Konica Minolta bizhub 500 Service Manual
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Konica Minolta bizhub 500 Service Manual

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Table of Contents

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SERVICE MANUAL
Theory of Operation
500 / 420
2006.02
Ver. 1.0

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Summary of Contents for Konica Minolta bizhub 500

  • Page 1 SERVICE MANUAL Theory of Operation 500 / 420 2006.02 Ver. 1.0...

  • Page 2: Table Of Contents

    MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-15 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub 500 / 420 Main Body OUTLINE ........................1 COMPOSITION/OPERATION ..................9 * For particulars, see the contents of the main body.
  • Page 3 FS-510/PU-501/OT-601 OUTLINE ........................1 COMPOSITION/OPERATION ..................9 * For particulars, see the contents of FS-510/PU-501/OT-601. FS-511/RU-502 OUTLINE ........................1 COMPOSITION/OPERATION..................7 * For particulars, see the contents of FS-511/RU-502. SD-502 OUTLINE ........................1 COMPOSITION/OPERATION ..................3 * For particulars, see the contents of SD-502. MT-501 OUTLINE ........................

  • Page 4: Safety And Important Warning Items

    Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT- trained service technicians.

  • Page 5: Safety Warnings

    [1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Konica Minolta brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 6 SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.
  • Page 7 SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE Konica Minolta brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and CE from the risk of injury.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS Connection to Power Supply WARNING • Check whether the product is grounded properly. If current leakage occurs in an ungrounded product, you may suffer electric shock while operating the product. Connect power plug to grounded wall outlet. Power Plug and Cord WARNING •...
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • Check whether dust is collected around the power plug and wall outlet. Using the power plug and wall outlet without removing dust may result in fire. • Do not insert the power plug into the wall outlet with a wet hand.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS Installation Requirements Prohibited Installation Places WARNING • Do not place the product near flammable materials or vola- tile materials that may catch fire. A risk of fire exists. • Do not place the product in a place exposed to water such as rain.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS Inspection before Servicing CAUTION • Before conducting an inspection, read all relevant docu- mentation (service manual, technical notices, etc.) and proceed with the inspection following the prescribed pro- cedure in safety clothes, using only the prescribed tools. Do not make any adjustment not described in the docu- mentation.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check the exterior and frame for edges, burrs, and other damages. The user or CE may be injured. • Do not allow any metal parts such as clips, staples, and screws to fall into the product. They can short internal circuits and cause electric shock or fire.
  • Page 13 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When replacing a lithium battery, replace it with a new lith- ium battery specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority. Improper replacement can cause explosion.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Consumables WARNING • Never throw the used cartridge and toner into fire. You may be burned due to dust explosion. Handling of Service Materials CAUTION • Unplug the power cord from the wall outlet. Isopropyl alcohol and acetone are highly flammable and must be handled with care.

  • Page 15: Safety Information

    SAFETY INFORMATION SAFETY INFORMATION IMPORTANT NOTICE The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin- istration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This copier is certified as a "Class 1"...

  • Page 16: Indication Of Warning On The Machine

    SAFETY INFORMATION INDICATION OF WARNING ON THE MACHINE Caution labels shown below are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. 50gap0e001na S-13...
  • Page 17 SAFETY INFORMATION 50gap0e002na CAUTION: • You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. And also, when the caution label is peeled off or soiled and cannot be seen clearly, replace it with a new caution label.

  • Page 18: 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 19 MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-16...

  • Page 20: Composition Of The Service Manual

    Composition of the service manual This service manual consists of the following sections and chapters: <Theory of Operation section> OUTLINE: System configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating system, and explanation of the control system This section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.

  • Page 21: Notation Of The Service Manual

    Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) IC board: Standard printer (2) bizhub 500 / 420: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98:...
  • Page 22 Classification Load symbol Ex. of signal name Description Power to drive the motor CONT Drive signal DRV1 Motor DRV2 Drive signals of two kinds Drive signals (control signals) of three kinds DRV1 DRV2 DRV3 DRV A DRV A DRV B Drive signals (control signals) of four kinds Motor, phases A and B control signals DRV B...
  • Page 23 Classification Load symbol Ex. of signal name Description SG, S.GND, S_GND Signal ground Ground PG, P.GND Power ground Data carrier detection Serial input SOUT Serial output Data terminal operation available Signal ground (earth) Serial com- DSR, DSET Data set ready munication Transmission request signal Consent transmission signal...
  • Page 24 SERVICE MANUAL Theory of Operation 500 / 420 Main body 2006.02 Ver. 1.0...
  • Page 25 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 26: Outline

    CONTENTS CONTENTS bizhub 500 / 420 OUTLINE 1. SYSTEM CONFIGURATION ............1 2.
  • Page 27 CONTENTS Theory of Operation Ver1.0 Feb.2006 10.2.3 Transfer exposure lamp (TSL) control ..........27 11.
  • Page 28 Theory of Operation Ver1.0 Feb.2006 CONTENTS 16.3 Operation ..............58 16.3.1 Loop control .
  • Page 29 CONTENTS Theory of Operation Ver1.0 Feb.2006 23.2.1 Composition............. . 100 23.2.2 Operation .

  • Page 30: System Configuration

    Desk (DK-501) [28] Mount kit (MK-708) [14] Large capacity unit (LU-201) "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details. Dehumidifier heater is set up as service part. Swedish punch kit G is for Europe only.
  • Page 31 1. SYSTEM CONFIGURATION Theory of Operation Ver1.0 Feb.2006 B. Configuration for optional device connection Note • Any combination other than those listed below is not available. Combinations for paper feeding Combinations for finishing Remarks DK-501/PC-202/PC-402 *1 OT-501 DK-501/PC-202/PC-402 *1 OT-501 JS-502 DK-501/PC-202/PC-402 *1 RU-502 + FS-511...

  • Page 32: Product Specifications

    Theory of Operation Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS 2. PRODUCT SPECIFICATIONS A. Type Type Desktop type Copying method Indirect electrostatic method Original stand Fixed Original alignment Left rear standard Photo conductor Sensitizing method Laser writing Paper feed trays Two trays 500 sheet x 2, 80g/m Bypass feed 150 sheet x 1, 80g/m...
  • Page 33 Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%) fication Warm-up time 60 seconds or less (bizhub 500) 30 seconds or less (bizhub 420) First copy out time 3.2 seconds or less (bizhub 500) 3.6 seconds or less (bizhub 420) Continuous copy speed 50 copies /min.
  • Page 34 Label paper is loaded and fed one sheet at a time. D. Maintenance Maintenance Every 250,000 prints Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500) 1,800,000 prints or 5 years (whichever earlier) (bizhub 420) E. Machine data Power source Inch:...
  • Page 35 2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Feb.2006 Operating environment Temperature 10 to 30 °C Humidity 10 to 80%RH (with no condensation) Note • The information herein may be subject to change for improvement without notice.

  • Page 36: Unit Configuration

    Theory of Operation Ver1.0 Feb.2006 3. UNIT CONFIGURATION 3. UNIT CONFIGURATION [17] [16] [15] [14] [13] [12] [11] [10] 50gat1c002na Scanner section [10] PC or DK (option) Paper reverse/exit section [11] Paper feed section (tray 1/2) Fusing section [12] Developing section Photo conductor section [13] Writing section...

  • Page 37: Paper Path

    4. PAPER PATH Theory of Operation Ver1.0 Feb.2006 4. PAPER PATH 50gat1c003na Reverse conveyance Tray 2 paper feed ADU conveyance Tray 1 paper feed Bypass paper feed Registration conveyance LU paper feed Paper exit PC paper feed...

  • Page 38: Composition/Operation

    Theory of Operation Ver1.0 Feb.2006 5. OVERALL CONFIGURATION COMPOSITION/OPERATION 5. OVERALL CONFIGURATION Time chart when the power is turned ON [1] [2] [3][4] Item Normal Scanner motor rotation (M2) Reverse rotation Exposure lamp (L1) Fusing heater lamp /1 (L2) Fusing heater lamp /2 (L3) Fusing motor (M11) Drum motor (M1) Developing motor (M3)

  • Page 39: Control Block Diagram

    5. OVERALL CONFIGURATION Theory of Operation Ver1.0 Feb.2006 Control block diagram FK, MK RS232C Parallel OACB Write Section PRCB DCPU FS, RU 50gat2c090na Image bus Other buses Clock synchronous serial bus Individual signal line UART bus...

  • Page 40: Scanner Section

    Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION 6. SCANNER SECTION Composition CCD unit (CCDB) Mirror unit Exposure unit Shading correction plate 50gat2c001na Drive 50gat2c002na Scanner wire /Rr Exposure unit Scanner wire /Fr Scanner motor (M2) V-mirror unit...

  • Page 41: Operation

    6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006 Operation 6.3.1 Scan/exposure lamp control A. Operation when the power is turned ON A specified period of time after the power switch (SW2) is turned on, the exposure unit conducts the home posi- tion search.
  • Page 42 Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION B. Operation when the start key is turned ON For the original read mode, the following two types are available: the platen mode and the DF mode. While in the platen mode, the exposure unit scans the original for reading. And while in the DF mode, since DF conveys the original, the exposure unit remains at the prescribed position (DF read position) to read the original.
  • Page 43 6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006 (2) When DF is used (when DF is closed) 50gat2c038na Exposure unit stand-by position Shading correction position 1 Scanner home sensor (PS30) Shading correction position 2 DF read position Exposure lamp (L1) ON...

  • Page 44: Original Size Detection Control

    Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION 6.3.2 Original size detection control A. Detection method The original size detection method varies for the DF mode and the platen mode. (1) DF mode See DF-607 Service Manual. (2) Platen mode •...

  • Page 45: Ae Control

    6. SCANNER SECTION Theory of Operation Ver1.0 Feb.2006 6.3.3 AE control When AE is selected, the density level of the original is detected to adjust it to an appropriate density automati- cally. The sampling range of the original density in the AE control varies for the platen mode and the DF mode. (1) AE sampling range in the platen mode 50gat2c039na Original...

  • Page 46: Image Processing

    Theory of Operation Ver1.0 Feb.2006 6. SCANNER SECTION 6.3.4 Image processing The following items are provided for the image processing. For details, See "22. IMAGE PROCESSING". • AOC (Auto offset control) • AGC (Auto gain control) • Shading correction • AE processing •...

  • Page 47: Write Section

    7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006 7. WRITE SECTION Composition CY2 lens Index lens Collimator lens unit Cleaner Dust-proof glass Laser drive board (LDB) Index mirror CY1 lens θ lens Polygon mirror Index board (INDEXB) 50gat2c003na...

  • Page 48: Operation

    Theory of Operation Ver1.0 Feb.2006 7. WRITE SECTION Operation 7.2.1 Laser beam path [10] 50gat2c041na Dust-proof glass Polygon mirror CY2 lens CY1 lens Drum Collimator lens Index board (INDEXB) Laser diode θ lens [10] Index mirror 7.2.2 Write control Image data that has been processed is converted into laser beam on the laser drive board (LDB) to be irradiated on the drum.

  • Page 49: Image Processing

    7. WRITE SECTION Theory of Operation Ver1.0 Feb.2006 7.2.4 Image processing The following items are provided for the image processing. For details, See "22.2 Image processing in the write section". • Rotation/elongation • 2 dots PWM • • Frequency conversion...

  • Page 50: Photo Conductor Section

    Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION 8. PHOTO CONDUCTOR SECTION Composition IDC sensor (IDCS) Drum claw PGC sensor Drum 50gat2c004na...

  • Page 51: Drive

    8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006 Drive 8.2.1 Drum drive 50gat2c005na Drum motor (M1) Drum drive shaft 8.2.2 Drum claw drive 50gat2c006na Drum claw Drum claw solenoid (SD2)

  • Page 52: Operation

    Theory of Operation Ver1.0 Feb.2006 8. PHOTO CONDUCTOR SECTION Operation 8.3.1 Image creation control When the print start signal turns ON [1], various motors turn ON to place each unit in the operating condition. At the same time, the erase lamp (EL) turns ON to neutralize the drum and the charging corona charges the drum. A specified period of time after the print start signal turns ON, the developing bias turns ON [2] and then a high voltage is impressed [3] on the guide plate.

  • Page 53: Drum Claw Control

    8. PHOTO CONDUCTOR SECTION Theory of Operation Ver1.0 Feb.2006 8.3.2 Drum claw control A. Purpose Two drum claws are employed to prevent paper from winding up around the drum (winding-up jam). The contact and severance of the drum claws to and from the drum are made by the ON/OFF of the drum claw solenoid (SD2).

  • Page 54: Charging Section

    Theory of Operation Ver1.0 Feb.2006 9. CHARGING SECTION 9. CHARGING SECTION Composition Charging control plate Erase lamp (EL) Charging wire 50gat2c007na Operation 9.2.1 Charging control A. Charging wire The high voltage unit (HV) pressurizes 24V DC to impress a minus (–) DC voltage on the charging wire for dis- charge.

  • Page 55: Transfer/Separation Section

    10. TRANSFER/SEPARATION SECTION Theory of Operation Ver1.0 Feb.2006 10. TRANSFER/SEPARATION SECTION 10.1 Composition Transfer wire Plunging prevention plate Transfer exposure lamp (TSL) Separation wire 50gat2c008na...

  • Page 56: Operation

    Theory of Operation Ver1.0 Feb.2006 10. TRANSFER/SEPARATION SECTION 10.2 Operation 10.2.1 Transfer guide control A. Purpose To prevent the transfer guide plate from getting stained, a minus (–) DC voltage is impressed from the high volt- age unit (HV). Voltage impressed: –500 V B.

  • Page 57: Developing Unit

    11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT 11.1 Composition Developer restriction blade Developing roller Agitator screw Agitator plate TCR sensor (TCRS) 50gat2c009na...

  • Page 58: Drive

    Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT 11.2 Drive 50gat2c010na Drum Agitator screw Developing roller Developing unit Developing motor (M3) Agitator plate...

  • Page 59: Operation

    11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006 11.3 Operation 11.3.1 Developer conveyance Developer in the developing unit is supplied by the agitator plate [4] to the developing roller [2]. The thickness of developer attaching to the developing roller is restricted by the developer restriction blade [5]. After completion of transfer to the drum [1], developer remaining on the developing roller is sent back to the agitator screws [3].

  • Page 60: Developing Bias

    Theory of Operation Ver1.0 Feb.2006 11. DEVELOPING UNIT 11.3.2 Developing bias A. Purpose To make toner get easily attached to the drum while in developing, a developing bias is impressed onto the developing roller [1]. 50gat2c044na Developing roller Developing bias shaft Main pole position adjusting plate Developing bias contact B.

  • Page 61: Developing Suction Control

    11. DEVELOPING UNIT Theory of Operation Ver1.0 Feb.2006 11.3.3 Developing suction control A. Purpose To prevent the splash of toner from the developing roller, the duct [4] is provided at 2 places of the developing unit [1]. Toner guided into the duct is sucked in by the developing suction fan (FM6) [3] to be collected by the suction filter /A [2].

  • Page 62: Toner Supply Section

    Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION 12. TONER SUPPLY SECTION 12.1 Composition Toner bottle position Toner supply motor Toner bottle sensor (PS4) Toner remaining sensor sensor (PS28) (M4) (PZS) Toner hopper Toner bottle motor (M10) Toner bottle 50gat2c011na...

  • Page 63: Drive

    12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006 12.2 Drive 50gat2e003na Toner agitator plate Toner bottle motor (M10) Toner conveyance screw Toner supply motor (M4) Toner solenoid (SD5)

  • Page 64: Operation

    Theory of Operation Ver1.0 Feb.2006 12. TONER SUPPLY SECTION 12.3 Operation 12.3.1 Toner level detection control A. Toner level detection control Toner remaining in the toner hopper is detected by the toner remaining sensor (PZS). When toner remaining in the hopper is found below the prescribed amount, a toner supply signal is issued to the printer control board (PRCB).

  • Page 65: Toner Conveyance Control

    12. TONER SUPPLY SECTION Theory of Operation Ver1.0 Feb.2006 12.3.4 Toner conveyance control A. Purpose To convey toner in the toner bottle to the toner hopper. B. Operation The exit [1] of the toner bottle is normally closed. However, by setting the bottle to the toner supply section, the accordion section is pushed and compressed to let the exit open.

  • Page 66: Cleaning/Toner Recycle Section

    Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION 13. CLEANING/TONER RECYCLE SECTION 13.1 Composition Collection screw Scraper Collection paddle Cleaning blade Drum Neutralizing sheet 50gat2c013na...

  • Page 67: Drive

    13. CLEANING/TONER RECYCLE SECTION Theory of Operation Ver1.0 Feb.2006 13.2 Drive 50gat2c014na Drum motor (M1) Developer agitation drive Cleaning/recycle section drive...

  • Page 68: Operation

    Theory of Operation Ver1.0 Feb.2006 13. CLEANING/TONER RECYCLE SECTION 13.3 Operation 13.3.1 Cleaning operation Toner scraped by the cleaning blade [4] is neutralized by the neutralizing sheet [2], then collected by the collec- tion paddle [1], and finally guided to the collection screw [5]. At this time, toner remaining on the collection pad- dle is scraped by the scraper [6].

  • Page 69: Paper Feed Section (Tray 1/2)

    14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) 14.1 Composition 14.1.1 Tray 1 Pick-up roller Feed roller Lift plate Separation roller Tray 1 50gat2c015na 14.1.2 Tray 2 Vertical conveyance roller Pick-up roller Feed roller Lift plate Separation roller...

  • Page 70: Drive

    Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) 14.2 Drive 14.2.1 Paper feed drive [13] [12] [11] [10] 50gat2c016na Feed motor (M9) Feed roller /2 Feed clutch /1 (CL4) Separation roller /2 Feed roller /1 [10] Pick-up roller /2 Separation roller /1 [11] Tray 2...

  • Page 71: Operation

    14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006 14.3 Operation 14.3.1 Up/down control A. Up drive operation The lift drive shaft [3] is rotated by the paper lift motors /1 (M7) [6] and /2 (M8) [7]. The lift drive shaft is provided with the lift arm [1] and the lift plate [2] is pushed up when the lift drive shaft rotates.

  • Page 72: Paper Size Detection Control

    Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) 14.3.2 Paper size detection control A. Paper size detection mechanism (1) Size detection in the main scan direction The side guide plate [12] is provided with the size detection actuator [7]. And interlocked with the side guide plate, this actuator sticks out to the rear side of the tray.
  • Page 73 14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006 B. Paper size detection table Paper size Paper size boards /1 (PSB/1), /2 (PSB/2) Paper size sensor Paper size sensor /Rr1 (PS10), /Rr2 /Fr1 (PS11), /Fr2 SW101 SW102 SW103 SW104 (PS16) (PS17)

  • Page 74: Paper Feed Control

    Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) 14.3.3 Paper feed control A. Pick-up mechanism The pick-up roller [4] is brought up and down mechanically by the lever [6] provided on the rear side of the paper feed unit.
  • Page 75 14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006 B. Pick-up control (1) Tray 1 pick-up control When the print start signal turn ON [1], the feed motor (M9) and the feed clutch /1 (CL4) also turn ON. In this way, the driving force of M9 is transmitted to the pick-up roller and the feed roller to pick up [2] the 1st sheet of paper.
  • Page 76 Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) C. Separation mechanism The separation roller [5] is pressed against the feed roller [8] by the operating pressure generated by the pres- sure [2] of the spring [4] and the torque of the torque limiter [3]. This operating pressure of the feed roller, sepa- ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.

  • Page 77: Paper Empty Control

    14. PAPER FEED SECTION (Tray 1/2) Theory of Operation Ver1.0 Feb.2006 14.3.4 Paper empty control The paper empty of the tray is detected by the paper empty sensors /1 (PS5) [3] and /2 (PS12) [4]. And to prompt the supply of paper before paper in the tray runs out completely, the paper near-empty sensors /1 (PS9) [7] and /2 (PS15) [8] are equipped.

  • Page 78: Paper Remaining Detection Mechanism

    Theory of Operation Ver1.0 Feb.2006 14. PAPER FEED SECTION (Tray 1/2) 14.3.5 Paper remaining detection mechanism The front cover [4] of the tray is provided with the paper remaining display window [3], and the paper remaining in the tray can be checked through this window. The inside of the paper remaining display window is provided with the display lever [2] which is interlocked with the up/down position of the lift plate [1].

  • Page 79: Bypass Section

    15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION 15.1 Composition Pick-up solenoid /BP (SD1) Feed roller Separation roller Lift plate 50gat2c019na...

  • Page 80: Drive

    Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION 15.2 Drive 15.2.1 Paper feed drive 50gat2c018na Feed clutch /BP (CL6) Separation roller Feed roller Feed motor (M9) 15.2.2 Tray lift drive 50gat2c020na Feed clutch /BP (CL6) Lift plate Pick-up solenoid /BP (SD1) Spring...

  • Page 81: Operation

    15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006 15.3 Operation 15.3.1 Up/down control A. Up drive operation The lift plate [4] is of the construction in which it is pushed up by the spring [5] provided on the lower section. However, while in the stand-by condition, it is hold down by the cam [3] provided on the lift drive shaft [6].

  • Page 82: Paper Size Detection Control

    Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION 15.3.2 Paper size detection control A. Size detection in the main scan direction According to the position of the guide plate connected to the paper size VR/BP (VR1), the paper size is detected in the main scan direction.

  • Page 83: Paper Feed Control

    15. BYPASS SECTION Theory of Operation Ver1.0 Feb.2006 15.3.3 Paper feed control A. Pick-up control When the feed motor (M9) is turned ON by the print start signal [1], the pick-up solenoid /BP (SD1) and the ver- tical conveyance clutch (CL3) also turn ON a specified period of time after that. When SD1 turns ON, the lift plate goes up [2] and paper comes into contact with the feed roller.

  • Page 84: Paper Empty Control

    Theory of Operation Ver1.0 Feb.2006 15. BYPASS SECTION B. Separation mechanism The separation roller [7] is pressed against the feed roller [1] by the operating pressure generated by the pres- sure [4] of the spring [5] and the torque of the torque limiter [6]. This operating pressure of the feed roller, sepa- ration roller and torque limiter becomes a limit torque to prevent the double feed of paper.

  • Page 85: Registration Section

    16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION 16.1 Composition Registration roller Loop roller 50gat2c021na...

  • Page 86: Drive

    Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION 16.2 Drive 50gat2c022na Registration roller Loop roller Feed motor (M9) Tray 1 Loop clutch (CL2) Registration clutch (CL1)

  • Page 87: Operation

    16. REGISTRATION SECTION Theory of Operation Ver1.0 Feb.2006 16.3 Operation 16.3.1 Loop control A. Registration path Paper fed from the tray 1 [10], the tray 2 [8], the by-pass tray [6], PC/LU [7] and ADU [4] hits against the registra- tion roller [2] through the loop roller [12].
  • Page 88 Theory of Operation Ver1.0 Feb.2006 16. REGISTRATION SECTION B. Registration operation The feed motor (M9) and the loop clutch (CL2) are turned ON by the print start signal [1]. In this way, the driving force of M9 is transmitted to the loop roller and paper conveyed from each of the paper feed sections is con- veyed to the registration roller.

  • Page 89: Adu Section

    17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION 17.1 Composition Conveyance roller /1 Conveyance roller /2 50gat2c023na...

  • Page 90: Drive

    Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION 17.2 Drive [1] [2] [3] [4] 50gat2c024na ADU conveyance clutch /Up (CL7) Conveyance roller /2 Conveyance roller /1 Conveyance roller /3 ADU conveyance clutch /Lw (CL8) Feed motor (M9)

  • Page 91: Operation

    17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 17.3 Operation 17.3.1 Conveyance path Paper the one side of which has been printed is conveyed to ADU by the reverse roller [12]. The paper conveyed to ADU is also conveyed to the loop roller [6], the registration roller [7] and the drum [8] by the conveyance rollers /1 [2], /2 [3] and /3 [5] and the other side is printed.

  • Page 92: Conveyance Control

    Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION 17.3.2 Conveyance control When printing two or more sheets of paper in the double sided print mode, the conveyance control in ADU var- ies according to the length of paper in the sub scan direction. The following 3 control methods are provided for the conveyance control.
  • Page 93 17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 The 1st sheet of paper in ADU is conveyed with- out interruption. 50gat2c060na The 1st sheet of paper is fed again and the image of the 1st page (the front side of the 1st sheet of paper when the original is double sided) is printed.
  • Page 94 Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION B. 2 sheets self-contained double sided print operation Note • A figure in the illustration (shown in the square) represents the page number. With the 1st sheet of paper fed, the image of the 2nd page (the back side of the 1st sheet of paper when the original is double sided) is printed.
  • Page 95 17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 The 1st sheet of paper is fed again and the image of the 1st page (the front side of the 1st sheet of paper when the original is double sided) is printed. At this time, the 3rd sheet of paper is fed and the 2nd sheet of paper is turned over at the paper reverse/exit section to be conveyed into ADU.
  • Page 96 Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION While the 2nd sheet of paper is being exited, the image of the 8th page (the back side of the 4th sheet of paper when the original is double sided) is printed on the 4th sheet of paper. At this time, the 3rd sheet of paper is standing by on this side of the conveyance roller /3.
  • Page 97 17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 C. 3 sheets self-contained double sided print operation Note • A figure in the illustration (shown in the square) represents the page number. The 1st sheet of paper is fed and the image of the 2nd page (the back side of the 1st sheet of paper when the original is double sided) is printed.
  • Page 98 Theory of Operation Ver1.0 Feb.2006 17. ADU SECTION The 3rd sheet of paper is conveyed to the paper reverse/exit section and the 2nd sheet of paper is conveyed in ADU without interruption. However, the 1st sheet of paper remains standing by at the conveyance roller /3.
  • Page 99 17. ADU SECTION Theory of Operation Ver1.0 Feb.2006 The 2nd sheet of paper is fed again and the image of the 3rd page (the front side of the 2nd sheet of paper when the original is double sided) is printed. The 4th sheet of paper is turned over to be sent to ADU with the 3rd sheet of paper standing by at the conveyance roller /3.

  • Page 100: Fusing Section

    Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION 18. FUSING SECTION 18.1 Composition Fusing heater Paper exit roller Fusing web Decurler roller Fusing roller lamp /1 (L2) Fusing heater lamp /2 (L3) Fusing pressure roller Fusing claw 50gat2c025na 18.2 Drive 50gat2c026na Fusing unit drive Fusing motor (M11)

  • Page 101: Operation

    The time of preliminary rotation varies according to the detected temperature of the drum temperature sensor and the thermistors /1 (TH1) and /2 (TH2). And the starting temperature of the preliminary rotation varies for bizhub 500 and 420. C. Rotation control while in the print The fusing motor (M11) that drives the fusing roller and the fusing pressure roller is turned ON by the print start signal.

  • Page 102: Fusing Temperature Control

    While in the warm-up, the fusing heater lamps /1 (L2) and /2 (L3) turn ON. And it turns OFF at the prescribed temperature. The temperature at which the warm-up completes varies for bizhub 500 and 420. B. While in the print The set temperature of the fusing roller varies according to the type of paper and the paper size.

  • Page 103: Fusing Roller Edge Cooling Control

    18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006 D. Low power mode and sleep mode When each key is not pressed within a specified period of time after the completion of the last print, the system changes into the low power mode or the sleep mode. The starting time for operation can be set individually for the low power mode and the sleep mode.

  • Page 104: Envelope Conveyance Mechanism

    Theory of Operation Ver1.0 Feb.2006 18. FUSING SECTION C. Fusing cooling path The air inside the machine is sucked in by the fusing cooling fans /Fr (FM2) [6] and /Rr (FM8) [1] to be blown against the edges of the fusing roller [3] through the ducts [2] and [5]. In this way, the edges of the fusing roller are cooled down and the surface temperature of the edges of the fusing pressure roller [4] that is in contact also goes down.

  • Page 105: Protection Against Abnormality

    18. FUSING SECTION Theory of Operation Ver1.0 Feb.2006 18.3.6 Protection against abnormality When the thermistors /1 (TH1) and /2 (TH2) detects a stipulated temperature (233°C) 5 times at the prescribed intervals, this is deemed to be a high temperature abnormality and the fusing heater lamps /1 (L2) and /2 (L3) are turned OFF.

  • Page 106: Reverse/Exit Section

    Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION 19. REVERSE/EXIT SECTION 19.1 Composition Reverse roller Exhaust fan /Fr (FM3) Exhaust fan /Rr (FM9) Reverse gate Reverse roller Reverse gate Reverse solenoid (SD3) 50gat2c027na 19.2 Drive 50gat2c028na Reverse motor (M6) Reverse gate Reverse solenoid (SD3) Reverse roller...

  • Page 107: Operation

    19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006 19.3 Operation 19.3.1 Conveyance control A. Reverse gate The reverse gate is driven by the ON/OFF of the reverse solenoid (SD3). Paper conveyed from the fusing section is switched by the reverse gate between the paper exit section and the reverse section. B.
  • Page 108 Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION (2) Reverse path While in the double sided print, the reverse solenoid (SD3) turns ON when the print on the back side is com- pleted, and the reverse gate [1] is switched in the direction in which the conveyance path to the reverse roller [4] is opened.

  • Page 109: Reverse Control

    19. REVERSE/EXIT SECTION Theory of Operation Ver1.0 Feb.2006 19.3.2 Reverse control A. Switch-back mechanism While in the double sided print, paper that passes through the reverse gate [3] is conveyed to the outside of the main body by the reverse roller [5] and then sent back again to the inside of the main body. At this time, the paper is guided to the conveyance roller /1 [1] side, not to the reverse gate side from the metal frame form of the conveyance path.
  • Page 110 Theory of Operation Ver1.0 Feb.2006 19. REVERSE/EXIT SECTION B. Reverse control While in the double sided print, when the fusing exit sensor (PS3) detects the leading edge of paper of which the printing of the back side has been completed and turns ON [1], the reverse solenoid (SD3) turns ON to switch the reverse gate a specified period of time after the registration clutch (CL1) turns ON for back side printing.

  • Page 111: Interface Section

    20. INTERFACE SECTION Theory of Operation Ver1.0 Feb.2006 20. INTERFACE SECTION 20.1 Composition Serial port (RS-232C) Parallel port (based on IEEE1284) USB port (USB TypeB) RJ45 Ethernet connector 50gat2c089na 20.2 Specifications Item Specifications Serial port (RS-232C) For CS Remote Care Parallel port (based on IEEE1284) For ISW of the copier/printer USB port (USB TypeB)

  • Page 112: Image Stabilization Control

    Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL 21. IMAGE STABILIZATION CONTROL 21.1 Outline This machine employs various image stabilization controls to realize the top quality print image at all times. The operation of the image stabilization control varies between while in the power switch (SW2) ON and while in the print.
  • Page 113 Make uniform the surface temperature of the fusing roller and the fusing pressure roller. (2) Execution timing When the detected temperature of the thermistors /1 (TH1) and /2 (TH2) gets to the stipulated temperature. Note • The stipulated temperature at which the fusing preliminary rotation is made varies for bizhub 500 and 420.
  • Page 114 Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL E. Environmental decision control (1) Purpose To detect the environmental temperature and humidity to maintain the image quality, feedback is made to vari- ous controls. (2) Method A temperature sensor and a humidity sensor are equipped inside the machine. (3) Execution timing When the power switch (SW2) is turned ON, and only when it has been left unused for more than 8 hours after the SW2 was turned OFF last time and the fusing temperature is considered below the stipulated temperature,...

