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Konica Minolta A00F011 Service Manual

Service manual
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SERVICE MANUAL
THEORY OF OPERATION
magicolor 4650EN
magicolor 4650EN
magicolor 4650DN
magicolor 4650DN
2007.11
Ver. 1.0

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Summary of Contents for Konica Minolta A00F011

  • Page 1 SERVICE MANUAL THEORY OF OPERATION magicolor 4650EN magicolor 4650EN magicolor 4650DN magicolor 4650DN 2007.11 Ver. 1.0...

  • Page 2: Table Of Contents

    THEORY OF OPERATION TOTAL CONTENTS SAFETY AND IMPORTANT WARNING ITEMS ..............S-1 IMPORTANT NOTICE ....................S-1 DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION ......S-1 SAFETY WARNINGS ....................S-2 WARNING INDICATIONS ON THE MACHINE ............S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-21 Composition of the service manual .................
  • Page 3 Blank Page...

  • Page 4: Safety And Important Warning Items

    IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.

  • Page 5: Safety Warnings

    [1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 6 SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.

  • Page 7: Connection To Power Supply

    SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS Work Performed with the Product Powered On WARNING • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.

  • Page 13: Handling Of Consumables

    SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...
  • Page 15 SAFETY AND IMPORTANT WARNING ITEMS [4] Used Batteries Precautions ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie.

  • Page 16: Internal Laser Radiation

    SAFETY AND IMPORTANT WARNING ITEMS [5] Laser Safety • This is a digital machine certified as a Class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class 1 Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 18 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 15 mW aallonpituus 770-800 nm VARNING!

  • Page 19: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. A00FP0E500DA Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. A00FP0E501DA S-16...

  • Page 20: Precautions For Handling The Laser Equipment

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

  • Page 21: Warning Indications On The Machine

    SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. High voltage •...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an elec- tric shock. High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an elec-...
  • Page 23 SAFETY AND IMPORTANT WARNING ITEMS WARNING • Do not burn used Print Units. Toner expelled from the fire is dangerous. WARNING • Do not burn used Waste Toner Bottle. Toner expelled from the fire is dangerous. WARNING • Do not burn used Toner Cartridge. Toner expelled from the fire is dangerous.

  • Page 24: 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 25 MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-22...

  • Page 26: Composition Of The Service Manual

    Composition of the service manual This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.

  • Page 27: 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) magicolor 4650EN/4650DN Main body (2) Microsoft Windows 98: Windows 98 Microsoft Windows Me: Windows Me Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT Microsoft Windows 2000: Windows 2000 Microsoft Windows XP:...

  • Page 28: Main Body

    SERVICE MANUAL THEORY OF OPERATION magicolor 4650EN magicolor 4650DN Main Body 2007.11 Ver. 1.0...

  • Page 29: Revision History

    Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 30 Theory of operation Ver. 1.0 Nov. 2007 CONTENTS magicolor 4650EN/4650DN main body Outline System configuration....................1 Product specifications ..................... 2 Section configuration....................5 Media path ......................6 Image creation process ................... 7 Composition/Operation Overall composition....................9 Timing chart at main body power on ..............9 Control block diagram ..................
  • Page 31 Theory of operation Ver. 1.0 Nov. 2007 Operation......................23 9.2.1 Print unit life detection ................23 9.2.2 Print unit life control ..................23 Print unit section (photo conductor) ..............24 10.1 Composition ....................... 24 10.2 Drive ........................24 10.3 Operation......................25 10.3.1 Photo conductor drive mechanism .............
  • Page 32 Theory of operation Ver. 1.0 Nov. 2007 Transfer section (2nd transfer)................44 14.1 Composition......................44 14.2 Drive ........................45 14.3 Operation ......................45 14.3.1 2nd transfer roller pressure mechanism............45 14.3.2 2nd transfer voltage control................. 47 14.3.3 2nd transfer voltage setting control (ATVC: auto transfer voltage control) .. 47 14.3.4 2nd transfer roller cleaning control..............
  • Page 33 Theory of operation Ver. 1.0 Nov. 2007 17.3.6 Tray open/close detection control ............... 65 17.3.7 Media misfeed detection control ..............65 Conveyance section (IDC sensor)................. 66 18.1 Composition ....................... 66 18.1.1 Drive ......................67 18.2 Operation......................67 18.2.1 Toner density detection control ..............67 18.2.2 IDC sensor calibration control..............
  • Page 34 Theory of operation Ver. 1.0 Nov. 2007 22.1 Fan control ......................86 22.1.1 Composition ....................86 22.1.2 Function ...................... 86 22.1.3 Control ......................87 Switchback/Duplex section..................89 23.1 Composition......................89 23.2 Drive ........................90 23.3 Operation ......................91 23.3.1 Outline......................91 23.3.2 Switchback guide movable mechanism ............
  • Page 35 Theory of operation Ver. 1.0 Nov. 2007 Blank Page...

