Konica Minolta magicolor 2490MF Service Manual
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Konica Minolta magicolor 2490MF Service Manual

Konica Minolta magicolor 2490MF Service Manual

Theory of operation
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SERVICE MANUAL
magicolor 2490MF
THEORY OF OPERATION
2006.07
2006.07
Ver. 1.0
Ver. 1.0

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  • Page 1 SERVICE MANUAL THEORY OF OPERATION magicolor 2490MF 2006.07 2006.07 Ver. 1.0 Ver. 1.0...

  • Page 2: Table Of Contents

    WARNING INDICATIONS ON THE MACHINE ............S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-20 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 magicolor 2490MF Main Unit Outline ..........................1 Composition/Operation ....................9 Auto Document Feeder Unit Outline ..........................

  • Page 4: Safety And Important Warning Items

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

  • Page 5: Safety Warnings

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

  • Page 7: Checkpoints When Performing On-Site Service

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

  • Page 13: Handling Of Consumables

    SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...

  • Page 15: Internal Laser Radiation

    SAFETY AND IMPORTANT WARNING ITEMS [4] 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 16 SAFETY AND IMPORTANT WARNING ITEMS the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden VARO! • Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle. Puolijohdelaser Laserdiodin suurin teho 10 mW...

  • Page 18: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety labels is attached to the outside of the machine as shown below. COMPLIES WITH 21 CFR 1040.10 AND 1040.11 EXCEPT FOR DEVIATIONS PURSUANT TO LASER NOTICE NO.50, DATED JULY 26, 2001. or/and 4139P0E501DA S-15...

  • Page 19: Laser Caution Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Caution Label • A laser caution label is attached to the inside of the machine as shown below. 4139P0E503DA 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 copier 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 temperature High voltage 4139P0E504DA...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS High voltage 4139P0E505DA CAUTION: • You may be burned or injured if you touch any area that you are advised not to touch by any caution label. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, contact our Service Office.

  • Page 23: Measures To Take In Case Of An Accident

    MEASURES TO TAKE IN CASE OF AN ACCIDENT MEASURES TO TAKE IN CASE OF AN ACCIDENT 1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.

  • Page 24: Composition Of The Service Manual

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

  • Page 25: Notation Of The Service Manual

    Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) IC board: Standard printer (2) magicolor 2490MF: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...

  • Page 26: Main Unit

    SERVICE MANUAL THEORY OF OPERATION magicolor 2490MF magicolor 2490MF ® Main Unit 2006.07 Ver. 1.0...

  • Page 27: Revision History

    Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 28 Theory of operation ver. 1.0 July. 2006 CONTENTS magicolor 2490MF main unit Outline System configuration....................1 Product specifications ..................... 2 Built-in controllers ....................4 Fax specifications ....................5 Center cross section ....................6 Paper path....................... 7 Image creation process ................... 8 Composition/operation Overall composition....................
  • Page 29 Theory of operation ver. 1.0 July. 2006 10.2 Drive ........................24 10.3 Operation......................25 10.3.1 Photo conductor drive mechanism ............. 25 10.3.2 Photo conductor cleaning mechanism............25 Charge corona section..................26 11.1 Composition ....................... 26 11.2 Operation......................27 11.2.1 Charge corona unit ON/OFF control............27 Developing section....................
  • Page 30 Theory of operation ver. 1.0 July. 2006 15.3.1 Paper feed control ..................53 15.3.2 Paper feed speed control ................53 15.3.3 Paper feed mechanism ................54 15.3.4 Double feed prevention mechanism............55 15.3.5 Paper empty condition detection..............55 15.3.6 Paper feed retry function................55 Conveyance section/registration roller ..............
  • Page 31 Theory of operation ver. 1.0 July. 2006 20.1.1 Construction....................73 20.1.2 Control ......................74 20.2 Temperature/humidity sensor ................75 20.2.1 Composition....................75...

  • Page 32: Outline

    Theory of operation ver. 1.0 July. 2006 1. System configuration Outline System configuration Machine front view 4139T2E562AA magicolor 2490MF Lower feeder unit Duplex option Dust cover* *: Standard for U.S.A and europe...