  • Page 115: Image Stabilization Control Flow While In The Print And The Idle

    21. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Feb.2006 21.2.2 Image stabilization control flow while in the print and the idle The following shows the image stabilization control flow while in the print and the idle. Print start signal ON Every 20 prints Start of print A.
  • Page 116 Theory of Operation Ver1.0 Feb.2006 21. IMAGE STABILIZATION CONTROL C. Dot diameter adjustment (1) Purpose While in the continuous print, reduce the variance in image density for each print. (2) Method • Create a dot pattern patch between images of which more than 20 prints have been run off. The laser PWM at this time is maximum.

  • Page 117: Image Processing

    22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING 22.1 Image processing in the scanner section A. Shading correction B. AE control C. Area discrimination D. Brightness/density conversion E. Filter/magnification F. Density gamma (conversion) G. Half tone processing (error diffusion) H.

  • Page 118: Shading Correction

    Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING 22.1.1 Shading correction This is the measure to obtain an even distribution from light of the CCD sensor. The following corrections are made at the prescribed timing. White correction The output voltage of each pixel of the CCD sensor when the white reference plate is exposed to the exposure lamp is stored as the maximum output of the pixel.

  • Page 119: Ae Control

    22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006 22.1.2 AE control Through the AE control, a density suitable for the original density is automatically selected and the copy is made properly. A. Sampling area (1) While in the platen mode 50gat2c092na Original 10 mm...

  • Page 120: Area Discrimination

    Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING 22.1.3 Area discrimination To make a copy of the original under the correct condition (to make a correct filter processing), check the read section to see if it is a character or a dot picture, and use the results at the image processing unit at the later stage.

  • Page 121: Filter/Magnification

    22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006 22.1.5 Filter/magnification A. Filter processing An appropriate filter processing is made according to the type of an original and the magnification selected. (1) Character : Make the shading of an original conspicuous. (2) Dot section : Suppress moire.
  • Page 122 Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING (2) Main scan magnification processing while in reduction As shown in drawing below, if the data of each pixel obtained when the original is read by the CCD are D1 to D5, the positions of the data read when reduced are R1 to R5. They are overlapping each other and do not cor- respond to the write position.

  • Page 123: Scanner Gamma Correction

    22. IMAGE PROCESSING Theory of Operation Ver1.0 Feb.2006 22.1.6 Scanner gamma correction To the data obtained after the filter/magnification processing, select a density curve corresponding to the den- sity button selected on the operation panel. An appropriate density curve is provided for each of the character/ picture/character and the picture/thin character modes.

  • Page 124: Image Processing In The Write Section

    Theory of Operation Ver1.0 Feb.2006 22. IMAGE PROCESSING 22.2 Image processing in the write section A. Rotation/elongation B. PWM C. Frequency conversion A. Rotation/elongation Rotate the image in the direction of 90 degrees and 180 degrees as necessary. When outputting images from the memory, expand the compressed data to restore them to their original state. B.

  • Page 125: Others

    23. OTHERS Theory of Operation Ver1.0 Feb.2006 23. OTHERS 23.1 Fan control 23.1.1 Composition [10] 50gat2c029na Exhaust fan /Rr (FM9) Fusing cooling fan /Fr (FM2) Exhaust fan /Fr (FM3) Fusing cooling fan /Rr (FM8) Conveyance suction fan (FM5) Power supply cooling fan (FM1) Drum cooling fan (FM4) Overall control board cooling fan (FM10) Developing suction fan (FM6)

  • Page 126: Operation

    Theory of Operation Ver1.0 Feb.2006 23. OTHERS 23.1.2 Operation A. Power supply cooling fan (FM1) control (1) Purpose Cool down the DC power supply (DCPS) and the high voltage unit (HV2) with suction air. (2) ON timing • It turns ON a specified period of time after the drum motor (M1) turns ON. •...
  • Page 127 23. OTHERS Theory of Operation Ver1.0 Feb.2006 D. Drum cooling fan (FM4) control (1) Purpose Cool around the drum and the toner bottle with suction air. (2) ON timing • After completion of the print, it turns ON a specified period of time after the drum motor (M1) turns OFF. •...
  • Page 128 Theory of Operation Ver1.0 Feb.2006 23. OTHERS G. Developing cooling fan (FM7) (1) Purpose Take in fresh air to cool down the developing motor (M3). (2) ON timing • After completion of the print, it turns ON a specified period of time after M3 turns OFF. •...

  • Page 129: Counter Control

    23. OTHERS Theory of Operation Ver1.0 Feb.2006 23.2 Counter control 23.2.1 Composition CN35 CN36 CN939 OACB PRCB CN30 CN936 CN64 LCDB 50gat2c030na Coin vendor /2...

  • Page 130: Operation

    Key counter (KCT), optional • Counting the designated number of prints allows no fur- ther copy operation (can be removed). For data collected, See "10.6 Counter" in Field service bizhub 500/420 Main body. (See P.178) 50gat2c031na CN936 (KCT connecting connector) Total counter (TCT)
  • Page 131 23. OTHERS Theory of Operation Ver1.0 Feb.2006 B. Coin vendor/2 (Parallel) The following shows the specifications of the connecting connector. Connector Pin No. Signal name Description Output timing Type of signal M1 signal Output from the start L output while in the Open collec- key being turned ON print operation...

  • Page 132: Parts That Operate When The Power Switch Is Turned On

    Theory of Operation Ver1.0 Feb.2006 23. OTHERS 23.3 Parts that operate when the power switch is turned ON 23.3.1 Parts that operate when the main power switch (SW1) is turned ON A. Composition PSWB DCPS 5VDC 12VDC DCPS OACB section 24VDC PRCB 50gat2c032na...

  • Page 133: Parts That Operate When The Power Switch (Sw2) Is Turned On

    23. OTHERS Theory of Operation Ver1.0 Feb.2006 23.3.2 Parts that operate when the power switch (SW2) is turned ON A. Composition PSWB OACB 24VDC DCPS section L2, L3 AC drive section DCPS 50gat2c033na B. Operation Turning ON the power switch (SW2) transmits an ON signal of SW2 to the overall control board (OACB) through the operation board (OB).
  • Page 134 SERVICE MANUAL Theory of Operation DF-607 2006.02 Ver. 1.0...
  • Page 135 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 136 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS DF-607 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................4 In 1-sided mode ....................4 In 2-sided mode ....................4 COMPOSITION/OPERATION COMPOSITION .......................5 DRIVE........................6 OPERATION......................7 Document pick-up mechanism................7 5.1.1 Pick-up operation ..................7 Document feed/conveyance mechanism ..............8 Raised/lowered position detecting mechanism...........12 5.3.1 DF 15°...
  • Page 137 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 138: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Reverse Automatic Document Feeder Paper Feed Paper Feed from top of stack Type Turnover Switch back system Paper Exit Straight exit system Installation Screw cramp to the main unit Document Alignment Center Document Loading...

  • Page 139: Product Specifications

    1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006 D. Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Feed failure, damage to the original, or drive failure Original that is stapled or clipped. due to clip clogging Book original Feed failure, damage to the original, or drive failure...
  • Page 140 Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS F. Mixed original feed chart For Metric Reference original (original with a maximum width) — — — — — — Other originals — — — — — — — — —...

  • Page 141: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH In 1-sided mode 16eat1c001na [1] Exit [3] Feed (Scanning the 1st side) [2] Conveyance and turnover In 2-sided mode 16eat1c002na [1] Exit [3] Feed (Scanning the 1st side) Conveyance and turnover (Scanning the 2nd [2] Conveyance and switchback side)

  • Page 142: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Document feed section Switchback section Document exit section Conveyance section 16eat2c001na...

  • Page 143: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE 16eat2c002na [1] Original Feed Motor (M1) [2] Original Conveyance Motor (M2)

  • Page 144: Operation

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION OPERATION Document pick-up mechanism • The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation Roller, and this section is driven by the Original Feed Motor (M1). 5.1.1 Pick-up operation •...

  • Page 145: Document Feed/Conveyance Mechanism

    5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006 Document feed/conveyance mechanism • When the original reaches the Registration Sensor, the Original Feed Motor (M1) [5] starts rotating forward and, at the same time that the Pickup Roller goes up, drive is then supplied to the Registration Roller [3].
  • Page 146 Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION A. Operation flow in the 1-sided mode 16eat2c005na [1] Exit [3] Scanning the 1st side [2] Original Exit Sensor (PS10) [4] Original Detection Sensor (PS8) 1. When the Start key is pressed, the Original Feed Motor (M1) starts rotating backward, causing the Pick-Up Roller to lower and start a paper take-up sequence.
  • Page 147 5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006 B. Operation flow in the 2-sided mode 1. When the Start key is pressed, the Original Feed Motor (M1) starts turning backward, causing the Pick-Up Roller to lower and start feeding the 1st page of the document. A specified period of time after the leading edge of the original turns ON the Original Detection Sensor (PS8) [4], the scanning of the 1st side of the original starts.
  • Page 148 Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATION 4. To ensure that pages of the document are in the proper order, the page is turned over [3] again before being ejected [1] into the Exit Tray. 16eat2c008na [1] Exit [3] Turnover [2] Scanning the 2nd side...

  • Page 149: Raised/Lowered Position Detecting Mechanism

    5. OPERATION Theory of Operation Ver. 1.0 Feb. 2006 Raised/lowered position detecting mechanism 5.3.1 DF 15° open/close detection mechanism • When DF is closed down to about 15° or less, the Original Cover Angle Detection Lever of the main body is pressed down to turn ON the APS Timing Sensor (PS31). 5.3.2 DF open/close detection mechanism •...
  • Page 150 SERVICE MANUAL Theory of Operation PC-202 500 / 420) 2006.02 Ver. 1.0...
  • Page 151 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 152 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS PC-202 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper Feed Section ....................5 5.1.1 Paper feed mechanism..................5 5.1.2 Paper lifting motion..................6 Tray Section ......................7 5.2.1 Paper size detection ..................7 5.2.2 Paper level indicator mechanism..............8...
  • Page 153 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 154: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center B. Paper type Paper Type Plain paper 56 to 90 g/m Metric: A3, B4, A4, A4S, B5, A5S, 11 ×...

  • Page 155: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH 4061t1c001na [1] Convey to the main body [3] Tray 4 paper feed [2] Vertical conveyance through PC [4] Tray 3 paper feed...

  • Page 156: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Tray 3 Paper Feed Section Tray 4 4061t2c001na...

  • Page 157: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE 4061t2c002na [1] Vertical Conveyance Motor /3 (M120) [3] Vertical Conveyance Motor /4 (M121) [2] Paper Feed Motor /4 (M123) [4] Paper Feed Motor /3 (M122)

  • Page 158: Operations

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS OPERATIONS Paper Feed Section 5.1.1 Paper feed mechanism • The Paper Feed Motor (M122, M123) drives the Pick-up Roller [8] and Feed Roller [6] to take up and feed a sheet of paper into the main body. •...

  • Page 159: Paper Lifting Motion

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.1.2 Paper lifting motion • When the Tray is slid into the main body and the Tray Set Sensor /3, /4 (PS112, PS121) is activated, the Paper Lift Motor /3, /4 (M124, M125) starts rotating to raise the Lifting Plate [3].

  • Page 160: Tray Section

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS Tray Section 5.2.1 Paper size detection • Moving the Sub Scan Direction Restriction Plate of the Tray rotates the Circular Plate [1] provided on the bottom of the Tray. • The length of paper in the sub scan direction is detected by the Paper Size Detection Switch [8] provided on the Paper Size Detect Boards /3 and /4 (PSDB3, PSDB49) [7] that is driven by the Lever interlocked with the Circular Plate.

  • Page 161: Paper Level Indicator Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.2.2 Paper level indicator mechanism • All Trays are universal paper size tray. • There is a window in the front cover of the Tray that serves as the Paper Level Indicator [3] showing the amount of paper that is still available for use.
  • Page 162 SERVICE MANUAL Theory of Operation PC-402 500 / 420) 2006.02 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 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS PC-402 OUTLINE PRODUCT SPECIFICATION...................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper Feed Section ....................5 5.1.1 Paper feed mechanism..................5 Tray Section ......................6 5.2.1 Up/down mechanism..................6 5.2.2 Shift Gate drive mechanism ................7 5.2.3 Shifter drive mechanism................8 5.2.4...
  • Page 165 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 166: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATION OUTLINE PRODUCT SPECIFICATION A. Type Name 2500 sheets paper feed cabinet Type Front loading type LCC Installation Desk type Document Alignment Center B. Paper type Paper Type Plain paper 56 to 90 g/m Metric: A4 Paper Size Inch: 8...

  • Page 167: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH 4061t1c201na [1] Convey to the main body [4] From the Sub Tray to Main Tray [2] Tray paper feed [5] Sub Tray [3] Main Tray...

  • Page 168: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Tray Section Paper Feed Section Main Tray Sub Tray 4061t2c201na...

  • Page 169: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE [10] 4061t2c202na [1] Paper Lift Motor (M5) [6] Shift Gate Drive Section [2] Paper Lift Drive Section [7] Tray Lock Solenoid (SD1) [3] Shifter Drive Section [8] Paper Feed Motor (M1) [4] Shift Motor (M4) [9] Vertical Conveyance Motor (M2) [5] Shift Gate Motor (M3)

  • Page 170: Operations

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS OPERATIONS Paper Feed Section 5.1.1 Paper feed mechanism • The Paper Feed Motor (M1) drives the Pick-up Roller [8] and Feed Roller [6] to take up and feed a sheet of paper into the main body. •...

  • Page 171: Tray Section

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Tray Section 5.2.1 Up/down mechanism • The Main Tray [3] is suspended by the cables [1] at the front and rear. • As the Paper Lift Motor (M5) [5] turns forward or backward, the cables are wound to raise or lower the Main Tray.

  • Page 172: Shift Gate Drive Mechanism

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.2.2 Shift Gate drive mechanism • If the Main Tray runs out of paper, while the Sub Tray is loaded with paper, the paper stack on the Sub Tray is moved to the Main Tray [2]. •...

  • Page 173: Shifter Drive Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.2.3 Shifter drive mechanism • After completion of the evacuation of the Shift Gate, starts the movement of the Shifter [2]. • The movement of paper from the Sub Tray to the Main Tray is made by the Shifter that is driven by the Shift Motor (M4) [1].

  • Page 174: Paper Empty Detection

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.2.4 Paper empty detection • Paper empty detection of Main Tray is performed by Main Tray Empty Board (MEB) [2]. • Paper empty detection of Sub Tray is performed by Sub Tray Empty Sensor (PS9) [3]. 4061t2c207na [1] Main Tray [3] Sub Tray Empty Sensor (PS9)
  • Page 175 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...
  • Page 176 SERVICE MANUAL Theory of Operation LU-201 2006.02 Ver. 1.0...
  • Page 177 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 178 Theory of Operation Ver1.0 Feb.2006 CONTENTS CONTENTS LU-201 OUTLINE 1. PRODUCT SPECIFICATION ............1 2.
  • Page 179 CONTENTS Theory of Operation Ver1.0 Feb.2006 Blank page...

  • Page 180: Outline

    11 Recommended paper Plain paper Inch: Hammermill Tidal MP (20 lbs) Metric: Konica Profi (80 g/m ), Konica Minolta Original (80 g/m Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs) Metric: Nautilus (80 g/m D. Maintenance Maintenance Same as the main body...

  • Page 181: Paper Path

    2. PAPER PATH Theory of Operation Ver1.0 Feb.2006 2. PAPER PATH 16aat1c001na Lift plate Feed roller Separation roller Pick-up roller Conveyance roller...

  • Page 182: Composition/Operation

    Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION COMPOSITION/OPERATION 3. COMPOSITION Paper feed section Tray section 16aat2c001na...

  • Page 183: Paper Feed Section

    4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION Drive 4.1.1 Paper feed drive A. Front side drive 16aat2c002na Pick-up solenoid (SD151) Feed roller Conveyance roller Pick-up roller B. Rear side drive 16aat2c007na Feed motor (M150) Feed clutch (CL151) Conveyance roller...

  • Page 184: Operation

    Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION Operation 4.2.1 Paper feed control A. Pick-up mechanism (1) Drive transmission The driving force of the feed motor (M150) is transmitted to the paper feed gear /3 [4] through various gears. The paper feed gear /3 is connected with the pick-up solenoid (SD151) [1] through the claw [2].
  • Page 185 4. PAPER FEED SECTION Theory of Operation Ver1.0 Feb.2006 (2) Paper feed roller unit up/down mechanism On the inside of the paper feed gear /3 [2], the cam [3] is provided. While in the standby, the cam pushes the lift- up shaft [1].

  • Page 186: Remaining Paper Detection Control

    Theory of Operation Ver1.0 Feb.2006 4. PAPER FEED SECTION 4.2.2 Remaining paper detection control As paper in the tray gets reduced, the lift plate goes up gradually. The actuator [1] provided on the rear side of LU rotates in interlock with the up/down operation of the lift plate. The actuator is provided with the remaining paper sensors /1 (PS154) [3] and /2 (PS151) [2] and the remaining paper is detected by the combination of the ON/OFF of these sensors.

  • Page 187: Tray Section

    5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006 5. TRAY SECTION Drive 5.1.1 Tray lift drive 16aat2c006na Actuator Lift plate Wire Wire Coupling Spring Parallel pin Paper lift motor (M151)

  • Page 188: Operation

    Theory of Operation Ver1.0 Feb.2006 5. TRAY SECTION Operation 5.2.1 Tray lift control When the upper door is closed, a parallel pin for the up drive of the lift plate is pushed out to be coupled to the coupling of the paper lift motor (M151). Closing the upper door also turn ON the upper door interlock switch (MS151) to supply a 24V DC to the load of the drive system.
  • Page 189 5. TRAY SECTION Theory of Operation Ver1.0 Feb.2006 Blank page...
  • Page 190 SERVICE MANUAL Theory of Operation FS-510/PU-501/ OT-601 2006.02 Ver. 1.0...
  • Page 191 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 192 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS FS-510/PU-501/OT-601 OUTLINE PRODUCT SPECIFICATIONS ................1 FS-510 ........................1 PU-501........................3 OT-601 ........................4 PAPER PATH ......................5 Exiting Paper to the Tray /1 ...................5 Exiting Paper to the Tray /2 ...................6 Exiting Paper to OT....................7 COMPOSITION/OPERATION COMPOSITION .......................9 DRIVE........................10 FS-510 ........................10...
  • Page 193 Theory of Operation Ver. 1.0 Feb. 2006 PU-501........................30 Composition ....................... 30 Operation......................30 6.2.1 Registration mechanism ................30 6.2.2 Punch mechanism ..................31 6.2.3 Punch status detection ................31 6.2.4 Punch Scraps Box full detection mechanism..........32 OT-601 ........................33 Composition .......................

  • Page 194: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS FS-510 A. Type Name Multi tray finisher built into the main body Installation Installed in the main body Document Alignment Center Consumables Staples (5,000 staples/cartridge) B. Functions Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted) C.
  • Page 195 1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006 (3) Sort Staple Type Size Weight Max. Capacity Metric: Tray /1 200 sheets A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S A4S, 8 x 11S 1000 11 x 17, 8 x 14, or less sheets...
  • Page 196 Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS PU-501 A. Type Type FS built-in type punching operation device Installation Screwed to the FS Metric: A3, B4, A4, A4S, B5, B5S 11 x 17, 8 x 11, 8 x 11S, Foolscap Paper Size Inch: 2 holes: 11 x 17, 8...
  • Page 197 1. PRODUCT SPECIFICATIONS Theory of Operation Ver. 1.0 Feb. 2006 OT-601 A. Type Type Additional Tray to FS Installation Screwed to the FS Mode Non sort, sort, group, and sort staple Number of Bins 1 bin Document Alignment Center B. Paper Type Mode Size Type...

  • Page 198: Paper Path

    Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH PAPER PATH Exiting Paper to the Tray /1 4349t1c001na [1] From the main body [3] Exiting paper to the Tray /1 [2] Convey to the Tray /1...

  • Page 199: Exiting Paper To The Tray /2

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 Exiting Paper to the Tray /2 4349t1c002na [1] From the main body [3] Exiting paper to the Tray /2 [2] Convey to the Tray /2...

  • Page 200: Exiting Paper To Ot

    Theory of Operation Ver. 1.0 Feb. 2006 2. PAPER PATH Exiting Paper to OT 4349t1c003na [1] From the main body [3] Exiting paper to OT [2] Convey to OT...
  • Page 201 2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 202: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Up/down Section Conveyance Section Staple Section 4349t2c001na...

  • Page 203: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE FS-510 4349t2c002na [1] Stapler Drive Section [5] Paper Exit Opening Drive Section [2] Exit Drive Section [6] Conveyance/Alignment Drive Section [3] Up/down Drive Section [7] Entrance Drive Section [4] Shutter Drive Section...
  • Page 204 Theory of Operation Ver. 1.0 Feb. 2006 4. DRIVE PU-501 4512t2c001na [1] Punch Drive Section...

  • Page 205: Operations

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 OPERATIONS Conveyance Section • The Conveyance Section is divided into the entrance conveyance section [3], intermediate conveyance section [1], and the exit conveyance section [2]. It controls to convey the paper fed from the main body, stop the paper at the punching and folding positions, and drive the paper for feeding into the exit section.

  • Page 206: Entrance/Conveyance Section

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.1.1 Entrance/Conveyance section • A paper [5] fed from the main body is conveyed to the intermediate conveyance section. • The Entrance Motor (M3) [3] provides the drive for conveying a paper. •...

  • Page 207: Intermediate Conveyance Section

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.1.2 Intermediate Conveyance Section • A paper conveyed from the entrance conveyance section is brought to a stop at the punch- ing and folding position. • A paper is also conveyed to the exit conveyance section. •...

  • Page 208: Exit Conveyance Section

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.1.3 Exit Conveyance Section • The paper is exited onto each of the trays. • The Exit Motor (M1) [1] provides drive for the Exit Roller [3], Stacker Paddle [5], and Exit Paddle [2].

  • Page 209: Up/Down Section

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Up/down Section 5.2.1 Up/down mechanism • The Up/down mechanism is operated to select a specific tray, thereby feeding the paper exit onto a specific tray. 4349t2c007na [1] Tray Lift Motor (M11)

  • Page 210: Tray Up/Down Operation

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.2.2 Tray Up/Down operation • The Tray is moved up or down by the Tray Lift Motor (M11) that turns forward or backward to drive the front and rear belts. • The Lower Limit Sensor (PS14) [1] detects the Tray at its lower limit position. •...

  • Page 211: Tray Upper Limit Position Detection Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.2.3 Tray Upper Limit Position Detection Mechanism • Each of the Tray moves up or down according to the amount of paper fed onto it. • When the Upper Limit Sensor (PS15) [1] turns ON for each exit of paper, bring down once the Lift Tray until PS15 turns OFF so that the upper surface of paper on the Tray is kept at the same level at all times while in the paper exit.
  • Page 212 Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS A. Tray Position Detection • Tray position detection is controlled according to the number of times the Tray Position Sen- sor (PS3) [1] is activated after the Lower Limit Sensor (PS14) [2] has been activated. (1) Tray position detection operation 1.
  • Page 213 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 2. After PS14 has been activated, the Up/Down Section is subjected to an ascent motion. 3. When PS3 [1] is activated a first time after the ascent motion of the Up/Down Section has been started, it is determined that the Up/Down Section is now located at the paper exit opening for the Tray /1.

  • Page 214: Shutter Open/Close Mechanism

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.2.4 Shutter Open/Close Mechanism • The paper exit section is provided with the Shutter [3] and this Shutter is normally in the up condition (the condition in which the Paper Exit Opening is opened). However, when the Tray goes up and down, the Paper Exit Opening is closed to prevent an accident such as hands getting caught in the Paper Exit Opening.

  • Page 215: Stacker Section

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Stacker section 5.3.1 Paper aligning mechanism (sub scan direction) • Sheets of paper are aligned properly and stapled together inside the stacker section before being fed out onto the corresponding tray. •...

  • Page 216: Paper Aligning Mechanism (Main Scan Direction)

    Theory of Operation Ver. 1.0 Feb. 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 stapling position. • The paper in the Stacker is aligned in the main scan direction by two Alignment Motors and aligning plates.
  • Page 217 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 B. Paper aligning sequence • In normal print and staple mode, the paper is fed into the tray at its center position. • If no stapling is involved in the Sort or Group Print mode, the aligning plate shifts 15 mm to the front or rear from the center.

  • Page 218: Exit Mechanism

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.3.3 Exit mechanism • The paper exit roller section is provided with the Paper Holding Paddle [3] to hold the paper exited onto the Tray while in the sort mode so that the paper does not have an uneven edge. •...
  • Page 219 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 A. Exit Roller up/down mechanism • While in the sort mode and the staple mode, the Exit Roller /Up is pressed to the Exit Roller /Lw after the paper is stacked in the Stacker. •...

  • Page 220: Stapling

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS Stapling 5.4.1 Stapling mechanism • Stapling is performed by the Stapling Unit. • When the Stapling Motor [1] is rotated, the Clinch Arm [3] lowers. The Stapler [2] thereafter goes up to drive a staple in the paper. •...

  • Page 221: Stapling Unit Moving Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 5.4.2 Stapling Unit moving mechanism • The Stapling Unit is moved by the Stapler Movement Motor (M7) [3]. • M7 drives the belt so that the Stapling Unit is moved to the corresponding stapling position. •...

  • Page 222: Staple Empty Detection

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.4.4 Staple empty detection • Staple Empty Sensor [2] detect whether or not there are staples still left. • When the number of staples left in the staple cartridge becomes about 20, a staple sheet empty condition results, causing a corresponding empty message to appear on the opera- tion panel.

  • Page 223: Composition

    6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006 PU-501 Composition 4512t2c002na Operation 6.2.1 Registration mechanism • For punch and holding operations, a loop is formed in the paper at the Registration Roller [2] to correct skew of the paper. •...

  • Page 224: Punch Mechanism

    Theory of Operation Ver. 1.0 Feb. 2006 6. PU-501 6.2.2 Punch mechanism • After a given period of time after the Entrance Sensor (PS4) [3] has detected the trailing edge of the paper, the Conveyance Motor (M2) of FS is deenergized and a punch hole oper- ation is made at the trailing edge portion in each sheet of paper.

  • Page 225: Punch Scraps Box Full Detection Mechanism

    6. PU-501 Theory of Operation Ver. 1.0 Feb. 2006 6.2.4 Punch Scraps Box full detection mechanism • Punch scraps produced as a result of punching operation is stored in the Punch Scraps Box. • The Punch Scraps Box is provided with the Punch Scraps Full Sensor (PS1) [1]. When a punch waste is detected, the corresponding message is displayed on the operation panel.

  • Page 226: Composition

    Theory of Operation Ver. 1.0 Feb. 2006 7. OT-601 OT-601 Composition 4625t2c001na Operation 7.2.1 Overview • Mounting the optional OT provides a total of three trays. • The OT is attached at different positions depending on whether options SD or MT is mounted or not.
  • Page 227 7. OT-601 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...
  • Page 228 SERVICE MANUAL Theory of Operation FS-511/RU-502 2006.02 Ver. 1.0...
  • Page 229 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 230 Theory of Operation Ver1.0 Feb.2006 CONTENTS CONTENTS FS-511/RU-502 OUTLINE 1. PRODUCT SPECIFICATION ............1 FS-511 .
  • Page 231 CONTENTS Theory of Operation Ver1.0 Feb.2006 Blank page...

  • Page 232: Outline

    Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION OUTLINE 1. PRODUCT SPECIFICATION FS-511 A. Type Type Multi staple finisher Installation Floor-mounted type Document alignment Center Consumables Staples B. Functions Mode Normal Non-sort, sort, group, sort-staple Punch Non-sort-punch, sort-punch, group-punch, sort-staple-punch C.
  • Page 233 1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006 (2) Non-sort, sort, group Type of paper Size of paper Weight Max. capacity Exit tray Max. number of sheets stapled Plain paper A3, B4, A4, A4S, B5, 50 to 130 g/m 3000 sheets Main tray —...
  • Page 234 Theory of Operation Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION D. Stapling Staple filling method Dedicated staple cartridge (5000 staples) Staple detection Available (near empty: 20 remaining staples) Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5 Inch: 8 x 11, 11 x 17 Front: Diagonal 45°...
  • Page 235 1. PRODUCT SPECIFICATION Theory of Operation Ver1.0 Feb.2006 RU-502 A. Type Type Roller method relay conveyance unit B. Functions Conveyance Paper conveyance from the main body to FS C. Type of paper Paper size Same as the main body. Paper type Same as the main body.

  • Page 236: Paper Path

    Theory of Operation Ver1.0 Feb.2006 2. PAPER PATH 2. PAPER PATH A. Non-sort mode (sub tray paper exit) 4521t1c004na Paper exit roller (main body) FS-511 Bypass gate Punch Main gate RU-502 Sub tray Note: Even when mixed with the punch mode, the paper path is the same. B.
  • Page 237 2. PAPER PATH Theory of Operation Ver1.0 Feb.2006 C. Staple mode [10] [11] 4521t1c006na Paper exit roller (main body) Paper path for other than the 1st paper of the 2nd and succeeding copies. Bypass gate Paper path for the 1st paper of the 2nd and FS-511 succeeding copies Main gate...

  • Page 238: Composition/Operation

    Theory of Operation Ver1.0 Feb.2006 3. COMPOSITION COMPOSITION/OPERATION 3. COMPOSITION Conveyance Punch section Sub tray section RU-502 Main tray section Staple section 4521t2c001na...

  • Page 239: Drive

    4. DRIVE Theory of Operation Ver1.0 Feb.2006 4. DRIVE FS-511 [12] [13] [14] [11] [10] 4521t2e001na Paddle motor /Lw (M9) Paper exit motor (M3) Hole punch selector motor (M14) (for inch Paddle motor /Up (M15) area) [10] Paper exit roller release motor (M13) Tray lift motor (M7) [11] Conveyance motor /Lw (M2)
  • Page 240 Theory of Operation Ver1.0 Feb.2006 4. DRIVE RU-502 16fat2c001na Main body - fusing motor (M11) Conveyance roller Entrance conveyance roller (FS-511) Coupling gear Belt...

  • Page 241: Operation

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 5. OPERATION RU conveyance section 5.1.1 Conveyance mechanism • The driving force from the fusing motor (M11) is transmitted through the coupling gear [2] to rotate the con- veyance roller [5]. • Paper conveyed from the paper exit roller [1] on the main body side is conveyed by the conveyance roller to the entrance roller [3] on the FS side.

