Konica Minolta bizhub C250 Service Manual
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Konica Minolta bizhub C250 Service Manual

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Download this manual See also: Service Manual, Function Manual
SERVICE MANUAL
THEORY OF OPERATION
This Service Manual is designed for machine
This Service Manual is designed for machine
with Firmware Card Ver. G4 and onward.
with Firmware Card Ver. G4 and onward.
2006.08
Ver. 3.0

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Summary of Contents for Konica Minolta bizhub C250

  • Page 1 SERVICE MANUAL THEORY OF OPERATION This Service Manual is designed for machine This Service Manual is designed for machine with Firmware Card Ver. G4 and onward. with Firmware Card Ver. G4 and onward. 2006.08 Ver. 3.0...

  • Page 2: Table Of Contents

    WARNING INDICATIONS ON THE MACHINE ............S-18 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 C250/C252 main unit General ........................... 1 Composition/operation ....................15 DF-601 Outline ..........................1 Composition/Operation ....................
  • Page 3 MT-501 Outline ..........................1 Composition/Operation ....................3 SD-503 Outline ..........................1 Composition/Operation ....................3 JS-601 Outline ..........................1 Composition/Operation ....................3 FS-603 Outline ..........................1 Composition/Operation ....................7 PK-501/PK-4/PK-131 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 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] FUSE CAUTION Double pole / neutral fusing ATTENTION Double pôle / fusible sur le neutre. [6] 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 U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class 1 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 LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 10 mW aallonpituus 775-800 nm VARNING!

  • Page 19: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. * Only for the U.S.A. 4038P0E505DA Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. 4038P0C503DA S-16...

  • Page 20: Precautions For Handling The Laser Equipment

    SAFETY AND IMPORTANT WARNING ITEMS PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. • When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the printer OFF.

  • Page 21: 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. High voltage •...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS WARNING WARNING • Do not position the used Waste • Do not burn used Toner Cartridges. Toner Box so that it is standing Toner expelled from the fire is dan- on end or tilted, otherwise toner gerous.

  • 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) PWB-MFP: MFP Control Board (2) bizhub C250/C252: Main Unit (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...

  • Page 26: Main Unit

    SERVICE MANUAL THEORY OF OPERATION Main Unit 2006.08 Ver. 3.0...
  • 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 Theory of operation ver. 3.0 Aug. 2006 CONTENTS bizhub C250/C252 main unit General System configuration....................1 Product specifications ..................... 4 Type ........................4 Functions ......................5 Types of paper ...................... 6 Maintenance ......................6 Machine specifications..................7 Operating environment ..................7 Print functions .......................
  • Page 29 Theory of operation ver. 3.0 Aug. 2006 8.2.5 Laser emission area ................... 28 8.2.6 Registration control (color shift correction) system........29 8.2.7 Skew control mechanism ................30 Imaging unit section (IU section)................31 Composition ....................... 31 Drive ........................32 Operation......................33 9.3.1 IU life control ....................
  • Page 30 16.3.3 Paper near-empty/paper empty detection........... 74 16.3.4 Paper type setting ..................75 16.3.5 Paper size detection control................ 76 16.3.6 Paper Interval control (PPM control) ............79 16.3.7 Tray2 paper lifting motion control ..............82 Bypass section (bizhub C250) ................83...
  • Page 31 Theory of operation ver. 3.0 Aug. 2006 17.1 Drive ........................84 17.2 Operation......................85 17.2.1 Bypass paper take-up control ..............85 17.2.2 Paper empty detection ................85 17.2.3 Paper width detection ................. 86 17.2.4 Bypass paper lifting motion control............. 87 Bypass section (bizhub C252) ................
  • Page 32 Theory of operation ver. 3.0 Aug. 2006 20.3.14 High temperature error detection (thermostat protection)......112 20.3.15 Detection of a new fusing unit ..............112 Paper exit section ....................113 21.1 Composition...................... 113 21.2 Drive ......................... 114 Image stabilization control................... 115 22.1 Overview......................
  • Page 33 Theory of operation ver. 3.0 Aug. 2006 Blank Page...

  • Page 34: General

    Theory of operation ver. 3.0 Aug. 2006 1. System configuration General System configuration 1/2 System front view (bizhub C250) [13] [12] [11] [10] 4038T1E101AA Machine Paper feed cabinet PC-403 Reverse automatic document feeder Desk DK-502 DF-601 Original cover OC-501 [10]...
  • Page 35 1. System configuration Theory of operation ver. 3.0 Aug. 2006 1/2 System front view (bizhub C252) [18] [17] [16] [15] [14] [11] [13] [12] [10] 4038F1E507DA Machine [10] Finisher FS-501 Reverse automatic document feeder DF-601 [11] Job separator JS-601 Original cover OC-501 [12] Finisher FS-603 Working table WT-501...
  • Page 36 Theory of operation ver. 3.0 Aug. 2006 1. System configuration 2/2 System rear view [11] [10] PC-103 DK-502 PC-203 PC-403 4038T1E102AC Machine Scan accelerator kit SA-501 Vendor kit VK-501 Security kit SC-503 * Only for Europe, North America, and latin America (only 120V area) Mount kit MK-706 Local interface kit EK-702...

  • Page 37: Product Specifications

    2. Product specifications Theory of operation ver. 3.0 Aug. 2006 Product specifications Type Type Desktop/Console*1 scanner/printer Copying system Electrostatic dry-powdered image transfer to plain paper Printing process Tandem-type indirect electrostatic recording system PC drum type OPC (organic photo conductor) Scanning density Equivalent to 600 dpi Exposure lamp White rare-gas fluorescent lamp 30 W...

  • Page 38: Functions

    Theory of operation ver. 3.0 Aug. 2006 2. Product specifications Functions Types of original Sheets, books, and three-dimensional objects A3 or 11 × 17 (ledger) Max. original size Max. original weight Max. 2 kg Multiple copies 1 to 999 110 sec. or less Warm-up time (at ambient temperature of 23°...

  • Page 39: Types Of Paper

    2. Product specifications Theory of operation ver. 3.0 Aug. 2006 Types of paper Paper source Type Tray1 Tray2 Multiple bypass Plain paper ❍ ❍ ❍ (60 to 90 g/m Translucent paper – – – OHP transparencies (crosswise – feeding only) Thick paper 1 –...

  • Page 40: Machine Specifications

    Max power consumption Less than 1,500 W (120 V, 12 A / 220 - 240 V, 8 A) 653 *2 (W) × 755 (D) × 771 *3 (H) mm bizhub C250 25.7 *2 (W) × 29.8 (D) × 30.4 (H) inch Dimensions 650 *2 (W) ×...

  • Page 41: Print Functions

    2000, Windows XP, or Windows NT 4.0 (SP6a) Mac OS 9.2 or later or Mac OS X 10.2 or 10.3 Scan functions Driver KONICA MINOLTA scanner driver Compatible operating sys- Windows 98/98SE/Me, Windows NT 4.0 (SP6 or later), Windows 2000, tems...

  • Page 42: Center Cross Section

    Theory of operation ver. 3.0 Aug. 2006 3. Center cross section Center cross section [18] [19] [20] [17] [16] [15] [14] [13] [12] [11] [10] 4038T1C103AA CCD unit [11] Print head unit (PH unit) /Y Fusing unit [12] Waste toner box Transfer belt unit [13] Imaging unit/Y...

  • Page 43: Paper Path

    4. Paper path Theory of operation ver. 3.0 Aug. 2006 Paper path C250 paper path 4038T1C104AA...

  • Page 44: C250 Paper Path

    Theory of operation ver. 3.0 Aug. 2006 4. Paper path C250 paper path 9J06T1C501AB...

  • Page 45: Image Creation Process

    5. Image creation process Theory of operation ver. 3.0 Aug. 2006 Image creation process [11] Transfer belt cleaning [1] Photoelectric conversion [10] Paper [8] 1st image transfer separation [2] IR Image processing [3] Printer Image processing [9] 2nd image transfer [4] PC drum [5] PC drum charging...
  • Page 46 Theory of operation ver. 3.0 Aug. 2006 5. Image creation process • A DC positive voltage is applied to the backside of the paper, thereby [9] 2nd image transfer allowing the visible, developed image on the surface of the transfer belt to be transferred onto the paper.
  • Page 47 5. Image creation process Theory of operation ver. 3.0 Aug. 2006 Blank Page...

  • Page 48: Composition/Operation

    Theory of operation ver. 3.0 Aug. 2006 6. Overall composition Composition/operation Overall composition Timing chart at machine power up Main motor (M1) Drum charge corona remote (K) Grid (K) Developing bias DC (K) Color PC drum motor (M2) Drum charge corona remote (Y, M, C) Grid (Y, M, C) Developing bias DC (Y, M, C)

  • Page 49: Control Block Diagram

    6. Overall composition Theory of operation ver. 3.0 Aug. 2006 Control block diagram IR Section Exposure Lamp (FL201) CCD Sensor Inverter Board (PWB-A) Board (PU201) Scanner Moter Drive Automatic Board (PWB-IC) Document Feeder (DF-601) Scanner Moter (M-201) Image Processing Board (PWB-A) Control Panel(UN-201) Printer Section Slide Interface...

  • Page 50: Scanner Section (Ir Section)

    Theory of operation ver. 3.0 Aug. 2006 7. Scanner section (IR section) Scanner section (IR section) Composition 4038T2C103AA 4038T2C121AA Original size detection sensor /1 (PC203) Scanner motor (M201) Scanner motor Original size detection drive board (PWB-IC) sensor /2 *2 (PC204) Original cover Lens angle sensor (PC202)

  • Page 51: Ccd Unit

    7. Scanner section (IR section) Theory of operation ver. 3.0 Aug. 2006 7.1.1 CCD unit Scanning direction CCD sensor 37.3 µm 37.3 µm Main scanning direction 9.325 µm 9.325 µm 4036ma2602c0 Drive Scanner motor Exposure unit Mirror unit Scanner drive cable/R Scanner drive Scanner home sensor...

  • Page 52: Operation

    Theory of operation ver. 3.0 Aug. 2006 7. Scanner section (IR section) Operation 7.3.1 Scan and exposure lamp control A. When the power is ON 1. Exposure unit moves from the home position to the shading position (under the shading correction sheet) and stops (in scanning direction.) 2.
  • Page 53 7. Scanner section (IR section) Theory of operation ver. 3.0 Aug. 2006 B. When the start key is pressed 1. Turning the start key ON will turn the exposure lamp ON (at the front edge of the image.) The scanner cooling fan motor (M202) will rotate. 2.

  • Page 54: Original Size Detection Control

    Theory of operation ver. 3.0 Aug. 2006 7. Scanner section (IR section) 7.3.2 Original size detection control A. Detection method • For detection of the original size, the reflective size sensors detect the length of the orig- inal while the CCD detects the width of the original. •...
  • Page 55 7. Scanner section (IR section) Theory of operation ver. 3.0 Aug. 2006 Metric area & China areas Table 1 Original size CCD width (mm) detection sen- sor /1 ~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~261.5 ~275.0 278.1~ (PC203) 16KS Table 2 Original size detection CCD width (mm)
  • Page 56 Theory of operation ver. 3.0 Aug. 2006 7. Scanner section (IR section) B. Detection timing Validates the original length Validates the original size Original size sensors /1 (PC203), and / 2 (PC204) Original cover angle sensor (PC202) Exposure lamp (FL201) Scanner motor (M201) Size reset switch (S201) 4037T2C563AA...