  • Page 36: Outline

    Theory of operation Ver. 1.0 Nov. 2007 1. System configuration Outline System configuration A011T1C501AA magicolor 4650EN/4650DN Hard disk kit Lower feeder unit CF adapter Memory (DIMM)

  • Page 37: Product Specifications

    2. Product specifications Theory of operation Ver. 1.0 Nov. 2007 Product specifications A. Type Type Desktop tandem full-color A4 laser beam printer Printing system Electro photographic Printing System Exposure system 4 laser diode and 1 polygon mirror PC drum type OPC (organic photo conductor) Photoconductor Blade cleaning system...
  • Page 38 Theory of operation Ver. 1.0 Nov. 2007 2. Product specifications C. Media Paper source (maximum tray capacity) Type Tray1 Tray2 Plain paper (100 sheets) (250 sheets) (60 to 90 g/m2; 16 to 24 lb bond) Thick 1 (91 to 150 g/m2) Thick 2 (151 to 210 g/m2) Label Letterhead...
  • Page 39 2. Product specifications Theory of operation Ver. 1.0 Nov. 2007 G. Print functions Type Built-in type controller Pentium 2: 400 MHz (Pentium 3: 500 MHz or higher is recom- mended) Personal computer Power Mac G3 or later (G4 or later is recommended) Macintosh equipped with an Intel processor Microsoft Windows Vista Home Basic/Home Premium/Ulti- mate/Business/Enterprise, Windows Vista Home Basic /Home...

  • Page 40: Section Configuration

    Theory of operation Ver. 1.0 Nov. 2007 3. Section configuration Section configuration Fusing section Toner supply section Transfer belt section Transfer section Duplex section Media feed section (Tray 1) Write section Media feed section A011T1C502AA (Tray 2) Print unit section...

  • Page 41: Media Path

    4. Media path Theory of operation Ver. 1.0 Nov. 2007 Media path A011T1C503AA...

  • Page 42: Image Creation Process

    Theory of operation Ver. 1.0 Nov. 2007 5. Image creation process Image creation process [8] Media separation [7] 2nd image transfer [9] Transfer belt cleaning [6] 1st image transfer [10] PC drum cleaning [2] PC drum [5] Developing [3] PC drum charging [1] Printer processing [4] LD exposure Printer processing...
  • Page 43 5. Image creation process Theory of operation Ver. 1.0 Nov. 2007 Blank Page...

  • Page 44: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2007 6. Overall composition Composition/Operation Overall composition Timing chart at main body power on Conditions: A4S plain paper Polygon motor Transport motor(M3) Color PC drum motor(M2) Color developing motor(M1) K developing motor(M5) Charge K Charge YMC Developing Y Developing Y...

  • Page 45: Control Block Diagram

    6. Overall composition Theory of operation Ver.1.0 Nov. 2007 Control block diagram Operation board Print control board (PRCB) MFP board (MFPB) Media feed and conveyance Image processing Process Fusing Leser drive board TC/Y TC/M TC/C TC/K PU/Y PU/M PU/C PU/K Control system line Lower feeder unit Image bus line...

  • Page 46: Write Section

    Theory of operation Ver. 1.0 Nov. 2007 7. Write section Write section Composition 4138to2001c0 G2 lens A011T2C515AA Return mirror/2nd Separation mirror SOS lens Return mirror/1st Index board G1 lens Synthetic mirror 4138to2002c0 Polygon mirror Semiconductor laser...

  • Page 47: Operation

    7. Write section Theory of operation Ver.1.0 Nov. 2007 Operation 7.2.1 Overview • Four semiconductor lasers provided, one for each of the four different colors. A single polygon motor is used to make a scan motion. • Each photo conductor is irradiated with a laser light so that an electrostatic latent image is formed on it.

  • Page 48: Laser Emission Timing

    Theory of operation Ver. 1.0 Nov. 2007 7. Write section 7.2.3 Laser emission timing • When a ready signal is detected after the lapse of a given period of time after the print cycle has been started, a laser ON signal is output from the MFP board. •...

  • Page 49: Laser Light Intensity Control

    7. Write section Theory of operation Ver.1.0 Nov. 2007 7.2.5 Laser light intensity control • The laser light intensity control corrects the target level of fluctuations in fine line repro- duction and reverse image (white on black) reproduction that occur due to variations in photo conductor electrostatic characteristics, developing characteristics, and transfer characteristics (part-to-part variations, environment, durability).

  • Page 50: Toner Supply Section

    Theory of operation Ver. 1.0 Nov. 2007 8. Toner supply section Toner supply section Composition A011T2C525AA A011T2C516AA TC detection board (CSIC) A011T2C006DA Toner collecting port Conveyance screw Agitating blade A011T2C007DA Conveyance screw...

  • Page 51: Drive

    8. Toner supply section Theory of operation Ver.1.0 Nov. 2007 Drive Front view Toner supply motor/C, K (M7) Toner supply motor/Y, M (M6) 4138to2599c0 3D view Toner supply motor/C, K (M7) Toner supply motor/Y, M (M6) Agitating blade Conveyance screw A011T2C008DA...

  • Page 52: Operation

    Theory of operation Ver. 1.0 Nov. 2007 8. Toner supply section Operation 8.3.1 Toner conveying mechanism • The toner supply motor is turned either forward or backward to drive the agitating blade and the conveyance screw. • The agitating blade provided in the toner cartridge agitates and conveys toner to the con- veyance screw.