  • Page 242: Fs Conveyance Section

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION FS conveyance section • The conveyance section is made up of the entrance conveyance mechanism [6] that conducts the convey- ance drive, the main route conveyance mechanism [2], the sub tray conveyance mechanism [5], the han- dling/paper exit conveyance mechanism [3], the gate mechanism [1] that switches the paper path and the roller separation mechanism [4] that conducts the pressure/release of the roller.
  • Page 243 5. OPERATION Theory of Operation Ver1.0 Feb.2006 5.2.1 Entrance conveyance mechanism • The driving force of the entrance conveyance motor (M1) [4] rotates the entrance roller [1] to convey [3] paper [2] into FS. 4521t2c005na Entrance roller Paper conveyance direction Paper Entrance conveyance motor (M1) A.

  • Page 244: Gate Mechanism

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.2.2 Gate mechanism • On the conveyance path, the following 2 types of gates are provided: the bypass gate [6] and the main gate [3]. • The bypass gate is driven by the bypass gate solenoid (SD1) [5]. •...
  • Page 245 5. OPERATION Theory of Operation Ver1.0 Feb.2006 A. Operation • The paper conveyance path of the bypass gate [1] is switched over in the bypass route direction [2] when the bypass gate solenoid (SD1) turns OFF and switched over in the main gate direction [10] when it turns •...

  • Page 246: Sub Tray Conveyance Mechanism

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.2.3 Sub tray conveyance mechanism • The paper conveyance to the sub tray is made while in the non-sort mode. • The conveyance motor /Up (M4) [5] drives the conveyance roller /Up [1] and the sub tray paper exit roller [2] to convey [3] paper [4] to the sub tray.

  • Page 247: Main Tray/Handling Tray Conveyance Mechanism

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 5.2.4 Main tray/handling tray conveyance mechanism • The conveyance motor /Lw (M2) [7] drives the conveyance roller /Lw [1] and the intermediate conveyance roller [9] to convey paper in the main tray direction [4]. When rotating M2 in the reverse direction, paper is switched back [10].
  • Page 248 Theory of Operation Ver1.0 Feb.2006 5. OPERATION A. Switch back control When the FS start signal turns ON, the conveyance motor /Lw (M2) rotates in the normal direction. And when the bypass route conveyance sensor (PS2) [3] detects the trailing edge of the 1st paper [1] of the 2nd copy that has been conveyed to the bypass route, M2 turns OFF.
  • Page 249 5. OPERATION Theory of Operation Ver1.0 Feb.2006 B. Handling tray conveyance operation (1) Sort mode • When the FS start signal turns ON, the paper exit motor (M3) rotates in the normal direction to convey paper to the main tray. M3 turns OFF a specified period of time after the intermediate conveyance sensor (PS3) detects the trailing edge of the last paper.

  • Page 250: Roller Separation Mechanism

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.2.5 Roller separation mechanism • The intermediate conveyance roller and the paper exit roller are provided with a separation mechanism that releases the pressure from the roller. • The intermediate conveyance roller release motor (M12) [1] drives the cam [5] to pressure/release the inter- mediate conveyance roller [2].
  • Page 251 5. OPERATION Theory of Operation Ver1.0 Feb.2006 A. Intermediate conveyance roller separation control When printing continuously a large size paper (217 mm or larger) in the staple mode, the leading edge of the 2nd paper [4] gets to the intermediate conveyance roller [2] while in the switch back [1] of the 1st paper of the 2nd and succeeding copies.
  • Page 252 Theory of Operation Ver1.0 Feb.2006 5. OPERATION B. Paper exit roller separation control To stack [1] paper in the handling tray [2] while in the staple mode, FS start signal turns ON, and the paper exit roller release motor (M13) turns ON. After the pressure of the paper exit roller [3] is released and the paper exit roller is separated [4], M13 turns OFF.

  • Page 253: Conveyance Operation

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 5.2.6 Conveyance operation A. Continuous copy in the staple mode (in case of A4S, 3 originals, and 2 copies) The 1st paper [2], the 2nd paper [3] and the 3rd paper [4] of the 1st copy are conveyed to the handling tray [1].
  • Page 254 Theory of Operation Ver1.0 Feb.2006 5. OPERATION After completion of the stapling operation of the paper [1] of the 1st copy, the paper exit roller [2] is pres- sured to exit the paper of the 1st copy. At this time, the moment the paper of the 1st copy is exited, the 1st and the 2nd sheets of paper [3] of the 2nd copy are also conveyed in the main tray direction.

  • Page 255: Main Tray Section

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 Main tray section 5.3.1 Main tray up/down mechanism • The up/down of the main tray is made by the normal/reverse rotation of the tray lift motor (M7) [2]. 4521t2c018na Main tray upper limit LED (LED19) Main tray upper limit sensor (PS19) Tray lift motor (M7) Main tray reset sensor (PS8)

  • Page 256: Main Tray Shift Mechanism

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.3.2 Main tray shift mechanism • While in the sort/group mode, the shift motor (M8) [4] is driven to shift the main tray [5] 30 mm in the main scan direction through the shift plate [3]. •...

  • Page 257: Punch Section

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 Punch section 5.4.1 Punch mechanism • For the punch, a hole is punched on the rear side of paper for each paper. • The driving force from the punch motor (M11) [5] is transmitted to the eccentric cam [6] by the punch clutch (CL1) [4].

  • Page 258: Punch Hole Switchover Mechanism (For Inch Area)

    Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.4.2 Punch hole switchover mechanism (for inch area) • The hole punch selector motor (M14) [5] and the hole punch position switch (SW4) [4] are employed to move the lock holder [2] as necessary to select the hole positions (2 or 3 holes [1][6]). 4521t2e002na 2 holes Hole punch selector motor (M14)

  • Page 259: Staple Section

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 Staple section 5.5.1 Alignment mechanism • While in the staple mode, paper is conveyed to the handling tray for alignment operation. • The alignment in the main scan direction is made by the movement of the alignment plate, and the align- ment in the sub scan direction is made by the rotation of the paddle.
  • Page 260 Theory of Operation Ver1.0 Feb.2006 5. OPERATION B. Paddle • The paddle /Up [3] and /Lw [6] hit paper against the stopper to conduct the alignment in the sub scan direction. • The drive of the paddle /Up is made by the paddle motor /Up (M15) [5] and the paddle solenoid (SD3) [4]. •...

  • Page 261: Stapler Movement Mechanism

    5. OPERATION Theory of Operation Ver1.0 Feb.2006 5.5.2 Stapler movement mechanism • The movement/rotation of the staplers /Fr [4] and /Rr [1] are made by the stapler moving motor (M6) [3]. • The home position is detected by the stapler home sensor (PS14) [2] and the position is decided according to the drive amount of M6.
  • Page 262 Theory of Operation Ver1.0 Feb.2006 5. OPERATION 5.5.3 Stapling mechanism • The stapling operation is made by the stapler. • When the stapler motors /Rr (M16) and /Fr (M17) [1] are driven, the clinch arm [3] goes down to drive the staple blade [2] and hit in a staple.
  • Page 263 5. OPERATION Theory of Operation Ver1.0 Feb.2006 5.5.4 Staple sheet empty control A. Detection mechanism • The detection of the staple sheet [6] is made by the staple empty sensors /Rr (PS20) and /Fr (PS23) [4]. • The detection of the staple ready is made by the staple ready sensors /Rr (PS21) and /Fr (PS24) [2]. 4521t2c025na No staple condition Staple empty sensors /Rr, /Fr (PS20, PS23)
  • Page 264 SERVICE MANUAL Theory of Operation SD-502 500 / 420) 2006.02 Ver. 1.0...
  • Page 265 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 266 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS SD-502 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 Half-fold section ....................4 Saddle Stitching Section ..................4 OPERATIONS ......................5 Paper Conveyance mechanism ................5 Conveyance roller pressure/release ..............6 5.2.1 Pressure/release mechanism................6 5.2.2 Operation.......................7 Stapling mechanism....................8...
  • Page 267 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 268: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type FS built-in saddle-stitching device Installation Screwed to the FS Document Alignment Center Center parallel two points Stapling Function No. of sheets to be stapled together: 2 to 15 Consumables Staples (2000 staples/cartridge) B.

  • Page 269: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH 4511t1c001na...

  • Page 270: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Saddle-Stitching Section Half-Fold Section 4511t2c001na...

  • Page 271: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE Half-fold section 4511t2c013na [1] Folding Roller [3] Half-folding Blade [2] Folding Motor (M10) Saddle Stitching Section 4511t2c003na [1] Conveyance Roller /Up [3] Exit Open/Close Motor (M9) [2] Conveyance Motor (M8)

  • Page 272: Operations

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS OPERATIONS Paper Conveyance mechanism • Paper is conveyed by the Exit Rollers of FS and Conveyance Roller /Up [5], /Lw [2]. • The Conveyance Motor (M8) [3] provides the drive for the Conveyance Roller /Lw [2]. •...

  • Page 273: Conveyance Roller Pressure/Release

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Conveyance roller pressure/release 5.2.1 Pressure/release mechanism • The Conveyance Roller /Up [1] is moved away from, or pressed up against, the Conveyance Roller /Lw [2], when the paper is fed out as a bundle of papers. •...

  • Page 274: Operation

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.2.2 Operation 1. The Conveyance Roller /Up [5] is moved up or down by the cams which are driven by the Exit Open/Close Motor (M9) [6]. 2. When a bundle papers moves past the Conveyance Roller /Up and /Lw, the motor is energized to press the Conveyance Roller /Up up against the Conveyance Roller /Lw, thereby feeding a bundle papers out into the tray.

  • Page 275: Stapling Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Stapling mechanism • The Staple units [2] position are fixed. • Since the unit are for center stapling only, it is made up of the upper clincher portion [1] and the lower stapling portion. A bundle papers moves through the space between the upper and lower portions of the staplers.

  • Page 276: Staple Guide

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS Staple guide • The Staple Guide is used to guide the leading edge of the first sheet of paper when the first sheet of paper is stored, thereby preventing the leading edge from contacting the Stapling Unit and jamming.

  • Page 277: Half-Folding Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Half-folding mechanism • The Entrance Sensor (PS4) [2] of FS detects the trailing edge of the paper. • The paper feed amount is determined for each paper size as counted from the timing when the trailing edge is detected.

  • Page 278: Operation

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS 5.5.1 Operation • When the Folding Motor (M10) is energized for one cycle of operation, the Conveyance Guides /Lw [2] are retracted to the right and left and the Half-folding Blade [3] makes one up-and-down reciprocating motion.

  • Page 279: Paper Guide

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Paper guide • When a bundle papers is fed onto the tray, the Paper Guide supports the leading edge of the paper of a large size so as to prevent it from pushing the trailing edge of the paper that has previously been fed out.

  • Page 280: Tray Paper Detection

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS Tray paper detection • When paper is fed onto the tray, it pushes the actuator, which causes the Tray Empty Sen- sor (PS21) [1] to detect the paper. 4511t2c012na [1] Tray Empty Sensor (PS21)
  • Page 281 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...
  • Page 282 SERVICE MANUAL Theory of Operation MT-501 500 / 420) 2006.02 Ver. 1.0...
  • Page 283 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 284 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS MT-501 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 DRIVE........................4 OPERATIONS ......................5 Paper conveyance mechanism ................5 Paper path selection mechanism ................6 Paper detection .....................7...
  • Page 285 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 286: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type 4 bins Mailbin (available only for printing from PC) Installation Screwed to the FS Number of Bins 4 bins Number of Sheets 125 sheets (80 g/m Stored per Bin Storable Paper Plain Paper (56 to 90 g/m...

  • Page 287: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH 4510t1c001na...

  • Page 288: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION 4510t2c001na...

  • Page 289: Drive

    4. DRIVE Theory of Operation Ver. 1.0 Feb. 2006 DRIVE 4510t2c003na [1] Conveyance Roller [3] Conveyance Motor (M1) [2] Exit Roller...

  • Page 290: Operations

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS OPERATIONS Paper conveyance mechanism • When the Mailbin is selected as the exit source, paper is fed off from the Finisher (FS-510) and toward the Mailbin. • Drive for the Conveyance Rollers [2] of the Mailbin is transmitted from the Conveyance Motor (M1) [1] by way of a belt.

  • Page 291: Paper Path Selection Mechanism

    5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Paper path selection mechanism • The Gate Solenoid /1, /2, /3 (SD1, SD2, SD3) [1] are energized or deenergized to direct paper fed from the Finisher into a specific tray. • There are SD1, SD2, SD3 provided that will be energized or deenergized to operate the cor- responding Gate [2], thereby selecting a specific paper path into a specific tray.

  • Page 292: Paper Detection

    Theory of Operation Ver. 1.0 Feb. 2006 5. OPERATIONS Paper detection • The Paper Detection Sensor /1, /2, /3, /4 (PS1, PS2, PS3, PS4) [2] detects any sheet of paper that is fed into the tray, causing the DF LED to light up green steadily to inform the user that a sheet of paper has been fed into the tray.
  • Page 293 5. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...
  • Page 294 SERVICE MANUAL Theory of Operation JS-502 500 / 420) 2006.02 Ver. 1.0...
  • Page 295 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 296 Theory of Operation Ver. 1.0 Feb. 2006 CONTENTS JS-502 OUTLINE PRODUCT SPECIFICATIONS ................1 PAPER PATH ......................2 COMPOSITION/OPERATION COMPOSITION .......................3 OPERATIONS ......................4 Job Tray Conveyance/Exit..................4...
  • Page 297 Theory of Operation Ver. 1.0 Feb. 2006 Blank Page...

  • Page 298: Outline

    Theory of Operation Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Job Separator Type Expansion tray Installation Installed in the main body Document Alignment Center B. Paper type Exit Tray Size Type Capacity Inch: 11 x 17, 8 x 14, 250 sheets Plain Paper (56 to 90 g/m...

  • Page 299: Paper Path

    2. PAPER PATH Theory of Operation Ver. 1.0 Feb. 2006 PAPER PATH 4347t1c001na [1] Conveyance from the main body...

  • Page 300: Composition/Operation

    Theory of Operation Ver. 1.0 Feb. 2006 3. COMPOSITION COMPOSITION/OPERATION COMPOSITION Job Separator section Switchback Unit section 4347t2c001na...

  • Page 301: Operations

    4. OPERATIONS Theory of Operation Ver. 1.0 Feb. 2006 OPERATIONS Job Tray Conveyance/Exit • The Switchback Unit functions to convey paper through, and feed it out from, the Job Tray. • The paper sensor section of the Job Tray is mounted to the Switchback Unit, thereby detect- ing paper.
  • Page 302 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to avoid NN50GAPE1-0900 disclosure of confidential information.
  • Page 303 SERVICE MANUAL Field Service 500 / 420 2006.02 Ver. 1.0...
  • Page 304 INDICATION OF WARNING ON THE MACHINE .............S-13 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-15 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub 500 / 420 Main Body OUTLINE ........................1 MAINTENANCE......................7 ADJUSTMENT/SETTING ................... 147 TROUBLESHOOTING....................
  • Page 305 LU-201 OUTLINE ........................1 MAINTENANCE ......................3 ADJUSTMENT/SETTING ..................... 21 * For particulars, see the contents of LU-201. FS-510/PU-501/OT-601 OUTLINE ........................1 MAINTENANCE ......................5 ADJUSTMENT/SETTING ..................... 21 * For particulars, see the contents of FS-510/PU-501/OT-601. FS-511/RU-502 OUTLINE ........................1 MAINTENANCE ......................

  • Page 306: Safety And Important Warning Items

    Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, Konica Minolta Business Technologies, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT- trained service technicians.

  • Page 307: 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 308 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 309 SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE Konica Minolta brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and CE from the risk of injury.
  • Page 310 SAFETY AND IMPORTANT WARNING ITEMS Connection to Power Supply WARNING • Check whether the product is grounded properly. If current leakage occurs in an ungrounded product, you may suffer electric shock while operating the product. Connect power plug to grounded wall outlet. Power Plug and Cord WARNING •...
  • Page 311 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • Check whether dust is collected around the power plug and wall outlet. Using the power plug and wall outlet without removing dust may result in fire. • Do not insert the power plug into the wall outlet with a wet hand.
  • Page 312 SAFETY AND IMPORTANT WARNING ITEMS Installation Requirements Prohibited Installation Places WARNING • Do not place the product near flammable materials or vola- tile materials that may catch fire. A risk of fire exists. • Do not place the product in a place exposed to water such as rain.
  • Page 313 SAFETY AND IMPORTANT WARNING ITEMS Inspection before Servicing CAUTION • Before conducting an inspection, read all relevant docu- mentation (service manual, technical notices, etc.) and proceed with the inspection following the prescribed pro- cedure in safety clothes, using only the prescribed tools. Do not make any adjustment not described in the docu- mentation.
  • Page 314 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check the exterior and frame for edges, burrs, and other damages. The user or CE may be injured. • Do not allow any metal parts such as clips, staples, and screws to fall into the product. They can short internal circuits and cause electric shock or fire.
  • Page 315 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When replacing a lithium battery, replace it with a new lith- ium battery specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority. Improper replacement can cause explosion.
  • Page 316 SAFETY AND IMPORTANT WARNING ITEMS Handling of Consumables WARNING • Never throw the used cartridge and toner into fire. You may be burned due to dust explosion. Handling of Service Materials CAUTION • Unplug the power cord from the wall outlet. Isopropyl alcohol and acetone are highly flammable and must be handled with care.

  • Page 317: Safety Information

    SAFETY INFORMATION SAFETY INFORMATION IMPORTANT NOTICE The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin- istration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This copier is certified as a "Class 1"...

  • Page 318: Indication Of Warning On The Machine

    SAFETY INFORMATION INDICATION OF WARNING ON THE MACHINE Caution labels shown below are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. 50gap0e001na S-13...
  • Page 319 SAFETY INFORMATION 50gap0e002na CAUTION: • You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. And also, when the caution label is peeled off or soiled and cannot be seen clearly, replace it with a new caution label.

  • Page 320: 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 321 MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-16...

  • Page 322: Composition Of The Service Manual

    Composition of the service manual This service manual consists of the following sections and chapters: <Theory of Operation section> OUTLINE: System configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating system, and explanation of the control system This section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.

  • Page 323: Notation Of The Service Manual

    Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) IC board: Standard printer (2) bizhub 500 / 420: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98:...
  • Page 324 Classification Load symbol Ex. of signal name Description Power to drive the motor CONT Drive signal DRV1 Motor DRV2 Drive signals of two kinds Drive signals (control signals) of three kinds DRV1 DRV2 DRV3 DRV A DRV A DRV B Drive signals (control signals) of four kinds Motor, phases A and B control signals DRV B...
  • Page 325 Classification Load symbol Ex. of signal name Description SG, S.GND, S_GND Signal ground Ground PG, P.GND Power ground Data carrier detection Serial input SOUT Serial output Data terminal operation available Signal ground (earth) Serial com- DSR, DSET Data set ready munication Transmission request signal Consent transmission signal...
  • Page 326 SERVICE MANUAL Field Service 500 / 420 Main body 2006.02 Ver. 1.0...
  • Page 327 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 328 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU ..... . .
  • Page 329 CONTENTS Field Service Ver1.0 Feb.2006 3.12.3 Replacing the feed roller/pick-up roller (tray 2) ........51 3.12.4 Replacing the separation roller assy (tray 2) .

  • Page 330: Adjustment/Setting

    Field Service Ver1.0 Feb.2006 CONTENTS 6.3.10 Removing/reinstalling the upper cover /Rr ........127 6.3.11 Removing/reinstalling the front cover .
  • Page 331 CONTENTS Field Service Ver1.0 Feb.2006 10.5.2 Tel/Fax Number ............174 10.5.3 Serial Number .
  • Page 332 Field Service Ver1.0 Feb.2006 CONTENTS 10.12.2 Paper Size Setting ............238 10.12.3 DipSW Setting .
  • Page 333 CONTENTS Field Service Ver1.0 Feb.2006 14.8 MT-501 ..............342 14.9 RU-502 .

  • Page 334: Outline

    Desk (DK-501) [28] Mount kit (MK-708) [14] Large capacity unit (LU-201) "6.4 Option counter" in Field Service bizhub 500 / 420 main body for details. Dehumidifier heater is set up as service part. Swedish punch kit G is for Europe only.
  • Page 335 1. SYSTEM CONFIGURATION Field Service Ver1.0 Feb.2006 B. Configuration for optional device connection Note • Any combination other than those listed below is not available. Combinations for paper feeding Combinations for finishing Remarks DK-501/PC-202/PC-402 *1 OT-501 DK-501/PC-202/PC-402 *1 OT-501 JS-502 DK-501/PC-202/PC-402 *1 RU-502 + FS-511 DK-501/PC-202/PC-402 *1...

  • Page 336: Product Specifications

    Field Service Ver1.0 Feb.2006 2. PRODUCT SPECIFICATIONS 2. PRODUCT SPECIFICATIONS A. Type Type Desktop type Copying method Indirect electrostatic method Original stand Fixed Original alignment Left rear standard Photo conductor Sensitizing method Laser writing Paper feed trays Two trays 500 sheet x 2, 80g/m Bypass feed 150 sheet x 1, 80g/m PC-402 *1...
  • Page 337 Horizontal magni- x 0.25 to x 4.00 (at the step of 0.1%) fication Warm-up time 60 seconds or less (bizhub 500) 30 seconds or less (bizhub 420) First copy out time 3.2 seconds or less (bizhub 500) 3.6 seconds or less (bizhub 420) Continuous copy speed 50 copies /min.
  • Page 338 Label paper is loaded and fed one sheet at a time. D. Maintenance Maintenance Every 250,000 prints Machine service life 2,250,000 prints or 5 years (whichever earlier) (bizhub 500) 1,800,000 prints or 5 years (whichever earlier) (bizhub 420) E. Machine data Power source Inch:...
  • Page 339 2. PRODUCT SPECIFICATIONS Field Service Ver1.0 Feb.2006 Operating environment Temperature 10 to 30 °C Humidity 10 to 80%RH (with no condensation) Note • The information herein may be subject to change for improvement without notice.

  • Page 340: Periodic Check

    3. PERIODIC CHECK MAINTENANCE 3. PERIODIC CHECK Schedule 3.1.1 Main body (bizhub 500) / DF / PC / LU / FS / MT / SD / RU Guarantee period: 5 years or 2,250,000 prints Service item x 10,000 prints No. of...

  • Page 341: Main Body (Bizhub 420) / Df / Pc / Lu / Fs / Mt / Sd / Ru

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.1.2 Main body (bizhub 420) / DF / PC / LU / FS / MT / SD / RU Guarantee period: 5 years or 1,800,000 prints Service item x 10,000 prints No. of executions Maintenance 1 7 times...
  • Page 342 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Maintenance item Note • For the replacement procedure of periodically replaced parts, see "3.5 Maintenance procedure of the external section" "3.15 Maintenance procedure of the fusing section". • The alcohol described in this section represents the isopropyl alchol. 3.2.1 Main body A.
  • Page 343 Cleaning Check Lubrication Replacement Bypass tray Feed roller Alcohol/cleaning pad section Separation roller Alcohol/cleaning pad Fusing Fusing roller section 50GE5303 (bizhub 500) 50GA5303 (bizhub 420) Fusing pressure roller 50GA5304 Fusing web 50GA-540 • Fusing counter reset Heat insulating sleeve /A 26NA5372...
  • Page 344 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK B. Maintenance 2 (Every 500,000 prints) Unit Description Quantity Implementation classification Materials classification Tools used Cleaning Check Lubrication Replacement Transfer/sep- Transfer/separation aration sec- unit tion 50GA-260 Fusing Fusing sensor assy section 50GA-544 Fuse holder assy 26NA-535 Fusing claw assy 50GA-533...
  • Page 345 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 D. Maintenance 4 (Every 1,250,000 prints) Unit Description Quantity Implementation classification Materials classification Tools used Cleaning Check Lubrication Replacement Registration Registration bearing /Rt section 26NA4536 Registration bearing /Lt 26NA4537 Loop roller 50GA3865 Registration roller /Rt 50GA3848 Loop bearing 26NA4082...
  • Page 346 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK B. Maintenance 2 (Every 500,000 prints) Unit Description Quantity Implementation classification Materials classification Tools used Cleaning Check Lubrication Replacement Paper feed Pick-up roller Actual: 200,000 faces section 43445003 Feed roller Actual: 200,000 faces 45823014 Separation roller Actual: 200,000 faces...
  • Page 347 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.2.4 A. Maintenance 1 (Every 250,000 prints) Unit Description Quantity Implementation classification Materials classification Tools used Cleaning Check Lubrication Replacement Preparations Paper through check Paper feed Pick-up rubber Alcohol/cleaning pad section Feed rubber Alcohol/cleaning pad Separation rubber Alcohol/cleaning pad...
  • Page 348 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.2.6 A. Maintenance 1 (Every 250,000 prints) Unit Description Quantity Implementation classification Materials classification Tools used Cleaning Check Lubrication Replacement Preparations Paper through check Conveyance Each roller Alcohol/cleaning pad section Final check Paper through check Exterior cleaning 3.2.7 A.

  • Page 349: Replacement Parts List

    Loop roller 50GA3865 1,250,000 P.69 section Registration roller /Rt 50GA3848 1,250,000 P.69 Registration bearing /Rt 26NA4536 1,250,000 P.69 Registration bearing /Lt 26NA4537 1,250,000 P.69 Loop bearing 26NA4082 1,250,000 P.69 Fusing Fusing roller 50GE5303 250,000 P.86 section (bizhub 500) 50GA5303 (bizhub 420)
  • Page 350 26NA4012 200,000 (See P.5 in "Field Service DF-607") (See P.6 in "Field Service DF-607") (See P.7 in "Field Service PC-202 (bizhub 500/420)" See P.7 in "Field Service PC-402 (bizhub 500/420)") (See P.4 in "Field Service PC-202 (bizhub 500/420)" See P.4 in "Field Service PC-402 (bizhub 500/420)")

  • Page 351: Life Value

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Life value 3.4.1 Life value of materials Item Number of prints Remarks Drum 250,000 The life value is defined only by the number of prints. Developer 250,000...

  • Page 352: Maintenance Procedure Of The External Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Maintenance procedure of the external section 3.5.1 Replacing the ozone filter A. Periodically replaced part/cycle • Ozone filter: Every 250,000 prints B. Procedure Remove the right cover /Up. (See P.122) Remove the ozone filter [1]. Note •...

  • Page 353: Replacing The Filter Cover Assy And The Suction Filter /A Assy

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.5.2 Replacing the filter cover assy and the suction filter /A assy A. Periodically replaced parts/cycle • Filter cover assy: Every 250,000 prints • Suction filter /A assy: Every 250,000 prints B. Procedure Remove the screw [1] and then remove the filter cover assy [2].
  • Page 354 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Note • Be sure to install the suction filter /A assy with the white filter face [1] inside. Reinstall the above parts following the removal steps in reverse. 50gaf2c017na...

  • Page 355: Replacing The Paper Exit Suction Filter

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.5.3 Replacing the paper exit suction filter A. Periodically replaced part/cycle • Paper exit suction filter: Every 250,000 prints B. Procedure Remove the screw [1] and then remove the paper exit suction filter cover [2]. 50gaf2c018na Remove the paper exit suction filter [1].

  • Page 356: Maintenance Procedure Of The Write Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Maintenance procedure of the write section 3.6.1 Replacing the write unit Warning • Be sure not to turn on the write unit with it shifted from its regular installation position. • Be absolutely sure not to remove the write unit cover. Otherwise, laser beams get in your eyes and you may suffer loss of sight.
  • Page 357 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 6 screws [1] and then remove the write cover [2]. Note • When installing the write cover, be sure to set the projections [3] at 3 places into each of the holes [4] of the frame.
  • Page 358 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 3 connectors [1]. Remove the 3 screws [2] and then remove the write unit [3]. Note • When removing the write unit, be sure to avoid touching the dust-proof glass. 50gaf2c024na Note •...
  • Page 359 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Note • When installing the write unit, be sure to set the projections [1] at 2 places provided on the bottom to the 2 holes [2] of the main body frame for positioning. Reinstall the above parts following the removal steps in reverse.

  • Page 360: Maintenance Procedure Of The Photosensitive Material Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Maintenance procedure of the photosensitive material section 3.7.1 Replacing the drum unit Note • When removing the drum unit, be sure to hold it at both ends. • When removing the drum unit, be sure to avoid holding it at the separation claw unit section. •...

  • Page 361: Replacing The Drum

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.7.2 Replacing the drum Note • Be sure to avoid touching the drum and the cleaning blade with bare hands, and also be careful not to damage them. • When storing the drum, be sure to store it in the dark place with a drum cover attached. •...
  • Page 362 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK A. Periodically replaced part/cycle • Drum: Every 250,000 prints B. Procedure Remove the drum unit from the main body. (See P.27) Remove the C-clip [1] and pull out the cleaning rod [2]. Note •...
  • Page 363 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the connector [1]. Open the lock lever [2] and remove the charging corona unit [3]. 50gaf2c030na...
  • Page 364 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the screw [1] and then remove the shaft mounting plate [2]. Pull out the drum shaft [3] for removal. Note • When installing the drum shaft, be sure to insert the drum shaft until the shaft mounting plate comes into contact firmly with it as shown in the drawing.
  • Page 365 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the seal blocks [1] and [2]. Hold the drum [3] at both ends and remove it. Note • When removing the drum, be careful not to damage the photosensitive surface. • When removing the drum, be careful not to hit it against the metal frame section [4] of the cleaning blade.
  • Page 366 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Note • When installing the drum, using the attached jig [2] with the drum unit cover [1] before installing the charging corona unit, rotate the drum 1 full turn in the arrow-marked direction [3].

  • Page 367: Maintenance Procedure Of The Transfer/Separation Corona Section

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Maintenance procedure of the transfer/separation corona section 3.8.1 Replacing the transfer/separation corona unit A. Periodically replaced part/cycle • Transfer/separation corona unit: Every 500,000 prints B. Procedure Open ADU. (See P.122) Open the conveyance unit. (See P.27) Release the lock levers [1] and [2] and remove the transfer/separation corona unit [3].

  • Page 368: Maintenance Procedure Of The Developing Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Maintenance procedure of the developing section 3.9.1 Replacing the developing unit A. Periodically replaced part/cycle • Developing unit: Every 750,000 prints B. Procedure Open the front door [1]. Loosen the screw [2] and remove the developing unit [3].

  • Page 369: Replacing Developer

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.9.2 Replacing developer A. Periodically replaced part/cycle • Developer: Every 250,000 prints B. Procedure Remove the developing unit from the main body. (See P.35) Release the locks [1] at 2 places and remove the developing unit cover /1 [2].
  • Page 370 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Note • When installing the developing unit cover /1 [1], be sure to install it so that the splash pre- vention sheet [2] does not get caught into the developing roller [3]. 50gaf2c037na...
  • Page 371 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Tilt the developing unit [1], and rotate the develop- ing gear [2] in the arrow-marked direction [3] to discharge thoroughly developer in the developing unit [1]. Clean developer and toner that adhere to the developing roller [4].

  • Page 372: Maintenance Procedure Of The Toner Supply Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.10 Maintenance procedure of the toner supply section 3.10.1 Replacing the filter mounting plate assy A. Periodically replaced part/cycle • Filter mounting plate assy: Every 250,000 prints B. Procedure Remove the developing unit from the main body. (See P.35) Open ADU.