  • Page 57: Write Section (Ph Section)

    8. Write section (PH section) Theory of operation ver. 3.0 Aug. 2006 Write section (PH section) Composition 4038T2C008AA Printer head 4038T2C23AA Polygon motor SOS mirror Laser diode SOS sensor 4038T2C034AA...

  • Page 58: Outline

    Theory of operation ver. 3.0 Aug. 2006 8. Write section (PH section) Operation 8.2.1 Outline • 4 types of the printer head are used for exposure process. • The surface of the photo conductor is irradiated with a laser light and an electrostatic latent image is thereby formed.

  • Page 59: Laser Exposure Process

    8. Write section (PH section) Theory of operation ver. 3.0 Aug. 2006 8.2.2 Laser exposure process 1. Laser beam irradiated by the laser diode is reflected on the polygon mirror. 2. The polygon mirror is a four-faced mirror that rotates at high speed motored by the polygon motor.

  • Page 60: Laser Shutter Mechanism

    Theory of operation ver. 3.0 Aug. 2006 8. Write section (PH section) 8.2.4 Laser shutter mechanism • There is a shutter mechanism provided to prevent the PH from being contaminated with foreign matter such as dust when the front cover is opened or closed, or prevent the emission laser from leaking outside for any reason.

  • Page 61: Laser Emission Area

    8. Write section (PH section) Theory of operation ver. 3.0 Aug. 2006 8.2.5 Laser emission area A. Main scan direction (CD) • The print start position in the CD direction is determined by the CD print start signal (/ HSYNC) that is output from the MFP control board (PWB-MFP) and the width of the paper.

  • Page 62: Registration Control (Color Shift Correction) System

    Theory of operation ver. 3.0 Aug. 2006 8. Write section (PH section) 8.2.6 Registration control (color shift correction) system • In a tandem engine, in which an independent image reproduction process is provided for each of the four different colors of toner. Incorrect color registration, or color shift, is therefore more likely to occur due to each of the PH assemblies being out of correct posi- tion.

  • Page 63: Skew Control Mechanism

    8. Write section (PH section) Theory of operation ver. 3.0 Aug. 2006 8.2.7 Skew control mechanism • When the printer head is mounted on the main body installation plate, image distortion (skew) occurs due to mounting error. Therefore the printer head adopts the correction system.

  • Page 64: Imaging Unit Section (Iu Section)

    Theory of operation ver. 3.0 Aug. 2006 9. Imaging unit section (IU section) Imaging unit section (IU section) Composition 4038T2C010AA Imaging unit/Y, M, C 4038T2C22AA 4038T2C009AA Imaging unit/K PC drum/Y, M, C, K Toner collecting screw Developing unit/ Cleaning blade Y, M, C, K PC drum charge corona/Y, M, C, K...

  • Page 65: Drive

    9. Imaging unit section (IU section) Theory of operation ver. 3.0 Aug. 2006 Drive Main motor (M1) Developing clutch/K (CL4) Color PC drum motor (M2) Color developing motor (M3)

  • Page 66: Operation

    Theory of operation ver. 3.0 Aug. 2006 9. Imaging unit section (IU section) Operation 9.3.1 IU life control • Each IU has EEPROM board that detects a new IU and keeps track of the service life of the IU. A. New IU detection •...
  • Page 67 9. Imaging unit section (IU section) Theory of operation ver. 3.0 Aug. 2006 B. When life is reached • The IU life counter is used to keep track of IU life. • When the life value is reached, a warning message is given on the screen. When a pre- determined number of printed pages are produced after the life value has been reached, the machine inhibits the initiation of a new print cycle with a message prompting the user to replace the IU given on the screen.

  • Page 68: 10. Photo Conductor Section

    Theory of operation ver. 3.0 Aug. 2006 10. Photo conductor section 10. Photo conductor section 10.1 Composition Charge generating layer (CGL) Charge transport layer (CTL) Aluminum cylinder 4036ma2338c0 4038T2C013AA PC drum 10.2 Drive Main motor (M1) PC drum/K PC drum/C Color PC drum motor (M2) PC drum/Y PC drum/M...

  • Page 69: 10.3 Operation

    10. Photo conductor section Theory of operation ver. 3.0 Aug. 2006 10.3 Operation 10.3.1 PC drum drive mechanism • Two independent PC drum motors (for color and monochrome) are used for the drive mechanism to suppress incorrect color registration and uneven pitch. •...

  • Page 70: Pc Drum Small Amount Rotation Control

    Theory of operation ver. 3.0 Aug. 2006 10. Photo conductor section 10.3.3 PC drum small amount rotation control • Humidity around the IU can produce a difference in sensitivity among different PC drums. This could lead to drum memory, allowing black bands to occur in the image. In addition, ozone stagnant in areas near the PC drum charge corona reduces sensitivity of the PC drums, causing white bands to occur in the image.

  • Page 71: 11. Charge Corona Section

    11. Charge corona section Theory of operation ver. 3.0 Aug. 2006 11. Charge corona section Comb electrode 4038T2C027AA Grid mesh 4038T2C029AA Grid mesh Comb electrode cleaning lever (only IU/K) Cleaning blade Comb electrode/Y, M, C, K...

  • Page 72: 11.1 Operation

    Theory of operation ver. 3.0 Aug. 2006 11. Charge corona section 11.1 Operation 11.1.1 PC drum charge corona ON/OFF control • The grid voltage (Vg) applied to the grid mesh is controlled through the image stabiliza- tion control. Main motor (M1) ON Color PC drum motor (M2) ON Drum charge corona bias Y, M, C Drum charge corona bias K...

  • Page 73: 12. Developing Section

    12. Developing section Theory of operation ver. 3.0 Aug. 2006 12. Developing section 12.1 Composition Doctor blade Toner conveying Developing screw roller Toner supply screw 4038to503c0 4038T2C22AA Main motor (M1) Developing clutch/K (CL4) Color PC drum motor (M2) PC drum/K Developing roller Color developing motor (M3) PC drum/Y...

  • Page 74: 12.2 Drive

    Theory of operation ver. 3.0 Aug. 2006 12. Developing section 12.2 Drive Main motor (M1) Toner collecting screw Developing clutch/K (CL4) PC drum/K Color PC drum motor (M2) Developing roller Color developing motor (M3) PC drum/Y Supply/agitating/ conveying screws...

  • Page 75: 12.3 Operation

    12. Developing section Theory of operation ver. 3.0 Aug. 2006 12.3 Operation 12.3.1 Developing drive control Main motor (M1) Color PC drum motor (M2) Color developing motor (M3) Developing clutch/K (CL4) Drum charge corona bias/K Drum charge corona bias/Y, M, C Developing bias/K (DC) Developing bias/K (AC) Developing bias/Y, M, C (DC)

  • Page 76: Developing Bias

    Theory of operation ver. 3.0 Aug. 2006 12. Developing section 12.3.3 Developing bias • The developing bias voltage (Vdc) is applied to the developing roller so that an adequate amount of toner is attracted onto the surface of the PC drum. •...

  • Page 77: Tcr Sensor Control

    12. Developing section Theory of operation ver. 3.0 Aug. 2006 12.3.5 TCR sensor control • The TCR sensor is mounted on the underside of each of the developing sections. The sensor for C, M, Y and K is a magnetic type. Each of these sensors detects toner-to-car- rier ratio (T/C) of the developer.

  • Page 78: 13. Toner Supply Section

    Theory of operation ver. 3.0 Aug. 2006 13. Toner supply section 13. Toner supply section 13.1 Composition 4038T2C014AA Toner cartridge/K 4038T2C21AA 4038T2C015AA Toner cartridge/Y, M, C Toner supply Toner supply drive section/K drive section/M Toner supply Toner supply drive section/Y drive Section/C 4038T2C004AA Agitating blade/K...

  • Page 79: 13.2 Drive

    13. Toner supply section Theory of operation ver. 3.0 Aug. 2006 13.2 Drive Toner supply motor C/K (M7) Toner supply motor Y/M (M6)

  • Page 80: 13.3 Operation

    Theory of operation ver. 3.0 Aug. 2006 13. Toner supply section 13.3 Operation 13.3.1 Toner replenishing mechanism/control A. Toner replenishing mechanism • A single toner supply motor is turned either forward or backward to supply toner of two different colors (toner supply motor for K and C, and toner supply motor for Y and M). Toner supply Toner supply K toner...

  • Page 81: Toner Cartridge Life Control

    13. Toner supply section Theory of operation ver. 3.0 Aug. 2006 13.3.2 Toner cartridge life control A. Toner cartridge detection/new unit detection timing • detection is controlled by confirming the data of each unit with access to TC EEPROM board when the front door is closed. •...

  • Page 82: Shutter Mechanism

    Theory of operation ver. 3.0 Aug. 2006 13. Toner supply section 13.3.3 Shutter mechanism • To prevent toner from being spilled when the toner cartridge is removed from the machine, there is a shutter mechanism provided. When the toner cartridge is installed in the machine, the shutter opens.

  • Page 83: 14. Transfer Corona Section

    14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.1 Composition 14.1.1 1st image transfer section 4038T2C105AA 4038T2C122AA 2nd image transfer roller 1st image transfer roller/M 1st image transfer roller/K 1st image transfer roller/Y 1st image transfer roller/C Retraction roller Cleaning blade...