  • Page 53: Toner Collecting Port Shutter Mechanism

    8. Toner supply section Theory of operation Ver.1.0 Nov. 2007 8.3.2 Toner collecting port shutter mechanism • The toner collecting port is equipped with a shutter mechanism that prevents toner from being spilled out when the toner cartridge is removed from the main body. •...

  • Page 54: Toner Replenishing Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 8. Toner supply section 8.3.3 Toner replenishing mechanism • The toner supply motor is energized according to the condition of the toner level sensor for each color of toner. Toner is then supplied from the toner cartridge to the print unit as necessary.

  • Page 55: Toner Level Detection

    8. Toner supply section Theory of operation Ver.1.0 Nov. 2007 8.3.4 Toner level detection • The toner level is determined by the accumulated time of rotation of the toner supply motor. • The toner level can be checked through MENU/PRINT MENU/STATISTICS PAGE. 8.3.5 Toner near-empty condition detection •...

  • Page 56: Toner Empty Condition Detection

    Theory of operation Ver. 1.0 Nov. 2007 8. Toner supply section 8.3.6 Toner empty condition detection A. Toner empty condition detection mechanism • The print unit has a toner empty condition detecting mechanism. Based on the amount of toner conveyed from the toner cartridge to the print unit, a toner empty condition is detected.

  • Page 57: Print Unit Section (Overall Composition)

    9. Print unit section (overall composition) Theory of operation Ver.1.0 Nov. 2007 Print unit section (overall composition) Composition A011T2C526AA A011T2C517AA PC motor PU detection board (CSIC) Developing motor A011T2C013DA Photo conductor Replenishing screw Cleaning blade Agitating screw Supply roller Charge corona Developing roller Toner collecting screw...

  • Page 58: Operation

    Theory of operation Ver. 1.0 Nov. 2007 9. Print unit section (overall composition) Operation 9.2.1 Print unit life detection • Based on the photo conductor driving time, the cartridge life is determined. • When the photo conductor driving time reaches its near life, the near life warning mes- sage appears.

  • Page 59: Print Unit Section (Photo Conductor)

    10. Print unit section (photo conductor) Theory of operation Ver.1.0 Nov. 2007 10. Print unit section (photo conductor) 10.1 Composition Photo conductor A011T2C517AA A011T2C526AA Photo conductor Charge transport layer Aluminum base Charge corona Charge generating layer Direction of 4138to2018c4 4138to2505c1 rotation 10.2 Drive Transport motor (M3)

  • Page 60: Operation

    Theory of operation Ver. 1.0 Nov. 2007 10. Print unit section (photo conductor) 10.3 Operation 10.3.1 Photo conductor drive mechanism • Motors are used for the drive mechanism independently of the developing system to sup- press incorrect color registration and uneven pitch. •...

  • Page 61: Photo Conductor Post-Exposure Control

    10. Print unit section (photo conductor) Theory of operation Ver.1.0 Nov. 2007 10.3.2 Photo conductor post-exposure control • The entire surface of the photo conductor is exposed to light before the photo conductor stops rotating during the stop sequence or color change sequence (from the color print to monochrome print) after a print cycle.

  • Page 62: Print Unit Section (Charge Corona)

    Theory of operation Ver. 1.0 Nov. 2007 11. Print unit section (charge corona) 11. Print unit section (charge corona) 11.1 Composition A011T2C517AA A011T2C526AA Charge corona Charge corona Grid mesh Electrode A011T2C018DA A011T2C017DA...

  • Page 63: Operation

    11. Print unit section (charge corona) Theory of operation Ver.1.0 Nov. 2007 11.2 Operation 11.2.1 Charge corona unit ON/OFF control Polygon motor semiconductor laser Transport motor (M3) Color PC drum motor (M2) Color developing motor (M1) K developing motor (M5) Charge K Charge YMC A011T2C574AA...

  • Page 64: Print Unit Section (Developing)

    Theory of operation Ver. 1.0 Nov. 2007 12. Print unit section (developing) 12. Print unit section (developing) 12.1 Composition A011T2C526AA A011T2C517AA Photo conductor Replenishing screw Cleaning blade Charge corona Agitating screw Supply roller Developing roller Toner collecting A011T2C014DA screw Color developing motor (M1) K developing motor (M5) A011T2C512AA A011T2C019DA...

  • Page 65: Operation

    12. Print unit section (developing) Theory of operation Ver.1.0 Nov. 2007 12.2 Operation 12.2.1 Developing drive control Polygon motor Transport motor (M3) Color PC drum motor (M2) Color PC drum motor (M1) K developing motor (M5) Charge K Charge YMC Developing Y Developing M Developing C...

  • Page 66: Toner Collecting Port Shutter Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 12. Print unit section (developing) 12.2.2 Toner collecting port shutter mechanism • The toner collecting port is equipped with a shutter mechanism that prevents toner from being spilled out when the print unit is removed from the main body. •...

  • Page 67: Toner Flow

    12. Print unit section (developing) Theory of operation Ver.1.0 Nov. 2007 12.2.3 Toner flow 1. Toner stored in the toner cartridge is agitated by the agitating blade and conveyed onto the front side of the toner cartridge by the conveyance screw. 2.

  • Page 68: Developing System

    Theory of operation Ver. 1.0 Nov. 2007 12. Print unit section (developing) 12.2.4 Developing system • Two types of developing systems are used, a non-contact developing system and an alternating current application system. 1. A negative charge (supply bias voltage Vr) is applied the supply roller to regulate the amount of toner sticking to the developing roller.