  • Page 373: Replacing The Suction Cover /2 Assy

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.10.2 Replacing the suction cover /2 assy A. Periodically replaced part/cycle • Suction cover /2 assy: Every 250,000 prints B. Procedure Remove the developing unit from the main body. (See P.35) Open ADU. (See P.122) Open the conveyance unit.
  • Page 374 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 2 suction cover /2 assy's [1]. Reinstall the above parts following the removal steps in reverse. 50gaf2c045na...

  • Page 375: Cleaning/Toner Recycle Section

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.11 Cleaning/toner recycle section 3.11.1 Replacing the cleaning blade assy Note • Be sure to avoid touching the edge section of the cleaning blade assy with bare hands. • When installing the cleaning blade assy, be sure to apply setting powder to the circumference of the drum and the cleaning blade, regardless of these parts being new or used ones.
  • Page 376 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Note • When installing the cleaning blade assy [1], be sure to insert the transparent sheet section [2] of the unit the between the collection screw [3] and the collection paddle [4]. Reinstall the above parts following the removal steps in reverse.

  • Page 377: Maintenance Procedure Of The Paper Feed Section

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.12 Maintenance procedure of the paper feed section 3.12.1 Replacing the feed roller/pick-up roller (tray 1) A. Periodically replaced parts/cycle • Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) • Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) B.
  • Page 378 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Note • When installing the paper feed unit /1 [1], be sure to set the shafts [2] and [3] to the holes [4] and [5]. 50gaf2c109na...
  • Page 379 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 2 screws [1] and then remove the separation roller unit /1 [2]. [3][4] Note • When installing the separation roller unit /1, be sure to set the projections [3], 1 each, to each of the holes [4].
  • Page 380 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the C-ring [1] and then remove the bear- ing [2]. Detach the hook [4] of the spring [3] from the oblong hole [5]. Remove the bearing [6] and then remove the paper feed roller unit [7]. Note •...
  • Page 381 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the C-ring [1] and then remove the feed roller [2]. 50gaf2c163na Remove the C-rings [1], 1 each, and then remove the 2 bearings [2]. Remove the pick-up roller assy [3]. 50gaf2c164na Remove the C-ring [1] and then remove the pick- up roller [2].

  • Page 382: Replacing The Separation Roller Assy (Tray 1)

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.12.2 Replacing the separation roller assy (tray 1) A. Periodically replaced part/cycle • Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) B. Procedure Remove the tray 1. (See P.143) Remove the paper feed unit /1.
  • Page 383 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the guide [1]. Remove the C-ring [2] and then remove the sepa- ration roller assy [3]. Reinstall the above parts following the removal steps in reverse. 50gaf2c119na...

  • Page 384: Replacing The Feed Roller/Pick-Up Roller (Tray 2)

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.12.3 Replacing the feed roller/pick-up roller (tray 2) A. Periodically replaced parts/cycle • Feed roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) • Pick-up roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) B.
  • Page 385 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 2 screws [1] and then remove the conveyance roller cover [2]. 50gaf2c122na Remove 2 screws [1] and then remove the paper feed guide /2 [2] in the arrow-marked direction [3]. 50gaf2c123na...
  • Page 386 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 2 connectors [1]. Remove the 3 screws [2] and then remove the paper feed unit /2 [3]. 50gaf2c124na...
  • Page 387 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 2 screws [1] and then remove the separation roller unit /2 [2]. Note • When installing the separation roller unit /2, be sure to set the projection [3] to the hole [4]. 50gaf2c125na Remove the 2 screws [1].
  • Page 388 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the connector [1]. Remove the C-ring [2] and then remove the feed clutch /2 (CL5) [3]. Note • When installing CL5, be sure to set the stop- per [4] to the guide plate [5]. 50gaf2c127na...
  • Page 389 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Detach the hook [2] of the spring [1] from the oblong hole [3]. Remove the C-rings [4], 1 each, and then remove the 2 bearings [5]. Remove the paper feed roller unit [6]. Note •...
  • Page 390 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the C-ring [1] and then remove the feed roller [2]. 50gaf2c167na Remove the C-rings [1], 1 each, and then remove the 2 bearings [2]. Remove the pick-up roller assy [3]. 50gaf2c168na Remove the C-ring [1] and then remove the pick- up roller [2].

  • Page 391: Replacing The Separation Roller Assy (Tray 2)

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.12.4 Replacing the separation roller assy (tray 2) A. Periodically replaced part/cycle • Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) B. Procedure Remove the bypass unit. (See P.60) Pull out the tray 2.
  • Page 392 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the guide [1]. Remove the C-ring [2] and then remove the sepa- ration roller assy [3]. Reinstall the above parts following the removal steps in reverse. 50gaf2c135na...

  • Page 393: Maintenance Procedure Of The Bypass Tray Section

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.13 Maintenance procedure of the bypass tray section 3.13.1 Removing/reinstalling the bypass unit A. Procedure Remove the right cover /Lw. (See P.123) Remove the screw [1] and then remove the bypass cover /Fr [2]. Loosen the screw [3] and then remove the screw [4] to remove the bypass cover /Rr [5].
  • Page 394 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 3 connectors [1]. Remove the screw [2] and then remove the ground terminal [3]. Remove the 5 screws [4] and then remove the bypass unit [5]. 50gaf2c002na...
  • Page 395 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Reinstall the above parts following the removal steps in reverse. After installing the bypass unit, open the tray 2 paper feed guide [1] and the bypass feed guide [2] in the arrow-marked direction [3] to check to see if they operate smoothly.

  • Page 396: Replacing The Separation Roller Assy

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.13.2 Replacing the separation roller assy A. Periodically replaced part/cycle • Separation roller assy: Every 750,000 prints (Actual replacement cycle: Every 200,000 prints) Note • When replacing the separation roller assy, be sure also to replace the feed roller at the same time. B.
  • Page 397 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Detach the hook [1] from the hole [2] and remove the push-up plate assy [3]. 50gaf2c005na Note • When installing the push-up plate assy, be sure to install it while pressing the push-up plate [3] so that each of the springs [1] does not comes off each cross-headed boss [2].
  • Page 398 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 2 screws [1] and then remove the separation roller fixing plate assy [2]. 50gaf2c007na Detach the support axis [2] of the holder [1] from the mounting plate [3] and remove the holder. Note •...

  • Page 399: Replacing The Feed Roller

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.13.3 Replacing the feed roller A. Periodically replaced part/cycle • Feed roller: Every 750,000 prints (Actual replacement cycle: Every 200,000 prints) Note • When replacing the feed roller, be sure also to replace the separation roller assy at the same time. B.
  • Page 400 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the C-ring [1] and then remove the feed clutch /BP (CL6) [2]. Note • When installing CL6, be sure to set the stop- per [3] to the guide plate [4]. 50gaf2c170na Remove the gear [1]. 50gaf2c171na...
  • Page 401 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the C-ring [1] and then remove the bear- ing [2]. Remove the bearing [3] and slide the shaft [4]. 50gaf2c172na Remove the C-ring [1] and then remove the feed roller [2] from the shaft [3]. Note •...

  • Page 402: Maintenance Procedure Of The Registration Section

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.14 Maintenance procedure of the registration section 3.14.1 Cleaning the paper dust removing brush A. Periodic cleaning cycle • Paper dust removing brush: Every 250,000 prints B. Procedure Open ADU. (See P.122) Open the conveyance unit. (See P.27) Remove the developing unit from the main body.
  • Page 403 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 5 screws [1] and then remove the ADU drive assy [2]. Note • When installing the ADU drive assy, be sure to set the stopper [4] of the registration clutch (CL1) [3] to the guide plate [5]. 50gaf2c154na...
  • Page 404 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the connector [1]. Remove the screw [2]. Remove the C-clip [3] and slide CL1 [4] in the arrow-marked direction [5]. Remove the 2 C-clips [6] to release the bearing [7]. Note • When installing the 2 C-clips [6], be sure to install them with their collars come face to face each other.
  • Page 405 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the bearing [1] and CL1 [2]. Remove the E-ring [3] and then remove the loop clutch (CL2) [4]. Note • When installing CL2, be sure to set the stop- per [5] to the screw [6]. Remove the screw [7] and then remove the regis- tration main body assy [8].
  • Page 406 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the E-rings [1], 1 each, and release the 2 loop bearings [2]. Remove the loop roller [3]. Remove the 2 loop bearings from the loop roller. 50gaf2c157na...
  • Page 407 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 2 springs [1]. Remove the E-rings [2], 1 each, and then remove the 2 registration bearings /Lt [3]. Remove the registration roller /Lt [4]. Note • When attaching the spring, be sure to couple the hook [5] of the spring at the position as shown in the drawing left.
  • Page 408 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the E-rings [1], 1 each, and then remove the 2 registration bearings /Rt [2]. Remove the registration roller /Rt [3]. Reinstall the above parts following the removal steps in reverse. 50gaf2c159na...

  • Page 409: Maintenance Procedure Of The Fusing Section

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.15 Maintenance procedure of the fusing section 3.15.1 Removing/reinstalling the fusing unit Caution • Since the fusing section gets hot immediately after turning off the main power switch (SW1) or the power switch (SW2), you may suffer a burn. Be sure to conduct the operations when the tempera- ture goes down sufficiently.
  • Page 410 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 2 connectors [1]. Remove the screw [2] and then remove the filter cover [3]. Remove the 2 screws [4]. Loosen the 2 screws [5]. And after sliding the entire reverse unit [6] in the arrow-marked direc- tion [7], tilt the front side in the arrow-marked direction [8] for removal.

  • Page 411: Replacing The Fusing Claw Assy

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the 2 screws [1] and then remove the fusing unit [2]. Note • When lifting the fusing unit, be sure to hold it at both ends. • When installing/removing it, be careful not to damage rollers.
  • Page 412 Remove the connector [4] from the fusing claw assy. Note • The fusing claw assy varies for bizhub 500 and 420. Be sure to check a punch mark [5] and replace it with a right fusing claw assy. bizhub 500: 50 GA bizhub 420: 42 GA •...

  • Page 413: Replacing The Fusing Web

    Apply pressure from the inside of the ducts [3] at 2 places to release the lock and remove the fusing web [4]. Note • The fusing web varies for bizhub 500 and 420. Be sure to check a punch mark [5] and 50gaf2c092na replace it with a right fusing web.
  • Page 414 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK • The performance of a new fusing web [1] is guaranteed from the position at which a brown line [2] is broken. When replacing the fusing web, be sure to take up the fusing web up to the position at which the distance [5] from the nip section [4] of the fusing roller [3] and the fusing web to the brown line becomes...

  • Page 415: Replacing The Fusing Driven Roller Assy /A And /B

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.15.4 Replacing the fusing driven roller assy /A and /B A. Periodically replaced parts/cycle • Fusing driven roller assy /A: Every 250,000 prints • Fusing driven roller assy /B: Every 250,000 prints B. Procedure Remove the fusing unit.
  • Page 416 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the 4 screws [1]. Remove the 2 fusing driven roller assy's /A [2] and the 2 fusing driven roller assy's /B [3]. Note • The gear [4] is not fixed. Take care when mov- ing it.

  • Page 417: Removing/Reinstalling The Fusing Heater Lamps /1 (L2) And /2 (L3)

    3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 3.15.5 Removing/reinstalling the fusing heater lamps /1 (L2) and /2 (L3) Note • Be careful not to touch the lamp sections of L2 and L3 with bare hands. When touched, be sure to clean them with a roller cleaner.
  • Page 418 Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK Remove the screw [1] and then remove the lamp fixing plate /Fr [2]. Pull out the fusing heater lamps /1 (L2) [3] and /2 (L3) [4] in the arrow-marked direction [5] and remove them. Note •...

  • Page 419: Replacing The Fusing Roller, The Fusing Pressure Roller, The Heat Insulating Sleeve /A, The Fusing Bearings /Up And /Lw And The Fusing Input Gear Assy

    Release the 2 envelope levers [9]. Note • The envelope lever varies in the number of the release steps for bizhub 500 and 420. Be sure to release it up to the limit in either case. bizhub 500: 2 steps...
  • Page 420 When replacing it with a new one, be sure to install one that is suitable for the model. Model Diameter Wall thickness φ bizhub 500 35 mm t 2.0 mm φ bizhub 420 35 mm t 0.8 mm...
  • Page 421 Remove the fusing pressure roller [1]. Note • The fusing pressure roller varies in the diame- ter for bizhub 500 and 420. When replacing it with a new one, be sure to install one that is suitable for the model.

  • Page 422: Replacing The Fusing Sensor Assy

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.15.7 Replacing the fusing sensor assy Caution • After installing the fusing sensor assy, be sure to check to see if it is in touch with the fusing roller. A. Periodically replaced part/cycle •...
  • Page 423 3. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the screws [1], 1 each, and then remove the fusing sensor assy [2]. Note • When installing the fusing sensor assy, be careful not to deform the sensor section. • After installing the fusing sensor assy, be sure to check to see if the wiring harness is not in touch with the fusing roller.

  • Page 424: Replacing The Fuse Holder Assy

    Field Service Ver1.0 Feb.2006 3. PERIODIC CHECK 3.15.8 Replacing the fuse holder assy Caution • After installing the fuse holder assy, be sure to check to see if it is in touch with the fusing roller. A. Periodically replaced part/cycle •...

  • Page 425: Service Tools

    4. SERVICE TOOLS Field Service Ver1.0 Feb.2006 4. SERVICE TOOLS Service material list Material No. Name Shape Remark 000V-19-0 Setting powder 25 g 000V-18-0 Cleaning pad 10 pcs/1 pack 00GR0026 Multemp FF-RM 25 g 00GR0021 Solvest 240 Multemp FF-RM is rec- ommended.

  • Page 426: Jig List

    Field Service Ver1.0 Feb.2006 4. SERVICE TOOLS Jig list Parts No. Name Shape Quantity Remark 26NA2134 Drum rotation mem- Mounted to the drum unit 26NAJG01 Optic unit positioning 40347940 Test chart Without a KONICA (A3 size) MINOLTA logo 40347942 Test chart Without a KONICA (A3 size) MINOLTA logo...

  • Page 427: Materials

    4. SERVICE TOOLS Field Service Ver1.0 Feb.2006 Parts No. Name Shape Quantity Remark 00VE-100 Tester 14G54631 Stapler unit position- For SD staple adjust- ing jig ment Materials A. Item Parts name Useful life Type name Toner bottle 32,200 prints TN511 Drum 250,000 prints DR510...

  • Page 428: Firmware Version Up

    Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP 5. FIRMWARE VERSION UP 5.1.1 Outline A. ISW (In-System Writer) The operation to rewrite firmware stored in the flash ROM that is built in each control board in the main body with the board left built in the main body is called an ISW. Executing ISW allows you to upgrade the firmware ver- sion without replacing the board, or install the latest firmware when replacing the board.

  • Page 429: Settings On The Main Body Side While In Isw

    5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 5.1.3 Settings on the main body side while in ISW Following the description given below, be sure to make appropriate settings on the main body side to conduct the operations of the firmware version upgrade and writing. A.

  • Page 430: Iswtrns

    Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP ISWTrns 5.2.1 Specifications A. ISWTrns (PC software) (1) Operating environment of the software • Windows95/98/98SE/Me/NT4.0/2000/XP • CPU: Pentium 75 MHz or above • Memory: 16 MB or more • Free space in hard disk: 100 MB or more •...

  • Page 431: Installation Of The Iswtrns

    Following the instructions on the screen, check the folder to which an installation is made, and then click [Next]. Note • For default, "C:\Program Files\KONICA MINOLTA\ISWTrns" is set as a folder to which an installation is made. • When changing the folder to which an installation is made, click [Browse] and specify the folder.
  • Page 432 Click [Make Folder] Note • A folder (C:\Program Files\KONICA MINOLTA\ISWTrns) into which the ISWTrns program is installed as a storage folder is set by default. • When changing the storage folder, click [Browse] to specify it arbitrarily or enter it directly in the editor box in full path.

  • Page 433: Usage Of The Iswtrns

    [Next]. Check the driver name and click [Next]. Driver name: KONICA MINOLTA 500/420 USB Driver for ISW When the "Completing the Found New Hardware Wizard" screen is displayed, click [Finish] to exit the installation.
  • Page 434 Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP B. Firmware copy By using the ISWTrns, firmware that transfers it to the main body is copied into the specified folder. (1) Procedure Step Operation Start the PC. Select [ISWTrns] from the start menu or double click the [ISWTrns] icon on the desktop to start up the ISWTrns.
  • Page 435 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 Step Operation Click [Copy] automatically copies the selected file into the specified folder created by installing the ISWTrns. Note • When copying all of the files that are displayed in the lower display section of the "Origi- nal Files", click [Copy All] instead of [Copy].
  • Page 436 Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP (2) ISW transfer standby Open the Service mode of the main body to put the ISW transfer in the standby condition. Step Operation Enter the Service mode. Press the [System 2] in "Service mode screen." Press the [ISW] in the sub menu shown to the right of the screen.
  • Page 437 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 D. Connection to the main body (1) When using the parallel cable Preparations are made of the following when a connection is made. • PC which firmware have been copied. • Parallel cable Procedure Step Operation...
  • Page 438 Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP (2) When using the USB cable Preparations are made of the following when a connection is made. • PC which firmware have been copied. • UBS cable Procedure Step Operation Connect the UBS cable [2] to the USB port [1] of the PC. 50gaf2c178na Note •...
  • Page 439 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 E. Rewriting of firmware (1) Relationship between the ISW and the display of the operation panel When the ISWTrns starts up, the main screen is displayed. In the main screen, the transmission file (firmware) is selected, the information is diplayed, the checksum and the transmission file are sent out.
  • Page 440 "??": Checksum file (*.sum) not found [10] [FileSend] The transmission of the transferred file is started. (2) Procedure e.g.: When conducting the ISW of the MFP controller for bizhub 500. Step Operation Start the ISWTrns program. Click [Set-up (S)] from the menu and then click [Communication setting (C)].
  • Page 441 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 Step Operation Press the [FileCheck] to check if the data to be used has any problem. Place the main body in the ISW standby condition. Check to see if "Please execute the data transfer. The data reading is begun." is displayed. When a connection is made with a USB cable, connect the USB cable [2] to the USB connector [1] of the main body.

  • Page 442: Error List

    Field Service Ver1.0 Feb.2006 5. FIRMWARE VERSION UP Step Operation The following window is displayed on the PC while in the data transfer. When the data transfer is completed, the following window is displayed and click [OK]. "ISWTrns" When the data writing is completed, the reboot is automatically made to show the trouble reset dis- play.
  • Page 443 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 B. ISWTrns error list The ISWTrns displays messages when an error is shown or the operation is completed. The table below shows the contents of the message and the status of the ISWTrns. Message Status of the ISWTrns Cannot open a checksum file...
  • Page 444 Device initialization error A USB or parallel device initialization error occurs. Machine type/board incompatible The data transferred from the PC is not the data for bizhub 500/420, or not for the board selected from the panel. Time-out error While in the file transfer from the PC, a time-out error occurs.
  • Page 445 5. FIRMWARE VERSION UP Field Service Ver1.0 Feb.2006 Condition Cause Measure taken "NG" is displayed while The transferred firmware is damaged. Copy the firmware and check it again. in the file checksum. When "NG" still recurs, contact the supplier of the firmware. "??"...

  • Page 446: Others

    Field Service Ver1.0 Feb.2006 6. OTHERS 6. OTHERS Items not allowed to be disassembled and adjusted 6.1.1 Scanner section A. CCD unit (1) Parts not allowed to be removed • 7 screws that are used to assemble the CCD unit. •...
  • Page 447 6. OTHERS Field Service Ver1.0 Feb.2006 B. Mirror unit/exposure unit (1) Positions not allowed to be adjusted • Positions at which the mirror unit and the exposure unit are installed 50gaf2c137na Mirror unit Exposure unit (2) Reason for prohibition The distance between the mirror unit and the exposure unit has an effect on the magnification in the sub scan direction of the original to be read.

  • Page 448: Write Section

    Field Service Ver1.0 Feb.2006 6. OTHERS 6.1.2 Write section A. Write section cover (1) Parts not allowed to be removed • 4 attaching screws of the write section cover 50gaf2c138na Screws not allowed to be removed Write section cover (2) Reason for prohibition The inside of the write section becomes a laser beam path.
  • Page 449 6. OTHERS Field Service Ver1.0 Feb.2006 B. Write attaching plate (1) Parts not allowed to be removed • 5 attaching screws of the write mounting board 50gaf2c139na Screws not allowed to be removed Write attaching plate (2) Reason for prohibition The write attaching plate is a reference for the attaching angle of the write section against the drum.

  • Page 450: Developing Unit

    Field Service Ver1.0 Feb.2006 6. OTHERS 6.1.3 Developing unit (1) Parts not allowed to be removed • 2 attaching screws of the developer restriction blade • 1 fixing screw of the magnet adjustment plate • Ds adjustment screws Developing unit at 2 places (inside the cover) 50gaf2c140na Developer restriction blade Screws not allowed to be removed...

  • Page 451: Drum Unit

    6. OTHERS Field Service Ver1.0 Feb.2006 6.1.4 Drum unit (1) Parts not allowed to be removed • Ds adjustment screws, 2 pcs. 50gaf2c188na Screws not allowed to be removed (Ds adjustment screws) (2) Reason for prohibition The Ds adjustment screws are used to determine the distance between the drum and the developing roller and they are adjusted to an appropriate value in advance.

  • Page 452: List Of Parts To Be Disassembled And Reassembled

    Field Service Ver1.0 Feb.2006 6. OTHERS List of parts to be disassembled and reassembled Note • This list shows the explanation of the disassembly and reassembly of the parts which are consid- ered necessary to replace (other than periodically replaced parts). However, these parts except for the covers are not required to be disassembled while in normal service operations.

  • Page 453: Disassembling/Assembling Procedure

    6. OTHERS Field Service Ver1.0 Feb.2006 Disassembling/assembling procedure Caution • When disassembling or assembling the parts, be sure the power cord has been unplugged from the power outlet. 6.3.1 Removing/reinstalling the rear cover /1 A. Procedure Remove the 6 screws [1] and then remove the rear cover /1 [2].

  • Page 454: Removing/Reinstalling The Rear Cover /3

    Field Service Ver1.0 Feb.2006 6. OTHERS Remove the 2 screws [1] and then remove the rear cover /2 [2]. Reinstall the above parts following the removal steps in reverse. 50gaf2c051na 6.3.3 Removing/reinstalling the rear cover /3 A. Procedure Remove the screw [1]. Note •...

  • Page 455: Removing/Reinstalling The Right Cover /Up

    6. OTHERS Field Service Ver1.0 Feb.2006 6.3.4 Removing/reinstalling the right cover /Up A. Procedure Open the bypass tray. (See P.123) Pull the ADU release lever [1] to open ADU [2]. 50gaf2c053na Remove the 2 screws [1] and then remove the right cover /Up [2].

  • Page 456: Removing/Reinstalling The Right Cover /Lw

    Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.5 Removing/reinstalling the right cover /Lw A. Procedure Open the bypass tray [1]. Remove the 2 screws [2] and then remove the right cover /Lw [3]. Reinstall the above parts following the removal steps in reverse. 50gaf2c055na 6.3.6 Removing/reinstalling the left cover...

  • Page 457: Removing/Reinstalling The Front Door

    6. OTHERS Field Service Ver1.0 Feb.2006 6.3.7 Removing/reinstalling the front door A. Procedure Open the front door [1]. Remove the screw [2] and then remove the sup- port plate [3] and the front door at the same time. Note • When installing the front door, be sure first to fit the installation hole [4] to the shaft [5].

  • Page 458: Removing/Reinstalling The Original Glass

    Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.8 Removing/reinstalling the original glass A. Procedure Remove the 4 screws [1] and then remove the upper cover /Rt [2]. 50gaf2c058na Remove the 2 screws [1] and then remove the glass attaching plate /Up [2]. 50gaf2c059na...
  • Page 459 6. OTHERS Field Service Ver1.0 Feb.2006 Loosen the 2 screws [1] and slide the glass attaching plate /Lw [2]. Loosen the screw [3] and slide the glass holding plate [4]. Remove the original glass [5]. Note • When removing the original glass, be careful not to stain the position to which the shading correction plate [6] is attached.