  • Page 33: Theory Of Operation Ver. 1.0 July

    2. Product specifications Theory of operation ver. 1.0 July. 2006 Product specifications A. Type Type Desktop Printing system Semiconductor laser and electrostatic image transfer to plain paper Exposure system 2 laser diodes and polygon mirror PC drum type OPC (organic photo conductor) Photoconductor Blade cleaning system cleaning...
  • Page 34 Theory of operation ver. 1.0 July. 2006 2. Product specifications B. Functions Average: 45 seconds (100 V area) Warm-up time Average: 49 seconds (200 - 240 V area) (at ambient temperature of 23 °C/73.4 °F and rated source voltage) Plain paper 126.78 mm/second System speed Thick stock...

  • Page 35: Built-In Controllers

    2. Product specifications Theory of operation ver. 1.0 July. 2006 E. Operating environment 10 °C to 35 °C / 50 °F to 95 °F (with a fluctuation of 10 °C / 18 °F or less per Temperature hour) Humidity 15% to 85% (with a fluctuation of 20% or less per hour) Built-in controllers Embedded RISC processor 48MHz 128 MB on IPB...

  • Page 36: Fax Specifications

    Theory of operation ver. 1.0 July. 2006 2. Product specifications Fax specifications Standard (203 dpi x 98 dpi) Resolution Fine (203 dpi x 196 dpi) Super fine (203 dpi x 392dpi) Standard/Fine/Super fine Halftone level Half tone standard/Half tone fine/Half tone super fine Receive Supported Automatic reduction...

  • Page 37: Center Cross Section

    3. Center cross section Theory of operation ver. 1.0 July. 2006 Center cross section [11] [10] 4139T1C501AA Fusing section Toner cartridge section Duplex unit section * Drum cartridge section 2nd transfer section Transfer belt section Lower feeder section * [10] IR section Paper feed section [11]...

  • Page 38: Paper Path

    Theory of operation ver. 1.0 July. 2006 4. Paper path Paper path <Machine right side view> 4139T1C502AA <Machine front view> 4139T1C504AA...

  • Page 39: Image Creation Process

    5. Image creation process Theory of operation ver. 1.0 July. 2006 Image creation process [1] CCD (Photoelectric conversion) [2] Image processing board [11] Transfer belt cleaning [12] Fusing [7] 1st image transfer [6] Developing [9] Paper separation [8] 2nd image transfer [10] Photo conductor cleaning [4] Photo conductor [5] Photo conductor charging...
  • Page 40 Theory of operation ver. 1.0 July. 2006 5. Image creation process • Light reflected off the surface of the original is converted to a corre- CCD (Photoelectric sponding electric signal by CCD and the resultant electric signal is sent conversion) to the image processing board.
  • Page 41 5. Image creation process Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 42: Composition/Operation

    Theory of operation ver. 1.0 July. 2006 6. Overall composition Composition/operation Overall composition Operation sequence Print Request Fusing Motor (M4) Main Motor (M1) Polygon Motor Charge output 1st transfer output 2nd transfer output 2nd Transfer Roller retracted Pressure/Retraction Solenoid /Cleaning Blade (SD3) Developing Motor (M3) Rack Motor (M2) Tray1 Paper Pick-up Solenoid (SD1)

  • Page 43: Control Block Diagram

    6. Overall composition Theory of operation ver. 1.0 July. 2006 Control block diagram CCD unit Scanner motor Auto Operation document Various IR sensors panel feeder IR cooling f an motor Image processing board (IPB) NCUB IR unit open /close sensor Image processing LANB DC power supply2...

  • Page 44: Scanner Section (Ir Section)

    Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section) Scanner section (IR section) Composition 4139T2C568AA 4139T2C502AA Scanner unit Scanner motor IR cooling fan motor 4139T2C565AA...