  • Page 69: Cleaning Mechanism

    12. Print unit section (developing) Theory of operation Ver.1.0 Nov. 2007 12.2.5 Cleaning mechanism A. Cleaning operation 1. The cleaning blade is pressed against the surface of the photo conductor to remove toner left off the surface (fixed blade system). 2.

  • Page 70: Transfer Section (1St Transfer)

    Theory of operation Ver. 1.0 Nov. 2007 13. Transfer section (1st transfer) 13. Transfer section (1st transfer) 13.1 Composition A011T2C527AA A011T2C518AA 1st image transfer retraction position sensor (PS9) Sliding plate Transfer belt drive roller Retraction lever/Y, M, C Transfer belt 1st transfer roller/C 1st transfer roller/Y 1st transfer roller/K...

  • Page 71: Drive

    13. Transfer section (1st transfer) Theory of operation Ver.1.0 Nov. 2007 13.2 Drive 1st image transfer pressure/retraction clutch (CL4) Transport motor (M3) 4138to2038c0 Mechanism for driving the belt 1st image transfer pressure/retraction clutch (CL4) Transfer belt drive roller Transport motor (M3) Transfer belt Driven roller 4138to2041c1...

  • Page 72: Operation

    Theory of operation Ver. 1.0 Nov. 2007 13. Transfer section (1st transfer) 13.3 Operation 13.3.1 1st transfer output control • To transfer the toner image from the photo conductor to the transfer belt, the transfer volt- age is applied to the 1st transfer roller. •...

  • Page 73: 1St Transfer Roller Pressure Operation

    13. Transfer section (1st transfer) Theory of operation Ver.1.0 Nov. 2007 13.3.3 1st transfer roller pressure operation 1. Rotation of the Transport motor is transmitted by a gear train to the 1st image trans- fer pressure/retraction clutch. 2. Rotation of the 1st image transfer pressure/retraction clutch turns the pressure cam, which moves the sliding plate.

  • Page 74: 1St Transfer Roller Retraction Operation

    Theory of operation Ver. 1.0 Nov. 2007 13. Transfer section (1st transfer) 13.3.4 1st transfer roller retraction operation 1. Rotation of the Transport motor is transmitted by a gear train to the 1st image trans- fer pressure/retraction clutch. 2. Rotation of the 1st image transfer pressure/retraction clutch turns the pressure cam, which moves the sliding plate.

  • Page 75: 1St Transfer Roller Pressure/Retraction Position Control

    13. Transfer section (1st transfer) Theory of operation Ver.1.0 Nov. 2007 13.3.5 1st transfer roller pressure/retraction position control A. Pressure position control • The pressure and retraction operation of the 1st transfer roller is controlled as the 1st image transfer retraction position sensor detects the movement of the sliding plate. 1.

  • Page 76: Transfer Belt Cleaning Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 13. Transfer section (1st transfer) 13.3.6 Transfer belt cleaning mechanism • To scrape residual toner off the surface of the transfer belt, the transfer belt is provided with a cleaning blade. • The cleaning blade is in pressed contact with the transfer belt at all times. That is, it cleans the surface of the transfer belt as long as the belt turns.

  • Page 77: 1St Transfer Belt Cleaning Control

    13. Transfer section (1st transfer) Theory of operation Ver.1.0 Nov. 2007 13.3.7 1st transfer belt cleaning control • If there is a possibility of the main body being stopped with toner left on the surface of the transfer belt between the cleaning blade position and the 2nd transfer position (due to a media misfeed or malfunction), the Transport motor is energized to turn the transfer belt.

  • Page 78: Toner Collecting Port Shutter Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 13. Transfer section (1st transfer) 13.3.9 Toner collecting port shutter mechanism • A shutter mechanism is provided to prevent waste toner from being spilled from the toner collecting port when the waste toner box is removed and reinstalled. •...

  • Page 79: Transfer Section (2Nd Transfer)

    14. Transfer section (2nd transfer) Theory of operation Ver.1.0 Nov. 2007 14. Transfer section (2nd transfer) 14.1 Composition 2nd transfer roller A011T2C519AA A011T2C528AA Retraction gear 2nd transfer roller Pre-transfer guide plate A011T2C567AA...

  • Page 80: Drive

    Theory of operation Ver. 1.0 Nov. 2007 14. Transfer section (2nd transfer) 14.2 Drive 2nd image transfer pressure/retraction clutch (CL5) A011T2C566AA 14.3 Operation 14.3.1 2nd transfer roller pressure mechanism • The main body is provided with a mechanism that presses the 2nd transfer roller up against, and retracts it from, the transfer belt.
  • Page 81 14. Transfer section (2nd transfer) Theory of operation Ver.1.0 Nov. 2007 C. Pressure/retraction operation 1. Rotation of the Transport motor is transmitted to the drive roller of the intermediate transfer belt unit. 2. Rotation of the drive roller is transmitted to the 2nd image transfer pressure/retraction clutch 3.