  • Page 460: Removing/Reinstalling The Upper Covers /Fr And /Lt

    Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.9 Removing/reinstalling the upper covers /Fr and /Lt A. Procedure Remove the original glass. (See P.125) Loosen the screw [1]. Remove the 2 screws [2] and then remove the upper cover /Fr [3]. Remove the connector [4]. Remove the 4 screws [5] and then remove the upper cover /Lt [6].
  • Page 461 6. OTHERS Field Service Ver1.0 Feb.2006 6.3.11 Removing/reinstalling the front cover A. Procedure Open the front door [1]. Pull out the tray 1 [2]. Remove the screw [3] and then remove the front cover [4]. Reinstall the above parts following the removal steps in reverse.
  • Page 462 Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.12 Removing/reinstalling the operation panel A. Procedure Remove the 4 screw caps [1] and then remove the 4 screws [2]. Remove the connector [4] of the operation board (OB) [3] and then remove the operation panel [5]. Note •...
  • Page 463 6. OTHERS Field Service Ver1.0 Feb.2006 6.3.13 Removing/reinstalling the CCD unit A. Procedure Remove the original glass. (See P.125) Remove the 2 screws [1] and the remove the lens light blocking cover assy [2]. Remove the connector [3]. Remove the 9 screws [4] and then remove the lens light blocking cover [5].
  • Page 464 Field Service Ver1.0 Feb.2006 6. OTHERS Note • When removing the ribbon cable [1], be sure to bring down the lock lever [3] of the connec- tor [2] in the arrow-marked direction to release the lock and pull out the ribbon cable. 50gaf2c067na •...
  • Page 465 6. OTHERS Field Service Ver1.0 Feb.2006 Remove the 4 screws [1] and then remove the CCD unit [2]. Reinstall the above parts following the removal steps in reverse. Note • After installing the CCD unit, be sure to con- duct the image adjustment in the service mode.
  • Page 466 Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.14 Replacing the exposure lamp Note • Be careful not to touch the lamp section of the exposure lamp (L1) with bare hands. A. Procedure Remove the original glass. At this time, remove also the glass attaching plate /Lw. (See P.125) Remove the connector [1].
  • Page 467 6. OTHERS Field Service Ver1.0 Feb.2006 6.3.15 Removing/reinstalling the exposure unit Note • When installing the exposure unit, be sure to use the optics unit positioning jig. • When installing the exposure unit, be sure to conduct the image adjustment in the service mode. (See P.163, P.164, P.165, P.166, P.167, P.168) A.
  • Page 468 Field Service Ver1.0 Feb.2006 6. OTHERS Move the exposure unit [1] to the notch [2] of the frame. Remove the connector [3]. Remove the screws [4] and [5] and then remove the exposure unit from the exposure unit mount- ing plates /Fr [6] and /Rr [7]. Slide the exposure unit [1] for removal.
  • Page 469 6. OTHERS Field Service Ver1.0 Feb.2006 B. Procedure for reinstallation Move the V-mirror unit [1] to the vicinity of the V- mirror positioning hole [2]. Insert the optics unit positioning jig [3] into the V- [10] mirror positioning hole and fix the V-mirror unit. Note •...
  • Page 470 Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.16 Stretching the scanner wire Note • Be sure to wind the scanner wire around the pulley closely with no scanner wire overlapping each other. • When restretching or replacing the scanner wire, be sure to use the optics unit positioning jig. •...
  • Page 471 6. OTHERS Field Service Ver1.0 Feb.2006 Loosen the 2 hexagon socket screws [3] of the drive pulley on the side so that the drive pulley [1] can rotate freely against the pulley shaft [2]. Drop the metal ball [5] provided at the intermedi- ate section of the scanner wire [4] into the drive pulley installation hole and, with this as a starting point, wind the wire 6 turns [6] outwards and 5...
  • Page 472 Field Service Ver1.0 Feb.2006 6. OTHERS Note • When fixing the screw thread side of the scanner wire, be sure fix it with a tension of 1.3 to 1.7 kg applied by a spring balance in the arrow-marked direction [1]. •...
  • Page 473 6. OTHERS Field Service Ver1.0 Feb.2006 Remove the 2 screws [1] and then remove the rib- bon cable cover [2]. Remove the ribbon cable [3]. Remove the 7 connectors [4]. Remove the 11 screws [5] and then remove the overall control board mounting box [6]. 50gaf2c081na...
  • Page 474 Field Service Ver1.0 Feb.2006 6. OTHERS Remove the connector [1]. Remove the 3 screws [2] and then remove the ozone filter mounting assy [3]. 50gaf2c082na Remove the connector [1]. Remove the 4 screws [2]. Remove the board support [3] and the remove the drum motor (M1) [4].
  • Page 475 6. OTHERS Field Service Ver1.0 Feb.2006 Remove the 4 connectors [1]. Remove the 5 screws [2] and then remove the toner supply unit [3]. Reinstall the above parts following the removal steps in reverse. 50gaf2c084na...
  • Page 476 Field Service Ver1.0 Feb.2006 6. OTHERS 6.3.18 Removing/reinstalling the trays 1 and 2 Note • The trays 1 and 2 are of the same form and of the same mechanism. The procedure given here shows mainly the operations employed for the tray 1. •...
  • Page 477 6. OTHERS Field Service Ver1.0 Feb.2006 Option counter 6.4.1 Configuration of the key counter As shown below, the key counter is configured as a product so that it can be supplied according to the applica- tion. In principle, the key counter can be installed by obtaining the key counter kit 4. [1] Cover [2] Mounting [3] Key...
  • Page 478 Field Service Ver1.0 Feb.2006 6. OTHERS 6.4.2 Installation procedure of the key counter Remove the upper cover /Lt. (See P.127) Remove the split cover [1] of the upper cover /Lt. Put the harness [2] for the key counter through the upper cover /Lt.
  • Page 479 6. OTHERS Field Service Ver1.0 Feb.2006 Blank page...
  • Page 480 Field Service Ver1.0 Feb.2006 7. HOW TO USE THE ADJUSTMENT/SETTING SECTION ADJUSTMENT/SETTING 7. HOW TO USE THE ADJUSTMENT/SETTING SECTION Composition This part "ADJUSTMENT/SETTING" describes items to be adjusted and the method of adjustment that is required by this machine, it also gives detailed explanations. A.
  • Page 481 8. UTILITY MENU Field Service Ver1.0 Feb.2006 8. UTILITY MENU List of utility mode Note • For detail on the utility mode, refer to "User's guide". [1] One-Touch [1] Scan [1] Address [1] E-Mail Registration Book [2] FTP [3] SMB [4] User Box [2] Group [3] Program...
  • Page 482 Field Service Ver1.0 Feb.2006 8. UTILITY MENU [2] User Setting [6] Printer Set- [1] Basic Setting ting [2] Paper Setting [3] PCL Setting [1] Typeface [2] Symbol Set [3] Font Size [4] Line/Page [5] CR/LF Mapping [4] PS Setting [5] Print Report [3] Administrator [1] System Set- [1] Power Save Setting...
  • Page 483 8. UTILITY MENU Field Service Ver1.0 Feb.2006 [3] Administrator [3] One-Touch [2] Fax [1] Address [1] Abbr. Dial Setting Registration Book [2] E-Mail [3] User Box [2] Group [3] Program [4] Subject/Text [1] Subject (for E-mail) [2] Text [3] User Box [1] Public/Personal Use Box [2] Bulletin Board User Box [4] One-Touch...
  • Page 484 Field Service Ver1.0 Feb.2006 8. UTILITY MENU [3] Administrator [8] Fax Setting [1] Header Information Setting [2] Header/Footer Position [3] Telephone Line Setting [4] TX/RX Setting [5] Function [1] Function ON/OFF Setting Setting [2] Dial-In Setting [3] Memory RX [4] Closed Network RX [5] Forward TX Setting [6] Remote RX [7] Confidential RX Password Check...
  • Page 485 9. LIST OF ADJUSTMENT ITEMS Field Service Ver1.0 Feb.2006 9. LIST OF ADJUSTMENT ITEMS Replacement parts/Others Adjustment/setting items Print Positioning: Leading Edge P.157 Machine Printer Print Positioning: Side Edge P.158 Area Paper Feed Direction Adj. P.159 Printer Resist Loop P.161 Bypass Tray Adjustment P.162 Image Position: Leading Edge...
  • Page 486 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10. SERVICE MODE 10.1 List of service mode Adjustment/setting items page Machine Printer Area Print Positioning: Leading Edge P.157 Print Positioning: Side Edge P.158 Paper Feed Direction Adj. P.159 Printer Resist Loop P.161 Bypass Tray Adjustment P.162 Scan Area...
  • Page 487 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Adjustment/setting items page System 1 Initialization Utility/Administrator Job memory Setting P.177 Setting Data Data FAX Setting Data Network Setting Data Destination Storage Data CS Remote Care Setting Data Service Mode Setting Image Process Adj. (Adj.) Data Data Machine and ADF...
  • Page 488 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Adjustment/setting items page Finisher Center Staple Position P.219 Half-Fold Position P.220 Punch Horizontal Position P.221 Punch Resist Loop P.222 Firmware Version P.223 CS Remote Care P.224 System 2 Data Capture P.238 Paper Size Setting •...
  • Page 489 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.2 Setting Method This machine is provided with a service mode for various types of adjustments/settings. Data adjusted and/or set in this mode are stored in the NVRAM board (NRB). 10.2.1 Start and exit of the service mode You can access the service mode while the power is both turned ON and OFF.
  • Page 490 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.3 Machine Adjust 10.3.1 Print Positioning: Leading Edge (Printer Area) Adjusts the leading edge timing of the printer image. This adjustment is used to change the restart timing of paper of the registration roller and adjust the relative position in the sub scan direction of the image against the paper.
  • Page 491 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.3.2 Print Positioning: Side Edge (Printer Area) Changes the laser write timing and also changes the image position on the drum in the main scan direction to adjust the mis-centering of the printer image. For each paper feed (each tray, bypass feed, ADU) and for each paper size (common, small size, large size), the adjustment can be made.
  • Page 492 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.3.3 Paper Feed Direction Adj. (Printer Area) A. Printer Adjusts the magnification of the printer in the sub scan direction. This adjustment is used to change uniformly the process speed of the drum and the registration roller and change the magnification in the sub scan direction of the image on the drum.
  • Page 493 10. SERVICE MODE Field Service Ver1.0 Feb.2006 B. Fixing motor clock Makes appropriate a paper feed loop amount between the registration roller and the fusing roller to prevent the transfer slippage at the position about 20 mm from the trailing edge of the transfer paper. The adjustment can be made for each type of paper (normal paper, OHP, thick paper, envelope, label, custom paper and user paper).
  • Page 494 1 step = 0.13 mm For other than the above: • Setting range for bizhub 500: – 32.00 to + 31.75 mm 1 step = 0.25 mm • Setting range for bizhub 420: – 26.88 to + 26.67 mm 1 step = 0.13 mm Press [Restore] to return to the value before change.
  • Page 495 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.3.5 Bypass Tray Adjustment Conduct this adjustment when the paper size of the bypass tray is not detected correctly. A. Procedure "Service Mode screen" Press [Machine]. "Machine Adjust screen" Press [Bypass Tray Adjustment]. "Bypass Tray Adjustment screen"...
  • Page 496 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.3.6 Image Position: Leading Edge (Scan Area) Adjusts the leading edge timing while in the scan in the platen mode. This adjustment is used to adjust the position at which the read is started in the sub scan direction while the original is being scanned by the exposure unit.
  • Page 497 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.3.7 Image Position: Side Edge (Scan Area) Adjusts the mis-centering of the image in the main scan direction while in the scan in the platen mode. Note • Be sure that the adjustment of the Print Position: Side Edge has been completed. (See P.158) A.
  • Page 498 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.3.8 Cross Direction Adjustment (Scan Area) Adjusts the magnification of the image in the main scan direction while in the scan in the platen mode and in the DF mode. A. Procedure "Service Mode screen" Press [Machine].
  • Page 499 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.3.9 Feed Direction Adjustment (Scan Area) Adjusts the magnification of the image in the sub scan direction while in the scan on the original glass. This adjustment is used to change the scan speed of the exposure unit. A.
  • Page 500 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.3.10 Lead Edge Erase Adjustment Adjusts the leading edge erasure amount. A. Procedure "Service Mode screen" Press [Machine]. "Machine Adjust screen" Press [Lead Edge Erase Adjustment]. "Lead Edge Erase Adjustment screen" Press [Test Copy]. "Test Copy screen"...
  • Page 501 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.3.11 Non-Image Area Erase Check When installing this machine, or when moving its installation location, check to see if the non-image area erase check mechanism of the copy applied setting operates correctly in its installation location, and adjust automati- cally the sensitivity with which the non-image area is detected.
  • Page 502 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.4 Imaging Process Adjustment 10.4.1 Charging Main Manual Adj. Do not conduct this adjustment in the field. 10.4.2 Transfer Manual Adj. Do not conduct this adjustment in the field. 10.4.3 Separation (AC) Manual Adj. Do not conduct this adjustment in the field.
  • Page 503 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.4.9 Toner Density Adjustment This adjustment can be used to increase and/or decrease the toner density of developer. Use this adjustment when an image fogging occurs due to the increased toner density of developer and you want to decrease the toner density.
  • Page 504 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.4.10 Laser Diameter Adjustment The MPC value can be corrected by entering a set value to change the image density (dot diameter). Major cases in which this adjustment is used. • When you want to change the image density. •...
  • Page 505 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.4.11 LD1 Offset Adj. / LD2 Offset Adj. Adjusts the 2 laser beam amount (LD1/LD2) equally. Be sure to make this adjustment when replacing the write unit, drum and developer. Note • Make sure that the TCR adjustment, the toner density adjustment and the dot diameter adjust- ment have been completed.
  • Page 506 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.5 System 1 10.5.1 Marketing Area Sets the marketing area of the main body and the fax. • Marketing area of the main body: Japan, US, Europe, Other 1, Other 2, Other 3, Other 4 •...
  • Page 507 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.5.2 Tel/Fax Number Sets the telephone number and the fax number of the service station that are displayed on the screen when a service call occurs. These telephone and fax numbers are also displayed as the service center contact of the basic screen help of the user screen.
  • Page 508 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.5.4 Trouble Isolation When each function (device) is in trouble, isolating a trouble allows the limited use of this machine. A. Procedure "Service Mode screen" Press [System 1]. "System Input screen" Press [Trouble Isolation]. "Trouble Isolation screen"...
  • Page 509 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.5.7 Original Size Detection Sets the detection size of the original size on the original glass and ADF. A. Procedure "Service Mode screen" Press [System 1]. "System Input screen" Press [Original Size Detection]. Press [Original Glass Original Size Detect] of the menu.
  • Page 510 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.5.9 Install Date Sets the start date of the total counter. A. Procedure "Service Mode screen" Press [System 1]. "System Input screen" Press [Install Date]. "Install Date screen" Press Year (4 digits), Month (2 digits), Day (2 digits) with the copy count setting key and press [Entry]. Check the display "The present contents of a setting"...
  • Page 511 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.6 Counter 10.6.1 Display of the Counter Displays the following data held by this machine on the touch panel. The counter can be also checked by the output list, CSRemoteCare. • Total Service •...
  • Page 512 Field Service Ver1.0 Feb.2006 10. SERVICE MODE B. Total Service Displays the total copy count printed in the service mode and the user mode. Note • The maximum count is 99,999,999. CSRC parameter Item collected Count condition — Total Service Number of paper printed and exited in the single and double sided copy modes.
  • Page 513 10. SERVICE MODE Field Service Ver1.0 Feb.2006 CSRC parameter Item Count condition (F1) BOX Housing: Copy – Proof Print 1 count for each completion of a job. BOX Housing: Copy – BOX Hold BOX Housing: Print – Proof Print BOX Housing: Print – BOX Hold BOX Housing: Print –...
  • Page 514 Field Service Ver1.0 Feb.2006 10. SERVICE MODE E. ADF Counter Displays the number of the paper through by modes of ADF. Note • The maximum count is 99,999,999. • 1 count for the single sided copy and 2 counts for the double sided copy. CSRC parameter Item Remarks...
  • Page 515 10. SERVICE MODE Field Service Ver1.0 Feb.2006 CSRC SC cord CSRC SC cord CSRC SC cord parameter parameter parameter (E0) (E0) (E0)
  • Page 516 Field Service Ver1.0 Feb.2006 10. SERVICE MODE CSRC SC cord CSRC SC cord CSRC SC cord parameter parameter parameter (E0) (E0) (E0) G. Time Series Trouble (SC) For the latest 50 SC's, displays the SC code of cause, the total count, the date of occurrence, the time of occur- rence, and the firmware version.
  • Page 517 10. SERVICE MODE Field Service Ver1.0 Feb.2006 CSRC Jam cord CSRC Jam cord CSRC Jam cord parameter parameter parameter Upper Lower Upper Lower Upper Lower (J0) (J0) (J0) — — — — — Paper Jam History For the latest 100 jams, displays JAM code, Total Count, Date of Occurrence, Paper Tray, Paper Size, and Zoom.
  • Page 518 Field Service Ver1.0 Feb.2006 10. SERVICE MODE CSRC parameter Item Count condition (F5) Print operating time (single sided mode) Accumulated hours from start to stop of the print. 1 count for 1 second (not including the time period during which the counter stops due to a jam).
  • Page 519 10. SERVICE MODE Field Service Ver1.0 Feb.2006 K. Each Size Displays the number of print of each paper size. Note • The maximum count is 99,999,999. • 1 count each time paper is exited (0 count for a blank sheet and 2 counts for the double sided print).
  • Page 520 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.6.2 Present Parts Life Displays the counter of an intended part. And, when replacing an intended part, the counter of the replaced part is reset to manage the service history. A. Procedure for the display/reset "Service Mode screen"...
  • Page 521 Parts No. parameter (Z1) Fusing unit Fusing roller (bizhub 500) 50GE5303 Fusing roller (bizhub 420) 42GA5303 Fusing pressure roller (bizhub 500) 50GA5304 Fisung pressure roller (bizhub 420) 42GA5304 Fusing cleaner assy (bizhub 500) 50GA-540 Fusing cleaner assy (bizhub 420) 42GA-540...
  • Page 522 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.6.3 Sets the PM execution cycle or resets the PM counter. Note • The PM cycle setting has been input in advance and be sure not to change this setting normally. A. Procedure for the counter reset "Service Mode screen"...
  • Page 523 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.7 State Confirmation 10.7.1 Sensor Check This machine is provided with an input/output check function as a self-diagnostic function. For the sensor check (input check), the state confirmation of each signal can be made. A.
  • Page 524 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Display and signal source Name PS12 Paper empty sensor /2 No paper Paper PS15 Near-empty sensor /2 Near-empty Non-near-empty PS13 Upper limit sensor /2 Upper limit Not at upper limit PS14 Tray set sensor /2 Not set PS16 Paper size sensor /Rr2...
  • Page 525 Serial communication check when the power is turned ON (SubCPU) — Serial communication check when the power is turned ON (Main body) — Main body identification signal bizhub 420 bizhub 500 — Machine type code "129" = "128" = bizhub 420 bizhub 500 —...
  • Page 526 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Display and signal source Name Toner remaining sensor Detected Not detected Toner bottle sensor TH1/ The higher value of thermistor /1 and ther- 0 to 255 mistor /2 Original empty sensor Original No original Original feed sensor Original registration sensor Original detection sensor...
  • Page 527 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Display and signal source Name PS14 Lower limit sensor Lower limit Not at lower limit PS15 Upper limit sensor Upper limit Not at upper limit — OT-601 connection detection Connection Non-connection Tray position sensor Tray detected Tray not detected...
  • Page 528 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Display and signal source Name Paper full sensor /1 (MT) Full Other than full Paper detection sensor /2 (MT) No paper Paper Paper full sensor /2 (MT) Full Other than full Paper detection sensor /3 (MT) No paper Paper Paper full sensor /3 (MT)
  • Page 529 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Display and signal source Name PS24 ADU conveyance sensor /1 Paper No paper PS25 ADU conveyance sensor /2 PS27 Reverse sensor PS26 ADU open/close sensor Open Close — Not set Resolution 1024 is also displayed as resolution 256. The size in the main scan direction is shown by the combination of the ON/OFF of the paper size sensors /Rr and /Fr.
  • Page 530 Field Service Ver1.0 Feb.2006 10. SERVICE MODE The combination of the ON/OFF of the paper size sensors /BP1 (PS19), /BP2 (PS20), /BP3 (PS21) and /BP4 (PS22) is shown in 4-bit data (0 to 15). Sensor check display PS19 PS20 PS21 PS22 The combination of the ON/OFF of the paper size boards and the paper size detection boards (4 in all) is shown in 4-bit data (0 to 15).
  • Page 531 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.7.2 Load Check This machine is provided with an input/output check function as a self-diagnostic function. For the load check, the check and adjustment (output check) of the load operation can be made. A.
  • Page 532 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Name Restrictive conditions M150 Feed motor (LS250) (LU) Feed motor (LS210) (LU) Feed motor (LS250), registration CL1, clutch, loop clutch turn ON at the same time M122 Paper feed motor /3 (LS125) (PC-202) Valid only when the paper empty sen- sor /3 (PS115) detects a no paper condition.
  • Page 533 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Name Restrictive conditions M124 Paper lift motor /3 (PC-202) The upper limit sensor /3 (PS114) turns ON, or it is stopped by the stop button. M125 Paper lift motor /4 (PC-202) The upper limit sensor /4 (PS123) turns ON, or it is stopped by the stop button.
  • Page 534 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Name Restrictive conditions Drum motor (LS250) Drum motor (LS210) Drum motor (LS125) FM3, Exhaust fan /Fr, /Rr turn ON at the same time Drum cooling fan FM2, Fusing cooling fan /Fr, /Rr turns ON at the same time Power supply cooling fan Developing suction fan...
  • Page 535 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Name Restrictive conditions Toner bottle motor (CW) Toner bottle motor (CCW) Toner remaining sensor ON/OFF Toner remaining sensor ON Main relay Original feed motor Original conveyance motor Cooling fan Pressure roller release solenoid Stamp solenoid Print lamp (LED board) green ON Print lamp (LED board) red ON...
  • Page 536 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Name Restrictive conditions Release/press operation of exit roller once Open/close operation once of paper exit opening (SD) — — — — — — — — — — — — After 2-staple positioning, home posi- tion search —...
  • Page 537 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Name Restrictive conditions Feed motor, ADU conveyance clutch /Lw turn ON at the same time Feed motor, ADU conveyance clutch CL7, /Up, /Lw turn ON at the same time Reverse solenoid — PM counter clear —...
  • Page 538 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.7.3 Memory/HDD Condition Displays the memory capacity and the hard disc capacity (total/free space). A. Procedure "Service Mode screen" Press [State Confirmation]. "State Confirmation screen" Press [Memory/HDD condition]. The memory package capacity, and the total capacity and the free capacity of HDD are displayed. Press [END].
  • Page 539 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.7.6 HDD Format (Memory/HDD Adjustment) Formats HDD. Note • When formatting HDD, all the data stored in HDD gets lost and becomes unrecoverable. A. Procedure "Service Mode screen" Press [State Confirmation]. "State Confirmation screen" Press [Memory/HDD Adjustment].
  • Page 540 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.7.8 Adj. Data Table Display Adjustment item 1/28 Print position adjustment: leading edge (tray 1) Print position adjustment: leading edge (tray 2) Print position adjustment: leading edge (tray 3) Print position adjustment: leading edge (tray 4) Print position adjustment: leading edge (LCT) Print position adjustment: leading edge (bypass (normal paper)) Print position adjustment: leading edge (bypass (thick paper: large))
  • Page 541 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Display Adjustment item 6/28 Magnification in the printer feed direction (printer: OHP (small)) Magnification in the printer feed direction (printer: thick paper (large)) Magnification in the printer feed direction (printer: thick paper (small)) Magnification in the printer feed direction (printer: envelope) Magnification in the printer feed direction (printer: label (large)) Magnification in the printer feed direction (printer: label (small))
  • Page 542 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Display Adjustment item 12/28 Printer registration loop amount (bypass (label: large)) — Printer registration loop amount (ADU (small)) Printer registration loop amount (ADU (large)) Tray adjustment (maximum width) Tray adjustment (minimum width) Scan area (scanning position: leading edge) 13/28 Scan area (scanning position: side edge) Magnification in the scanner feed crossover direction...
  • Page 543 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Display Adjustment item 18/28 ADF registration loop amount (single sided) ADF registration loop amount (double sided) ADF original size (maximum width) ADF original size (minimum width) ADF density ADF scan position Center staple position (B5S) 19/28 Center staple position (A4S) Center staple position (B4)
  • Page 544 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Display Adjustment item 24/28 DipSW No.05 DipSW No.06 DipSW No.07 DipSW No.08 DipSW No.09 DipSW No.10 DipSW No.11 25/28 DipSW No.12 DipSW No.13 DipSW No.14 DipSW No.15 DipSW No.16 DipSW No.17 DipSW No.18 26/28 DipSW No.19 DipSW No.20...
  • Page 545 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.8 ADF 10.8.1 Paper Feed Direction Adjusts the magnification in the sub scan direction while in the DF original scan. This adjustment adjusts the magnification of the image data in the sub scan direction by changing the scan speed of DF.
  • Page 546 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.8.2 Lead Edge Adjusts the position at which the image read is started while in the DF original scan. This adjustment adjusts the leading edge position of the image by changing the image read start timing after the leading edge of the original passes through the read position.
  • Page 547 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.8.3 Side Edge Adjusts the mis-centering of the image in the main scan direction while in the DF original scan. The adjustment is made for each mode (1-Sided, 2-Sided (Front/Back)). Note • Make sure that the adjustment of the printer position: side edge has been completed. (See P.158) A.
  • Page 548 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.8.4 Resist Loop Adj. Adjusts the original loop amount (1-Sided or 2-Sided) at the registration roller section of DF to adjust a paper skew, wrinkles or an original jam at the registration section. This adjustment adjusts the re-start timing of the DF registration roller.
  • Page 549 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.8.6 Density Adj. This adjustment is made when the slit glass is replaced. The slit glass at the scanner section is coated, and therefore, its transmittance of the exposure lamp is different when compared to the original glass. Prearrangements •...
  • Page 550 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.8.7 Scan Position Adjustment Adjusts the read start position of the exposure unit in the sub scan direction. A. Procedure "Service Mode screen" Press [ADF]. "ADF Adjustment screen" Press [Scan Position Adjustment]. "Scan Position Adjustment screen" Press [Test Copy].
  • Page 551 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.8.8 Sensor Auto Adjust This adjustment is made when an erroneous detection occurs with the reflective sensor, or after the DF control board (DFCB) and each of the reflective sensors are replaced. Conducting this adjustment backs up the sensi- tivity value of each of the reflective sensors to RAM in DFCB.
  • Page 552 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.9 Finisher 10.9.1 Center Staple Position (SD-502) Adjusts the stapling position in the sub scan direction while in the stitch-and-fold by SD-502. Note • Before conducting this adjustment, make sure that the adjustment of the half-fold position has been completed.
  • Page 553 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.9.2 Half-Fold Position (SD-502) Adjusts the folding position while in the stitch-and-fold print by SD-502. A. Procedure "Service Mode screen" Press [Finisher]. "Finisher Adjustment screen" Press [Half-Fold Position]. "Half-Fold Position Adjustment screen" Press each key to select the paper size to be adjusted. Press [Test Copy].
  • Page 554 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.9.3 Punch Horizontal Position (PU) Adjusts the position of the punch holes by PU-501 in the sub scan direction. A. Procedure "Service Mode screen" Press [Finisher]. "Finisher Adjustment" Press [Punch Horizontal Position]. "Punch Horizontal Position Adj. screen" Press [Test Copy].
  • Page 555 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.9.4 Punch Resist Loop (PU) Adjusts the registration loop amount while in the punch by PU-501. This adjustment is made when there occurs a tilt with the punch hole, or when a jam occurs frequently in the punch mode.
  • Page 556 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.10 Firmware Version Displays the version of the firmware (main body and optional). • MFP Controller • Image Controller • Operation Panel Message Data • Finisher • • Fax board controller 1 • Fax board controller 2 •...
  • Page 557 "10.11.8 Detail on settings". (See P.232) • When using the telephone line for connection, use the recommended modem. (For recommended modem, contact responsible person of KONICA MINOLTA.) Step Procedure Register the device ID to the application at CS Remote Care Center.
  • Page 558 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Step Procedure Setting the Center ID Select [Service Mode] → [CS Remote Care], and touch [Detail Setting]. Touch [Machine Setting] → [Center ID], and input the Center ID (five digits). (See P.232) Setting the Device ID Select [Service Mode] →...
  • Page 559 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.11.3 Software SW setting for CS Remote Care Note • SW bits data are written into the NVRAM every time a change is made. In case you changed bit data by accident, be sure to restore the previous state. A.
  • Page 560 Field Service Ver1.0 Feb.2006 10. SERVICE MODE SW No. Functions Default SW 03 Reservation — — Auto call on the toner empty Do not call Call Reservation — — Auto call on the waste toner bottle full Do not call Call 4 to 7 Reservation —...
  • Page 561 10. SERVICE MODE Field Service Ver1.0 Feb.2006 SW No. Functions Default SW 11 Timer 1 RING reception → CONNECT reception SW 12 Timer 2 Dial request completed → CONNECT reception SW 13 0 to 7 Reservation — — SW 14 Timer 4 Line connection →...
  • Page 562 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Baud rate Mode 01-7 01-6 01-5 01-4 9600 bps 19200 bps "38400 bps" Modem redial interval Mode 05-3 05-2 05-1 05-0 1 minute 2 minutes "3 minutes" 4 minutes 5 minutes 6 minutes 7 minutes 8 minutes 9 minutes...
  • Page 563 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Retransmission times on E-Mail delivery error Mode 09-6 09-5 09-4 09-3 09-2 09-1 09-0 0 to 9 times 000 0000 to 000 1001 "10 times" 11 to 99 times 000 1011 to 110 0011 Timer 1 (RING reception →...
  • Page 564 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.11.4 Setup confirmation • Follow the steps below to make sure that CS Remote Care has been properly set up. Call the Service Mode to the screen. Touch [CS Remote Care]. Check to make sure that only selected item is displayed. 10.11.5 Calling the Maintenance •...
  • Page 565 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.11.8 Detail on settings A. System Selection Functions • To select the system type for remote diagnosis. • Use to newly build or change the system. Setting/ • Select E-Mail, Modem, or Fax. Procedure •...
  • Page 566 Field Service Ver1.0 Feb.2006 10. SERVICE MODE (2) Date & Time Setting Functions • To set the data and time-of-day • Use to set or change the date and time-of-day. Setting/ Call the Service Mode to the screen. Procedure Touch [CS Remote Care]. Touch [Detail Setting] to access Date &...
  • Page 567 • Check if the power of the modem is ON. • Check the connecting condition between the modem and the main unit. 0004 Timeout of Incoming request response • Contact responsible person of (No response to incoming (starting) request MSG) KONICA MINOLTA.
  • Page 568 0007 Shut down of the data modem line (Main unit) • Contact responsible person of (Line is shut down forcibly due to event) KONICA MINOLTA. 0008 Timeout of start request telegram delivery • Transmit again manually. (Start request telegram is not delivered after line con-...
  • Page 569 Error code Error Solution 0015 Status Error • Contact responsible person of (During modem operation is being confirmed) KONICA MINOLTA. 0016 Status Error (During receiving) • Contact responsible person of KONICA MINOLTA. 0017 Status Error • Contact responsible person of (During line is being shut down) KONICA MINOLTA.
  • Page 570 Solution 0024 Event Data Acquisition Function Error • Contact responsible person of (Although the transmitting phase response MSG is KONICA MINOLTA. OK, the function for Data acquisition shows “No event,”.) 0025 Timeout of Driver transmitting check MSG • Contact responsible person of (Transmitting check MSG from the driver task is tim- KONICA MINOLTA.
  • Page 571 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.12 System 2 10.12.1 Data Capture Set the availability/unavailability of the capture of the print job data. Keeping the print data captured allows the reproduction of a print with which a trouble occurred. (For particulars, see "IV.
  • Page 572 Field Service Ver1.0 Feb.2006 10. SERVICE MODE B. List of software DipSW Note • Be sure not to change bits with no particular reference made of the function. DIPSW No. Bit Function Default setting Japan Inch Metric DipSW1 Operation at key counter Ignore.
  • Page 573 10. SERVICE MODE Field Service Ver1.0 Feb.2006 DIPSW No. Bit Function Default setting Japan Inch Metric DipSW5 — — — — — — — — — — — — — — — Toner save setting — — — DipSW6 Preliminary drum rotation of Not rotate Rotate when the power is on...
  • Page 574 Field Service Ver1.0 Feb.2006 10. SERVICE MODE DIPSW No. Bit Function Default setting Japan Inch Metric DipSW9 — — — — — — — — — — — — — — — — — — — — — — — —...
  • Page 575 10. SERVICE MODE Field Service Ver1.0 Feb.2006 DIPSW No. Bit Function Default setting Japan Inch Metric DipSW14 — — — — — — — — — — — — — — — — — — — — — — — —...
  • Page 576 Field Service Ver1.0 Feb.2006 10. SERVICE MODE DIPSW No. Bit Function Default setting Japan Inch Metric DipSW18 Separation of a defective part Normal Separated from the tray 1 (upper stage of the main body) Separation of a defective part Normal Separated from the tray 2 (lower stage of the main body)
  • Page 577 10. SERVICE MODE Field Service Ver1.0 Feb.2006 DIPSW No. Bit Function Default setting Japan Inch Metric DipSW21 — — — — — — Platen/ADF size recognition x 14 Foolscap switchover — — — — — — Platen small size (8 x 11/A4 or less) setting —...
  • Page 578 Field Service Ver1.0 Feb.2006 10. SERVICE MODE DIPSW No. Bit Function Default setting Japan Inch Metric DipSW25 — — — — — — — — — Switchover of the TSL control Normally All OFF ON/OFF — — — — — —...
  • Page 579 10. SERVICE MODE Field Service Ver1.0 Feb.2006 DIPSW No. Bit Function Default setting Japan Inch Metric DipSW29 Transfer/separation output selection of the user paper (tray) TSL (transfer exposure lamp) control of the user paper (tray) — — — — — —...
  • Page 580 Field Service Ver1.0 Feb.2006 10. SERVICE MODE DIPSW No. Bit Function Default setting Japan Inch Metric DipSW34 System ON/OFF while in the sleep or the power switch (SW2) OFF FS-510 paper exit tray position Print start permission when Permit Prohibit SD-502 is supplied with paper.
  • Page 581 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Toner level detection (toner supply display) Mode Set the copy count that is printed until the print oper- After 0 print or its equiva- ation is terminated from the toner near empty is dis- lent played after the toner level sensor (PZS) detects toner After 100 print or its...
  • Page 582 Field Service Ver1.0 Feb.2006 10. SERVICE MODE Discrimination level of the non-image auto erase Mode 13-7 13-6 mode Corresponding to dark This setting is made in the non-image erase mode of original an applicable function. The image area detection Standard threshold value is set when the non-image erase Corresponding to light function set by the administrator is set to no limit.
  • Page 583 10. SERVICE MODE Field Service Ver1.0 Feb.2006 Foolscap size setting Mode 17-2 17-1 17-0 Set the definition of the foolscap size. x 13 x 13 x 13 8 x 13 Platen small size (8 x 11/A4 or less) setting Mode 21-5 Default setting is "1"...
  • Page 584 Field Service Ver1.0 Feb.2006 10. SERVICE MODE *13 Selection of the transfer/separation output of the Mode 29-2 29-1 29-0 user paper (tray) Normal paper (Japan) Set the transfer/separation output that is applicable Normal paper (inch) when selecting the user paper in [Paper type] of [Util- Normal paper (metric) ity menu].
  • Page 585 10. SERVICE MODE Field Service Ver1.0 Feb.2006 *18 FS-510 paper exit tray position Mode 34-3 34-2 34-1 Set the stop position of the paper exit tray. Not fixed Tray 1 Tray 2 Tray 3 Folding/stitch-and-fold tray (SD) Not fixed *19 Fusing temperature setting while in the selection Mode 36-3 36-2...
  • Page 586 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.12.4 ISW For particulars, see "5. FIRMWARE VERSION UP". (See P.95) 10.12.5 Option Let the main body recognize the installing condition of the optional HDD and FAX. A. Procedure "Service Mode screen" Press [System 2]. "System Input screen"...