  • Page 45: Drive

    7. Scanner section (IR section) Theory of operation ver. 1.0 July. 2006 Drive 4139T2C566AA...

  • Page 46: Operation

    Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section) Operation 7.3.1 IR unit open/close mechanism • The machine is provided with the IR unit open/close mechanism to allow the toner car- tridge, drum cartridge, and other disposables to be replaced with new ones. •...
  • Page 47 7. Scanner section (IR section) Theory of operation ver. 1.0 July. 2006 A. IR unit open/close operation • Pulling the IR unit lock release lever will disengage the IR unit lock pawl, allowing the IR unit to be opened. IR unit lock pawl IR unit lock release lever 4139T2C550AA •...

  • Page 48: Auto Document Feeder Unit Open/Close

    Theory of operation ver. 1.0 July. 2006 7. Scanner section (IR section) 7.3.2 Auto document feeder unit open/close • To prevent the auto document feeder unit from being raised or lowered when the IR unit is opened or closed, the auto document feeder unit is secured to the IR unit when the IR unit is to be opened or closed.

  • Page 49: Write Section (Ph Section)

    8. Write section (PH section) Theory of operation ver. 1.0 July. 2006 Write section (PH section) Composition 4139to2002c0 Semiconductor laser 4139T2C503AA G2 lens SOS sensor SOS mirror G1 lens G2 lens (SOS lens) Polygon mirror Return mirror 4139T2C511AA...

  • Page 50: Operation

    Theory of operation ver. 1.0 July. 2006 8. Write section (PH section) Operation 8.2.1 Outline • The surface of the photo conductor is irradiated with a laser light and an electrostatic latent image is thereby formed. • The polygon mirror has four faces. The machine uses a two-beam array LD to inhibit the speed of the polygon mirror from increasing because of the decreased number of faces the polygon mirror has as compared with the conventional models.

  • Page 51: Laser Emission Timing

    8. Write section (PH section) Theory of operation ver. 1.0 July. 2006 8.2.3 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 print control board. •...

  • Page 52: Cartridge Section

    Theory of operation ver. 1.0 July. 2006 9. Cartridge section Cartridge section Composition Drum Cartridge 4139to2053e0 Toner Cartridge 4139T2C504AA 4139to2054e0...

  • Page 53: Drive

    9. Cartridge section Theory of operation ver. 1.0 July. 2006 Drive Main Motor Drum Cartridge Photo Conductor Developing Motor Toner Cartridge 4139to2055e0 Operation 9.3.1 Drum cartridge (DC) life control • The drum cartridge offers the following life controls: detecting a new DC and resetting the life counter.

  • Page 54: Toner Cartridge (Tc) Life Control

    Theory of operation ver. 1.0 July. 2006 9. Cartridge section 9.3.2 Toner cartridge (TC) life control A. Toner cartridge detection and new cartridge detection timing • The machine attempts to perform a detection sequence when the front door is closed. B.

  • Page 55: Photo Conductor Section

    10. Photo conductor section Theory of operation ver. 1.0 July. 2006 10. Photo conductor section 10.1 Composition Drum Cartridge Photo Conductor 4139to2056e0 4139T2C505AA Charge Generating Layer Charge Transport Layer Aluminum Base 4139to2057e0 10.2 Drive Main Motor Photo Conductor 4139to1058e0...

  • Page 56: Operation

    Theory of operation ver. 1.0 July. 2006 10. Photo conductor section 10.3 Operation 10.3.1 Photo conductor drive mechanism • The photo conductor is driven by the main motor. • When the main motor is energized, it turns the drive gear, which in turn rotates the photo conductor.

  • Page 57: Charge Corona Section

    11. Charge corona section Theory of operation ver. 1.0 July. 2006 11. Charge corona section 11.1 Composition Charge Corona 4139T2C505AA 4139T2C512AA Grid mesh Electrode 4139T2C513AA...

  • Page 58: Operation

    Theory of operation ver. 1.0 July. 2006 11. Charge corona section 11.2 Operation 11.2.1 Charge corona unit ON/OFF control • The grid voltage (Vg) applied to the grid mesh is controlled by image stabilization control. Standby Position Polygon Motor Energized Belt Positioning K Toner Developing Position Sensor Activated...