  • Page 82: 2Nd Transfer Voltage Control

    Theory of operation Ver. 1.0 Nov. 2007 14. Transfer section (2nd transfer) 14.3.2 2nd transfer voltage control • The transfer voltage is applied to the 2nd transfer roller in order to transfer the toner image from the transfer belt to the media. •...

  • Page 83: 2Nd Transfer Roller Cleaning Control

    14. Transfer section (2nd transfer) Theory of operation Ver.1.0 Nov. 2007 14.3.4 2nd transfer roller cleaning control • DC positive and negative transfer bias voltages are alternately applied to the 2nd transfer roller. This allows toner residue on the surface of the 2nd transfer roller to be transferred back to the transfer belt, thus cleaning the 2nd transfer roller.

  • Page 84: Waste Toner Collecting Section

    Theory of operation Ver. 1.0 Nov. 2007 15. Waste toner collecting section 15. Waste toner collecting section 15.1 Composition A011T2C059DA A011T2C520AA K developing motor (M5) Waste toner transport unit Toner collecting screw (Print unit) Waste toner collecting bottle Suction transport unit A011T2C559AA...

  • Page 85: Drive

    15. Waste toner collecting section Theory of operation Ver.1.0 Nov. 2007 15.2 Drive K developing motor (M5) Waste toner collecting screw (Waste toner transport unit) Waste toner collecting screw 2nd conveyance screw (Suction transport unit) (Waste toner bottle) 1st conveyance screw A011T2C560AA (Waste toner bottle)

  • Page 86: Operation

    Theory of operation Ver. 1.0 Nov. 2007 15. Waste toner collecting section 15.3 Operation 15.3.1 Toner flow at the 1st transfer section 1. Toner scraped off by the cleaning blade in the print unit is conveyed to the toner col- lecting port by the toner collecting screw.

  • Page 87: Toner Flow At The 2Nd Transfer Section

    15. Waste toner collecting section Theory of operation Ver.1.0 Nov. 2007 15.3.2 Toner flow at the 2nd transfer section 1. Toner scraped off by the cleaning blade provided in the transfer belt unit is collected onto the middle of the transfer belt unit by the toner collecting screw. 2.

  • Page 88: Toner Collecting Port Shutter Mechanism At The Suction Transport Unit

    Theory of operation Ver. 1.0 Nov. 2007 15. Waste toner collecting section 15.3.3 Toner collecting port shutter mechanism at the suction transport unit • A dual-shutter is used to prevent waste toner from being spilled from the toner collecting port when the waste toner box is removed and reinstalled. •...

  • Page 89: Waste Toner Box Locking Mechanism

    15. Waste toner collecting section Theory of operation Ver.1.0 Nov. 2007 15.3.5 Waste toner box locking mechanism • When the box lock lever is in the unlocked position (the 12 o'clock position), the protru- sion provided at the toner collecting port interferes with the main body frame, thus pre- venting the waste toner box from being removed.

  • Page 90: Waste Toner Box-In-Position Detection Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 15. Waste toner collecting section 15.3.7 Waste toner box-in-position detection mechanism • The waste toner box set detection lever is provided to detect a waste toner box loaded in position. • When the waste toner box is not loaded, the set detection lever lowers by its own weight to plug the set detection window.

  • Page 91: Waste Toner Near-Full Condition Detection Control

    15. Waste toner collecting section Theory of operation Ver.1.0 Nov. 2007 15.3.9 Waste toner near-full condition detection control • A waste toner near-full condition is detected when the waste toner sensor continuously blocks for a predetermined period of time. • At this time, a waste toner near-full condition warning is given on the panel. When the sensor is unblocked When the sensor is blocked Detection window...

  • Page 92: Media Feed Section (Tray 1)

    Theory of operation Ver. 1.0 Nov. 2007 16. Media feed section (Tray 1) 16. Media feed section (Tray 1) 16.1 Composition A011T2C529AA A011T2C521AA Feed roller Media lift plate Separation roller A011T2C553AA Transport motor (M3) Tray1 media feed clutch (M2) Feed roller Tray1 media empty sensor A011T2C554AA Separation roller...

  • Page 93: Drive

    16. Media feed section (Tray 1) Theory of operation Ver.1.0 Nov. 2007 16.2 Drive Tray1 media feed clutch (CL2) Feed roller Transport motor (M3) A011T2C557AA 16.3 Operation 16.3.1 Media lift plate mechanism • The media lift plate will be locked under the media lift plate lock lever by pressing it down (in which the media is loaded in position).

  • Page 94: Media Separation Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 16. Media feed section (Tray 1) 16.3.2 Media separation mechanism • Drive from the Transport motor is transmitted through the Tray1 media feed clutch to turn the feed roller. • The feed roller rotates to take up and feed media into the main body. •...

  • Page 95: Media Empty Condition Detection Control

    16. Media feed section (Tray 1) Theory of operation Ver.1.0 Nov. 2007 16.3.4 Media empty condition detection control • A media empty condition is detected when the empty sensor actuator unblocks the tray1 media empty sensor. • No mechanism is provided for detecting a media near-empty condition. The media sup- ply level indicator serves this purpose.