  • Page 587 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.13 List Output 10.13.1 List output Outputs various types of lists. Lists that can be output are as shown below. • Machine Management List • Adjustment List • Service Parameter • Protocol Trace Last •...
  • Page 588 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.14 Test Mode 10.14.1 Test pattern list The following test patterns can be output. • Full Image Halftone (No. 1) • Gradation Pattern (No. 2) • Gradation Pattern (No. 3) • Gradation Pattern (No. 5) •...
  • Page 589 10. SERVICE MODE Field Service Ver1.0 Feb.2006 No.1 Overall halftone (8-bit output) [Check item] • When the density is set at 70 (halftone) When there are white stripes or black stripes, check to see if an abnormality is found with the scanner system or process system [Recommended sections to be checked]: Developing unit, cleaning glass, charging corona, transfer/sep- aration corona, scanner mirror, slit glass and original glass...
  • Page 590 Field Service Ver1.0 Feb.2006 10. SERVICE MODE No.2 Gradation pattern [Check item] When fogging appears or density is thin, check the process system and the gamma correction to see if which is defective. Regardless of this test pattern being normal, any trouble is found with the print image, the image processing system or scanner system is considered defective.
  • Page 591 10. SERVICE MODE Field Service Ver1.0 Feb.2006 No.3 Gradation pattern (8-bit output) [Check item] • Check to see if the laser output of LD1/LD2 is uniform and if the gradation is reproduced without a break. [Recommended sections to be checked]: Write unit, and LD offset adjustment For LD offset adjustment, see "10.4.11 LD1 Offset Adj.
  • Page 592 Field Service Ver1.0 Feb.2006 10. SERVICE MODE No.5 Gradation pattern (8-bit output) [Check item] • Check the pattern to see if the laser output of LD1/LD2 is uniform with the gradation continuously repro- duced. [Recommended checkpoints]: Write unit, LD offset adjustment For LD offset adjustment, see "10.4.11 LD1 Offset Adj.
  • Page 593 10. SERVICE MODE Field Service Ver1.0 Feb.2006 No.11 Beam check (8-bit output) [Check item 1] • Check to see if there is a difference in density found with the solid black pattern in the main scan and sub scan directions. [Recommended sections to be checked]: Charging corona, transfer/separation corona, developing unit, and write dust-proof glass.
  • Page 594 Field Service Ver1.0 Feb.2006 10. SERVICE MODE No.16 Linearity evaluation pattern (1-bit error diffusion output) [Check item] Judge from this test pattern whether the scanner system or the printer system is abnormal. Items that can be checked include main scan magnification, sub scan magnification, image skew, and leading edge timing of the printer system.
  • Page 595 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.14.2 Test pattern output There are two methods provided for the test pattern output. • Output it by selecting the item of each test pattern. (Procedure A) • Output it by specifying the test pattern number. (Procedure B) Note •...
  • Page 596 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.14.3 Running Mode Conduct a continuous print operation test. In this mode, the following items can be selected. • Intermittent Copy Mode The machine shifts into the ready condition after completion of the print operation of the set copy count and conducts the same operation after waiting for 0.5 sec.
  • Page 597 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.15 Fax setting For particulars of the setting, see FK-502 Service Manual.
  • Page 598 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.16 Enhanced Security 10.16.1 List of the security setting Adjustment/setting item Enhanced Security CE Password Administrator Password Administrator Feature Level Level 1 Level 2 Prohibit CE Authentication 10.16.2 Start and termination of the security mode Security setting is made on "Enhanced security screen"...
  • Page 599 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.16.3 CE Password Set a password to enter the service mode. Note • Be sure to avoid using as a password the name and the birth day that can be easily suspected by other people.
  • Page 600 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.16.5 Administrator Feature Level Set the range of the administrator feature to be displayed in Administrator Setting in the Utility menu. When the setting is made to [Prohibit] in this feature, the following features are not displayed. A.
  • Page 601 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.17 Billing Setting 10.17.1 List of the billing setting Adjustment/setting item Billing Setting Counter Setting Management Function Choice 10.17.2 Start and termination of the billing setting mode The billing setting is made in [Billing Setting screen] in the billing setting mode. A.
  • Page 602 Field Service Ver1.0 Feb.2006 10. SERVICE MODE 10.17.3 Counter Setting Set the counter mode of the counters of 2 types. • Total Counter Mode • Large Size Counter Mode A. Procedure "Billing Setting screen" Press [Counter Setting]. "Counter Setting screen" Select a count mode of the total counter in either of [Mode 1] or [Mode 2].
  • Page 603 10. SERVICE MODE Field Service Ver1.0 Feb.2006 10.17.4 Management Function Choice Set the installation/non-installation of the key counter and the management device. A. Procedure "Billing Setting screen" Press [Management Function Choice]. "Management Function Choice screen" Select the management device. Note •...
  • Page 604 Field Service Ver1.0 Feb.2006 11. MECHANICAL ADJUSTMENT 11. MECHANICAL ADJUSTMENT 11.1 Mis-centering adjustment of the trays 1 and 2 This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode. A. Procedure Pull out the tray [1]. If there remains any paper, remove it thoroughly.
  • Page 605 11. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 11.2 Mis-centering adjustment of the bypass tray This adjustment is made when there occurs a mis-centering that cannot be adjusted in the service mode. A. Procedure Open the bypass tray [1]. If paper is set, remove it. When the paper guide [2] is set to the small size position, expand it.
  • Page 606 Field Service Ver1.0 Feb.2006 12. JAM CODE TROUBLESHOOTING 12. JAM CODE 12.1 Jam code list Classification Jam code Cause Resulting Correction operation Bypass J-1000 The vertical conveyance sensor (PS2) If there is a Pull out the paper from does not turn ON within a specified sheet of paper the bypass tray and period of time after the feed clutch...
  • Page 607 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation PC-402 J-1306 The paper feed sensor (PS1) does not If there is a Open the right door of turn OFF within a specified period of sheet of paper PC and the vertical time after the PS1 turns ON.
  • Page 608 Field Service Ver1.0 Feb.2006 12. JAM CODE Classification Jam code Cause Resulting Correction operation J-2006 While in the print, the front door The main body Remove jammed paper opens. and the optional if any from optional device stop device / main body. FS-510 J-2007 While in the print, the guide plate...
  • Page 609 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation J-6001 The DF open/close switch (SW3) The DF stops Open the open/close turns OFF while in the DF operation. immediately. If cover and remove there is paper jammed paper if any.
  • Page 610 Field Service Ver1.0 Feb.2006 12. JAM CODE Classification Jam code Cause Resulting Correction operation J-6108 When feeding the third original in the The DF stops Open the open/close mode other than the single sided immediately. If cover and remove mode, the original feed sensor (PS6) there is paper jammed paper if any.
  • Page 611 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation J-6208 When feeding the third original in the The DF stops Open the open/close mode other than the single sided immediately. If cover and remove mode, the original registration sensor there is paper jammed paper if any.
  • Page 612 Field Service Ver1.0 Feb.2006 12. JAM CODE Classification Jam code Cause Resulting Correction operation J-6308 When feeding the third original in the The DF stops Open the open/close mode other than the single sided immediately. If cover and remove mode, the original detection sensor there is paper jammed paper if any.
  • Page 613 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation J-6604 When feeding the third original in the The DF stops Open the open/close mode other than the single sided immediately. If cover and remove mode, the original exit sensor (PS10) there is paper jammed paper if any.
  • Page 614 Field Service Ver1.0 Feb.2006 12. JAM CODE Classification Jam code Cause Resulting Correction operation J-7205 While in the idle, the conveyance sen- FS, RU, MT, SD, Remove jammed paper sor /Up (PS9) or /Lw (PS10) is ON. main body stop if any from the FS/main immediately.
  • Page 615 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation FS-511 J-7217 The intermediate conveyance sensor FS, RU, MT, SD, Remove jammed paper (PS3) does not turn ON within a spec- main body stop if any from the FS/main ified period of time after the main immediately.
  • Page 616 Field Service Ver1.0 Feb.2006 12. JAM CODE Classification Jam code Cause Resulting Correction operation J-7284 The clincher motor /Fr does not return FS, RU, MT, SD, Remove jammed paper to the home position within a speci- main body stop if any from the FS/main fied period of time after the clincher immediately.
  • Page 617 12. JAM CODE Field Service Ver1.0 Feb.2006 Classification Jam code Cause Resulting Correction operation J-9702 The ADU conveyance sensor /2 The printer sec- Open ADU and remove (PS25) does not turn ON within a tion stops jammed paper if any. specified period of time after the ADU immediately.
  • Page 618 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE 13. MALFUNCTION CODE 13.1 Malfunction code list A. Note for use Turn OFF/ON the power switch (SW2) of the main body when releasing an abnormal condition. B. Code list NOTE • For codes with "*" given in the error code column, a message "Turn off the power and turn it on again"...
  • Page 619 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Drive C-0207 While in the paper feed, there The main body Pick-up solenoid /BP (SD1) occurs a condition twice in suc- stops immedi- Lift sensor (PS23) cession in which the lift sensor ately to turn OFF Feed motor (M9)
  • Page 620 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation FS-511 C-1102 Tray lift motor (M7) drive abnor- The main body Tray lift motor (M7) mality. stops immedi- Main tray upper limit sensor • While in the main tray up ately to turn OFF (PS19) drive, the main tray upper limit...
  • Page 621 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation FS-511 C-1105 Intermediate conveyance roller The main body Intermediate conveyance release motor (M12) drive abnor- stops immedi- roller release motor (M12) mality. ately to turn OFF Roller release home sensor •...
  • Page 622 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation FS-511 C-1108 Stapler motor /Fr (M17) drive The main body Stapler motor /Fr (M17) abnormality. stops immedi- Stapler home sensor /Fr • The stapler home sensor /Fr ately to turn OFF (PS25) (PS25) does not turn OFF...
  • Page 623 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation C-1110 Saddle stapler motor /Rr drive The main body Saddle stapler motor /Rr abnormality. stops immedi- SD control board (SDCB) • When the saddle stapler ately to turn OFF motor /Rr turns ON, it does the main relay...
  • Page 624 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation C-1113 Exit open/close motor (M9) drive The main body Exit open/close motor (M9) abnormality. stops immedi- Saddle exit home sensor • When starting a pressure ately to turn OFF (PS18) contact operation, the sad-...
  • Page 625 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation FS-510 C-1117 Alignment motor /Fr (M5) drive The main body Alignment motor /Fr (M5) abnormality. stops immedi- Alignment home sensor /Fr • While in the home position ately to turn OFF (PS7) search, the alignment home...
  • Page 626 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation C-1121 Punch motor (M1) drive abnor- The main body Punch motor (M1) mality. stops immedi- Punch position sensor /1 The punch position sensors /1 ately to turn OFF (PS2) (PS2) and /2 (PS3) do not turn the main relay...
  • Page 627 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Abnor- C-2401 High machine inside temperature The main body TCR sensor (TCRS) mality abnormality. stops immedi- Printer control board (PRCB) around When the temperature around the ately to turn OFF the drum drum is above 58 °C...
  • Page 628 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation High C-2803 TCR output abnormality. The main body TCR sensor (TCRS) voltage When the output ripple voltage of stops immedi- Printer control board (PRCB) power the TCR sensor (TCRS) is less ately to turn OFF source...
  • Page 629 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Fusing C-3801 Fusing main sensor low tempera- The main body Thermistor /1 (TH1) ture abnormality. stops immedi- Printer control board (PRCB) temper- While in the idle or in the low ately to turn OFF ature power mode, the fusing heater...
  • Page 630 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation Fusing C-3808 Fusing sub sensor high tempera- The main body Thermistor /2 (TH2) ture abnormality (sub CPU detec- stops immedi- Printer control board (PRCB) temper- tion) ately to turn OFF ature...
  • Page 631 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Image C-4001 Index board (INDEXB) contact The main body Index board (INDEXB) proces- abnormality. stops immedi- Overall control board (OACB) sing ately to turn OFF abnor- the main relay mality...
  • Page 632 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation C-5301 Exhaust fan /Fr (FM3) conversion The main body Exhaust fan /Fr (FM3) lock abnormality. stops immedi- Printer control board (PRCB) abnor- When FM3 is ON, an error signal ately to turn OFF mality is detected 5 times in succession...
  • Page 633 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Scanner C-6101 While in the exposure unit initial Scanner sec- Scanner motor (M2) abnor- search, the scanner home sensor tion stops Scanner home sensor mality (PS30) does not turn on within a immediately.
  • Page 634 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation C-B117 Time out error for ACK standby FAX breakdown FK-502 driver C-B118 Undefined frame reception error C-B119 DMA transfer error C-B120 JC software error C-B122 Device error (GA LOCAL SRAM) C-B123 Device error (DRAM)
  • Page 635 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation Line C-B150 External class instance acquisi- FAX breakdown FK-502 control tion error C-B151 Job start-up error (start-up JOB parameter/slave job generation error) C-B152 Doc access error (report Buf access error) C-B153 Time out for a response from the...
  • Page 636 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation Page C-B185 Incoming data size logic error FAX breakdown FK-502 control (The incoming data is not a multi- ple number of DotLine. C-B186 Image Buff acquisition (alloc) error C-B187 Error return from Compressor C-B188...
  • Page 637 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation C-D201 Overall control board cooling fan The main body Overall control board (OACB) lock (FM8) abnormality. stops immedi- Overall control board cool- abnor- ately to turn OFF ing fan (FM8) mality the main relay...
  • Page 638 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation System C-E085* Copy sequence abnormality. Engine section Overall control board (OACB) control Through copy sequence (FCOT) power OFF. commu- abnormality (the one that the nication cause of which cannot be identi- abnor- fied.)
  • Page 639 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation System C-E08E* Unrecoverable error (The count is Engine section Overall control board (OACB) control made by C-5402.) power OFF. commu- An abnormal operation occurs nication when an interrupt copy is made abnor- (FCOT print job).
  • Page 640 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation System C-E097* Unrecoverable error (The count is Engine section Overall control board (OACB) control made by C-5402.) power OFF. commu- An error occurs when the task n nication is started.
  • Page 641 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 Classification Code Causes Resulting Estimated abnormal parts operation System C-E0A1* Unrecoverable error (The count is Engine section Overall control board (OACB) control made by C-5402.) power OFF. commu- An abnormal operation occurs nication when an interrupt copy is made abnor- (scanner normal scan job 0).
  • Page 642 Field Service Ver1.0 Feb.2006 13. MALFUNCTION CODE Classification Code Causes Resulting Estimated abnormal parts operation System C-E0AA* Unrecoverable error (The count is Engine section Overall control board (OACB) control made by C-5402.) power OFF. commu- An abnormal operation occurs nication when an interrupt copy is made abnor- (copy scan user job).
  • Page 643 13. MALFUNCTION CODE Field Service Ver1.0 Feb.2006 C. Function to separate defective sections For setting of DipSW that is specified for the following items, it is possible to use them with a failed section sep- arated. After setting DipSW, however, no abnormality detection is made on the separated section. NOTE •...
  • Page 644 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING APPENDIX 14. PARTS LAYOUT DRAWING 14.1 Main body 14.1.1 Switch/sensor A. Main body rear side 50gaf5c017na Toner bottle sensor (PS4) Humidity sensor (HUMS) Toner bottle position sensor (PS28) Toner remaining sensor (PZS)
  • Page 645 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 B. Main body front side 50gaf5c018na Power switch (SW2) Main power switch (SW1) Interlock switch (MS) C. Main body upper surface 50gaf5c019na DF open/close switch (SW3) APS timing sensor (PS31) Scanner home sensor (PS30) APS sensor (PS32)
  • Page 646 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING D. Developing section 50gaf5c020na TCR sensor (TCRS) E. Paper feed section (1) Tray 1 50gaf5c034na Upper limit sensor /1 (PS6) Paper size sensor /Rr1 (PS10) Paper empty sensor /1 (PS5) Tray set sensor /1 (PS8) Paper size sensor /Fr1 (PS11) Near-empty sensor /1 (PS9)
  • Page 647 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 (2) Tray 2 50gaf5c035na Vertical conveyance sensor (PS2) Paper size sensor /Fr2 (PS17) Feed door open/close sensor (PS7) Paper size sensor /Rr2 (PS16) Paper empty sensor /2 (PS12) Tray set sensor /2 (PS14) Upper limit sensor /2 (PS13) Near-empty sensor /2 (PS15) (3) Registration...
  • Page 648 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING Bypass tray section 50gaf5c037na Paper size VR/BP (VR1) Paper size sensor /BP4 (PS22) Paper empty sensor /BP (PS18) Paper size sensor /BP2 (PS20) Lift sensor (PS23) Paper size sensor /BP1 (PS19) Paper size sensor /BP3 (PS21) G.
  • Page 649 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 H. Fusing section 50gaf5c021na Fusing exit sensor (PS3) Thermistor /1 (TH1) Thermistor /2 (TH2) Thermostat (TS) Reverse/paper exit section 50gaf5c039na Reverse sensor (PS27)
  • Page 650 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.1.2 Load A. Main body rear side [11] [10] 50gaf5c022na Toner supply motor (M4) Developing motor (M3) Toner bottle motor (M10) Feed motor (M9) Toner solenoid (SD5) Drum motor (M1) Power supply cooling fan (FM1) [10] Fusing motor (M11) Overall control board cooling fan (FM10)
  • Page 651 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 B. Main body inside 50gaf5c023na Fusing cooling fan /Rr (FM8) Drum cooling fan (FM4) Fusing cooling fan /Fr (FM2) Developing suction fan (FM6) C. Main body right side 50gaf5c024na Web solenoid (SD4) Coveyance suction fan (FM5)
  • Page 652 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING D. Write section 50gaf5c025na Polygon motor (M5) E. Photo conductor section 50gaf5c026na Drum claw solenoid (SD2)
  • Page 653 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 Paper feed section (1) Tray 1 50gaf5c040na Feed clutch /1 (CL4) Paper lift motor /1 (M7) (2) Tray 2 50gaf5c041na Vertical conveyance clutch (CL3) Paper lift motor /2 (M8) Feed clutch /2 (CL5)
  • Page 654 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING (3) Registration 50gaf5c042na Registration clutch (CL1) Loop clutch (CL2) G. Bypass tray section 50gaf5c043na Feed clutch /BP (CL6) Pick-up solenoid /BP (SD1)
  • Page 655 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 H. ADU section 50gaf5c044na ADU conveyance clutch /Up (CL7) ADU conveyance clutch /Lw (CL8) Reverse/paper exit section 50gaf5c045na Reverse motor (M6) Exhaust fan /Rr (FM9) Reverse solenoid (SD3) Exhaust fan /Fr (FM3)
  • Page 656 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.1.3 Boards and others A. Main body rear side 50gaf5c027na L1 inverter (L1 INVB) Paper size board /2 (PSB/2) Scanner drive board (SDB) Paper size board /1 (PSB/1) Printer control board (PRCB) Overall control board (OACB) Circuit breaker /1 (CBR1) NVRAM board (NRB)
  • Page 657 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 B. Main body front side 50gaf5c028na Total counter (TCT) C. Main body inside 50gaf5c029na DC power supply (DCPS) Hight voltage unit (HV2)
  • Page 658 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING D. Operation panel and main body upper surface 50gaf5c030na CCD board (CCDB) Operation board (OB) Panel key board (PKB) Speaker (SP) (option) OB inverter (OB INVB) Exposure lamp (L1) LCD board (LCDB) L1 relay board (L1 RLB) E.
  • Page 659 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 Photo conductor section 50gaf5c032na IDC sensor (IDCS) Erase lamp (EL) G. ADU section 50gaf5c046na Transfer exposure lamp (TSL)
  • Page 660 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING H. Fusing section 50gaf5c033na Fusing heater lamp /2 (L3) Fusing heater lamp /1 (L2)
  • Page 661 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.2 DF A. Front side 16eaf5c001na Pressure roller release solenoid (SD1) LED board (LB) B. Rear side 16eaf5c002na Cover open/close sensor (PS7) Cooling fan (FM3) Original conveyance motor (M2) DF control board (DFCB) Original feed motor (M1)
  • Page 662 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING C. Upper surface [10] [11] 16eaf5c003na Original size sensor /2 (PS2) Original empty sensor (PS5) Stamp solenoid (SD2) Original registration sensor (PS9) Original exit sensor (PS10) Original size sensor /1 (PS1) Original detection sensor (PS8) [10] Original size sensor /3 (PS3) Original feed sensor (PS6)
  • Page 663 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.3 PC 14.3.1 PC-202 [21] [20] [19] [22] [23] [18] [24] [17] [16] [25] [26] [15] [14] [13] [12] [11] [10] 4061f5c001na Vertical conveyance sensor /4 (PS126) [14] Paper size detect board /3 (PSDB3) Paper feed sensor /4 (PS125) [15] Paper size sensor /Rr3 (PS118)
  • Page 664 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.3.2 PC-402 [20] [19] [21] [18] [17] [22] [16] [23] [24] [15] [14] [13] [12] [10] [11] 4061f5c201na Paper empty sensor (PS3) [13] Shift gate motor (M3) Main tray empty board (MEB) [14] Shift gate position sensor (PS14) Paper lift motor (M5)
  • Page 665 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.4 LU [10] [11] [12] [13] 16aaf5c001na Remaining paper sensor /1 (PS154) Upper limit sensor (PS152) Remaining paper sensor /2 (PS151) Feed clutch (CL151) Dehumidifier heater (HTR101) LU set sensor (PS156) Service parts setting [10] Paper lift motor (M151) P/N 56AA-710#...
  • Page 666 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.5 FS 14.5.1 FS-510 [27] [26] [28] [25] [20] [24] [29] [21] [30] [23] [22] [19] [18] [17] [16] [13] [12] [11] [10] [15] [14] 4349f5c001na Registration clutch (CL1) [16] Tray lift motor (M11) Guide plate switch (SW4) [17] Lower limit sensor (PS14)
  • Page 667 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.5.2 FS-511 A. Front side 4521f5c001na Main gate solenoid (SD2) Tray lift motor (M7) Front door sensor (PS17) Main tray upper limit LED (LED19)
  • Page 668 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING B. Rear side [10] [11] [12] [13] [14] 4521f5c002na Main tray lower limit switch (SW3) Bypass gate solenoid (SD1) Main tray upper limit sensor (PS19) Entrance conveyance motor (M1) Paddle motor /Up (M15) [10] Conveyance motor /Up (M4) Paper exit motor (M3)
  • Page 669 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 C. Punch section 4521f5c003na Punch motor (M11) Punch encoder sensor (PS15) Punch clutch (CL1)
  • Page 670 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING D. Conveyance section [13] [14] [12] [15] [16] [11] [10] 4521f5e001na Hole punch position switch (SW4) Paddle motor /Lw (M9) Hole punch selector motor (M14) [10] Roller release home sensor (PS12) Intermediate conveyance sensor (PS3) [11] Main route conveyance sensor (PS4) Alignment tray sensor (PS5)
  • Page 671 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 E. Stapler section 4521f5c005na Stapler home sensor (PS14) Stapler moving motor (M6)
  • Page 672 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING Main tray section 4521f5c006na Shift home sensor (PS10) Shift motor (M8) Shift encoder sensor (PS11)
  • Page 673 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.6 PU-501 4512f5c001na Punch scraps full sensor (PS1) Encoder sensor (PS4) Punch position sensor /1 (PS2) Punch motor (M1) Punch position sensor /2 (PS3)
  • Page 674 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.7 SD-502 [14] [13] [12] [11] [10] 4511f5c001na Folding motor (M10) Tray empty sensor (PS21) Folding roller home sensor (PS22) Paper guide motor (M13) SD interlock switch (SW4) [10] Exit motor encoder sensor (PS25) Staple guide home sensor (PS26) [11] Conveyance motor (M8)
  • Page 675 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.8 MT-501 [12] [11] [13] [14] [10] [15] [16] 4510f5c001na Conveyance sensor /Up (PS9) Gate solenoid /2 (SD2) Paper full sensor /1 (PS5) [10] Conveyance motor (M1) Conveyance sensor /Lw (PS10) [11] Gate solenoid /3 (SD3) Paper detection sensor /1 (PS1) [12]...
  • Page 676 Field Service Ver1.0 Feb.2006 14. PARTS LAYOUT DRAWING 14.9 RU-502 16faf5c001na Path sensor (PS2) Door sensor (PS1)
  • Page 677 14. PARTS LAYOUT DRAWING Field Service Ver1.0 Feb.2006 14.10 JS-502 4347f5c001na Paper full sensor (PS1) Not used...
  • Page 678 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING 15. CONNECTOR LAYOUT DRAWING 15.1 Main body 15.1.1 Connector in the board A. Overall control board 44 (BN : 28 pin) 51 (BN : 5 pin) 43 (BN: 20 pin) 46 (BK : 50 pin) 50 (BN : 24 pin) 42 (BN : 8 pin) 57 (BK : 9 pin)
  • Page 679 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 B. Printer control board 29 (BN : 28 pin) 34 (BN : 32 pin) 28 (BN : 24 pin) 27 (GY : 22 pin) 37 (W : 8 pin) 36 (W : 10 pin) 38 (BN : 20 pin) 91 (BN : 2 pin) 21 (W : 11 pin)
  • Page 680 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING C. Scanner drive board 62 (BK : 3 pin) 63 (W : 10 pin) 65 (W : 2 pin) 61 (BN : 24 pin) 64 (W : 9 pin) 50gaf5c003na D. CCD board 60 (BN : 50 pin) 50gaf5c004na...
  • Page 681 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 E. DC power supply 10 (W : 2 pin) 9 (W : 3 pin) 1 (W : 4 pin) 4 (W : 8 pin) 5 (W : 10 pin) 6 (W : 8 pin) 2 (W : 5 pin) 3 (W : 12 pin) 7 (W : 6 pin)
  • Page 682 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING High voltage unit 71 (W : 11 pin) 70 (W : 6 pin) 72 (W : 3 pin) 50gaf5c006na G. Index board 51 (BN : 5 pin) 50gaf5c007na...
  • Page 683 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 H. L1 inverter 930 (W : 3 pin) 931 (W : 4 pin) 50gaf5c008na L1 relay board 97(2 pin) 97 (2 pin) 50gaf5c009na Laser drive board 50 (BN : 24 pin) 50gaf5c010na K.
  • Page 684 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING L. OB inverter 8 (BN : 3 pin) 9 (W : 4 pin) 50gaf5c012na M. NVRAM board 1 (BN : 20 pin) 2 (BN : 24 pin) 50gaf5c013na N. Panel key board 6 (BK : 22 pin) 50gaf5c014na...
  • Page 685 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 O. Paper size board /1, /2 87,88 (W : 5 pin) 50gaf5c015na Toner control sensor board 1 (W: 7 pin) 50gaf5c016na...
  • Page 686 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING 15.2 DF 15.2.1 Connector in the board A. DF control board (DFCB) 10 (W : 5 pin) 9 (W : 3 pin) 8 (W : 6 pin) 7 (W : 6 pin) 11 (W : 2 pin) 1 (W : 2 pin) 4 (W : 7 pin)
  • Page 687 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 15.3 PC 15.3.1 Connector in the board A. PC-202 (1) PC control board (PCCB) 5 (W : 8 pin) 3 (W : 14 pin) 6 (W : 15 pin) 4 (W : 5 pin) 1 (W : 12 pin) 8 (W : 13 pin) 2 (W : 2 pin)
  • Page 688 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING B. PC-402 (1) PC control board (PCCB) 3 (W : 11 pin) 5 (W : 15 pin) 4 (W : 13 pin) 7 (W : 5 pin) 6 (W : 8 pin) 1 (W : 12 pin) 2 (W : 2 pin) 4061f5c202na...
  • Page 689 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 15.4 LU 15.4.1 Connector in the board A. LU drive board (LUDB) 112 (W : 12 pin) 114 (W : 4 pin) 113 (GY : 22 pin) 111 (W : 2 pin) 110 (GY : 19 pin) 16aaf5c002na...
  • Page 690 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING 15.5 FS 15.5.1 Connector in the board A. FS-510 (1) FS control board (FSCB) 7 (W : 5 pin) 5 (W : 3 pin) 3 (W : 10 pin) 8 (W : 2 pin) 10 (W : 3 pin) 6 (W : 7 pin) 4 (W : 4 pin)
  • Page 691 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 B. FS-511 (1) FS control board (FSCB) 7 (W : 8 pin) 9 (W : 12 pin) 11 (W : 8 pin) 13 (W : 9 pin) 8 (W : 6 pin) 10 (W : 4 pin) 12 (W : N.C.) 6 (W : 2 pin) 5 (W : 4 pin)
  • Page 692 Field Service Ver1.0 Feb.2006 15. CONNECTOR LAYOUT DRAWING 15.6 SD 15.6.1 Connector in the board A. SD control board (SDCB) 5 (W : 4 pin) 6 (W : 3 pin) 8 (W : 7 pin) 7 (W : 8 pin) 4 (W : 9 pin) 2 (W : 3 pin) 12 (W : 5 pin)
  • Page 693 15. CONNECTOR LAYOUT DRAWING Field Service Ver1.0 Feb.2006 15.7 MT 15.7.1 Connector in the board A. MT control board (MTCB) 101 (W : 9 pin) 100 (W : 13 pin) 102 (W : 12 pin) 103 (W : 7 pin) 107 (W : 8 pin) 104 (W : 2 pin) 105 (W : 2 pin)
  • Page 694 Field Service Ver1.0 Feb.2006 16. TIMING CHART 16. TIMING CHART 16.1 Main body A. A4, 2 single sided originals, single sided copy (1 copy), paper feed tray 1 50gaf5c047na...
  • Page 695 16. TIMING CHART Field Service Ver1.0 Feb.2006 B. A4, 3 double sided original, double sided copy (1 copy), paper feed tray 1 50gaf5c048na...
  • Page 696 Field Service Ver1.0 Feb.2006 16. TIMING CHART 16.2 DF A. Single sided original mode (A4, 2 sheets feed) 16eaf5c009na...
  • Page 697 16. TIMING CHART Field Service Ver1.0 Feb.2006 B. Double sided original mode (A4, 2 sheets feed) 16eaf5c010na...
  • Page 698 Field Service Ver1.0 Feb.2006 16. TIMING CHART 16eaf5c011na...
  • Page 699 16. TIMING CHART Field Service Ver1.0 Feb.2006 C. FAX fine mode (A4, 2 sheets feed) 16eaf5c012na...
  • Page 700 Field Service Ver1.0 Feb.2006 16. TIMING CHART D. FAX immediate send mode (A4, 2 sheets feed) 16eaf5c013na...
  • Page 701 16. TIMING CHART Field Service Ver1.0 Feb.2006 16.3 LU A. A4, life size, 1-1 mode, 3 originals 16aaf5c003na...
  • Page 702 Field Service Ver1.0 Feb.2006 16. TIMING CHART 16.4 FS 16.4.1 FS-510 A. Non-sort, A4, 1 sheet setting 4349f5c004na...
  • Page 703 16. TIMING CHART Field Service Ver1.0 Feb.2006 B. 1 stapling, punch, A4, 2 originals, 2 copies setting 4349f5c005na...
  • Page 704 Field Service Ver1.0 Feb.2006 16. TIMING CHART 16.4.2 FS-511 A. No-sort, 1 original, 1 copy setting 4521f5c008na...
  • Page 705 16. TIMING CHART Field Service Ver1.0 Feb.2006 B. Sort, 2 originals, 2 copies setting 4521f5c009na...
  • Page 706 Field Service Ver1.0 Feb.2006 16. TIMING CHART C. 1 staple /Rr, A4S, 2 originals, 2 copies setting 4521f5c010na...
  • Page 707 16. TIMING CHART Field Service Ver1.0 Feb.2006 D. Non-sort, punch, 1 original, 1copy setting 4521f5c011na...
  • Page 708 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17. OVERALL WIRING DIAGRAM 17.1 Main body 1/4 RL24V RL1 POWER RL1 CNT FT20 FT21 FT22 J21-01 J13-2 Circuit breaker /1 CN9-1 AC(H) Main relay Thermostat CN10-1 AC(H) AC DRIVE AC(H) CBR 1 Fusing heater lamp /1 CR001 FT26...
  • Page 709 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 Main Body location list Symbol Part name Location CBR1 Circuit breaker /1 CBR2 Circuit breaker /2 DCPS DC power supply FM10 Overall control board cooling fan 12-K Fusing heater lamp /1 11-B Fusing heater lamp /2 11-B LCDB...
  • Page 710 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.2 Main body 2/4 Symbol Connector Faston CCDB Crimp Relay connector (CN55:FX2) 55-A 1 +12V -A 2 GND -A 3 +5V(main) -A 4 GND -A 5 GND -A 6 WAKEUP -A 7 GND -A 8 GND -A 9 AD1 -A10 +5V(STBY)
  • Page 711 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 Main Body location list Symbol Part name Location CCDB CCD board 17-B INDEXB Index board 18-K Laser drive board 16-K NVRAM board 20-F — FK-502 23-E — HD-505 15-F — IC-204 15-G —...
  • Page 712 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.3 Main body 3/4 DCPS(2/2) To developing bias To guide plate bias Separation Charging Transfer Coin vendor/2 IDC sensor IDCS PRCB(1/2) PS22 PS23 PS24 PS25 PS26 PS12 PS13 PS18 PS19 TCRS...
  • Page 713 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 Main Body location list Symbol Part name Location Vertical conveyance clutch Feed clutch /1 12-Y Feed clutch /2 ADU conveyance clutch /Up ADU conveyance clutch /Lw Erase lamp 10-Q Power supply cooling fan Fusing cooling fan /Fr Drum cooling fan Coveyance suction fan...
  • Page 714 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.4 Main body 4/4 for DCPS for DCPS 48-1 TX+ 48-2 TX- 48-3 RX+ 48-4 RX+ 48-5 CT 48-6 RX- 48-7 NC 48-8 FG 48-9 VDD1 48-10 LED1 48-11 LED2 48-12 VDD2 REVERSE UNIT DF-607 OACB(3/3)
  • Page 715 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 Main Body location list Symbol Part name Location Registration clutch 20-Y Loop clutch 20-Y Feed clutch /BP 14-Y Exhaust fan /Fr 23-Q Exhaust fan /Rr 24-Q HUMS Humidity sensor 20-Y Key counter 18-R Exposure lamp 17-S...
  • Page 716 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.5 DF DFCB CN17 CN19 CN18 PS10...
  • Page 717 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 DF-607 location list Symbol Part name Location DFCB DF control board Cooling fan LED board Original feed motor Original conveyance motor MOSDB Mix Original size detection board Original size sensor /1 Original size sensor /2 Original size sensor /3 Original size sensor /4 Original empty sensor...
  • Page 718 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.6 PC 17.6.1 PC-202 PS114 PS115 PS116 PS117 PS111 PS113 PS118 PS119 PS112 M122 M120 M124 PCCB M125 M123 M121 PS122 PS121 PS128 PS127 PS123 PS124 PS125 PS126 Symbol Connector Faston Crimp Relay connector...
  • Page 719 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 PC-202 location list Symbol Part name Location M120 Vertical conveyance motor /3 M121 Vertical conveyance motor /4 M122 Paper feed motor /3 M123 Paper feed motor /4 M124 Paper lift motor /3 M125 Paper lift motor /4 PCCB...
  • Page 720 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.6.2 PC-402 PCCB PS13 PS12 PS11 PS10 PS14 Symbol Connector Faston Crimp Relay connector...
  • Page 721 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 PC-402 location list Symbol Part name Location Paper feed motor Vertical conveyance motor Shift gate motor Shift motor Paper lift motor Main tray empty board PCCB PC control board Paper feed sensor Vertical conveyance sensor Paper empty sensor Upper limit sensor...
  • Page 722 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.7 LU Dehumidifier heater OPTIONAL HTR101 114-3 24V J121-1 J121-2 114-2 P_GND NC (2pin) FT102 (4pin) Upper door interlock switch 114-4 24V FT101 (1pin) 114-1 T5M_24V 121- 1 112-1 T5M_24V Paper lift motor 121- 2 M151 112-2 T5M_ON...
  • Page 723 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 LU-201 location list Symbol Part name Location CL151 Feed clutch HTR101 Dehumidifier heater LUDB LU drive board M150 Feed motor M151 Paper lift motor MS151 Upper door interlock switch PS151 Remaining paper sensor /2 PS152 Upper limit sensor PS153...
  • Page 724 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.8 FS 17.8.1 FS-510/PU-501 Guide plate switch SD-502/MT-501 Conveyance sensor (Option) Exit roller home sensor PS12 Stacker paddle solenoid Exit roller release motor Entrance sensor Registration clutch Entrance motor Exit paddle solenoid Door switch FSCB Conveyance motor...
  • Page 725 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 FS-510 location list PU-501 location list Symbol Part name Location Symbol Part name Location Registration clutch Punch motor FSCB FS control board Punch scraps full sensor Exit motor Punch position sensor /1 Conveyance motor Punch position sensor /2 Entrance motor...
  • Page 726 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.8.2 FS-511 Hole punch position switch Intermediate conveyance Stapler moving motor Only for inch Hole punch roller release motor destination selector motor Punch clutch Paper exit motor Conveyance motor/Lw Paddle motor/Lw Conveyance motor/Up Punch encoder sensor PS15 Entrance conveyance...
  • Page 727 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 FS-511 location list Symbol Part name Location Punch clutch FSCB FS control board LED19 Main tray upper limit LED Entrance conveyance motor Conveyance motor /Lw Paper exit motor Conveyance motor /Up Alignment motor Stapler moving motor Tray lift motor Shift motor...
  • Page 728 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.9 SD FS-510 PS21 PS18 PS20 PS23 PS26 PS25 PS22 SDCB Symbol Connector Faston Crimp Relay connector...
  • Page 729 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 SD-502 location list Symbol Part name Location Conveyance motor Exit open/close motor Folding motor Paper guide motor Staple guide motor PS18 Saddle exit home sensor PS20 Exit sensor PS21 Tray empty sensor PS22 Folding roller home sensor PS23...
  • Page 730 Field Service Ver1.0 Feb.2006 17. OVERALL WIRING DIAGRAM 17.10 MT PS10 PS11 MTCB Symbol FS-510 Connector Faston Crimp Relay connector...
  • Page 731 17. OVERALL WIRING DIAGRAM Field Service Ver1.0 Feb.2006 MT-501 location list Symbol Part name Location Conveyance motor MTCB MT control board Paper detection sensor /1 Paper detection sensor /2 Paper detection sensor /3 Paper detection sensor /4 Paper full sensor /1 Paper full sensor /2 Paper full sensor /3 Paper full sensor /4...
  • Page 732 SERVICE MANUAL Field Service DF-607 2006.02 Ver. 1.0...
  • Page 733 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 734 Field Service Ver. 1.0 Feb. 2006 CONTENTS DF-607 OUTLINE PRODUCT SPECIFICATIONS ................1 MAINTENANCE PERIODIC CHECK....................5 Maintenance procedure ..................5 2.1.1 Replacing the Pick-up Roller and Feed Roller..........5 2.1.2 Replacing the Separation Roller..............6 2.1.3 Cleaning of the Pick-up Roller, Feed Roller and Separation Roller....7 2.1.4 Cleaning of Miscellaneous Rolls ..............8 2.1.5...
  • Page 735 Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 736 Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Reverse Automatic Document Feeder Paper Feed Paper Feed from top of stack Type Turnover Switch back system Paper Exit Straight exit system Installation Screw cramp to the main unit Document Alignment Center Document Loading...