  • Page 84: 2Nd Image Transfer Section

    Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.1.2 2nd image transfer section 4038T2C117AA 4038T2C123AA IDC/registration IDC/registration sensor /2 (SE2) sensor /1 (SE1) 2nd image transfer roller Temperature/ humidity sensor (SE3) 4038T2C152AA 4038T2C106AA Temperature/humidity sensor (SE3) Shutter 2nd image transfer roller 2nd image transfer pressure position sensor (PC7)
  • Page 85 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 14.2 Drive 14.2.1 1st image transfer section Transfer belt Main motor (M1) 4038T2C020DA 1st image transfer roller/K Main motor (M1) 1st image transfer roller/C Fusing drive 1st image transfer roller/M motor (M4) 1st image transfer roller/Y Retraction roller...
  • Page 86 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.2.2 2nd image transfer section 2nd image transfer roller 2nd image transfer pressure Shutter position sensor (PC7) Pressure lever IDC/registration sensor/2 (SE2) 2nd image transfer pressure/ retraction motor (M5) IDC/registration sensor/1 (SE1) Shutter 4038T2C019DA...
  • Page 87 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 14.3 Operation 14.3.1 Transfer belt drive mechanism • The transfer belt is driven by the main motor (M1). • Revolving speed of the main motor (M1) can be switched by the motor clock. 14.3.2 1st image transfer roller mechanism •...
  • Page 88 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section Main motor (M4) Fusing drive motor (M4) 1st image transfer pressure/ retraction clutch (CL3) 4038T2C021DB • Operation timing Start key ON Paper moves past 2nd image transfer roller Fusing drive motor (M4) 1st image transfer pressure/ retraction clutch (CL3) 1st image transfer retraction...
  • Page 89 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 B. Pressure position changing mechanism • To extend the service life of the PC drum/Y, M, C, the pressure position of the 1st image transfer roller is changed between the monochrome mode and the color mode. in the monochrome mode, the 1st image transfer roller/Y, M, C is left in the retracted position and the PC drum/Y, M, C is stopped.
  • Page 90 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.3.3 2nd image transfer roller pressure mechanism • The 2nd image transfer roller has the pressure/retraction mechanism which presses to and retracts from the transfer belt so the patterns made on the transfer belt except by printing (such as detection pattern during image stabilization) will not affect the 2nd image transfer roller.
  • Page 91 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 14.3.4 IDC sensor shutter mechanism • The IDC sensor can be contaminated with toner since it is located under the transfer belt. There is a shutter mechanism provided for the sensor to prevent it from being contami- nated.
  • Page 92 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.3.5 ATVC (auto transfer voltage control) • To optimize image transfer output, the machine is provided with ATVC control, or auto transfer voltage control. The control lets a constant current flow through each of the image transfer rollers.
  • Page 93 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 D. 1st and 2nd image transfer ATVC operation timing • The 1st and 2nd image transfer ATVC operations are carried out immediately before the execution of image stabilization control. •...
  • Page 94 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.3.8 2nd image transfer roller cleaning • In order to remove the remaining toner on the 2nd image transfer roller, -/+ (DC) charge is applied alternately to transfer the remaining toner on the 2nd image transfer roller to the transfer belt.
  • Page 95 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 14.3.9 Charge neutralization and separation of paper • In order to remove the residual potential on the paper with the 2nd image transferred, the neutralization material is applied to the guide plate without contact after the 2nd image transfer roller.
  • Page 96 Theory of operation ver. 3.0 Aug. 2006 14. Transfer corona section 14.3.11 Pressure/retraction control during ACS mode • The pressure/retraction of the 1st image transfer roller is controlled by the number of multiple copies for the monochrome original during multi-copy cycle, so it promotes the high productivity and extends the consumables’...
  • Page 97 14. Transfer corona section Theory of operation ver. 3.0 Aug. 2006 When printing in monochrome with color mode (effecting monochrome printing with the four PC drums rotating) → → First sheet of color mode First sheet of monochrome mode First sheet of color mode 4038T2C165AA Switching to monochrome mode →...

  • Page 98: Toner Collecting Section

    Theory of operation ver. 3.0 Aug. 2006 15. Toner collecting section 15. Toner collecting section 15.1 Composition 4038T2C110AA 4038T2C124AA IU toner collecting screw Transfer belt toner collecting screw Waste toner box 4038T2C023DA Waste toner full sensor (PC8) Waste toner box Waste toner conveyance screw 4038T2C024DA...
  • Page 99 15. Toner collecting section Theory of operation ver. 3.0 Aug. 2006 15.2 Drive Main motor (M1) IU toner collecting screw Cleaning blade Transfer belt toner collecting screw 4038T2C025DA...
  • Page 100 Theory of operation ver. 3.0 Aug. 2006 15. Toner collecting section 15.3 Operation 15.3.1 Toner collecting mechanism • Toner collected by the cleaning blade of the transfer belt and waste toner in each of the imaging units are conveyed by the corresponding toner collecting screws to the waste toner box.
  • Page 101 15. Toner collecting section Theory of operation ver. 3.0 Aug. 2006 15.3.3 Waste toner near-full/full detection control A. Waste toner detection mechanism • To prevent false detection, an agitation screw is mounted in the waste toner box so that the waste toner is accumulated in the bottle evenly. •...
  • Page 102 Theory of operation ver. 3.0 Aug. 2006 15. Toner collecting section B. Waste toner level check control • The amount of toner is determined by the period of time the waste toner full sensor (PC8) is being blocked while the moving vane of the transport screw rotates five times. •...
  • Page 103 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section 16.1 Composition 16.1.1 Tray1 4038T2C111AA 4038T2C125AA Registration roller sensor (PC1) Tray1 paper take-up roller Tray1 separator roller 4038T2C171AA Tray1 paper feed clutch (CL2) Tray 1 device detection sensor (PC12) Tray1 paper empty sensor (PC10) Tray1 paper near-empty Tray1 paper take-up roller...
  • Page 104 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section 16.1.2 Tray2 Tray2 paper take-up roller 4038T2C126AA Tray2 separator roller 4038T2C127AA Tray 2 paper take-up sensor (PC9-PC) Tray 2 vertical transport sensor (PC8-PC) Tray2 paper take-up roller Vertical transport roller/2 4038T2C172AA Tray2 paper near-empty sensor (PC1-PC) Tray2 vertical transport motor (M2-PC)
  • Page 105 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 16.2 Drive 16.2.1 Tray1 Main motor (M1) Tray1 paper take-up roller Tray1 paper feed clutch (CL2) 4038T2C027DA 16.2.2 Tray2 Tray2 paper feed motor (M1-PC) Tray2 paper take-up roller Vertical transport roller Tray2 lift-up motor (M3-PC) Tray2 pick-up roller...
  • Page 106 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section 16.3 Operation 16.3.1 Paper take-up control (tray1) Start key ON Registration roller ON Main motor (M1) Tray1 paper feed clutch (CL2) Registration roller clutch (CL1) Registration roller sensor (PC1) 4038T2C138AA 16.3.2 Paper supply level detection control (tray2)
  • Page 107 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 16.3.3 Paper near-empty/paper empty detection • When the paper near-empty sensor is blocked, a corresponding warning display is given on the control panel. • The paper supply level when a paper near-empty condition is detected is about 50 ± 30 sheets.
  • Page 108 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section 16.3.4 Paper type setting • The paper type is set from the control panel. Control is provided on the main body side differently as detailed below depending on the paper type setting made. System speed Heating Developing...
  • Page 109 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 16.3.5 Paper size detection control • Paper width/length are detected to determine the paper size from their combination. A. Tray1 Metric area Tray1 paper size board (PWB-I) Tray1 CD paper size Paper size sensor (PC9) ON/OFF...
  • Page 110 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section Tray1 paper size board (PWB-I) Guide 4036ma2042c1...
  • Page 111 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 B. Tray2 Tray2 paper size board (PWB-I-PC) Tray2 CD paper Tray2 CD paper Paper size size sensor /1 size sensor /2 (PC4-PC) (PC3-PC) ON/OFF ON/OFF ON/OFF A5S *1 ON/OFF 11 ×...
  • Page 112 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section 16.3.6 Paper Interval control (PPM control) • It sets the proper interval between papers (pitch) according to the paper size and mode for multiple printing. A. Basic paper interval control Paper feed direction Space between...
  • Page 113 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 B. PPM control • It prevents the temperature at the edge of the fusing roller from increasing due to the multiple printing with small size paper. • It sets the appropriate paper interval (pitch) according to the paper size and mode. •...
  • Page 114 Theory of operation ver. 3.0 Aug. 2006 16. Paper feed section • PPM control paper interval list System Mode Group speed 331.20 mm 263.120 mm 340.40 mm 268.64 mm Plain paper/ 467.36 mm 388.24 mm 371.68 mm monochrome, 599.84 mm 441.6 mm 476.56 mm plain paper/...
  • Page 115 16. Paper feed section Theory of operation ver. 3.0 Aug. 2006 16.3.7 Tray2 paper lifting motion control A. When tray2 is slid in • When the tray 2 lift-up upper sensor (PC-7 PC) is unblocked (OFF) with the tray 2 being closed, tray 2 lift-up motor (M3-PC) will rotate to start lifting up the paper lifting plate.
  • Page 116 Theory of operation ver. 3.0 Aug. 2006 17. Bypass section (bizhub C250) 17. Bypass section (bizhub C250) Composition ･ Bypass paper Paper side plate empty sensor (PC13) 4038T2C128AA 4038T2C112AA Paper side plate Bypass paper take-up roller Bypass paper empty sensor (PC13)
  • Page 117 17. Bypass section (bizhub C250) Theory of operation ver. 3.0 Aug. 2006 17.1 Drive Bypass paper feed clutch (CL5) Bypass paper pick-up solenoid (SL2) 4038T2C113AA Bypass lift-up sensor (PC14) Bypass paper feed clutch (CL5) Bypass lift-up sensor (PC14) Paper lifting cam...
  • Page 118 Theory of operation ver. 3.0 Aug. 2006 17. Bypass section (bizhub C250) 17.2 Operation 17.2.1 Bypass paper take-up control Start key ON Move to standby position Main motor (M1) Bypass paper pick-up solenoid (SL2) Bypass lift-up sensor (PC14) Bypass paper feed clutch (CL5) 4038T2C142AA 17.2.2...
  • Page 119 17. Bypass section (bizhub C250) Theory of operation ver. 3.0 Aug. 2006 17.2.3 Paper width detection • The paper width detection resistor (UN1) slides with the rack which moves simulta- neously with the paper side guide plate. The output value indicated by the paper width detection resistor determines the paper width.
  • Page 120 Theory of operation ver. 3.0 Aug. 2006 17. Bypass section (bizhub C250) 17.2.4 Bypass paper lifting motion control • It turns the bypass pick-up solenoid (SL2) ON when the bypass paper feed is started. The lifting cam will rotate to move the paper lifting plate up to the feeding position.
  • Page 121 18. Bypass section (bizhub C252) Theory of operation ver. 3.0 Aug. 2006 18. Bypass section (bizhub C252) 18.1 Composition Paper empty sensor (PC13) Paper side plate 9J06T2C010DA 9J06T2C011DA Paper side plate Multi FD size1 Multi FD size2 Multi FD size3 Bypass paper sensor (PC19) sensor (PC20)
  • Page 122 Theory of operation ver. 3.0 Aug. 2006 18. Bypass section (bizhub C252) 18.2 Drive Bypass paper feed clutch (CL5) Bypass paper pick-up solenoid (SL2) 9J06T2C013DA Lift-up position sensor (PC14) Bypass paper feed clutch (CL5) Lift-up position sensor (PC14) Paper lifting cam Bypass paper take-up roller Main motor (M1)
  • Page 123 18. Bypass section (bizhub C252) Theory of operation ver. 3.0 Aug. 2006 18.3 Operation 18.3.1 Bypass paper take-up control Start key ON Move to standby position Main motor (M1) Bypass paper pick-up solenoid (SL2) Lift-up position sensor (PC14) Bypass paper feed clutch (CL5) 4038T2C142AA 18.3.2 Paper empty detection...
  • Page 124 Theory of operation ver. 3.0 Aug. 2006 18. Bypass section (bizhub C252) 18.3.3 Bypass paper lifting motion control • It turns the bypass paper pick-up solenoid ON when the bypass paper feed is started. The lifting cam will rotate to move the paper lifting plate up to the feeding position. •...
  • Page 125 18. Bypass section (bizhub C252) Theory of operation ver. 3.0 Aug. 2006 18.3.4 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 three multi FD size sensors and the paper width detection resis- tor.
  • Page 126 Theory of operation ver. 3.0 Aug. 2006 18. Bypass section (bizhub C252) Inch area Paper width detection resistor Multi FD size1 Multi FD size2 Multi FD size3 Paper size (UN1) (PC19) (PC20) (PC21) detected Width (mm) 80 to less than 115 115 to 144 inclusive 201 to 231 inclusive 5-1/2 ×...

