Paper Path Selection Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Paper path selection mechanism • The Bin Entrance Switching Solenoids are energized or deenergized to direct paper fed from the Finisher into a specific tray. • There are three Bin Entrance Switching Solenoids provided that will be energized or deenergized to operate the corresponding Bin Entrance Gate, thereby selecting a spe- cific paper path into a specific tray.
  • Page 264: Paper Detection

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Paper detection • The paper detection sensor detects any sheet of paper that is fed into the tray, causing the ADF LED to light up green steadily to inform the user that a sheet of paper has been fed into the tray.
  • Page 265 5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 266 SERVICE MANUAL THEORY OF OPERATION SD-502 2005.08 Ver. 1.0...
  • Page 267 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 268 Theory of Operation Ver. 1.0 Aug. 2005 CONTENTS SD-502 Outline Product specifications ..................... 1 Paper Path....................... 2 Composition/Operation Composition ......................3 Drive ........................4 Operations....................... 5 Paper transport mechanism.................. 5 Exit roller pressure/release ................... 6 5.2.1 Pressure/release mechanism ............... 6 5.2.2 Operation ......................
  • Page 269 Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 270: Product Specifications

    Theory of Operation Ver. 1.0 Aug. 2005 1. Product specifications Outline Product specifications A. Type Name Saddle Sticher SD-502 Type Built into the Finisher Installation Screwed to the Finisher Document Alignment Center Center parallel two points Stapling Function No. of sheets to be stapled together: 2 to 15 B.
  • Page 271: Paper Path

    2. Paper Path Theory of Operation Ver. 1.0 Aug. 2005 Paper Path 4511T2C504AA...
  • Page 272: Composition/Operation

    Theory of Operation Ver. 1.0 Aug. 2005 3. Composition Composition/Operation Composition 4511T2C501AA...
  • Page 273: Drive

    4. Drive Theory of Operation Ver. 1.0 Aug. 2005 Drive Saddle Exit Open/Close Motor (M9-SK) Upper Exit Roller Saddle Exit Motor (M8-SK) 4511T2C503AA...
  • Page 274: Operations

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Operations Paper transport mechanism • Paper is transported by the Exit Rollers of the Finisher and Exit Rollers of the Saddle Kit. • The Saddle Exit Motor provides the drive for the Exit Rollers of the Saddle Kit. •...
  • Page 275: Exit Roller Pressure/Release

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Exit roller pressure/release 5.2.1 Pressure/release mechanism • The Upper Exit Roller is moved away from, or pressed up against, the Lower Exit Roller, when the paper is fed out as a copy set/stack. •...
  • Page 276: Operation

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.2.2 Operation 1. The Upper Exit Roller is moved up or down by the cams which are driven by the Saddle Exit Open/Close Motor. 2. When the copy set/stack moves past the Exit Roller, the motor is energized to press the Upper Exit Roller up against the Lower Exit Roller, thereby feeding the copy set/stack out into the tray.
  • Page 277: Stapling Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Stapling mechanism • There are two The Stapling Units in the Saddle Kit, each being fixed to a specific posi- tion. • Since the unit is for center stapling only, it is made up of the upper clincher portion and the lower stapling portion.
  • Page 278: Layable Guide

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Layable guide • The Movable 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 curving.
  • Page 279: Center Creasing Mechanism

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Center creasing mechanism • The Entrance Sensor 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. Center creasing is effected as follows. Specifically, the paper undergoes a switchback operation and is transported to the center creasing position as the motor is turned backward.
  • Page 280: Operation

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations 5.5.1 Operation • When the Crease Motor is energized for one cycle of operation, the Lower Transport Guides are retracted to the right and left and the Crease Chopper makes one up-and- down reciprocating motion.
  • Page 281: In & Out Guide

    5. Operations Theory of Operation Ver. 1.0 Aug. 2005 In & out guide • When a copy set/stack is fed onto the tray, the In & Out 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 282: Tray Paper Detection

    Theory of Operation Ver. 1.0 Aug. 2005 5. Operations Tray paper detection • When paper is fed onto the tray, it pushes the actuator, which causes the Paper Detec- tion Sensor to detect the paper. Saddle Tray Empty Sensor (PC21-SK) 4511T2C513AA...
  • Page 283 5. Operations Theory of Operation Ver. 1.0 Aug. 2005 Blank Page...
  • Page 284 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to DD4040CE3 avoid disclosure of confidential information.

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