  • Page 737: Product Specifications

    1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 D. Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Feed failure, damage to the original, or drive failure Original that is stapled or clipped. due to clip clogging Book original Feed failure, damage to the original, or drive failure...
  • Page 738 Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS F. Mixed original feed chart For Metric Reference original (original with a maximum width) — — — — — — Other originals — — — — — — — — — —...
  • Page 739 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 740: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure NOTE • The alcohol described in the cleaning procedure of Maintenance represents the iso- propyl alcohol. 2.1.1 Replacing the Pick-up Roller and Feed Roller A. Periodically replaced part/cycle •...

  • Page 741: Replacing The Separation Roller

    2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 4. Remove two levers [6]. [12] 5. Remove five C-rings [7]. [13] 6. Remove the arm /Fr [8]. 7. Remove the belt [9]. 8. Remove the Pick-up Roller Shaft [11] [13] [9] from the Arm /Rr [10].

  • Page 742: Cleaning Of The Pick-Up Roller, Feed Roller And Separation Roller

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 3. Remove the Separation Roller Assy [4]. NOTE • Use care not to lose the spring at the bottom side of the Separation Roller Assy. 16eaf2c008na 4. While opening up the holder [5], remove the Separation Roller Shaft [6].

  • Page 743: Cleaning Of Miscellaneous Rolls

    2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 2. Using a soft cloth dampened with alco- hol, wipe the Pick-up Roller [2], Feed Roller [3] and Separation Roller [4]. 16eaf2c012na 2.1.4 Cleaning of Miscellaneous Rolls A. Periodic cleaning parts/cycle •...

  • Page 744: Cleaning Of Miscellaneous Rollers

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 7. Using a soft cloth dampened with alco- hol, wipe the roll [6]. 16eaf2c016na 2.1.5 Cleaning of Miscellaneous Rollers A. Periodic cleaning parts/cycle • Miscellaneous Rollers: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces) B.
  • Page 745 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 7. Remove the lever [6]. 16eaf2c020na 8. Remove the screw [7]. 16eaf2c021na...

  • Page 746: Cleaning Of The Scanning Guide

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 9. Remove seven screws [8], and remove the Paper Feed Unit [9]. 16eaf2c022na 10. Using a soft cloth dampened with alco- hol, wipe the roller [10]. [10] [10] 16eaf2c023na 2.1.6 Cleaning of the Scanning Guide A.

  • Page 747: Cleaning Of The Reflective Sensor Section

    2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 2.1.7 Cleaning of the Reflective Sensor Section A. Periodic cleaning part/cycle • Reflective Sensor: Every 250,000 prints (Actual replacement cycle: Every 50,000 faces) B. Procedure 1. Clean the Original Size Sensor /2 (PS2) [1] using a brush or other similar tools.

  • Page 748: Other

    Field Service Ver. 1.0 Feb. 2006 3. OTHER OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...

  • Page 749: Disassembling And Assembling List

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Disassembling and assembling list Section Part name Ref.Page Cover /Fr P.14 Cover Cover /Rr P.14 Original Feed Tray Cover /Lw P.14 DF Control Board (DFCB) P.15 Board and etc. Original Size VR (VR1) P.15 Complete Stamp Unit 2 P.17...

  • Page 750: Df Control Board (Dfcb)

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.2 DF Control Board (DFCB) 1. Turn OFF the Main Power Switch (SW1). 2. Remove the Cover /Rr. (See P.14) 3. Disconnect all the connectors on the DF Control Board (DFCB). 4. Remove three screws [1], and then remove the DFCB [2].
  • Page 751 Original Size VR (VR1). (See P.212 "10.8 ADF" in Field Service 16eaf2c031na bizhub 500 / 420 main body.) 2. Use the nut [2] and the washer [3] to install the VR1 [4]. NOTE • Align the protrusion of the VR1 and the cutout of the mounting plate.

  • Page 752: Complete Stamp Unit 2

    Field Service Ver. 1.0 Feb. 2006 3. OTHER NOTE • When VR1 is replaced, be sure to conduct the back-up data initialization and the orig- inal width detection adjustment. 3.3.4 Complete Stamp Unit 2 1. Open the Open/Close Cover [1]. 2.

  • Page 753: Replacing The Replace Stamp 2

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.5 Replacing the Replace Stamp 2 1. Open the Open/Close Cover [1]. 2. Open the Processing Guide [2]. 16eaf2c039na 3. Remove the stamp. 4. Reinstall the new Replace Stamp 2 [3]. NOTE •...

  • Page 754: Adjustment/Setting

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING MECHANICAL ADJUSTMENT Leading Edge Skew Adjustment 1. Load the test chart [1] in the DF and make one 1-sided copy five consecutive times. 16eaf3c001na 2. Fold each of the sample copies as illus- trated and check for any deviation.
  • Page 755 4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 7. If there is a deviation as shown on the figure, turn the screw clockwise to adjust it. 8. After the adjustment procedure has been completed, tighten the decorative screw and the nut which has been loos- ened in step 5.
  • Page 756 SERVICE MANUAL Field Service PC-202 500 / 420) 2006.02 Ver. 1.0...
  • Page 757 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 758 Field Service Ver. 1.0 Feb. 2006 CONTENTS PC-202 OUTLINE PRODUCT SPECIFICATIONS ................1 MAINTENANCE PERIODIC CHECK....................3 Maintenance procedure ..................3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Feed Roller................4 2.1.3 Replacing the Pick-up Roller .................7 OTHER ........................9 Disassembly/Adjustment prohibited items ............9 Disassembling, assembling and cleaning list............10 3.2.1 Disassembling and assembling list .............10...
  • Page 759 Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 760: Product Specifications

    Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center B. Paper type Paper Type Plain paper 56 to 90 g/m Metric: A3, B4, A4, A4S, B5, A5S, 11 ×...
  • Page 761 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 762: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure 2.1.1 Replacing the Separation Roller Assy A. Periodically replaced part/cycle • Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) NOTE • Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time. B.

  • Page 763: Replacing The Feed Roller

    2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 5. Remove the C-ring [8], the Guide [9], and remove the Separation Roller Assy [10] [10]. 6. Repeat steps 1 to 5 similarly for the Tray 4061f2c004na NOTE • When installing the Separation Roller Mounting Plate Assy, be sure to fix the holder with screws while holding it down.
  • Page 764 Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 5. Remove four screws [3] and remove the Paper Feed Unit [4]. 4061f2c007na 6. Remove two screws [5] and remove the Mounting Frame [6] for the Separation Roller Mounting Plate Assy. 4061f2c008na 7.
  • Page 765 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 9. Shift the Shaft Assy [11] in the orienta- [11] tion as shown on the left, and remove the C-ring [12] and the gear [13]. [13] [12] 4061f2c011na 10. Remove the C-ring [14], the bearing [15], and remove the shaft Assy [16].

  • Page 766: Replacing The Pick-Up Roller

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 2.1.3 Replacing the Pick-up Roller A. Periodically replaced part/cycle • Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) NOTE • Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time. B.
  • Page 767 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 7. Remove two screws [6] and remove the Feed Roller Cover [7]. 4061f2c018na 8. Remove two C-rings [8], two bearings [9], and remove the Pick-up Roller Assy [10]. [10] 4061f2c019na 9. Remove the C-ring [11] and remove the Pick-up Roller [12].

  • Page 768: Other

    Field Service Ver. 1.0 Feb. 2006 3. OTHER OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...

  • Page 769: Disassembling, Assembling And Cleaning List

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Disassembling, assembling and cleaning list 3.2.1 Disassembling and assembling list Section Part name Ref. page Right Door See P.11 Rear Right Cover See P.11 Covers Lower Right Cover See P.11 Front Right Cover See P.11 Rear Cover See P.11...

  • Page 770: Disassembling And Assembling Procedure

    Field Service Ver. 1.0 Feb. 2006 3. OTHER Disassembling and assembling procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3].

  • Page 771: Cleaning Procedure

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller A. Periodically cleaning cycle • Separation Roller: Every 250,000 prints B. Procedure 1. Remove the Right Door. (See P.11) 2.

  • Page 772: Feed Roller

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.4.2 Feed Roller A. Periodically cleaning cycle • Feed Roller: Every 250,000 prints B. Procedure 1. Remove the Tray 3. 2. Remove the Separation Roller Mounting Plate Assy. (See P.12) 3. Using a soft cloth dampened with alco- hol, wipe the Feed Roller [1] clean of dirt.
  • Page 773 3. OTHER Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 774: Adjustment/Setting

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING MECHANICAL ADJUSTMENT Mis-centering adjustment of the Trays 3 and 4 Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service mode. A. Procedure 1. Pull out the Tray [1]. 2.
  • Page 775 4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 776 SERVICE MANUAL Field Service PC-402 500 / 420) 2006.02 Ver. 1.0...
  • Page 777 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 778 Field Service Ver. 1.0 Feb. 2006 CONTENTS PC-402 OUTLINE PRODUCT SPECIFICATION...................1 MAINTENANCE PERIODIC CHECK....................3 Maintenance procedure ..................3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Feed Roller................4 2.1.3 Replacing the Pick-up Roller .................7 OTHER ........................9 Disassembly/Adjustment prohibited items ............9 Disassembling, assembling and cleaning list............10 3.2.1 Disassembling and assembling list .............10...
  • Page 779 Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 780: Product Specification

    Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATION OUTLINE PRODUCT SPECIFICATION A. Type Name 2500 sheets paper feed cabinet Type Front loading type LCC Installation Desk type Document Alignment Center B. Paper type Paper Type Plain paper 56 to 90 g/m Metric: A4 Paper Size Inch: 8...
  • Page 781 1. PRODUCT SPECIFICATION Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 782: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure 2.1.1 Replacing the Separation Roller Assy A. Periodically replaced part/cycle • Separation Roller Assy: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) NOTE • Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time. B.

  • Page 783: Replacing The Feed Roller

    2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 NOTE • When installing the Separation Roller Mounting Plate Assy, be sure to fix the holder with screws while holding it down. 4061f2c204na 2.1.2 Replacing the Feed Roller A. Periodically replaced part/cycle •...
  • Page 784 Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 6. Remove two screws [4] and remove the Mounting Frame [5] for the Separation Roller Mounting Plate Assy. 4061f2c207na 7. Remove two screws [6] and remove the Feed Roller Cover [7]. 4061f2c208na 8.
  • Page 785 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 9. Shift the Shaft Assy [10] in the orienta- tion as shown on the left, and remove [10] the C-ring [11] and the gear [12]. 10. Remove the Shaft Assy [10]. [12] [11] 4061f2c210na...

  • Page 786: Replacing The Pick-Up Roller

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK 2.1.3 Replacing the Pick-up Roller A. Periodic replaced part/cycle • Pick-up Roller: Every 750,000 prints (Actual replacement cycle: Every 300,000 prints) NOTE • Replace the Separation Roller Assy, Feed Roller and Pick-up Roller at the same time. B.
  • Page 787 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 7. Remove two screws [6] and remove the Paper Feed Roller Cover [7]. 4061f2c216na 8. Remove two C-rings [8], two bearings [9], and the Pick-up Roller Assy [10]. [10] 4061f2c217na 9. Remove the C-ring [11] and remove the Pick-up Roller [12].

  • Page 788: Other

    Field Service Ver. 1.0 Feb. 2006 3. OTHER OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...

  • Page 789: Disassembling, Assembling And Cleaning List

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Disassembling, assembling and cleaning list 3.2.1 Disassembling and assembling list Section Part name Ref. page Right Door P.11 Rear Right Cover P.11 Cover Lower Right Cover P.11 Front Right Cover P.11 Rear Cover P.11 Tray P.12...

  • Page 790: Disassembling And Assembling Procedure

    Field Service Ver. 1.0 Feb. 2006 3. OTHER Disassembling and assembling procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3].

  • Page 791: Tray

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.3 Tray 1. Press the Tray Release Key [1] and slide out the Tray [2]. 2. Remove the paper. 3. Remove four screws [3] and slide out the Tray [2]. 4061f2c221na 4. Remove two screws [4], the connector [5], and remove the Relay Board (RLB) [6].

  • Page 792: Wire

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.4 Wire 1. Remove the Tray. (See P.12) 2. Remove four screws [1] and remove the Front Cover Assy [2]. 3. Unplug the connector [3]. 4061f2c224na 4. Remove two screws [4] and the Inner Cover Assy [5].
  • Page 793 3. OTHER Field Service Ver. 1.0 Feb. 2006 NOTE • When assembling, be sure to engage rib of gear 1 [10] with concave section of gear 2 [11]. [10] [11] 4061f2c228na 7. Remove three screws [12] and remove [13] the Reinforcement Plate Assy [13]. [12] [12] 4061f2c229na...
  • Page 794 Field Service Ver. 1.0 Feb. 2006 3. OTHER 13. Remove four screws [20] and remove [21] the Side Guide Assy /Rr [21]. [20] [20] 4061f2c232na 14. Remove four screws [22] and remove [23] [22] the Side Guide Assy /Fr [23]. [22] 4061f2c233na 15.

  • Page 795: Cleaning Procedure

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller A. Periodic cleaning cycle • Separation Roller: Every 250,000 prints B. Procedure 1. Remove the Right Door. (See P.11) 2.

  • Page 796: Pick-Up Roller

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.4.3 Pick-up Roller A. Periodic cleaning cycle • Pick-Up Roller: Every 250,000 prints B. Procedure 1. Remove the Tray. 2. Remove the Separation Roller Mounting Plate Assy. (See P.16) 3. Using a soft cloth dampened with alco- hol, wipe the Pick-up Roller [1].
  • Page 797 3. OTHER Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 798: Adjustment/Setting

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING MECHANICAL ADJUSTMENT Mis-centering adjustment Conduct this adjustment when a mis-centering occurs that cannot be adjusted in the service mode. 1. Press the Tray Release Key [1] and slide out the Tray [2]. 4061f3c201na 2.
  • Page 799 4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 4. Close the Right Door and set the Tray. 5. Conduct the copy/print operation and check to see if the mis-centering between the center [1] of the paper and the center [2] of the copied image is within a standard value (±...

  • Page 800: Shifter Movement Timing Belt Adjustment

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT Shifter Movement Timing Belt Adjustment 1. Slide out the Tray and remove it. 2. Lift the Main Tray [1], and remove two screws [2] fixing the Shift Tray. NOTE • When reinstalling, take care not to unfasten the wire of the Main Tray.
  • Page 801 4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 802 SERVICE MANUAL Field Service LU-201 2006.02 Ver. 1.0...
  • Page 803 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 804 Field Service Ver1.0 Feb.2006 CONTENTS CONTENTS LU-201 OUTLINE 1. PRODUCT SPECIFICATION ............1 MAINTENANCE 2.
  • Page 805 CONTENTS Field Service Ver1.0 Feb.2006 Blank page...

  • Page 806: Product Specification

    11 Recommended paper Plain paper Inch: Hammermill Tidal MP (20 lbs) Metric: Konica Profi (80 g/m ), Konica Minolta Original (80 g/m Recycled paper Inch: Weyehaeuser Recycled Laser Copy (20 lbs) Metric: Nautilus (80 g/m D. Maintenance Maintenance Same as the main body...
  • Page 807 1. PRODUCT SPECIFICATION Field Service Ver1.0 Feb.2006 Blank page...

  • Page 808: Periodic Check

    Field Service Ver1.0 Feb.2006 2. PERIODIC CHECK MAINTENANCE 2. PERIODIC CHECK Maintenance procedure of the paper feed section Caution • When connected to the main body, make sure that the power cord of the main body is unplugged from the power outlet. 2.1.1 Replacing the pick-up rubber and the feed rubber A.
  • Page 809 2. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Note • When installing the paper feed roller unit, be sure to insert the shaft [1] into the ring of the actuator [2]. • When installing the paper feed roller unit, be sure to install it so that the hook [3] comes above the lift-up shaft [4].
  • Page 810 Field Service Ver1.0 Feb.2006 2. PERIODIC CHECK Remove the C-clip [1] and then remove the actua- tor [2]. Remove the C-clip [3] and then remove the bear- ing [4]. Pull out the shaft [5] in the arrow-marked direction [6] and remove the feed roller [7]. 16aaf2c003na Remove the feed rubber [2] from the paper feed roller [1].
  • Page 811 2. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the screw [1] and then remove the han- dle [3] from the roller mounting plate [2]. Remove the screw [4] and then remove the bear- ing holder [5] from the roller mounting plate [2]. 16aaf2c005na Remove the bearing [1] and then remove the pick- up roller [3] from the shaft [2].

  • Page 812: Replacing The Separation Roller

    Field Service Ver1.0 Feb.2006 2. PERIODIC CHECK 2.1.2 Replacing the separation roller A. Periodically replaced part/cycle • Separation rubber: Every 500,000 prints (Actual replacement cycle: Every 200,000 prints) B. Procedure Pull out LU from the main body. Open the upper door [1]. Lift up the paper feed roller unit [2].
  • Page 813 2. PERIODIC CHECK Field Service Ver1.0 Feb.2006 Remove the screw [1]. Note • When installing the separation roller assy, be sure to set the upper section of the claw [2] at the center of the marking-off [3] of the plate. In this way, the separation roller assy can be horizontally positioned.
  • Page 814 Field Service Ver1.0 Feb.2006 2. PERIODIC CHECK Pull out the shaft [2] while pressing the lever [1] and remove the separation roller [3]. 16aaf2c012na Remove the separation rubber [2] from the sepa- ration roller [1]. Note • Be sure to install the separation rubber [2] so that the paint mark [3] comes in the opposite direction of the projection [4].
  • Page 815 3. OTHERS Field Service Ver1.0 Feb.2006 3. OTHERS Disassembling and assembling list Note • This list shows the explanation of the disassembly and reassembly of the parts which are consid- ered necessary to replace (other than periodically replaced parts). However, these parts except for the covers are not required to be disassembled while in normal service operations.

  • Page 816: Disassembling And Assembling Procedure

    Field Service Ver1.0 Feb.2006 3. OTHERS Disassembling and assembling procedure Caution • When connected to the main body, make sure that the power cord of the main body is unplugged from the power outlet. 3.2.1 Removal and reinstallation of the right cover, the front cover and the rear cover A.
  • Page 817 3. OTHERS Field Service Ver1.0 Feb.2006 Loosen the 2 screws [1]. Remove the 2 screws [2] and then remove the front cover [3]. 16aaf2c015na Loosen the 2 screws [1]. Remove the screw [2] and then remove the auxil- iary cover /Rr [3]. 16aaf2c016na...
  • Page 818 Field Service Ver1.0 Feb.2006 3. OTHERS Remove the 3 screws [1] and then remove the cable cover [2]. Remove the 4 screws [3] and then remove the rear cover [4]. Reinstall the above parts following the removal steps in reverse. 16aaf2c017na...

  • Page 819: Replacing The Wires

    3. OTHERS Field Service Ver1.0 Feb.2006 3.2.2 Replacing the wires The length of the wires Wire /A: 707.2 mm Wire /B: 585.7 mm Wire /C: 558.7 mm Wire /D: 680.2 mm Auxiliary wire: 706.3 mm Detection wire: 609.6 mm A. Removing the wire Remove the right cover, the front cover and the rear cover.
  • Page 820 Field Service Ver1.0 Feb.2006 3. OTHERS Remove the 5 connectors [2] from the LU drive board (LUDB) [1]. 16aaf2c019na Remove the 6 screws [1] and then remove the LU drive board unit [2]. 16aaf2c020na...
  • Page 821 3. OTHERS Field Service Ver1.0 Feb.2006 Note • When removing the LU drive board unit, the bearings [1] and [2] may come off and fall. Be careful that they do not get lost. • On the inside of the gear [3], the spacer [4] is provided.
  • Page 822 Field Service Ver1.0 Feb.2006 3. OTHERS Remove the 4 screws [1] and then remove the motor mounting plate [2]. 16aaf2c023na Remove the E-ring [1], and remove the wire stop- per [2]. Remove the assist wire [4] from the spring [3]. Note •...
  • Page 823 3. OTHERS Field Service Ver1.0 Feb.2006 Remove the 2 E-rings [1] and the 2 wire stoppers [2]. Remove the 4 E-rings [4] and remove the 4 upper pulleys [5]. 16aaf2c025na Remove the E-ring [1] and the drive pulley [2], then remove the auxiliary wire [3], the wire A [4] and the wire B [5].
  • Page 824 Field Service Ver1.0 Feb.2006 3. OTHERS B. Stringing wires Pass the wire A [1], the wire B [2], the wire C [3] and the wire D [4] through the lift plate [5]. [14] [15] [15] Run the wire A [6] and the wire B [7] through the 2 upper pulleys [8] and the 2 lower pulleys [9], and then through the adjustment part [10].
  • Page 825 3. OTHERS Field Service Ver1.0 Feb.2006 Hold the drive pulley [1] and the drive pulley [2] with both hands and rotate them counterclock- wise as seen from the front side until there are no slacks found in the wires A, B, C, and D. [10] Rotate the coupling shaft [3] on the rear side to lift the lift plate [4] to the upper limit.

  • Page 826: Adjustment/Setting

    Field Service Ver1.0 Feb.2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING 4. MECHANICAL ADJUSTMENT Adjusting the tilt of the lift plate When the lift plate is tilted, paper may not be fed correctly. Adjust the lift plate so that it becomes parallel to the paper feed roller shaft.
  • Page 827 4. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Open the upper door [1]. Stand the scale [3] on the upper surface of the lift plate [2]. Move and adjust the wire adjusting member [6] so that the distance from each of the upper surfaces of the panels /Fr [4] and /Rr [5] to the upper sur- face of the lift plate become identical.
  • Page 828 SERVICE MANUAL Field Service FS-510/PU-501/ OT-601 2006.02 Ver. 1.0...
  • Page 829 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 830 Field Service Ver. 1.0 Feb. 2006 CONTENTS FS-510/PU-501/OT-601 OUTLINE PRODUCT SPECIFICATIONS ................1 FS-510 ........................1 PU-501........................3 OT-601 ........................4 MAINTENANCE PERIODIC CHECK....................5 Maintenance procedure ..................5 2.1.1 Cleaning of the Roller and Roll..............5 OTHER ........................7 Disassembly/Adjustment prohibited items ............7 Disassembling and assembling list ...............8 Disassembling and assembling procedure ............9 3.3.1 Conveyance Front Cover /Up, /Rt, /Lw ............9...
  • Page 831 Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 832 Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS FS-510 A. Type Name Multi tray finisher built into the main body Installation Installed in the main body Document Alignment Center Consumables Staples (5,000 staples/cartridge) B. Functions Modes Non sort, sort, group, sort staple, and punch (when PU-501 is mounted) C.
  • Page 833 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 (3) Sort Staple Type Size Weight Max. Capacity Metric: Tray /1 200 sheets A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S A4S, 8 x 11S 1000 11 x 17, 8 x 14, or less sheets...

  • Page 834: Product Specifications

    Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS PU-501 A. Type Type FS built-in type punching operation device Installation Screwed to the FS Metric: A3, B4, A4, A4S, B5, B5S 11 x 17, 8 x 11, 8 x 11S, Foolscap Paper Size Inch: 2 holes: 11 x 17, 8...
  • Page 835 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 OT-601 A. Type Type Additional Tray to FS Installation Screwed to the FS Mode Non sort, sort, group, and sort staple Number of Bins 1 bin Document Alignment Center B. Paper Type Mode Size Type...

  • Page 836: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure NOTE • The alcohol described in the cleaning procedure of Maintenance represents the iso- propyl alcohol. 2.1.1 Cleaning of the Roller and Roll 1. Remove the Lift Tray. (See P.13) 2.
  • Page 837 2. PERIODIC CHECK Field Service Ver. 1.0 Feb. 2006 8. Lower Processing Guide FN-3 [5]. 9. Using a soft cloth dampened with alco- hol, wipe the roll [6]. 4349f2c004na 10. Lower Processing Guide FN-4 [7]. 11. Using a soft cloth dampened with alco- hol, wipe the roll [8].

  • Page 838: Other

    Field Service Ver. 1.0 Feb. 2006 3. OTHER OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...
  • Page 839 3. OTHER Field Service Ver. 1.0 Feb. 2006 Disassembling and assembling list Section Part name Ref.Page Conveyance Front Cover /Up Conveyance Upper Cover Conveyance Front Cover /Rt Front Door P.10 Conveyance Front Cover /Lw Conveyance Front Cover /Lt P.10 Cover Paper Exit Front Cover P.11 Tray /2...