  • Page 127: Registration Roller Section

    19. Registration roller section Theory of operation ver. 3.0 Aug. 2006 19. Registration roller section 19.1 Composition Registration roller 4038T2C217AA 4038T2C118AA Registration roller clutch (CL1) OHP sensor (PC4) 19.2 Drive Registration roller clutch (CL1) Registration roller Main motor (M1) 4038T2C419AA...
  • Page 128 Theory of operation ver. 3.0 Aug. 2006 19. Registration roller section 19.3 Operation 19.3.1 Registration roller control • The paper will create a loop between the feed roller and the registration roller when the paper is being conveyed in order to correct the skew. •...
  • Page 129 19. Registration roller section Theory of operation ver. 3.0 Aug. 2006 19.3.2 OHP detection • OHP sensor (PC4) checks to prevent printing on the paper other than OHP. • OHP detection will be performed after paper made the loop at the registration roller. When the OHP detection shows the different result from the setting on the operation panel, printing will stop to display “media error.”...
  • Page 130 Theory of operation ver. 3.0 Aug. 2006 19. Registration roller section 19.3.3 Deceleration control • It controls the timing the paper reaches to the registration roller sensor (PC1). A. Operation • The vertical transport motor (vertical transport roller) for each tray will slow down its operation in order to adjust the speed of the paper being conveyed.

  • Page 131: Fusing Section

    20. Fusing section Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.1 Composition 4038T2C119AA 4038T2C129AA Heating roller thermistor/1 (TH1) Heating roller Pressure roller Heating roller thermistor/2 (TH3) Fusing pressure roller heater lamp (H3) Heating roller thermostat (TS1) Fusing pressure roller thermostat (TS2) Heating roller thermistor/3 (TH4)
  • Page 132 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section Heating roller thermistor/1 (TH1) Heating roller thermistor/3 (TH4) Heating roller thermistor/2 (TH3) Fusing pressure roller thermistor /1 (TH2) Fusing pressure roller 4038T2C154AA thermistor /1 (TH2) 4038T2C153AA Heating roller thermostat (TS1) Fusing pressure roller thermostat (TS2) 4038T2C155AA...
  • Page 133 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 20.2 Drive Fusing drive motor (M4) Fusing pressure roller Heating roller 4038T2C034DA...
  • Page 134 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.3 Operation 20.3.1 Fusing roller drive control A. Fusing roller speed change control • The fusing roller (heating roller/fusing pressure roller) is driven by the fusing motor (M4). The fusing motor (M4) drives the heating roller. The fusing pressure roller rotates along with the heating roller.
  • Page 135 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 B. Fusing loop control • By creating a paper loop, the speed difference between the fusing and paper convey- ance at 2nd transfer part will be adjusted. It prevents the double transferred image or brush effect.
  • Page 136 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.3.2 Heater lamp construction • Three heater lamps are controlled to be turned ON/OFF so the temperature of the heat- ing roller and the fusing pressure roller will stay appropriate to completely fuse the image.
  • Page 137 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 B. Fusing pressure thermistor Name Symbol Function Fusing pressure roller The main thermistor which detects the temperature at the cen- thermistor/1 ter of the fusing pressure roller Fusing pressure roller The protection thermistor which detects the abnormally high thermistor/2 temperature of the fusing pressure roller...
  • Page 138 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section A. Envelope position • By switching the release lever to the lower direction shown below, the pressure of the fusing pressure roller will be envelope position. • Envelope position is for preventing the wrinkle when feeding envelopes. •...
  • Page 139 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 B. Paper jam countermeasure position • By switching the release lever to the position fusing pressure roller will retract from the heating roller as shown below. • Paper jam release mechanism is equipped for removing the stuck paper. Paper jam release position Normal position (no pressure)
  • Page 140 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.3.6 Fusing roller small amount rotation control • Leaving the fusing roller in low power mode for a long period of time will deform the pressing part of the fusing roller due to the heat and pressure. Deformed roller surface may cause “uneven gloss”...
  • Page 141 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 • When the paper winding is detected, the unit will exceptionally stop. When other troubles occur, the unit will stop after the process to stop the unit. [The fusing drive motor (M4) needs to be rotated when going through this process.] •...
  • Page 142 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.3.9 Warm-up control • There are two modes for the warm-up control depending on the temperature inside the unit at the beginning of the warm-up. • The temperature inside the unit is determined by the temperature three minutes after the warm-up has started.
  • Page 143 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 20.3.11 Protecting from the abnormally high temperature The machine provides protection against abnormally high temperature of the fusing unit in the following three steps. Details for each control are described in the following sections. Level Name Control...
  • Page 144 Theory of operation ver. 3.0 Aug. 2006 20. Fusing section 20.3.12 Abnormally high temperature detection (software protection) • It detects when the temperature of the heating roller and the fusing pressure roller increase abnormally high. It informs the error and stops the operation. A.
  • Page 145 20. Fusing section Theory of operation ver. 3.0 Aug. 2006 20.3.14 High temperature error detection (thermostat protection) • When the software protection or hardware protection control is not executed due to the thermistor malfunction, etc., power for each heater lamp will be shut off by heating ther- mostat/fusing pressure thermostat.

  • Page 146: Paper Exit Section

    Theory of operation ver. 3.0 Aug. 2006 21. Paper exit section 21. Paper exit section 21.1 Composition 4038T2C120AA Paper exit roller/2 4038T2C130AA Paper exit roller/1 Paper exit roller/2 Exit sensor (PC2) Charge neutralizing brush 4038T2C192AA...
  • Page 147 21. Paper exit section Theory of operation ver. 3.0 Aug. 2006 21.2 Drive Fusing drive motor (M4) Paper exit roller/1 Paper exit roller/2 4038T2C036DA...

  • Page 148: Image Stabilization Control

    Theory of operation ver. 3.0 Aug. 2006 22. Image stabilization control 22. Image stabilization control 22.1 Overview • The machine provides the following image stabilization control to ensure stabilized copy image. Purpose Control Control means • IDC intensity control • Max. density control To stabilize image density •...

  • Page 149: Outline

    22. Image stabilization control Theory of operation ver. 3.0 Aug. 2006 22.2 Operation 22.2.1 IDC intensity control • Controls changes in characteristics due to change with time and contamination of the transfer belt and IDC/registration sensor, part-to-part variations in the sensors, and change of environment.
  • Page 150 Theory of operation ver. 3.0 Aug. 2006 22. Image stabilization control 22.3 Operation timing Mode Operation timing A new IU is detected; a new transfer belt unit is detected; panel displays initialization Mode 1 and stabilization mode. The number of copies made exceeds “140 counts” after the previous image stabiliza- Mode 2 tion (mode 1, 2, 3.) Power switch is turned ON;...

  • Page 151: Operation Flow

    22. Image stabilization control Theory of operation ver. 3.0 Aug. 2006 22.4 Operation flow Mode 1 Mode 2 Mode 3 2nd Image Transfer Cleaning IDC intensity IDC intensity control control Max. density control 1 LD intensity adjustment 1 Max. density Max.

  • Page 152: Image Processing

    Theory of operation ver. 3.0 Aug. 2006 23. Image processing 23. Image processing 23.1 Scanner section image processing block diagram 1. Photoelectric conversion CCD sensor board 2. Analog-to-digital conversion Image processing board 3. Shading correction 4. Line-to-line variation correction/color aberration correction 5.

  • Page 153: Write Section Image Processing Block Diagram

    23. Image processing Theory of operation ver. 3.0 Aug. 2006 23.2 Write section image processing block diagram From scanner section MFP control board 1. Resolution conversion processing in the sub scanning direction 2. AE processing 3. Image data editing 4. Image area discrimination 5.
  • Page 154 Theory of operation ver. 3.0 Aug. 2006 23. Image processing • The following detail the image processing operations performed by MFP control board on the write section. 1. Reduction processing is conducted in sub scanning direction. no processing is done at same size or zoom, but at reduction, the lines are thinned out. 2.
  • Page 155 23. Image processing Theory of operation ver. 3.0 Aug. 2006 22. Creates the density distribution of a predetermined pattern to enable outstanding gradation reproduction. 23. Adjust the processing speed in the board (main scanning) to conform to the input processing speed. 24.

  • Page 156: Other Control

    Theory of operation ver. 3.0 Aug. 2006 24. Other control 24. Other control 24.1 Fan control 24.1.1 Construction Scanner cooling fan motor (M202) Fusing cooling fan motor/1 (M13) Fusing cooling fan motor/2 (M11) Cooling fan motor/2 (M22) Cooling fan motor/1 (M12) Power supply cooling fan motor/2 (M9)
  • Page 157 24. Other control Theory of operation ver. 3.0 Aug. 2006 24.1.2 Operation A. Function Motor name Control conditions Power supply cooling fan It exhausts the accumulated heat inside the unit in order to prevent temper- motor/1 (M8) ature from increasing at DC power supply part and the controller part. •...
  • Page 158 Theory of operation ver. 3.0 Aug. 2006 24. Other control B. Fan control Motor name Control Control conditions (outline) • Plug-in/sub-power switch OFF Stop • When re-writing flash-ROM • In low-power or sleep • In standby Power supply cooling • At paper-jam, in trouble, or when the door is open Half speed fan motor/1 (M8) •...
  • Page 159 24. Other control Theory of operation ver. 3.0 Aug. 2006 Motor name Control Control conditions (outline) • At plug-in/sub-power switch OFF Stop • At warm-up, low power, or sleep • When re-writing flash-ROM • At initial operation, image stabilization, and function Suction fan motor (M10) •...

  • Page 160: Are Turned On

    Theory of operation ver. 3.0 Aug. 2006 24. Other control 24.2 Parts operated when the power switch and sub power switch are turned ON 24.2.1 Parts operated when the power switch and sub power switch are turned • When the sub power switch is turned ON, the MFP control board detects it and sends a control signal to the DC power supply trough the mechanical control board.

  • Page 161: Counter Control

    24. Other control Theory of operation ver. 3.0 Aug. 2006 24.3 Counter control 24.3.1 Construction Total counter PWB-MFPC Electronic counter Key counter (option) PWB-SIF 4038T2C193AA Name Function/system • Displays the cumulative number of copies and prints of all jobs. Total counter •...
  • Page 162 SERVICE MANUAL THEORY OF OPERATION DF-601 2005.07 Ver. 1.0...
  • Page 163 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 164: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS DF-601 Outline Product specifications ..................... 1 Mixed original feed ....................3 Mixed original feed chart..................3 Paper feed prohibited originals ................4 Paper feed not guaranteed originals..............4 Composition/Operation Overall composition....................5 Drive system ......................
  • Page 165 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 166: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specifications Outline Product specifications A. Type Name Duplexing Document Feeder Paper Take-Up Paper Take-Up from top of stack Transport Endless Belt Transport Mode Type Turnover Loop Turnover Mode U-turn Turnover + Switchback U-Turn Turnover Paper Exit Mode (only in 1-Sided Mode) Installation...
  • Page 167 1. Product specifications Theory of Operation Ver. 1.0 Jul. 2005 D. Machine specifications Power Requirements DC 24 V (supplied from the main body) DC 5 V (generated within the DF-601) Max. Power 60 W or less Consumption 586 mm (W) × 519 mm (D) × 135 mm (H) Dimensions 23 inch (W) ×...