  • Page 59: Developing Section

    12. Developing section Theory of operation ver. 1.0 July. 2006 12. Developing section 12.1 Composition 4139T2C559AA 4139T2C504AA Main motor (M1) Developing motor (M3) 4139T2C514AA Photo conductor Cleaning blade Hopper Waste toner Supply roller Agitating screw Developing roller Charge corona Regulator blade/2nd Agitating blade Regulator blade/1st 4139T2C515AA...

  • Page 60: Drive

    Theory of operation ver. 1.0 July. 2006 12. Developing section 12.2 Drive Main motor (M1) Photo conductor Developing motor (M3) Developing roller 4139T2C517AA A. Developing roller drive • The developing roller is driven by the developing motor and intermediate gear. •...

  • Page 61: Developing Drive Control

    12. Developing section Theory of operation ver. 1.0 July. 2006 12.2.1 Developing drive control Polygon Motor Energized K Toner Standby Position Developing Belt Positioning Position Print Start Sensor Activated Rack Motor (M2) Developing Motor (M3) Developing bias AC Developing bias DC Main Motor (M1) Charge output bias 4139to2102e0...

  • Page 62: Developing Bias

    Theory of operation ver. 1.0 July. 2006 12. Developing section 12.2.3 Developing bias • The developing bias voltage (Vb) is applied to the developing roller so that an adequate amount of toner is attracted onto the surface of the photo conductor. •...

  • Page 63: Toner Cartridge Rack

    12. Developing section Theory of operation ver. 1.0 July. 2006 12.2.5 Toner cartridge rack • The toner cartridge rack is mounted with four toner cartridges. The rack employs a rotary system. • Development of the image of each color of toner is performed by rotating the toner car- tridge rack.
  • Page 64 Theory of operation ver. 1.0 July. 2006 12. Developing section B. Toner cartridge rack stop position • The toner cartridge rack must be brought to a stop so that the toner cartridge of each color of toner is located at its correct position. To accomplish this task, three stop posi- tions are established: the standby (reference) position, the developing position, and the cartridge replacement position.
  • Page 65 12. Developing section Theory of operation ver. 1.0 July. 2006 (3) Cartridge replacement position • The cartridge replacement position is where the toner cartridge rack is rotated 70° from the developing position. For Developing of K 70˚ K Developing Position Cartridge Replacement Position 4139to2069e0 C.
  • Page 66 Theory of operation ver. 1.0 July. 2006 12. Developing section D. Color printing process (1) Operation sequence 1. The toner cartridge rack is stationary at the standby position. 2. When a print request is received from the controller, the toner cartridge rack is rotated to bring the Y toner cartridge to its developing position.
  • Page 67 12. Developing section Theory of operation ver. 1.0 July. 2006 E. Toner cartridge rack stop position detection • The toner cartridge rack stop position for each color of toner is detected by the rack motor and the rack positioning sensor. •...
  • Page 68 Theory of operation ver. 1.0 July. 2006 12. Developing section (2) Toner cartridge rack developing position • To bring the toner cartridge rack to a stop at the corresponding developing position, the rack is rotated from the standby position 45° through pulse control of the rack motor. (3) Cartridge replacement position •...

  • Page 69: Image Transfer Section

    13. Image transfer section Theory of operation ver. 1.0 July. 2006 13. Image transfer section 13.1 Composition 13.1.1 1st transfer section 4139to2019c0 4139T2C506AA Driven roller Transfer belt 1st transfer roller IDC sensor (IDC) Transfer belt drive roller Cleaning blade Toner collecting screw Belt positioning sensor (PS4) Photo conductor 4139T2C519AA...

  • Page 70: 2Nd Transfer Section

    Theory of operation ver. 1.0 July. 2006 13. Image transfer section 13.1.2 2nd transfer section 4139to2020c0 4139T2C506AA 2nd transfer roller Pressure/retraction clutch Pressure/ Retraction slider Pressure/Retraction roller 4139T2C520AA Pressure/ Retraction slider 2nd transfer roller 4139T2C521AA...