  • Page 96: Media Feed Section (Tray 2)

    Theory of operation Ver. 1.0 Nov. 2007 17. Media feed section (Tray 2) 17. Media feed section (Tray 2) 17.1 Composition A011T2C522AA A011T2C530AA Empty sensor actuator Feed roller Edge guide plate Separation Trailing edge guide plate roller A011T2C558AA Transport motor (M3) Tray2 media feed clutch (CL1) Tray2 media empty sensor (PS1) Tray2 set switch (SW5)

  • Page 97: Drive

    17. Media feed section (Tray 2) Theory of operation Ver.1.0 Nov. 2007 17.2 Drive Transport motor (M3) Tray2 media feed clutch (CL1) Feed roller A011T2C551AA 17.3 Operation 17.3.1 Media lift plate mechanism • The media lift plate is pressed down into the locked position (in which the media is loaded in position).

  • Page 98: Media Separation Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 17. Media feed section (Tray 2) 17.3.2 Media separation mechanism • Drive from the transport motor is transmitted through the tray2 media feed clutch to turn the feed roller. • The feed roller rotates to take up and feed media into the main body. •...

  • Page 99: Media Supply Level Detection Control

    17. Media feed section (Tray 2) Theory of operation Ver.1.0 Nov. 2007 17.3.4 Media supply level detection control • There is a window in the front cover of the cassette for indicating the media supply level. • When the media lift plate goes up, a red lever appears in the window. The lower the level of the media stack, the more the red portion is visible.

  • Page 100: Tray Open/Close Detection Control

    Theory of operation Ver. 1.0 Nov. 2007 17. Media feed section (Tray 2) 17.3.6 Tray open/close detection control • Whether tray is opened or closed is detected with the tray 2 set switch. 1. Closing the tray will make the detecting plate press and turn ON the tray 2 set switch mounted on the main body frame.

  • Page 101: Conveyance Section (Idc Sensor)

    18. Conveyance section (IDC sensor) Theory of operation Ver.1.0 Nov. 2007 18. Conveyance section (IDC sensor) 18.1 Composition 4138to2060c0 A011T2C523AA IDC sensor IDC sensor/Re (IDCSB/R) IDC sensor/Fr (IDCSB/F) sensor lever A011T2C569AA...

  • Page 102: Drive

    Theory of operation Ver. 1.0 Nov. 2007 18. Conveyance section (IDC sensor) 18.1.1 Drive A011T2C582AA 18.2 Operation 18.2.1 Toner density detection control • A reflective sensor is used for the IDC sensor that detects the amount of toner sticking to the surface of the transfer belt.

  • Page 103: Idc Sensor Calibration Control

    18. Conveyance section (IDC sensor) Theory of operation Ver.1.0 Nov. 2007 18.2.2 IDC sensor calibration control • Changes in various types of characteristics due to change with time of the IDC sensor (deteriorated LED, dirty sensor surface), part-to-part variations in the sensors, and change of environment affect the IDC sensor output corresponding to the clear transfer belt surface.

  • Page 104: Conveyance Section (Registration Roller)

    Theory of operation Ver. 1.0 Nov. 2007 19. Conveyance section (Registration roller) 19. Conveyance section (Registration roller) 19.1 Composition A011T2C531AA A011T2C519AA Media loop sensor (PS6) 2nd transfer roller Registration roller Registration sensor (PS4) A011T2C570AA...

  • Page 105: Drive

    19. Conveyance section (Registration roller) Theory of operation Ver.1.0 Nov. 2007 19.2 Drive Transport motor (M3) Registration roller clutch (CL3) Registration roller Transport roller A011T2C571AA...

  • Page 106: Operation

    Theory of operation Ver. 1.0 Nov. 2007 19. Conveyance section (Registration roller) 19.3 Operation 19.3.1 Conveyance speed control • The Transport motor provides drive for the conveyance section. • The conveyance speed is variable in two steps and the appropriate one is selected according to the media type and print mode as detailed below.

  • Page 107: Control Of Loop Formed Before Registration Roller

    19. Conveyance section (Registration roller) Theory of operation Ver.1.0 Nov. 2007 19.3.3 Control of loop formed before registration roller • Media conveyance is stopped after the lapse of a predetermined period of time after the leading edge of the media fed from the feed roller has reached the registration roller. This forms a loop in the media.

  • Page 108: Ohp Transparencies Detection Control

    Theory of operation Ver. 1.0 Nov. 2007 19. Conveyance section (Registration roller) 19.3.5 OHP transparencies detection control • To prevent incorrect prints on OHP transparencies, the type of the media being conveyed is detected by the OHP sensor. • The OHP detection is made after the loop has been formed in the media before the reg- istration roller.

  • Page 109: Media Size Error Detection Control

    19. Conveyance section (Registration roller) Theory of operation Ver.1.0 Nov. 2007 19.3.6 Media size error detection control • To prevent incorrect printed pages, the size of the media being conveyed is detected using the registration sensor and media feed sensor. •...

  • Page 110: Fusing Section

    Theory of operation Ver. 1.0 Nov. 2007 20. Fusing section 20. Fusing section 20.1 Composition A011T2C524AA A011T2C532AA Exit roller Fusing heater Thermistor 1 Thermostat Thermistor 2 Fusing roller Pressure belt A011T2C542AA...