  • Page 168: Mixed Original Feed

    Theory of Operation Ver. 1.0 Jul. 2005 2. Mixed original feed Mixed original feed 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...

  • Page 169: Paper Feed Prohibited Originals

    2. Mixed original feed Theory of Operation Ver. 1.0 Jul. 2005 Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Take-up failure, damaged sheet, defective drive Sheets stapled or clipped together mechanism due to jammed staples or clips Sheets glued together Take-up failure, damaged sheet...

  • Page 170: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 3. Overall composition Composition/Operation Overall composition Hookup Cord Turnover Cover Take-Up Cover Document Guide Document Feed Tray Transport Belt Exit Cover Magnet...

  • Page 171: Drive System

    4. Drive system Theory of Operation Ver. 1.0 Jul. 2005 Drive system Turnover/Exit Drive Mechanism Document Transport Drive Mechanism Document Take-Up/Feeding Drive Mechanism...

  • Page 172: Paper Path

    Theory of Operation Ver. 1.0 Jul. 2005 5. Paper path Paper path Single-sided Document Mode Double-sided Document Mode...

  • Page 173: Mechanical Operations

    6. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Mechanical operations Document pick-up mechanism • The Document Pick-Up Section consists of the Document Stoppers, Pick-Up Rollers, Take-Up Roller and Separation Roller, and this section is driven by the Take-Up Motor. •...

  • Page 174: Document Take-Up/Transport Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 6. Mechanical operations Document take-up/transport mechanism • The Pick-Up and Take-Up Rollers are rotated by the Take-Up Motor and an original is taken-up and transported to the Registration Roller. • Then, the original is transported onto the Original Glass by the Registration Roller driven by the Take-Up Motor, and the Transport Belt driven by the Transport Motor.
  • Page 175 6. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 A. Document take-up operation flow Registration Clutch: ON ↓ Take-Up Motor: Forward Rotation ↓ Pick-Up Rollers go down and rotated via timing belt & gears ↓ At the same time, Document Stoppers go up ↓...

  • Page 176: Document Exit Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 6. Mechanical operations Document exit mechanism 6.3.1 Single-sided document mode • The original transported by the Transport Belt is sent to the switchback section and then ejected onto the Exit Tray with its face-down in order to keep the original pages in proper order.

  • Page 177: Exit Operation Flow

    6. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 6.3.3 Exit operation flow A. Document exit motion in single-sided mode Exit Motor: Forward Rotation ↓ Transport Motor: Forward Rotation ↓ The original is transported to the switchback section. ↓ Transport Motor: OFF after the original leaves from the Transport Belt ↓...

  • Page 178: Turnover Mechanism (Two-Sided Mode)

    Theory of Operation Ver. 1.0 Jul. 2005 6. Mechanical operations Turnover mechanism (two-sided mode) • In the Double-Sided Mode, an original which has its 1st side scanned is turned-over and then transported to the scan position again for the 2nd side scanning. Exit Motor (M3-DF) Turnover Gate Turnover Solenoid...

  • Page 179: Raised/Lowered Position Detecting Mechanism

    6. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Raised/lowered position detecting mechanism 6.5.1 Document size detection • The 20 degree Open Detection Mechanism enables the main body to detect the docu- ment size when the RADF is used as the Original Cover of the main body, there is the Lever Actuator provided in the RADF body that blocks or unblocks a sensor to initiate a reconfirmation of the original size as read by the original size detection sensors.
  • Page 180 SERVICE MANUAL THEORY OF OPERATION PC-103/PC-203 2005.07 Ver. 1.0...
  • Page 181 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 182: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS PC-103/PC-203 Outline Product specifications ..................... 1 Paper Feed path...................... 2 Composition/Operation Composition ......................3 Drive system ......................4 Operations....................... 5 Paper Feed Section ....................5 5.1.1 Vertical transport drive mechanism............... 5 5.1.2 Paper lifting motion ..................
  • Page 183 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 184: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 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 Type Plain paper 60 to 90 g/m (16 to 24 lb)

  • Page 185: Paper Feed Path

    2. Paper Feed path Theory of Operation Ver. 1.0 Jul. 2005 Paper Feed path Paper feed from the 3rd tray Transportation to main body Main body transportation in PC PC-103/PC-203 Only PC-203 Paper feed from the 4th tray 4061t1c001aa...

  • Page 186: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 3. Composition Composition/Operation Composition Paper Feed Section Cassette Section PC-103/PC-203 Only PC-203 4061t2c001aa...

  • Page 187: Drive System

    4. Drive system Theory of Operation Ver. 1.0 Jul. 2005 Drive system <PC-103> Tray3 Paper Feed Motor (M120-PC) Tray3 Take-up Motor (M122-PC) 4348M005AA Tray3 Paper Feed Motor (M120-PC) <PC-203> Tray3 Take-up Motor (M122-PC) Tray4 Vertical Transport Motor (M121-PC) Tray4 Take-up Motor (M123-PC) 4348M002AB...

  • Page 188: Operations

    Theory of Operation Ver. 1.0 Jul. 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 body. •...

  • Page 189: Paper Lifting Motion

    5. Operations Theory of Operation Ver. 1.0 Jul. 2005 5.1.2 Paper lifting motion • When the drawer is slid into the main body and the Device Detection Sensor is activated, the Lift-up Motor starts rotating to raise the Paper Lifting Plate. •...

  • Page 190: Cassette Section

    Theory of Operation Ver. 1.0 Jul. 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 bot- tom of the drawer turns, allowing the four FD Paper Size Sensors on the Paper Size Board.

  • Page 191: Paper Level Indicator Mechanism

    5. Operations Theory of Operation Ver. 1.0 Jul. 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 192 SERVICE MANUAL THEORY OF OPERATION PC-403 2005.07 Ver. 1.0...
  • Page 193 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 194: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS PC-403 Outline Product specification ....................1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Drive ........................4 Operations....................... 5 Paper Feed Section ....................5 5.1.1 Paper Feed drive mechanism ............... 5 Tray Section ......................
  • Page 195 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 196: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification Outline Product specification A. Type Name Large Capacity Cabinet Type Front loading type LCC Installation Desk type Document Alignment Center B. Paper type Type Plain paper 60 to 90 g/m (16 to 24 lb) Recycled paper 60 to 90 g/m...

  • Page 197: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Jul. 2005 Paper Feed Path Transportation to main body Main body PC-403 Paper feed in LCC 4061t1c101aa Main tray Sub tray Move from sub-tray to the main tray...

  • Page 198: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 3. Composition Composition/Operation Composition Tray Section Paper Feed Section 4061t2c102aa Sub Tray Main Tray...

  • Page 199: Drive

    4. Drive Theory of Operation Ver. 1.0 Jul. 2005 Drive Tray Lock Solenoid (SL1-LCT) Take-up Motor (M1-LCT) Vertical Transport Motor (M2-LCT) Elevator Motor (M5-LCT) 4061t2c101aa Division Board Motor (M3-LCT) Shift Tray Motor (M4-LCT)

  • Page 200: Operations

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

  • Page 201: Tray Section

    5. Operations Theory of Operation Ver. 1.0 Jul. 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 202: Shift Gate Drive Mechanism

    Theory of Operation Ver. 1.0 Jul. 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 203: Paper Empty Detection

    5. Operations Theory of Operation Ver. 1.0 Jul. 2005 5.2.4 Paper empty detection • Paper empty detection of Main Tray is performed by Main Tray Empty Sensor Board. • Paper empty detection of Sub Tray is performed by Shift Tray Empty Sensor. Sub Tray Main Tray 4348M623AA...
  • Page 204 SERVICE MANUAL THEORY OF OPERATION AD-503 2006.02 Ver. 2.0...
  • Page 205 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 206: Outline

    Theory of Operation Ver. 2.0 Feb. 2006 CONTENTS AD-503 Outline Product specifications ..................... 1 Paper Feed Path ..................... 2 Composition/Operation Composition ......................3 Drive ........................4 Switchback Drive ....................4 Transport Drive ..................... 4 Operation ........................ 5 Switchback mechanism ..................5 5.1.1 Switchback operation ..................
  • Page 207 Theory of Operation Ver. 2.0 Feb. 2006 Blank Page...

  • Page 208: Outline

    Theory of Operation Ver. 2.0 Feb. 2006 1. Product specifications Outline Product specifications A. Type Name Duplex Unit Type Switchback and Circulating Duplex Unit Installation Mounted on the right side door of main body Document Alignment Center B. Paper type Plain paper 64 to 90 g/m (17 to 24 lb)

  • Page 209: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 2.0 Feb. 2006 Paper Feed Path Switchback to Main Body paper is fed into the main body again 4066T1J500DA...

  • Page 210: Composition/Operation

    Theory of Operation Ver. 2.0 Feb. 2006 3. Composition Composition/Operation Composition Switchback section Transport section 4066T2C514DA...

  • Page 211: Drive

    4. Drive Theory of Operation Ver. 2.0 Feb. 2006 Drive Switchback Drive Switchback Motor (M1 DU) Main Body Duplex Unit Paper Exit Roller/1 Paper Exit Roller/2 4066T2C517DA Transport Drive Duplex Control Board (PWB-A DU) Duplex Unit Transport Roller 1 Duplex Unit Transport Roller 2 Duplex Unit Transport Motor (M2 DU)

  • Page 212: Operation

    Theory of Operation Ver. 2.0 Feb. 2006 5. Operation Operation Switchback mechanism 5.1.1 Switchback operation • The Paper Exit Roller of the main body is used to subject the 1-sided print to a switch- back sequence so that the 1-sided print is to be transported through the Duplex Unit. Paper Exit Roller/1 Paper Exit Roller/2 Feeding the Paper into Duplex Unit...