  • Page 71: Drive

    13. Image transfer section Theory of operation ver. 1.0 July. 2006 13.2 Drive Main motor (M1) 2nd transfer roller Transfer belt drive roller Transfer belt unit 1st transfer Roller 4139T2C522AA 13.3 Operation 13.3.1 Transfer belt cleaning mechanism • To scrape residual toner off the surface of the transfer belt, there is a cleaning blade pro- vided.
  • Page 72 Theory of operation ver. 1.0 July. 2006 13. Image transfer section A. Cleaning blade pressure/retraction mechanism • In color printing, an image is formed on the transfer belt for each color of toner. The cleaning blade is therefore provided with a pressure/retraction mechanism. •...
  • Page 73 13. Image transfer section Theory of operation ver. 1.0 July. 2006 (2) Operation timing SD3 Energization Signal (after Main Motor has been energized) When power is turned ON: Main Motor (M1) Pressure/Retraction Solenoid To pressed position /Cleaning Blade (SD3) Retraction Position Sensor /Cleaning Blade (PS6) K print completed Y-TOD (CD Print Start signal for yellow)
  • Page 74 Theory of operation ver. 1.0 July. 2006 13. Image transfer section (4) Pressure sequence 1. When the pressure/retraction solenoid/cleaning blade is energized in the condition, in which the cleaning blade is retracted from the transfer belt, the pressure cam rotates a half turn. This pushes the lever backward. 2.

  • Page 75: 1St Transfer Roller Voltage On/Off Control

    13. Image transfer section Theory of operation ver. 1.0 July. 2006 13.3.2 1st transfer roller voltage ON/OFF control Image write start position for Image write start position for a paper size of A4 or smaller a paper size greater than A4 Belt Positioning Sensor (PS4) /TOD (Image Write Start signal) Rack Motor (M2)
  • Page 76 Theory of operation ver. 1.0 July. 2006 13. Image transfer section (1) Pressure sequence 1. Drive from the main motor is transmitted to the drive gear. 2. Rotation of the drive gear is transmitted to the pressure/retraction clutch. 3. When the pressure/retraction solenoid /2nd image transfer is energized, the pres- sure/retraction clutch rotates a half turn.

  • Page 77: 2Nd Transfer Roller Cleaning

    13. Image transfer section Theory of operation ver. 1.0 July. 2006 13.3.4 2nd transfer roller cleaning • 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 78: Neutralization And Separation Of Paper

    Theory of operation ver. 1.0 July. 2006 13. Image transfer section 13.3.5 Neutralization and separation of paper • To neutralize the paper that has undergone the 2nd transfer process, a charge neutraliz- ing cloth is provided for the guide plate after the 2nd transfer roller. Charge Neutralizing Cloth Charge Neutralizing Cloth 2nd Transfer Roller...

  • Page 79: Atvc (Auto Transfer Voltage Control)

    13. Image transfer section Theory of operation ver. 1.0 July. 2006 13.3.7 ATVC (Auto Transfer Voltage Control) • The ATVC, or auto transfer voltage control, is for optimizing the transfer output. A con- stant current is made to flow through each of the transfer rollers. From the voltage thereby detected, the resistance of each of the 1st transfer roller, 2nd transfer roller, and transfer belt is measured.

  • Page 80: Toner Collecting Section

    Theory of operation ver. 1.0 July. 2006 14. Toner collecting section 14. Toner collecting section 14.1 Composition Toner collecting screw Waste toner conveyance unit 4139T2C507AA Toner agitating screw 4139T2C523AA 14.2 Drive Toner collecting screw Transfer belt Waste toner conveyance unit Driven roller Main motor (M1) Toner agitating screw...

  • Page 81: Operation

    14. Toner collecting section Theory of operation ver. 1.0 July. 2006 14.3 Operation 14.3.1 Toner collecting mechanism • Waste toner scraped off by the cleaning blade of the transfer belt and that scraped off by the cleaning blade of the photo conductor are conveyed by each of the toner collecting screws into the drum cartridge.