  • Page 111: Drive

    20. Fusing section Theory of operation Ver.1.0 Nov. 2007 20.2 Drive Pressure belt Fusing roller Fusing motor (M4) A011T2C543AA 20.3 Operation 20.3.1 Fusing roller drive control A. Fusing speed switching control • The fusing motor provides drive for the fusing section. •...
  • Page 112 Theory of operation Ver. 1.0 Nov. 2007 20. Fusing section (1) Fusing deceleration (low speed): • When the media loop length is small, the actuator of the media loop sensor is pushed up a small amount and the sensor is unblocked. When the sensor is unblocked, the fusing speed is decelerated.
  • Page 113 20. Fusing section Theory of operation Ver.1.0 Nov. 2007 C. Fusing roller deformation prevention control • To prevent the fusing roller from being deformed, the fusing roller is forcibly turned if it is left idle for a predetermined period of time. •...
  • Page 114 Theory of operation Ver. 1.0 Nov. 2007 20. Fusing section E. Detection of media full in the exit tray (magicolor 4650DN only) • The media full sensor detects the load capacity of output media in the exit tray. • When the is low, the edge of the shades the media full sensor.

  • Page 115: Fusing Temperature Control

    20. Fusing section Theory of operation Ver.1.0 Nov. 2007 20.3.2 Fusing temperature control • To fuse the toner image on the media (image yet to be permanently fixed) properly into the media, the heater lamps are turned ON and OFF as necessary to bring the fusing temperature to an appropriate level.

  • Page 116: Wait Control

    Theory of operation Ver. 1.0 Nov. 2007 20. Fusing section C. Control start decision • Either of the following two control start decisions is made according to the temperature detected by the temperature/humidity sensor (TEM/HUMS). The fusing temperature dur- ing the print cycle varies depending on the type of start control, whether low temperature start control or ordinary start control.

  • Page 117: Ppm Control

    20. Fusing section Theory of operation Ver.1.0 Nov. 2007 D. Print control temperature adjustments • The temperature during print control is adjusted using the menu available from the con- trol panel. The temperature can, however, be decreased only. • Adjustment steps are 0°C, -5°C, and -10°C. 20.3.6 PPM control •...

  • Page 118: Image Stabilization Control

    Theory of operation Ver. 1.0 Nov. 2007 21. Image stabilization control 21. Image stabilization control • To ensure that a stabilized output image is produced at all times, a comprehensive con- trol is provided for the developing bias voltage, laser light intensity, registration correction, gamma characteristics detection, and other parameters.

  • Page 119: Simplified Correction Control

    21. Image stabilization control Theory of operation Ver.1.0 Nov. 2007 21.1.2 Simplified correction control • If the simplified correction control is not effective in making a good correction, the com- plete correction control is executed. Control name Purpose To check the low gain output value and offset voltage value of 1 IDC sensor offset value check the IDC sensor when the shutter is closed.

  • Page 120: Image Stabilization Control Execution Request

    Theory of operation Ver. 1.0 Nov. 2007 21. Image stabilization control 21.1.4 Image stabilization control execution request • A request for execution of the complete correction control, simplified correction control, or individual registration control is made at the following timing. Stabilization request Stabilization request timing Execution processing...

  • Page 121: Miscellaneous

    22. Miscellaneous Theory of operation Ver.1.0 Nov. 2007 22. Miscellaneous 22.1 Fan control 22.1.1 Composition Fusing fan motor (FM2) DC power supply DC power supply fan motor (FM1) fan motor (FM1) Fusing fan motor (FM2) 4138to2111c0 Ozone ventilation Ozone ventilation fan motor (FM3) fan motor (FM3) A011T2C578AA...

  • Page 122: Control

    Theory of operation Ver. 1.0 Nov. 2007 22. Miscellaneous 22.1.3 Control A. DC power supply fan motor control <Full speed rotation conditions> • For the period of time that begins when the warm-up cycle is started and ends when a predetermined period of time elapses after the warm-up cycle has been completed.
  • Page 123 22. Miscellaneous Theory of operation Ver.1.0 Nov. 2007 C. Ozone ventilation fan motor <Full speed rotation conditions> • At the start of a warm-up cycle • During a print cycle • During when the image stabilization control is performed • For the period of time when the thermistor/3 provided in the print head detects the tem- perature of predetermined degrees or more <Stop conditions>...

  • Page 124: Switchback/Duplex Section

    Theory of operation Ver. 1.0 Nov. 2007 23. Switchback/Duplex section 23. Switchback/Duplex section • Only for the magicolor 4650DN 23.1 Composition A011T2C533AA A011T2C534AA Switchback roller feed clutch Switchback roller reverse clutch A011T2C547AA...

  • Page 125: Drive

    23. Switchback/Duplex section Theory of operation Ver.1.0 Nov. 2007 23.2 Drive A011T2C540AA...

  • Page 126: Operation

    Theory of operation Ver. 1.0 Nov. 2007 23. Switchback/Duplex section 23.3 Operation 23.3.1 Outline • As the duplex system doesn’t have its dedicated motor and board, the paper exit roller, switchback roller, Duplex transport roller are driven by the fusing motor. Paper is trans- ported to exist out direction or to switchover roller direction controlled with the switchback guide.