  • Page 213: Transport Control

    5. Operation Theory of Operation Ver. 2.0 Feb. 2006 Transport Control 5.2.1 Duplex Unit Transport Motor Control • Rotation of the Duplex Unit Transport Motor is controlled by the signals output from the Duplex Control Board. 5.2.2 2-sided printing method •...
  • Page 214 Theory of Operation Ver. 2.0 Feb. 2006 5. Operation Operation 4 • The main body 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. 4066T2C504DA Operation 5 •...
  • Page 215 5. Operation Theory of Operation Ver. 2.0 Feb. 2006 B. Operations in 2-sided printing with two sheets of paper resident in the system Operation 1 Paper Exit Roller • The first sheet of paper is taken up and fed in from the main body drawer and the main body starts the first print cycle to produce the print image of the second page of the original.
  • Page 216 Theory of Operation Ver. 2.0 Feb. 2006 5. Operation Operation 6 • Immediately before the first 1-sided print leaves the Paper Exit Roller, the direction of rotation of the Paper Exit Roller is reversed and the first 1-sided print for the third sheet is transported toward and into the Duplex Unit.
  • Page 217 5. Operation Theory of Operation Ver. 2.0 Feb. 2006 Blank Page...
  • Page 218 SERVICE MANUAL THEORY OF OPERATION FS-501 2005.07 Ver. 1.0...
  • Page 219 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 220: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS FS-501 Outline Product specification ....................1 Composition/Operation Overall composition....................5 Center cross section ....................6 Drive system ......................7 Mechanical operations .................... 8 Paper transport ..................... 8 5.1.1 Paper transport mechanism ................8 5.1.2 Paper switchback mechanism..............
  • Page 221 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 222: Outline

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification Outline Product specification A. Type Type Single Staple Finisher Installation Freestanding Document Alignment Center Supplies Staple Cartridge Option Job separator (JS-601) B. Functions Modes Group, Sort, Offset/Group, Offset/Sort, Sort Staple and Group Staple C.
  • Page 223 1. Product specification Theory of Operation Ver. 1.0 Jul. 2005 D. Stapling Staple Filling Mode Dedicated Staple Cartridge Mode (3000 staples) Staple Detection Available (Nearly Empty: 40 remaining staples) Diagonal back side (45 °C) 1 point Stapling Position Rear Parallel 1 point B5S/B5 to A3 Stapled Paper Size 8-1/2 ×...
  • Page 224 Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification F. Machine specifications DC 24 V (supplied from the main body) Power Requirements DC 5 V (generated by Finisher) Max. Power 63 W or less Consumption 538 mm (W) × 637 mm (D) × 978 mm (H) Dimensions 21-1/4 inch (W) ×...
  • Page 225 1. Product specification Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 226: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 2. Overall composition Composition/Operation Overall composition Lower Front Cover Tray Upper Cover Elevator Tray Upper Front Cover Rear Cover...

  • Page 227: Center Cross Section

    3. Center cross section Theory of Operation Ver. 1.0 Jul. 2005 Center cross section [13] [14] [11] [10] [12] Entrance Roll Tray Exit Roll Lower Path Transport Roll Tray Exit Roller Upper Path Transport Roller [10] Lower Path Transport Roller Upper Path Transport Roll [11] Storage Roller...

  • Page 228: Drive System

    Theory of Operation Ver. 1.0 Jul. 2005 4. Drive system Drive system Lower Paddle Motor (M9-FN) CD Aligning Motor (M5-FN) Stapling Unit Moving Motor (M6-FN) Shift Motor (M8-FN) Elevator Motor (M7-FN) Upper Entrance Motor (M4-FN) Entrance Motor (M1-FN) Lower Entrance Motor (M2-FN) Exit Roller/Rolls Storage Roller/Rolls Spacing Motor (M13-FN)

  • Page 229: Mechanical Operations

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Mechanical operations Paper transport 5.1.1 Paper transport mechanism A. Entrance section paper transport mechanism • The Entrance Roller is turned to transport the paper into the Finisher as the Entrance Motor is energized.
  • Page 230 Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations B. 1 tray paper transport mechanism • Paper transport to the 1 Tray takes place when the Finisher is in the Group/Sort mode. • The Upper Path Transport Roller and 1 Tray Exit Roller turn to transport the paper into the 1 Tray as the motor is energized.
  • Page 231 5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 C. Finisher tray paper transport mechanism • Paper transport to the Finisher Tray takes place when the Finisher is in the Staple mode. • As the Lower Entrance Motor is energized, the Storage Roller turns to transport the paper toward the exit direction.
  • Page 232 Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations D. Elevator tray paper transport mechanism • Paper transport to the Elevator Tray takes place when the Finisher is in the Group, Sort, Offset/Group or Offset/Sort mode. • As the motor is energized, the Exit Roller turns to transport the paper into the Elevator Tray.

  • Page 233: Paper Switchback Mechanism

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 5.1.2 Paper switchback mechanism • When the last paper of the first print set is transported onto the Finisher Tray during a multi-print cycle in the Sort Staple mode, the first paper of the subsequent print set, which is to be next transported, undergoes a switchback sequence.

  • Page 234: Roller/Rolls Spacing Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations 5.1.3 Roller/rolls spacing mechanism A. Storage roller/rolls spacing mechanism • The Storage Roller briefly stops when the first sheet of paper completes a switchback sequence during a multi-print cycle in the Sort Staple mode. If, however, paper measures 217 mm or more in the FD direction, the leading edge of the second sheet of paper reaches the Storage Roller before the roller stops turning.

  • Page 235: Finisher Tray

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Finisher tray • Sheets of paper are properly aligned and stapled together on the Finisher Tray before being fed out into the Elevator Tray. Finisher Tray Elevator Tray...

  • Page 236: Paper Aligning Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations 5.2.1 Paper aligning mechanism • The Aligning Plate is moved and the Paddles are turned to align paper correctly for sta- pling. A. Aligning plate • The Aligning Plate is moved to align the paper in the crosswise direction with reference to the center position of the Finisher Tray.
  • Page 237 5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 B. Paddles • The Upper and Lower Paddles are turned to align the paper in the feeding direction. • The Upper Paddles are turned by the Upper Paddle Motor and Upper Paddle Solenoid. •...

  • Page 238: Stapling

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations Stapling 5.3.1 Stapling mechanism • The Stapling Unit performs the stapling action. • When the Stapling Motor turns, the Clinch Arm lowers. Then the Stapler moves up to drive a staple into paper and the staple is formed. •...

  • Page 239: Stapling Unit Moving Mechanism

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 5.3.2 Stapling unit moving mechanism • Stapling Unit is moved by the Stapling Unit Moving Motor. • The Staple Home Position Sensor detects Stapling Unit at respective home positions. The Stapling Unit is moved with reference to this home position. Stapling Unit Staple Home Position Sensor (PC14-FN) Stapling Unit Moving Motor (M6-FN)

  • Page 240: Staple Sheet Empty Detection

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations 5.3.3 Staple sheet empty detection • The Staple Empty Detecting Sensor is used to detect whether there is a staple sheet or not in the Staple Cartridge. • When there are about 20 staples left in the Staple Cartridge, a staple sheet empty condi- tion results and a staple-empty display is given on the control panel of the main body.

  • Page 241: Elevator Tray

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Elevator tray • The Elevator Tray moves up or down according to certain conditions. 5.4.1 Elevator tray ascent/descent mechanism • The Elevator Tray is moved up or down by the Elevator Motor that turns forward or back- ward.

  • Page 242: Elevator Tray Shifting Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations 5.4.2 Elevator tray shifting mechanism • When in the Sort mode, the Elevator Tray is moved to the front and rear by a motor to stack print sets in a sawtooth manner so that each print set is offset with respect to the others.

  • Page 243: Horizontal Transport Unit

    5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Horizontal transport unit Entrance Switching Solenoid (SL1-HO) Turnover Empty Sensor (PC6-HO) Horizontal Unit Door Sensor (PC4-HO) Paper Sensor (PC1-HO)

  • Page 244: Paper Transport Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Mechanical operations 5.5.1 Paper transport mechanism A. Paper path switching mechanism • The paper fed from the main body moves through either one of the two different paper paths. • A solenoid is used to select the paper path. For switchback sequence during 2-sided printing: Solenoid energized For transport onto the Finisher: Solenoid deenergized Turnover Empty Sensor (PC6-HO)
  • Page 245 5. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...
  • Page 246 SERVICE MANUAL THEORY OF OPERATION FS-514/PK-510 /OT-601 2006.08 Ver. 1.0...
  • Page 247 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 248 Theory of operation ver. 1.0 Aug. 2006 CONTENTS FS-514/PK-510/OT-601 Outline Product specifications ..................... 1 FS-514 ........................1 PK-510........................4 OT-601 ........................5 Paper feed path ....................... 7 Feeding paper to the 1st exit tray ................. 7 Feeding paper to the 2nd exit tray ................ 7 Feeding paper to the 2nd exit tray (When OT-601 is mounted) ......
  • Page 249 Theory of operation ver. 1.0 Aug. 2006 Punch kit (PK-510)....................27 Composition ....................... 27 Operation......................27 6.2.1 Skew correction mechanism ............... 27 6.2.2 Punch mechanism ..................28 6.2.3 Punch status detection ................28 6.2.4 Punch trash box full detection mechanism ..........29 Output tray (OT-601) .....................

  • Page 250: Outline

    Theory of operation ver. 1.0 Aug. 2006 1. Product specifications Outline Product specifications FS-514 A. Type Name Multi staple finisher built into the copier Installation Installed in the copier Document alignment Center Consumables Staples B. Functions Sort, group, sort offset, group offset, sort stable, and punch (when PK-510 is Modes mounted) C.
  • Page 251 1. Product specifications Theory of operation ver. 1.0 Aug. 2006 (2) Sort offset/group offset Type Size Weight Max. capacity Exit 200 sheets A5, B5S/B5, A4S/A4, B4, tray1 Plain paper 1000 A4S, 8 x 11S 50 to 90 g/m x 11S/8 x 11, Recycled sheets...
  • Page 252 Theory of operation ver. 1.0 Aug. 2006 1. Product specifications D. Stapling Staple filling mode Dedicated staple cartridge (5000 staples) Staple detection Available (Nearly Empty: 20 remaining staples) Back of the corner (30 degree) A4, A3, B5, B4 x 11, 11 x 17 Front of the corner (30 degree) Back of the corner (Parallel) A4S, B5S, A5...
  • Page 253 1. Product specifications Theory of operation ver. 1.0 Aug. 2006 PK-510 A. Type Name Punch kit PK-510 Installation Built into the finisher Metric B5S, A4, B4, A3 Inch (2 holes) 8 x 11S/8 x 11, 8 x 14, 11 x 17 Paper size Inch (3 holes) 8 x 11, 11 x 17...
  • Page 254 Theory of operation ver. 1.0 Aug. 2006 1. Product specifications OT-601 A. Type Name Output tray OT-601 Installation Fixed to the finisher Sort, group, and sort stable Mode Sort, group, sort offset, group offset, and sort stable Number of bins 1 bin Document alignment Center...
  • Page 255 1. Product specifications Theory of operation ver. 1.0 Aug. 2006 C. Machine specifications 282 mm (W) x 368 mm (D) x 57 mm (H) Dimensions 11 inch (W) x 14.5 inch (D) x 2.25 inch (H) Weight 0.7 kg (1.5 lb) D.

  • Page 256: Paper Feed Path

    Theory of operation ver. 1.0 Aug. 2006 2. Paper feed path Paper feed path Feeding paper to the 1st exit tray Transporting paper to the 1st exit tray Transporting paper from the main unit Feeding paper to the 1st exit tray 9J08T1C106AA Feeding paper to the 2nd exit tray Transporting paper to...

  • Page 257: Feeding Paper To The 2Nd Exit Tray (When Ot-601 Is Mounted)

    2. Paper feed path Theory of operation ver. 1.0 Aug. 2006 Feeding paper to the 2nd exit tray (When OT-601 is mounted) Feeding paper to the 2nd exit tray Transporting paper to Transporting paper from the 2nd exit tray the main unit 9J08T1C108AA...