  • Page 82: Waste Toner Full Detection System

    Theory of operation ver. 1.0 July. 2006 14. Toner collecting section 14.3.2 Waste toner full detection system • A waste toner near full condition is detected using the output state of the waste toner near full detect board/led. • A waste toner near full condition is detected by letting the light emitted from the LED mounted on the waste toner near full detect board/led travel through the light guide.

  • Page 83: Paper Feed Section

    15. Paper feed section Theory of operation ver. 1.0 July. 2006 15. Paper feed section 15.1 Composition Lower Feeder Unit 4139T2C525AA 4139T2C508AA Pick-up roller Tray1 paper pick-up solenoid Tray1 paper empty sensor (SD1) (PS9) 4139T2C551AA...

  • Page 84: Drive

    Theory of operation ver. 1.0 July. 2006 15. Paper feed section 15.2 Drive Main motor (M1) Paper pick-up clutch Pick-up roller Tray1 paper pick-up solenoid (SD1) 4139T2C527AA 15.3 Operation 15.3.1 Paper feed control Print Start Signal * C-TOD * C-TOD Main Motor (M1) Belt Positioning Sensor (PS4) Tray1 Paper Pick-up Solenoid (SD1)

  • Page 85: Paper Feed Mechanism

    15. Paper feed section Theory of operation ver. 1.0 July. 2006 15.3.3 Paper feed mechanism • When the tray1 paper pick-up solenoid is energized, drive from the main motor is trans- mitted to the pick-up roller via the paper pick-up clutch. The pick-up roller is thereby rotated.

  • Page 86: Double Feed Prevention Mechanism

    Theory of operation ver. 1.0 July. 2006 15. Paper feed section 15.3.4 Double feed prevention mechanism • The fixed separation pad system plus the claw stoppers are used for paper separation. This ensures that only the first sheet of paper is taken up and fed in. Pick-up Roller Separation Pad 4139to2090e0...

  • Page 87: Conveyance Section/Registration Roller

    16. Conveyance section/registration roller Theory of operation ver. 1.0 July. 2006 16. Conveyance section/registration roller 16.1 Composition Registration roller OHP sensor (PS2) Conveyance roller 4139T2C528AA 4139T2C509AA Registration roller Main motor (M1) Registration sensor (PS1) Registration roller solenoid (SD2) Conveyance roller 4139T2C529AA...

  • Page 88: Drive

    Theory of operation ver. 1.0 July. 2006 16. Conveyance section/registration roller 16.2 Drive Actuator Registration sensor (PS1) 4139T2C530AA 16.3 Operation 16.3.1 Registration roller control • The registration sensor detects whether or not the paper has reached the conveyance section. • Conveyance of paper is restarted by synchronizing the paper conveyed with the image. •...

  • Page 89: Ohp Film Detection

    16. Conveyance section/registration roller Theory of operation ver. 1.0 July. 2006 16.3.2 OHP film detection • To ensure that the paper of the correct type is being used, the OHP sensor detects the type of the paper being conveyed. • When the registration sensor is activated, the OHP sensor is also activated and the type of paper being conveyed is determined if it is OHP film or any type other than OHP.

  • Page 90: Fusing Section

    Theory of operation ver. 1.0 July. 2006 17. Fusing section 17. Fusing section 17.1 Composition 4139T2C567AA Thermistor 4139T2C510AA Exit sensor (PS7) Thermostat Fusing motor (M4) Cleaning roller Heater lamp Pressure roller Heating roller 4139T2C531AA 4139T2C532AA...

  • Page 91: Drive

    17. Fusing section Theory of operation ver. 1.0 July. 2006 17.2 Drive Fusing Motor Heating Roller 4139to2094e0 17.3 Operation 17.3.1 Heating Roller drive control A. Speed change control • Drive for the heating roller is provided by the fusing motor. •...
  • Page 92 Theory of operation ver. 1.0 July. 2006 17. Fusing section C. Operation flow 1. The initial fusing speed is set to the low speed, thereby forming a loop in the paper between the 2nd transfer roller and fusing rollers. When the length of the loop formed in the paper becomes greater, the fusing paper loop sensor is activated (blocked).