  • Page 127: Switchback Guide Movable Mechanism

    23. Switchback/Duplex section Theory of operation Ver.1.0 Nov. 2007 23.3.2 Switchback guide movable mechanism • The movable lever rotates driven by the fusing motor to push down the switchback guide. When the guide reaches to the bottom, the lever cannot be driven due to the torque lim- iter between the movable lever axis and the gear.

  • Page 128: Paper Exit Switching Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 23. Switchback/Duplex section 23.3.3 Paper exit switching mechanism • The position of the switchback guide and normal/reverse rotation of the switchback roller are controlled with the combination of the two clutches, DUP normal rotation clutch and DUP reverse rotation clutch.
  • Page 129 23. Switchback/Duplex section Theory of operation Ver.1.0 Nov. 2007 (2) Duplex printing 1. The switchback guide turns to the OPEN mode and the paper is transported to the direction of the switchback roller. 2. The switchback roller rotates forward. Switchback roller Paper exit roller OPEN mode A011T2C537AA...

  • Page 130: Transport /Paper Re-Feed Mechanism

    Theory of operation Ver. 1.0 Nov. 2007 23. Switchback/Duplex section 23.3.4 Transport /Paper re-feed mechanism • Duplex transport section is driven by the fusing motor. • Transportation is controlled by the transport roller clutch. • Duplex transport sensor controls the stop position of the paper at paper re-feeding and detects JAM.
  • Page 131 23. Switchback/Duplex section Theory of operation Ver.1.0 Nov. 2007 Blank Page...

  • Page 132: Service Manual

    SERVICE MANUAL THEORY OF OPERATION 2007.11 Ver. 1.0...
  • Page 133 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 134 Theory of operation Ver. 1.0 Nov. 2007 CONTENTS Lower feeder unit Outline Product specifications ..................... 1 Composition/Operation Overall composition....................3 Drive ........................4 Operations....................... 4 Media feed control ....................4 4.1.1 Media lift plate mechanism ................4 4.1.2 Feed roller/vertical transport roller control ............ 5 4.1.3 Media separation mechanism ...............
  • Page 135 Theory of operation Ver. 1.0 Nov. 2007 Blank Page...

  • Page 136: Outline

    Theory of operation Ver. 1.0 Nov. 2007 1. Product specifications Outline Product specifications A. Type Name Add-on 500-sheet media feed cassette Type Front-loading type Installation Desk type Media feeding system Media separation by a small-diameter roller with torque limiter Document alignment Center B.
  • Page 137 1. Product specifications Theory of operation Ver. 1.0 Nov. 2007 Blank Page...

  • Page 138: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2007 2. Overall composition Composition/Operation Overall composition A00TT2C501AA A00TT2C505AA Vertical transport roller Media feed sensor (PS3) Media feed clutch (CL1) Transport motor (M1) Media empty sensor (PS1) A00TT2C504AA Vertical transport roller Feed roller Separation roller Media lift plate A00TT2C503AA...

  • Page 139: Drive

    3. Drive Theory of operation Ver. 1.0 Nov. 2007 Drive A00TT2C502AA Operations Media feed control 4.1.1 Media lift plate mechanism • The media lift plate is pressed down into the locked position (in which the media is loaded in position). •...

  • Page 140: Feed Roller/Vertical Transport Roller Control

    Theory of operation Ver. 1.0 Nov. 2007 4. Operations 4.1.2 Feed roller/vertical transport roller control • The feed roller and vertical transport roller are rotated, which feeds media from the lower feeder unit and conveys it further into the inside of the main body 1.

  • Page 141: Media Separation Mechanism

    4. Operations Theory of operation Ver. 1.0 Nov. 2007 4.1.3 Media separation mechanism • A separation roller provided with a torque limiter is used to prevent double feeding of media. Feed roller Separation roller 4138to2115c0 4.1.4 Media detection mechanism • The media feed sensor detects the media fed in by the feed roller. •...

  • Page 142: Media Supply Level Detection Control

    Theory of operation Ver. 1.0 Nov. 2007 4. Operations 4.1.5 Media supply level detection control • There is a window in the front cover of the cassette for indicating the media supply level. • When the media lift plate goes up, a red lever appears in the window. The lower the level of the media stack in the tray, the more red that is visible.

  • Page 143: Edge Guide Plate

    4. Operations Theory of operation Ver. 1.0 Nov. 2007 4.1.7 Edge guide plate • The edge guide plate can be slid to the exact size in the width direction of the media to be loaded (A4, B5, 8/12). Edge guide plate 4138to2120c0 4.1.8 Trailing edge guide plate...

  • Page 144: Media Size Detection Control

    Theory of operation Ver. 1.0 Nov. 2007 4. Operations 4.1.9 Media size detection control • The media size switch detects the length size (feed direction) of the media. 1. The size detection board turns as the trailing edge guide plate is moved. 2.

  • Page 145: Media Reference Position Adjustment Mechanism

    4. Operations Theory of operation Ver. 1.0 Nov. 2007 4.1.10 Media reference position adjustment mechanism • The edge guide plate can be moved to allow the print start reference position for the media to be adjusted. 1. Through a hole in the media lift plate on top of the tray, loosen two screws that secure the edge guide plate.
  • Page 146 © 2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to DDA00F-A-TE1 avoid disclosure of confidential information.

This manual is also suitable for:

Bizhub c20pMagicolor 4650enMagicolor 4650dn

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