  • Page 258: Composition/Operation

    Theory of operation ver. 1.0 Aug. 2006 3. Composition Composition/Operation Composition Elevator section Entrance transport section/ Intermediate transport section Storage section/ Exit transport section Entrance switch section Staple section 9J08T1C100AA...

  • Page 259: Drive

    4. Drive Theory of operation ver. 1.0 Aug. 2006 Drive FS-514 Horizontal transport drive section Elevator drive section PK-510 9J08T2C001DA...

  • Page 260: Operations

    Theory of operation ver. 1.0 Aug. 2006 5. Operations Operations Transport section • The transport section is divided into the entrance transport section, intermediate trans- port section, storage 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 261: Entrance Switch Section

    5. Operations Theory of operation ver. 1.0 Aug. 2006 5.1.1 Entrance switch section • One-sided printing paper and the two sided printing paper for printing the second side which are loaded from the copier will be loaded to the intermediate transport section. (forward entrance) •...

  • Page 262: Entrance/Transport Section

    Theory of operation ver. 1.0 Aug. 2006 5. Operations 5.1.2 Entrance/transport section • The paper fed from the main unit is transported to the intermediate transport section. • The entrance motor provides the drive for transporting the paper. • When the entrance motor is energized, the entrance transport roller is driven to rotate. •...

  • Page 263: Storage Section

    5. Operations Theory of operation ver. 1.0 Aug. 2006 5.1.4 Storage section • The paper transported from the intermediate transport section is transported to the stor- age section. • Drive for the storage section is provided by the transport motor/2. Drive of the transport roller 2 and storage roller are controlled.

  • Page 264: Elevator Section

    Theory of operation ver. 1.0 Aug. 2006 5. Operations 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) 4349T 2C 508AA 5.2.2 Elevator tray ascent/descent •...

  • Page 265: Tray Position Detection Mechanism

    5. Operations Theory of operation ver. 1.0 Aug. 2006 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 top face detection sensor is activated when a sheet of paper is fed onto the tray, the elevator tray is temporarily lowered until the elevator top face detection sensor is deactivated and then the tray is raised to a level, at which the elevator tray.
  • Page 266 Theory of operation ver. 1.0 Aug. 2006 5. Operations 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 acti- vated.
  • Page 267 5. Operations Theory of operation ver. 1.0 Aug. 2006 4. When the elevator tray home position sensor is activated a second time after the ascent motion of the elevator tray has been started, it is determined that the eleva- tor tray is now located at the exit port for the 2nd exit tray. 5.

  • Page 268: Shutter Open/Close Mechanism

    Theory of operation ver. 1.0 Aug. 2006 5. Operations 5.2.4 Shutter open/close mechanism • The shutter at the exit is open with the opening for exit being disclosed. When the tray moves, the shutter closes to prevent the hand from being caught at the exit. •...

  • Page 269: Paper Aligning Section

    5. Operations Theory of operation ver. 1.0 Aug. 2006 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 270: Paper Aligning Mechanism (Main Scan Direction)

    Theory of operation ver. 1.0 Aug. 2006 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 sta- pling position. • The paper in the storage tray is aligned in the main scan direction by two align motors and aligning plates.

  • Page 271: Exit Mechanism

    5. Operations Theory of operation ver. 1.0 Aug. 2006 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 (Except the staple mode).
  • Page 272 Theory of operation ver. 1.0 Aug. 2006 5. Operations A. Upper exit roller up/down motion mechanism • The exit roller 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 273: Staple Section

    5. Operations Theory of operation ver. 1.0 Aug. 2006 Staple section 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 274: Stapling Unit Moving Mechanism

    Theory of operation ver. 1.0 Aug. 2006 5. Operations 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 275: Staple Sheet Empty Detection

    5. Operations Theory of operation ver. 1.0 Aug. 2006 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 276: Punch Kit (Pk-510)

    Theory of operation ver. 1.0 Aug. 2006 6. Punch kit (PK-510) Punch kit (PK-510) Composition 4512T 2C 001DA 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 277: Punch Mechanism

    6. Punch kit (PK-510) Theory of operation ver. 1.0 Aug. 2006 6.2.2 Punch mechanism • The entrance sensor will detect the back edge of the paper, and stop feeding the paper at the specified time. The puncher will move down to make the punch hole at the back edge of the paper.

  • Page 278: Punch Trash Box Full Detection Mechanism

    Theory of operation ver. 1.0 Aug. 2006 6. Punch kit (PK-510) 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 sensor. When a punch waste is detected, the corresponding message is displayed on the control panel.

  • Page 279: Output Tray (Ot-601)

    7. Output tray (OT-601) Theory of operation ver. 1.0 Aug. 2006 Output tray (OT-601) Composition 4349T 2C 531AA 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-503/ MT-501 are mounted or not.
  • Page 280 SERVICE MANUAL THEORY OF OPERATION MT-501 2006.08 Ver. 1.0...
  • Page 281 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 282 Theory of operation ver. 1.0 Aug. 2006 CONTENTS MT-501 Outline Product specification ....................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 283 Theory of operation ver. 1.0 Aug. 2006 Blank Page...

  • Page 284: Product Specification

    Theory of operation ver. 1.0 Aug. 2006 1. Product specification Outline Product specification A. Type Name Mailbin kit Installation Install at the top section of the finisher elevator tray. Number of bins 4 bins Number of sheets stored per bin 125 sheets (90 g/m , 24 lb) Plain paper...

  • Page 285: Paper Path

    2. Paper path Theory of operation ver. 1.0 Aug. 2006 Paper path 4510T 2C 501AA...

  • Page 286: Composition/Operation

    Theory of operation ver. 1.0 Aug. 2006 3. Composition Composition/Operation Composition 4510T1C600AA...

  • Page 287: Drive

    4. Drive Theory of operation ver. 1.0 Aug. 2006 Drive Transport motor (M1-MK) Transport rollers Exit rollers 4510T 2C 502AA...

  • Page 288: Operations

    Theory of operation ver. 1.0 Aug. 2006 5. Operations Operations Paper transport mechanism • When the mailbin is selected as the exit source, paper is fed off from the finisher (FS- 514) and toward the mailbin. • Drive for the transport rollers of the mailbin is transmitted from the transport motor by way of a belt.

  • Page 289: Paper Path Selection Mechanism

    5. Operations Theory of operation ver. 1.0 Aug. 2006 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 deen- ergized to operate the corresponding bin entrance gate, thereby selecting a specific paper path into a specific tray.

  • Page 290: Paper Detection

    Theory of operation ver. 1.0 Aug. 2006 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 291 5. Operations Theory of operation ver. 1.0 Aug. 2006 Blank Page...
  • Page 292 SERVICE MANUAL THEORY OF OPERATION SD-503 2006.08 Ver. 1.0...
  • Page 293 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 294 Theory of operation ver. 1.0 Aug. 2006 CONTENTS SD-503 Outline Product specification ....................1 Paper path....................... 2 Composition/Operation Composition ......................3 Drive ........................4 Center creasing section ..................4 Center stapling section ..................4 Operations....................... 5 Paper transport mechanism.................. 5 Exit roller pressure/release ...................
  • Page 295 Theory of operation ver. 1.0 Aug. 2006 Blank Page...

  • Page 296: Product Specification

    Theory of operation ver. 1.0 Aug. 2006 1. Product specification Outline Product specification A. Type Name Saddle sticher SD-503 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 297: Paper Path

    2. Paper path Theory of Operation Ver. 1.0 Mar. 2006 Paper path 4511T 2C 504AA...

  • Page 298: Composition/Operation

    Theory of operation ver. 1.0 Aug. 2006 3. Composition Composition/Operation Composition Center stapling section Center creasing section 4511T1C600AA...

  • Page 299: Drive

    4. Drive Theory of Operation Ver. 1.0 Mar. 2006 Drive Center creasing section Crease chopper Crease motor (M10-SK) Crease roller 4511T2C001DA Center stapling section Saddle exit open/close motor (M9-SK) Upper exit roller Saddle exit motor (M8-SK) 4511T2002DA...

  • Page 300: Operations

    Theory of operation ver. 1.0 Aug. 2006 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 301: Exit Roller Pressure/Release

    5. Operations Theory of Operation Ver. 1.0 Mar. 2006 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 302: Operation

    Theory of operation ver. 1.0 Aug. 2006 5. Operations 5.2.2 Operation 1. The upper exit roller is moved up or down by the cams which are driven by the sad- dle 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 303: Stapling Mechanism

    5. Operations Theory of Operation Ver. 1.0 Mar. 2006 Stapling mechanism • There are two the stapling units in the saddle kit, each being fixed to a specific position. • Since the unit is for center stapling only, it is made up of the upper clincher portion and the lower stapling portion.

  • Page 304: Layable Guide

    Theory of operation ver. 1.0 Aug. 2006 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 305: Center Creasing Mechanism

    5. Operations Theory of Operation Ver. 1.0 Mar. 2006 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 posi- tion as the motor is turned backward.

  • Page 306: Operation

    Theory of operation ver. 1.0 Aug. 2006 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 307: In & Out Guide

    5. Operations Theory of Operation Ver. 1.0 Mar. 2006 In & out guide • When the papers are discharged to the tray, the in and out guide keeps the front edge of the large size paper so the discharged paper will not be pushed at its back edge by the following discharged paper.

  • Page 308: Tray Paper Detection

    Theory of operation ver. 1.0 Aug. 2006 5. Operations Tray paper detection • When paper is fed onto the tray, it pushes the actuator, which causes the paper detection sensor to detect the paper. Saddle tray empty sensor (PC21-SK) 4511T2C010DA...
  • Page 309 5. Operations Theory of Operation Ver. 1.0 Mar. 2006 Blank Page...
  • Page 310 SERVICE MANUAL THEORY OF OPERATION J S-601 2005.07 Ver. 1.0...
  • Page 311 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 312 Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS JS-601 Outline Product specification ....................1 Composition/Operation Overall composition....................3 Center cross section ....................4 Mechanical operation ....................5 Job tray paper transport mechanism ..............5...
  • Page 313 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 314: Product Specification

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification Outline Product specification A. Type Name Job separator Installation Fixed to Finisher Document Alignment Center B. Functions Modes Non-Sort (in the fax or printer output mode) C. Paper type Type Size Weight Tray Capacity...
  • Page 315 1. Product specification Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 316: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 2. Overall composition Composition/Operation Overall composition Job Tray Job Separator Cover...

  • Page 317: Center Cross Section

    3. Center cross section Theory of Operation Ver. 1.0 Jul. 2005 Center cross section Job Separator Exit Roller Job Separator Transport Roller Job Separator Exit Roll Job Separator Transport Roll...