  • Page 93: Fusing Temperature Control

    17. Fusing section Theory of operation ver. 1.0 July. 2006 17.3.2 Fusing temperature control • A thermistor is used to detect the surface temperature of the heating roller. The heater lamp is then turned ON and OFF as necessary to achieve the set temperature. Temperature control during monochrome printing (plain paper) Power Switch ON Copy/Print Start...
  • Page 94 Theory of operation ver. 1.0 July. 2006 17. Fusing section Temperature control during color printing (plain paper) Copy/Print Start Power Switch ON Fusing Ready Temperature [*b] [*a] Approx. 45 sec. Warm-up completed (approx.70 seconds for 100 V area) 4139T2E564AA (approx.75 seconds for 200 V area) [1] During warm-up cycle [3] During a print cycle Heating roller temperature setting: 189 °C...
  • Page 95 17. Fusing section Theory of operation ver. 1.0 July. 2006 A. Warm-up • Control is provided until the heating roller temperature reaches 178 °C. • This control is performed when the power switch is turned ON, a malfunction or paper misfeed is reset, the energy saver mode is canceled, or the door is opened and closed.
  • Page 96 Theory of operation ver. 1.0 July. 2006 17. Fusing section (2) Color printing (1-sided) • If the print cycle is started in a condition, in which the temperature/humidity sensor detects 20 °C or more, control is returned back to one having a control temperature of more than 60 °C after five printed pages have been produced.

  • Page 97: Protection Against Abnormally High Temperature

    17. Fusing section Theory of operation ver. 1.0 July. 2006 17.3.3 Protection against abnormally high temperature • The machine provides protection at three different stages to prevent abnormally high temperature of the fusing Unit. A. Soft protection • If the thermistor detects a temperature exceeding a predetermined value, the malfunc- tion code representing abnormally high temperature is displayed.

  • Page 98: Ppm Control

    Theory of operation ver. 1.0 July. 2006 17. Fusing section 17.3.4 PPM control • PPM control is provided to prevent the temperature on edges of the heating roller from increasing during a multi-print cycle using plain paper of a small size. •...

  • Page 99: Paper Exit Section

    18. Paper exit section Theory of operation ver. 1.0 July. 2006 18. Paper exit section 18.1 Composition 4139T2C558AA 4139T2C510AA Exit sensor (PS7) Paper exit roller 4139T2C552AA...

  • Page 100: Drive

    Theory of operation ver. 1.0 July. 2006 18. Paper exit section 18.2 Drive Fusing motor (M4) Paper exit roller 4139T2C557AA 18.3 Operation 18.3.1 Exit tray full detection • The exit tray is provided with a paper full detection system. When the exit tray full sensor is unblocked, the corresponding message will be displayed on the control panel.

  • Page 101: Image Stabilization Control

    19. Image stabilization control Theory of operation ver. 1.0 July. 2006 19. Image stabilization control 19.1 Overview • To ensure that a stabilized output image is produced at all times, the following image sta- bilization controls are provided. Purpose Control Detection ATVC To ensure stabilized transfer...

  • Page 102: Operation

    Theory of operation ver. 1.0 July. 2006 19. Image stabilization control 19.2 Operation 19.2.1 Leak detection control • For the clearance between the photo conductor and developing roller, an optimum devel- oping bias voltage is established that does not result in a leak image or uneven density. 19.2.2 AIDC Sensor LED intensity control •...

  • Page 103: Operation Timing

    19. Image stabilization control Theory of operation ver. 1.0 July. 2006 19.3 Operation timing Mode Operation timing • The environment in which the power switch is turned ON is different from the environ- ment the machine was in when the power switch was turned OFF last. •...

  • Page 104: Other Control

    Theory of operation ver. 1.0 July. 2006 20. Other control 20. Other control 20.1 Fan control 20.1.1 Construction IR cooling fan motor Exhaust Power supply cooling fan motor Suction Ventilation fan motor Exhaust Ozone filter 4139T2C554AA...