  • Page 840: Disassembling And Assembling Procedure

    Field Service Ver. 1.0 Feb. 2006 3. OTHER Disassembling and assembling procedure 3.3.1 Conveyance Front Cover /Up, /Rt, /Lw 1. Open the Front Door. 2. Unhook the tab, and remove the Con- veyance Front Cover /Up [1]. 4349f2c008na 3. Remove two screws [2], and remove the Conveyance Front Cover /Rt [3].

  • Page 841: Front Door

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.3 Front Door 1. Open the Front Door [1]. 2. Remove the screw [2], and remove the stopper [3]. 3. Loosen two screws [4]. 4. Slide up the Fulcrum /Up [5] and remove the Front Door.

  • Page 842: Paper Exit Front Cover, Rear Cover, Connector Cover

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.5 Paper Exit Front Cover, Rear Cover, Connector Cover 1. Remove the Front Door. (See P.10) 2. Remove the Conveyance Front Cover /Lt. (See P.10) 3. Remove four screws [1], and remove the Paper Exit Front Cover [2].

  • Page 843: Tray /2

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.6 Tray /2 1. Remove two screws [1], and remove the Tray /2 [2]. 4349f2c016na 3.3.7 1. Remove two screws [1], and remove the OT [2]. 4625f2c001na 3.3.8 Tray /1 1. Remove two screws [1], and remove the Tray /1 [2].

  • Page 844: Lift Tray

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.9 Lift Tray NOTE • When removing the Lift Tray, be sure to bring the Tray down to the bottom. • If the OT is installed, remove it in advance. 1. Remove the Front Door. (See P.10) 2.

  • Page 845: Stapler

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.11 Stapler 1. Open the Front Door. 2. Turn the knob [1], and move the stapler forward. 3. Remove the Staple Cartridge. 4. Remove the screw [2], and remove the cover [3]. 4349f2c022na 5.
  • Page 846 Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.12 1. Remove the Lift Tray. (See P.13) 2. Remove the Conveyance Unit. (See P.13) 3. Remove the Conveyance Upper Cover. (See P.9) 4. Remove the Conveyance Front Cover /Lw. 4512f2c001na (See P.9) 5.

  • Page 847: Stacker Paddle Drive Clutch Assy

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.13 Stacker Paddle Drive Clutch Assy A. Removal Procedure 1. Remove the Lift Tray. (See P.13) 2. Remove the Conveyance Unit. (See P.13) 3. Remove the Conveyance Upper Cover. (See P.9) 4. Remove the E-ring [1]. 4349f2c026na 5.

  • Page 848: Paper Holding Paddle Drive Clutch Assy

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.14 Paper Holding Paddle Drive Clutch Assy A. Removal Procedure 1. Remove the Lift Tray. (See P.13) 2. Remove the Conveyance Unit. (See P.13) 3. Remove the Conveyance Upper Cover. (See P.9) 4.
  • Page 849 3. OTHER Field Service Ver. 1.0 Feb. 2006 Precaution for Reinstallation 4349f2c032na [1] Solenoid Flapper [4] Paper Holding Paddle Drive Clutch Assy [2] 107 ± 3mm [5] Paper Holding Paddle [3] Paper Holding Paddle 2. Install the bearing [2]. 4349f2c033na 3.
  • Page 850 Field Service Ver. 1.0 Feb. 2006 3. OTHER 4. Attach the C-ring and press the Paper Holding Paddle Drive Clutch Assy [6] to the bearing [5]. 5. Adjust the spacing [7] between the bushing [5] and the Paper Holding Pad- dle Drive Clutch Assy [6] to 0.2 mm and tighten two hexagonal socket head screws.
  • Page 851 3. OTHER Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 852: Adjustment/Setting

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING MECHANICAL ADJUSTMENT Staple Position Adjustment 1. Set the staple and make a print. 2. Check the staple position of the paper. • Slant one point Staple [1] (Paper Width: 216 to 297 mm) 279 to 297 mm: 45°, B5, B4: 30°...

  • Page 853: Adjustment Of The Installation Position Of The Shutter Drive Gear

    4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 4. Open the Front Door. 5. Turn the knob [1], and move the stapler forward. 6. Loosen the screw [2], and remove the cover [3]. 4349f3c002na 7. Loosen two adjustment screws [2] and move the Stapler Unit [3] in the direction of the arrow to make the adjustment.

  • Page 854: Punch Mis-Centering Adjustment (Pu-501)

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT Punch Mis-centering Adjustment (PU-501) 1. Set the copier into the Punch mode and make a 1-sided print from a 1-sided original. 2. Fold the output paper in half and check whether the punch hole positions are aligned.
  • Page 855 4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 856 SERVICE MANUAL Field Service FS-511/RU-502 2006.02 Ver. 1.0...
  • Page 857 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 858 Field Service Ver1.0 Feb.2006 CONTENTS CONTENTS FS-511/RU-502 OUTLINE 1. PRODUCT SPECIFICATION ............1 FS-511 .
  • Page 859 CONTENTS Field Service Ver1.0 Feb.2006 Blank page...

  • Page 860: Product Specification

    Field Service Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION OUTLINE 1. PRODUCT SPECIFICATION FS-511 A. Type Type Multi staple finisher Installation Floor-mounted type Document alignment Center Consumables Staples B. Functions Mode Normal Non-sort, sort, group, sort-staple Punch Non-sort-punch, sort-punch, group-punch, sort-staple-punch C. Type of paper •...
  • Page 861 1. PRODUCT SPECIFICATION Field Service Ver1.0 Feb.2006 (2) Non-sort, sort, group Type of paper Size of paper Weight Max. capacity Exit tray Max. number of sheets stapled Plain paper A3, B4, A4, A4S, B5, 50 to 130 g/m 3000 sheets Main tray —...
  • Page 862 Field Service Ver1.0 Feb.2006 1. PRODUCT SPECIFICATION D. Stapling Staple filling method Dedicated staple cartridge (5000 staples) Staple detection Available (near empty: 20 remaining staples) Staple position *1 Rear: Diagonal 45° 1 point Metric: A3, B4, A4, B5 Inch: 8 x 11, 11 x 17 Front: Diagonal 45°...
  • Page 863 1. PRODUCT SPECIFICATION Field Service Ver1.0 Feb.2006 RU-502 A. Type Type Roller method relay conveyance unit B. Functions Conveyance Paper conveyance from the main body to FS C. Type of paper Paper size Same as the main body. Paper type Same as the main body.

  • Page 864: Others

    Field Service Ver1.0 Feb.2006 2. OTHERS MAINTENANCE 2. OTHERS Disassembling and assembling list Section Part name Page referred to Cover Upper cover Front cover /Up Front cover /Lw Rear cover P.10 Punch section Punch unit P.11 Staple section Stapler unit P.13...

  • Page 865: Disassembling And Assembling Procedure

    2. OTHERS Field Service Ver1.0 Feb.2006 Disassembling and assembling procedure 2.2.1 Removal/reinstallation of the upper cover A. Procedure Remove the sub tray [1]. 4521f2c004na...
  • Page 866 Field Service Ver1.0 Feb.2006 2. OTHERS Open the upper door [2]. Remove the screw [3]. Loosen 2 screws [4]. Loosen the screw [5] and remove the upper cover [6]. Reinstall the above parts following the removal steps in reverse. 4521f2c005na...

  • Page 867: Removal/Reinstallation Of The Front Cover /Up

    2. OTHERS Field Service Ver1.0 Feb.2006 2.2.2 Removal/reinstallation of the front cover /Up A. Procedure Loosen 2 screws [1]. Loosen 2 screws [2] and remove the front cover /Up [3]. Reinstall the above parts following the removal steps in reverse. 4521f2c006na...

  • Page 868: Removal/Reinstallation Of The Front Cover /Lw

    Field Service Ver1.0 Feb.2006 2. OTHERS 2.2.3 Removal/reinstallation of the front cover /Lw A. Procedure Loosen 2 screws [1] and remove the front cover /Lw [2]. Reinstall the above parts following the removal steps in reverse. 4521f2c007na...

  • Page 869: Removal/Reinstallation Of The Rear Cover

    2. OTHERS Field Service Ver1.0 Feb.2006 2.2.4 Removal/reinstallation of the rear cover A. Procedure Remove the screw [1] and loosen the screw [2]. Loosen 2 screws [3] and remove the rear cover [4]. Reinstall the above parts following the removal steps in reverse.

  • Page 870: Removal/Reinstallation Of The Punch Unit

    Field Service Ver1.0 Feb.2006 2. OTHERS 2.2.5 Removal/reinstallation of the punch unit A. Installation of the Swedish punch kit G When installing the Swedish punch kit G, be sure to remove the existing punch unit and follow the procedure given below. B.
  • Page 871 2. OTHERS Field Service Ver1.0 Feb.2006 Note [13] [14] • When installing the punch unit, be sure to set the gear [9] of the main body to the gear [10] of the punch unit, and then insert the shaft [11] into the hole [12] of FS. •...

  • Page 872: Replacing The Stapler Unit

    Field Service Ver1.0 Feb.2006 2. OTHERS 2.2.6 Replacing the stapler unit A. Procedure Open the punch scraps box holder [1]. 4521f2c001na Rotate the dial [1] in the arrow-marked direction [2] to expand the intervals of the stapler units /Fr [3] and /Rr [4]. Note •...
  • Page 873 2. OTHERS Field Service Ver1.0 Feb.2006 Remove 2 connectors [6]. [10] Remove the screw [7] and then remove the ground terminal [8]. Remove the screw [9] and then remove the sta- pler unit /Rr [10]. Remove 2 connectors [11]. Remove the screw [12] and then remove the ground terminal [13].
  • Page 874 Field Service Ver1.0 Feb.2006 2. OTHERS Remove 2 screws [16] and then remove the plate [16] [17] [17], 1 each, from each of the stapler units. Reinstall the above parts following the removal steps in reverse. 4521f2c029na...
  • Page 875 2. OTHERS Field Service Ver1.0 Feb.2006 Blank page...

  • Page 876: Adjustment/Setting

    Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING 3. MECHANICAL ADJUSTMENT Output check mode 3.1.1 Switches provided inside the board Test switch [1] Dipswitch used for the mode setting of the output check mode. (All settings are off in the initial condition.) Output check switch /1 [2] Used to execute the output check mode.

  • Page 877: Output Check Mode

    3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 3.1.2 Output check mode A. Setting of the output check mode. (1) Procedure for setting Note • Before executing the output check mode, be sure to remove the upper cover, the front cover /Up and the rear cover of FS in advance.
  • Page 878 Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT (2) Method for release Turn OFF the power switch (SW2) of the main body. Set the test switch [1] to the initial condition (all OFF). Turn ON SW2. 4521f3c003na B. Types of the output check modes Output check mode Test switch LED1 to 4...
  • Page 879 3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 C. Operation of each of the output check modes (1) Sub tray paper exit mode The motor and the solenoid turn ON. Output check switch /1 : ON • Entrance conveyance motor (M1) •...
  • Page 880 Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT (4) Shift operation mode Output check switch /1 : ON The main tray shifts to the front side. • The shift motor (M8) turns ON. Output check switch /2 : ON The main tray shifts to the rear side. •...
  • Page 881 3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 (7) Paper exit roller release mode Output check switch /1 : ON Output check switch /2 : ON The paper exit roller is in the pressure/release opera- tion (8) Intermediate conveyance roller release mode Output check switch /1 : ON The intermediate conveyance roller is pressured.
  • Page 882 Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT (11) Sensor output check mode Sensor Status Main tray upper limit sensor (PS19) Light pass through Intermediate conveyance sensor (PS3) Light blocked Bypass route conveyance sensor (PS2) Light blocked Main route conveyance sensor (PS4) Light blocked : On : Off...

  • Page 883: Adjusting The Punch Hole Position In The Vertical Direction

    3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Adjusting the punch hole position in the vertical direction A. Procedure Set the punch hole mode, and make a copy in the single sided original -> single sided print mode. Fold the copy exited into two and check the posi- tion of the punch holes to see if the discrepancy "A"...
  • Page 884 Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT Open the upper door [2]. Loosen the screw [3] and move the handle [4] in the arrow-marked direction [5] to adjust the posi- tion of the punch unit [6]. Repeat steps 1 and 2 and check the punch holes to see if the discrepancy "A"...

  • Page 885: Adjusting The Solenoid

    3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Adjusting the solenoid 3.3.1 Adjustment of the bypass gate solenoid (SD1) A. Procedure Remove the upper cover. (See P.6) Remove the rear cover. (See P.10) Loosen the screw [1]. Move the bypass gate solenoid (SD1) [2] in the arrow-marked direction [3] and tighten the screw [1] when the length of "A"...

  • Page 886: Adjustment Of The Main Gate Solenoid (Sd2)

    Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT 3.3.2 Adjustment of the main gate solenoid (SD2) A. Procedure Remove the upper cover. (See P.6) Remove the front cover /Up. (See P.8) Loosen 2 screws [1]. Move the main gate solenoid (SD2) [2] and tighten the 2 screws [1] when the length of "A"...

  • Page 887: Adjusting The Belt Tension

    3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Adjusting the belt tension 3.4.1 Adjustment of the timing belt of the conveyance motor /Up (M4) A. Procedure Remove the upper cover. (See P.6) Remove the rear cover. (See P.10) Loosen 2 screws [1]. Press the timing belt at the center section [2] with a spring balance [3] from above.

  • Page 888: Adjustment Of The Timing Belt Of The Conveyance Motor /Lw (M2)

    Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT 3.4.2 Adjustment of the timing belt of the conveyance motor /Lw (M2) A. Procedure Remove the upper cover. (See P.6) Remove the rear cover /Up. (See P.10) Loosen 2 screws [1]. Pull the square hole [3] provided on the convey- ance motor /Lw mounting plate [2] with the spring balance [4] and tighten 2 screws [1] at the position in which the scale of the spring balance points to...

  • Page 889: Adjustment Of The Timing Belt Of The Paper Exit Motor (M3)

    3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 3.4.3 Adjustment of the timing belt of the paper exit motor (M3) A. Procedure Loosen the screw [1] and 2 screws [2]. Tighten the screw [1] and 2 screws [2] at the posi- tion [5] in which the external form of the screw [1] and that of the oblong hole [4] provided on the paper exit motor mounting plate [3] coincide each...

  • Page 890: Adjusting The Tray Upper Surface Detection Position

    Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT Adjusting the tray upper surface detection position This adjustment is made when replacing the FS control board (FSCB), or the main tray upper limit LED (LED19) or the main tray upper limit sensor (PS19). A.
  • Page 891 3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Check to see if LED4 [5] on FSCB turns OFF from ON. If it is left ON, rotate VR1 [1] slowly clockwise and stop the rotation of VR1 at the position in which LED4 turns OFF. 4521f3c013na...

  • Page 892: Adjusting The Tray Overload Detection Level

    Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT Adjusting the tray overload detection level This adjustment is made when replacing the FS control board (FSCB) or replacing the tray lift motor (M7). A. Procedure Set the output check mode "Main tray operation mode."...
  • Page 893 3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 Place the paper [3] to block the light of the main tray upper limit LED (LED19) [2]. 4521f3c015na Press the output check switch /2 [4] to bring down the main tray. 4521f3c016na...
  • Page 894 Field Service Ver1.0 Feb.2006 3. MECHANICAL ADJUSTMENT Load 1500 sheets of A3 paper (80 g/m ) on the main tray. Remove the paper that was put in step 3 to block the light and let the light of LED19 pass through. Note •...
  • Page 895 3. MECHANICAL ADJUSTMENT Field Service Ver1.0 Feb.2006 When LED3 [5] on FSCB turns ON, rotate VR2 [1] counterclockwise, and stop VR2 at the position in which LED3 changes to OFF from ON. 4521f3c018na...
  • Page 896 SERVICE MANUAL Field Service SD-502 500 / 420) 2006.02 Ver. 1.0...
  • Page 897 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 898 Field Service Ver. 1.0 Feb. 2006 CONTENTS SD-502 OUTLINE PRODUCT SPECIFICATIONS ................1 MAINTENANCE PERIODIC CHECK....................3 Maintenance procedure ..................3 2.1.1 Cleaning of the Rollers and Rolls ..............3 OTHER ........................4 Disassembly/Adjustment prohibited items ............4 Disassembling and assembling list ...............5 Disassembling and assembling procedure ............5 3.3.1 Paper Output Tray/Front Cover..............5 3.3.2...
  • Page 899 Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 900: Product Specifications

    Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type FS built-in saddle-stitching device Installation Screwed to the FS Document Alignment Center Center parallel two points Stapling Function No. of sheets to be stapled together: 2 to 15 Consumables Staples (2000 staples/cartridge) B.
  • Page 901 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 902: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure NOTE • The alcohol described in the cleaning procedure of Maintenance represents the iso- propyl alcohol. 2.1.1 Cleaning of the Rollers and Rolls A. Periodic cleaning cycle •...

  • Page 903: Other

    3. OTHER Field Service Ver. 1.0 Feb. 2006 OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...

  • Page 904: Disassembling And Assembling List

    Field Service Ver. 1.0 Feb. 2006 3. OTHER Disassembling and assembling list Section Part name Ref.Page Paper Output Tray Paper Output Tray Front Cover Cover Upper Cover Rear Cover Saddle Unit Unit Folding Unit Stapler Unit Paper Guide Motor (M13) P.14 Others Folding Roller...

  • Page 905: Rear Cover

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.2 Rear Cover 4511f2c005na 1. Remove two screws [1], and remove the Rear Cover [2]. 3.3.3 Upper Cover 1. Remove the Front Cover. (See P.5) 2. Remove the Rear Cover. (See P.6) 3.

  • Page 906: Saddle Unit

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 3.3.4 Saddle Unit 1. Remove the screw [1], and remove the Connector Cover [2]. 4511f2c007na 2. Remove the screw [3], and remove the ground terminal [4]. 3. Unplug two connectors [5]. 4511f2c008na 4.
  • Page 907 3. OTHER Field Service Ver. 1.0 Feb. 2006 7. Remove two screws [10], and remove [11] the Saddle Unit [11]. [10] 4511f2c011na 3.3.5 Folding Unit 1. Remove the Saddle Unit. (See P.7) 2. Remove the Lift Tray. (See P.13 in "Field Service FS-510/PU-501/OT-601") 3.

  • Page 908: Folding Unit

    Field Service Ver. 1.0 Feb. 2006 3. OTHER 7. Unplug the connector [8]. 4511f2c015na 8. Remove two screws [9], and remove the Folding Unit [10]. [10] 4511f2c016na 3.3.6 Stapler Unit 1. Remove the Saddle Unit. (See P.7) 2. Remove the Paper Output Tray. (See P.5) 3.
  • Page 909 3. OTHER Field Service Ver. 1.0 Feb. 2006 10. Remove the harness clamp [6] from the Metal Plate. 11. Remove the wiring harness from the harness clamp [6]. 4511f2c019na 12. Unplug four connectors [7]. [11] [10] 13. Remove the C-ring [8], and remove the bearing [9].
  • Page 910 Field Service Ver. 1.0 Feb. 2006 3. OTHER 17. Remove the Tray [16]. [16] 4511f2c023na 18. Unplug all the connectors on the SD Control Board (SDCB) [17]. 19. Remove the Board support, and then [17] remove the SDCB. 4511f2c024na 20. Remove the screw [18], and remove the lock release lever [19].
  • Page 911 3. OTHER Field Service Ver. 1.0 Feb. 2006 22. Remove the harness clamp and unplug [22] the connector. 23. Remove three screws [22], and remove the Clincher /1 [23]. [23] 4511f2c027na 24. Remove the Staple Cartridge /1 [24]. [24] 4511f2c028na 25.
  • Page 912 Field Service Ver. 1.0 Feb. 2006 3. OTHER 3. Loosen three screws [3] of the stopper. 4. Loosen three screws [4] of the Clincher. 4511f2c031na 5. Aligning the protrusions of the jig [6] with the recesses in the Staple Car- tridge [5], fit the jig to the Stapler.

  • Page 913: Paper Guide Motor (M13)

    3. OTHER Field Service Ver. 1.0 Feb. 2006 3.3.7 Paper Guide Motor (M13) 1. Remove the Saddle Unit. (See P.7) 2. Remove the Paper Output Tray. (See P.5) 3. Remove the Front Cover. (See P.5) 4. Remove the Rear Cover. (See P.6) 5.
  • Page 914 Field Service Ver. 1.0 Feb. 2006 3. OTHER 11. Remove eight screws [11], and remove [11] the Lower Cover [12]. [11] [12] [11] [11] 4511f2c038na 12. Remove the wire saddle [13], and unplug two connectors [14]. [13] [14] 4511f2c039na 13. Remove the screw [15], and remove the Paper Guide Motor Assy [16].

  • Page 915: Folding Roller

    3. OTHER Field Service Ver. 1.0 Feb. 2006 Precaution for M13 Reinstallation 4511f2c043na 1. Press the two Paper Guides [1] in and check that they touch the stopper [2] simulta- neously. 2. Check that pins [4] can be inserted through the positioning holes [3] (3 holes) of the Paper Guide Sensor Assy.
  • Page 916 Field Service Ver. 1.0 Feb. 2006 3. OTHER 4. Remove two screws [5], and remove the Folding Blade Assy [6]. 4511f2c046na NOTE • Install the Folding Blade Assy in the direction shown in the left figure. [A] Front [B] Rear 4511f2c047na 5.
  • Page 917 3. OTHER Field Service Ver. 1.0 Feb. 2006 6. Remove three C-rings [10], and remove [11] two bearings [11]. [10] 7. Remove the bearing [12]. [12] 4511f2c050na 8. Remove two screws [13], and remove the Rear Holder [14]. [14] [13] 4511f2c051na 9.
  • Page 918 Field Service Ver. 1.0 Feb. 2006 3. OTHER 10. Remove the screw [20]. [21] 11. Remove two C-rings [21], and remove [20] the Folding Roller A [22], B [23] and C [24]. [22] [24] [23] 4511f2c054na 12. Remove the gear [25] of Folding Roller [26] /Lt, and remove the Lower Guide Plate [26].
  • Page 919 3. OTHER Field Service Ver. 1.0 Feb. 2006 NOTE • When installing the Folding Rollers A, [36] B and C, be sure to align the direction of the mark [35] of the gear with the direction in which the screw [36] is tightened.
  • Page 920 Field Service Ver. 1.0 Feb. 2006 3. OTHER 15. Reinstall the above parts following the removal steps in reverse. [38] [37] NOTE • When installing the Folding Rollers /Rt and /Lt, be sure to install them so that the mark [37] of the Roller Gear /Rt provided on the front of the Folding Unit comes one tooth above the mark [38] of the Roller Gear /Lt.
  • Page 921 3. OTHER Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 922: Adjustment/Setting

    Field Service Ver. 1.0 Feb. 2006 4. MECHANICAL ADJUSTMENT ADJUSTMENT/SETTING MECHANICAL ADJUSTMENT Fold Skew Adjustment NOTE Make this adjustment after any of the following procedures has been performed. • When the Folding Unit has been replaced. • When skew occurs in the crease. 1.

  • Page 923: Center Staple Skew Adjustment

    4. MECHANICAL ADJUSTMENT Field Service Ver. 1.0 Feb. 2006 Center Staple Skew Adjustment NOTE Make this adjustment after any of the following procedures has been performed. • When Staple Unit 1 or 2 has been replaced. • When skew occurs in the position of the center staple. 1.
  • Page 924 SERVICE MANUAL Field Service MT-501 500 / 420) 2006.02 Ver. 1.0...
  • Page 925 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 926 Field Service Ver. 1.0 Feb. 2006 CONTENTS MT-501 OUTLINE PRODUCT SPECIFICATIONS ................1 MAINTENANCE PERIODIC CHECK....................3 Maintenance procedure ..................3 2.1.1 Cleaning of the Roller and Roll..............3 OTHER ........................4 Disassembly/Adjustment prohibited items ............4 Disassembling and assembling list ...............5 Disassembling and assembling procedure ............5 3.3.1 Rear Cover/Right Door ..................5 3.3.2...
  • Page 927 Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 928: Product Specifications

    Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Type 4 bins Mailbin (available only for printing from PC) Installation Screwed to the FS Number of Bins 4 bins Number of Sheets 125 sheets (80 g/m Stored per Bin Storable Paper Plain Paper (56 to 90 g/m...
  • Page 929 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 Blank Page...

  • Page 930: Periodic Check

    Field Service Ver. 1.0 Feb. 2006 2. PERIODIC CHECK MAINTENANCE PERIODIC CHECK Maintenance procedure NOTE • The alcohol described in the cleaning procedure of Maintenance represents the iso- propyl alcohol. 2.1.1 Cleaning of the Roller and Roll A. Periodic cleaning cycle •...

  • Page 931: Other

    3. OTHER Field Service Ver. 1.0 Feb. 2006 OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose. •...

  • Page 932: Disassembling And Assembling List

    Field Service Ver. 1.0 Feb. 2006 3. OTHER Disassembling and assembling list Section Part name Ref. page Rear Cover Front Cover Cover Upper Cover Right Door Paper Output Tray Paper Output Tray Disassembling and assembling procedure 3.3.1 Rear Cover/Right Door 1.
  • Page 933 3. OTHER Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 934 SERVICE MANUAL Field Service JS-502 500 / 420) 2006.02 Ver. 1.0...
  • Page 935 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 936 Field Service Ver. 1.0 Feb. 2006 CONTENTS JS-502 OUTLINE PRODUCT SPECIFICATIONS ................1 MAINTENANCE OTHER ........................3 Disassembly/Adjustment prohibited items ............3 Disassembling and assembling list ...............4 Disassembling and assembling procedure ............4 2.3.1 Upper Cover ....................4...
  • Page 937 Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 938 Field Service Ver. 1.0 Feb. 2006 1. PRODUCT SPECIFICATIONS OUTLINE PRODUCT SPECIFICATIONS A. Type Name Job Separator Type Expansion tray Installation Installed in the main body Document Alignment Center B. Paper type Exit Tray Size Type Capacity Inch: 11 x 17, 8 x 14, 250 sheets Plain Paper (56 to 90 g/m...
  • Page 939 1. PRODUCT SPECIFICATIONS Field Service Ver. 1.0 Feb. 2006 Blank Page...
  • Page 940 Field Service Ver. 1.0 Feb. 2006 2. OTHER MAINTENANCE OTHER Disassembly/Adjustment prohibited items A. Screws to which blue paint or green paint is applied • Blue paint or green paint is applied to some screws to prevent them from coming loose.

  • Page 941: Front Cover/Upper Cover/Paper Output Tray

    2. OTHER Field Service Ver. 1.0 Feb. 2006 Disassembling and assembling list Section Part name Ref.Page Cover Upper Cover See P.4 Disassembling and assembling procedure 2.3.1 Upper Cover 4347f2c001na 1. Remove two screws [1], and remove the Upper Cover [2].
  • Page 942 SERVICE MANUAL Field Service IC-204 2006.02 Ver. 1.0...
  • Page 943 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 944 Field Service Ver1.0 February.2006 CONTENTS CONTENTS IC-204 OUTLINE 1. PRODUCT SPECIFICATIONS............1 MAINTENANCE 2.
  • Page 945 CONTENTS Field Service Ver1.0 February.2006 Blank Page...

  • Page 946: Product Specifications

    No. of Print 1 to 999 Continuous Print Speed bizhub 500: 50 ppm (A4, 8.5 x 11) / (600 x 600 dpi) bizhub 420: 42 ppm (A4, 8.5 x 11) / (600 x 600 dpi) Printer Description Language PCL5e/PCL6/PostScript3 (compatible)
  • Page 947 1. PRODUCT SPECIFICATIONS Field Service Ver1.0 February.2006 D. Maintenance and Life Maintenance Same as copier Machine Service Life Same as copier E. Machine Data System Memory Same as copier Host Interface Ethernet, Serial (RS-232C/USB), Parallel (IEEE1284) Hard Disk Drive 40 GB (supporting HD-505) Power Same as copier Network Function...

  • Page 948: Firmware Version Up

    Field Service Ver1.0 February.2006 2. FIRMWARE VERSION UP MAINTENANCE 2. FIRMWARE VERSION UP Firmware for IC-204 is contained in the copier firmware (MFP Controller). With the updating of MFP controller version, the version of the IC-204 firmware is also updated. Firmware’s version is upgraded by ISW.

  • Page 949: Disassembly / Reassembly

    3. DISASSEMBLY / REASSEMBLY Field Service Ver1.0 February.2006 3. DISASSEMBLY / REASSEMBLY Caution • Assembly should be made in reverse order of disassembly unless otherwise noted. Precautions against static electricity. • Keep the image controller in an antistatic bag while transporting it or storing it. •...

  • Page 950: Removal / Installation Of Printer Key Control Board

    Field Service Ver1.0 February.2006 3. DISASSEMBLY / REASSEMBLY Removal / Installation of Printer key control board Turn the Sub and Main power switches OFF of the main body, and unplug the power cord from the outlet. Remove the back cover(6 screws). Back cover Remove the board cover(4 screws).
  • Page 951 3. DISASSEMBLY / REASSEMBLY Field Service Ver1.0 February.2006 Blank Page...

  • Page 952: Adjustment / Setting

    Field Service Ver1.0 February.2006 4. SERVICE MODE ADJUSTMENT / SETTING 4. SERVICE MODE In the service mode, various adjustments / settings are available. See “10. SERVICE MODE” in Field Service for the main body. 5. Starting and Finishing the Service Mode Confirm that the normal Copy Mode screen is on the display.
  • Page 953 5. Starting and Finishing the Service Mode Field Service Ver1.0 February.2006 Blank Page...

  • Page 954: Troubleshooting

    Field Service Ver1.0 February.2006 6. TROUBLESHOOTING THE PRINTING SYSTEM TROUBLESHOOTING 6. TROUBLESHOOTING THE PRINTING SYSTEM This table lists information about the symptoms, possible causes, and remedies for problems that may occur with the printing system (combination of the print controller and copier). It is intended to help engineers find information as quickly as possible, and provide basic solutions.

  • Page 955: Data Capture

    7. Data Capture Field Service Ver1.0 February.2006 7. Data Capture If any fault is caused in relation with the printer, acquire the print job data for the fault analysis. Capture data of up to 5 jobs can be saved. When new data is saved, oldest one is deleted. Caution To enable this function, following conditions should be met.
  • Page 956 Field Service Ver1.0 February.2006 7. Data Capture Set the file transfer mode to binary transfer with the [binary] command. Transfer the data to be captured to PC with the [get] or [mget] command. Exit from the command prompt. NOTE • If you set [Administrator Setting] - [Security Setting] - [Security Details] - [Print Data Cap- ture] to [Restrict] after acquiring the capture data, the job data saved in the hard disk will...
  • Page 957 7. Data Capture Field Service Ver1.0 February.2006 Blank Page...
  • Page 958 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to avoid NN50GAPE1-0900 disclosure of confidential information.

This manual is also suitable for:

Bizhub 420

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