  • Page 318: Mechanical Operation

    Theory of Operation Ver. 1.0 Jul. 2005 4. Mechanical operation Mechanical operation Job tray paper transport mechanism • The job Separator Transport Roller and job Separator Exit Roller turn to transport the paper into the job Tray as the motor is energized. •...
  • Page 319 4. Mechanical operation Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...
  • Page 320 SERVICE MANUAL THEORY OF OPERATION FS-603 2005.07 Ver. 1.0...
  • Page 321 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 322 Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS FS-603 Outline Product specification ....................1 Paper Feed Path ..................... 4 Output the 1st paper exit tray................4 Output the 2nd paper exit tray ................5 Composition/Operation Composition ......................7 Drive ........................8 Operation ........................
  • Page 323 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 324: Product Specification

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification Outline Product specification A. Type Type Multi Staple Finisher with Saddle (Booklet) Installation Freestanding Document Alignment Center Supplies Staple Cartridge B. Functions Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple, Center Staple &...
  • Page 325 1. Product specification Theory of Operation Ver. 1.0 Jul. 2005 (3) Sort staple No. of Sheets to Type Size Weight Tray Capacity Exit Tray be Stapled Plain Paper B5S/B5 to Normal Mode A4S/ Normal Mode *1 8.5 × 11S 8.5 × 14 Thick Paper paper 60 to 90 g/m...
  • Page 326 Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification E. No. of sheets to be stapled (sort staple) (1) A4S, 8.5 × 11S or smaller No. of Sets No. of Sheets to be Stapled Rear: Parallel Center: Parallel Front: Parallel 3 to 5 6 to 10 11 to 20...

  • Page 327: Paper Feed Path

    2. Paper Feed Path Theory of Operation Ver. 1.0 Jul. 2005 Paper Feed Path Output the 1st paper exit tray Aligning, Offset, Staple Transports to the punch position Transports to the Finishing tray Transportation from Main Body Output to 1st Paper Exit Tray 4583t1c001aa...

  • Page 328: Output The 2Nd Paper Exit Tray

    Theory of Operation Ver. 1.0 Jul. 2005 2. Paper Feed Path Output the 2nd paper exit tray Transports to the Finishing tray Transportation from Main Body Aligning, Paper stack 4583t1c002aa Transports to the folding position Transports to the center staple position Output to 2nd Paper Exit Tray...
  • Page 329 2. Paper Feed Path Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 330: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 3. Composition Composition/Operation Composition Finishing tray / Exit tray section Punch section (Option) Transport section Staple Section 4583t2c001aa Center Staple & Fold section...

  • Page 331: Drive

    4. Drive Theory of Operation Ver. 1.0 Jul. 2005 Drive Transport Motor (M1-FN) Entrance Motor (M9-FN) Paddle Motor (M2-FN) Staple/Folding Motor (M7-FN) Exit Motor (M3-FN) Slide Motor (M8-FN) Shift Motor (M6-FN) 4583t2c002aa Rear Aligning Motor (M5-FN) Front Aligning Motor (M4-FN)

  • Page 332: Operation

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation Operation Transport Section 5.1.1 Paper path switching mechanism • The path along which the paper is transported is selected with the Entrance Switching Solenoid. • During a 2-sided print mode, the solenoid is energized to feed the paper into the lower path and then feed it back to the main body.

  • Page 333: Finisher Paper Transport Mechanism

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.1.2 Finisher paper transport mechanism • Drive from the Transport Motor turns the Transport Roller to transport paper fed from the main body onto the Finisher. • The Transport Roller on the Finisher side is driven by the Transport Motor to feed the paper through the Finisher.

  • Page 334: Finishing Tray Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation Finishing tray mechanism 5.2.1 Paper stacking with finishing tray • After the paper has been fed through the Exit Roller, the paper drops onto the Finishing Tray. Then, the Paddle taps the top of the paper twice (once for the additional sheets) so that the trailing edge of the paper reaches the Finishing Tray Stopper.

  • Page 335: Aligning Mechanism

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.2.2 Aligning mechanism • Two Aligning Plates are moved by drive of the Front, or Rear Aligning Motor in the for- ward or reverse direction. • The Aligning Plates home position is detected with the Front, or Rear Aligning Plate Home Position Sensor.

  • Page 336: Exiting Operation

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.2.4 Exiting operation • The Paddle, driven by the Paddle Motor, makes the Swing Guide move down and then the paper is taken up with the Upper, and Lower Exit Arm. •...

  • Page 337: Offset Mode

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.2.6 Offset mode • In the Offset Mode, Paper is taken back onto the Finishing Tray and shifted to the front or rear side with the Aligning Plate. Then, a stack of paper per set is fed out onto the 1st Paper Exit Tray. •...

  • Page 338: Center Staple & Fold Mode

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.2.8 Center Staple & Fold mode • In Staple section, A stack of paper fed onto the Finishing Tray is stapled (at two places) and then transported to the Fold Section. •...

  • Page 339: Types And Positions Of Staples

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 Staple unit 5.3.1 Types and positions of staples • Shown here are the different stapling positions used with the FS-601. Type Paper Size (Metric area) Paper Size (Inch area) Corner stapling (Rear) B5, B5S, A4, A4S, B4, A3 8.5×11, 8.5×11S, 8.5×14, 11×17 Corner stapling (Front)

  • Page 340: Staple Unit Moving Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.3.2 Staple unit moving mechanism • When the Power Switch is turned ON, or the Front Door is opened and closed, the Staple Unit is moved to the front side with the forward rotation of the Slide Motor and stopped at the position where the Slide Home Position Sensor located at the bottom of the Staple Unit is blocked by the Light Shield Plate.

  • Page 341: Staple Operation

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.3.3 Staple operation • After the paper stacking and alignment operation on the Finishing Tray have been com- pleted, a stack of paper is taken up with the Upper, and Lower Exit Rollers by moving the Swing Guide down with the Paddle Motor rotating in the reverse direction.

  • Page 342: Staple Unit

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.3.4 Staple unit • The Stapling operation is accomplished by a Cam rotated once with the Staple/Folding Motor. • The Home position of this Cam is detected with the Staple Drive Home Position Sensor. If the Staple Drive Home Position Sensor is OFF, the Staple/Folding Motor rotates in the forward direction until the Sensor is blocked or the signal is ON, which designates that the position of the Cam is ready for the next stapling operation.

  • Page 343: Staple Unit Moving Control

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.3.5 Staple unit moving control • The Staple Unit is moved with the Slide Motor and its home position is detected with the Slide Home Position Sensor. • Regardless of the staple mode or paper size, the staple unit always returns to the stand by position on the rear side.

  • Page 344: 1St Paper Exit Tray Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.3.6 1st Paper Exit Tray mechanism • The 1st Paper Exit Tray is moved up or down by drive from the Shift Motor and the Exit Tray Sensor detects if the paper is stacked on the 1st Paper Exit Tray. •...

  • Page 345: Center Staple & Fold Section

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 Center Staple & Fold Section 5.4.1 2nd paper Exit Tray • The 2nd Paper Exit Tray is fixed and all the paper stacked as a booklet is exited onto this Tray. •...

  • Page 346: Transport Operation In Center Staple & Fold Section

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.4.2 Transport operation in Center Staple & Fold section A. Paper transport • After a stack of paper has been aligned on the Finishing Tray, it is taken up with the Upper and Lower Exit Rollers.
  • Page 347 5. Operation Theory of Operation Ver. 1.0 Jul. 2005 B. Stapling • The stack of paper is further transported and temporarily stopped when the center area of the paper (the area where stapling will be made) has reached the position of the sta- ples in the Staple Unit.
  • Page 348 Theory of Operation Ver. 1.0 Jul. 2005 5. Operation C. Booklet Transport • Next, the stack of paper that was stapled is transported to the paper folding / exit position with the Transport Rollers. The Paper folding /exit position is the position where the cen- ter of the paper (where stapled) is of the same height as that of the Paper Pressure Plate and nip area of the Folding Rollers.
  • Page 349 5. Operation Theory of Operation Ver. 1.0 Jul. 2005 D. Folding/exit • The Paper Pressure Plate presses the center of the paper to transport the paper toward the Paper Folding Rollers. Then the Paper Folding Rollers take up and fold the paper and feed the stack of paper onto the 2nd Paper Exit Tray through the Folding, and the Booklet Exit Rollers.

  • Page 350: Folding Mechanism

    Theory of Operation Ver. 1.0 Jul. 2005 5. Operation 5.4.3 Folding mechanism • The Paper Folding Mechanism consists of the Folding Rollers and Paper Pressure Plate. • They are driven by the Staple/ Folding Motor respectively through the combination of the Gears and Cams etc.

  • Page 351: Paper Folding Start Position

    5. Operation Theory of Operation Ver. 1.0 Jul. 2005 5.4.4 Paper folding start position • Paper folding is created by the Paper Folding Plate and the Paper Pressure Plate. At the same time when the Folding Rollers start to rotate, the Paper Pressure Plate starts pressing the stack of paper to the contact area of the Paper Folding Rollers.
  • Page 352 SERVICE MANUAL THEORY OF OPERATION PK-501/PK-4/ PK-131 2005.07 Ver. 1.0...
  • Page 353 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 354 Theory of Operation Ver. 1.0 Jul. 2005 CONTENTS PK-501/PK-4/PK-131 Outline Product specification ....................1 Composition/Operation Overall composition....................3 Mechanical operations .................... 4 Punching operation....................4 Side registration operation..................5...
  • Page 355 Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 356: Product Specification

    Theory of Operation Ver. 1.0 Jul. 2005 1. Product specification Outline Product specification A. Functions No. of Holes (optional) Metric: 4holes, Inch: 2holes / 3holes B. Paper type No. of Sheets Type Size Weight Tray Capacity Exit Tray to be Stapled 4 holes A4, A3 8-1/2 ×...
  • Page 357 1. Product specification Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...

  • Page 358: Composition/Operation

    Theory of Operation Ver. 1.0 Jul. 2005 2. Overall composition Composition/Operation Overall composition Punch Axis Punch Motor (M1P-PK) Off-center Cam Hole-Punch Waste Container...

  • Page 359: Mechanical Operations

    3. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Mechanical operations Punching operation • The Punch Section consists of the Dyes Section and the Punch Blade Section • The Punch, which is attached to the Off-Center Cam of the Punch Axis, is driven by the Punch Motor and creates the punching operation with a reciprocating movement con- verted from the rotation movement of the Punch Axis.

  • Page 360: Side Registration Operation

    Theory of Operation Ver. 1.0 Jul. 2005 3. Mechanical operations Side registration operation • The Side registration drive for the Punch Slide Unit is made by the Side Registration Motor. • The Home position of the Punch Slide Unit is detected with the Side Registration Home Position Sensor.
  • Page 361 3. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 B. Operation 2 1. Side Registration Sensor detects paper edge at rear side. 2. Side Registration Motor moves Punch Slide Unit at the specified position. 3. Punch Slide Unit stops. Side Registration Sensor 1 Rear side Side Registration Sensor 2...
  • Page 362 Theory of Operation Ver. 1.0 Jul. 2005 3. Mechanical operations C. Operation 3 1. Paper Trailing Edge Sensor detects paper trailing edge. 2. Transport Motor is stopped. 3. Paper transport is stopped. 4. Punch Motor is driven to punch holes. 5.
  • Page 363 3. Mechanical operations Theory of Operation Ver. 1.0 Jul. 2005 Blank Page...
  • Page 364 © 2005 KONIC A MINOLT A B USINESS T EC HNOLOGIES, INC . Printed in J apan Use of this manual should be strictly supervised to DD4038C E3-0800 avoid disclosure of confidential information.

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