  • Page 105: Control

    20. Other control Theory of operation ver. 1.0 July. 2006 20.1.2 Control A. Power supply cooling fan motor <Full-speed conditions> • For the predetermined period of time after the power switch has been turned ON • For the specified period of time up to the end of energy saver mode •...

  • Page 106: Temperature/Humidity Sensor

    Theory of operation ver. 1.0 July. 2006 20. Other control 20.2 Temperature/humidity sensor 20.2.1 Composition • The temperature/humidity sensor is used to detect the temperature of the inside of the machine. It is also used for image stabilization, transfer ATVC, and fusing temperature control. Temperature/humidity sensor (TEM/HUMS) 4139T2C555AA...
  • Page 107 20. Other control Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 108: Auto Document Feeder Unit

    SERVICE MANUAL THEORY OF OPERATION Auto Document Feeder Unit 2006.07 Ver. 1.0...
  • Page 109 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 110 Theory of operation ver. 1.0 July. 2006 CONTENTS Auto document feeder unit Outline Product specifications ..................... 1 Composition/operation Composition ......................3 Drive ........................4 Mechanical operations .................... 5 Document take-up mechanism ................5 4.1.1 Document take-up mechanism ..............5 4.1.2 Document separation mechanism..............
  • Page 111 Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 112: Outline

    Theory of operation ver. 1.0 July. 2006 1. Product specifications Outline Product specifications A. Type Name Automatic document feeder Installation Inserted at upper-rear side of main unit Document alignment Center Document loading Face up B. Functions Modes 1-sided mode C. Paper type Type of document 1-sided mode (plain paper): 60 g/m to 128 g/m...
  • Page 113 1. Product specifications Theory of operation ver. 1.0 July. 2006 E. Paper feed not guaranteed originals • If fed, paper feed will be possible to some extent but trouble occurrence will be possible. Type of original Possible trouble Sheets lightly curled (curled amount: 10 - 15 mm) Dog-eared, exit failure Heat sensitive paper Edge folded, exit failure, transport failure...

  • Page 114: Composition/Operation

    Theory of operation ver. 1.0 July. 2006 2. Composition Composition/operation Composition 4556T2C509AA 4556T2C505AA DF control board (DFCB) Pick-up roller Original detection sensor (PS1) Main motor (M1) Paper feed sensor (PS2) Paper leading edge detection sensor (PS3) 4556T2C507AA Take-up roller...

  • Page 115: Drive

    3. Drive Theory of operation ver. 1.0 July. 2006 3. Drive 4556T2C508AA...

  • Page 116: Mechanical Operations

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Mechanical operations Document take-up mechanism 4.1.1 Document take-up mechanism • The original detection sensor detects a document that has been properly loaded in the document feeder. • The document stopper establishes the leading edge position of the document loaded in the document feeder.

  • Page 117: Document Separation Mechanism

    4. Mechanical operations Theory of operation ver. 1.0 July. 2006 4.1.2 Document separation mechanism • Double feeding of paper is prevented using coefficient of friction between the take-up roller and separator pad. Take-up roller Separator pad 4556T2C502AA Single sheet feeding : The coefficient of friction on the front side of the paper fed between the take- up roller and separator pad is equal to that on the backside of the paper.

  • Page 118: Document Transport/Exit Mechanism

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Document transport/exit mechanism 4.2.1 Document transport mechanism • The original that has been taken up blocks the paper feed sensor. The transport roller turns to transport the original up to the document scanning position of the printer. •...

  • Page 119: Document Exit Mechanism

    4. Mechanical operations Theory of operation ver. 1.0 July. 2006 4.2.2 Document exit mechanism • The exit roller turns to feed the original out of the document feeder. During this sequence, the original blocks the paper leading edge detection sensor and is fed onto the document exit tray.

  • Page 120: Miscellaneous

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Miscellaneous 4.3.1 Document feeder raised/lowered position detection mechanism • There is a magnet provided in the document feeder, allowing the printer to detect the position of the document feeder whether the document feeder is raised or lowered. •...
  • Page 121 4. Mechanical operations Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 122: Lower Feeder Unit

    SERVICE MANUAL THEORY OF OPERATION Lower Feeder Unit 2006.07 Ver. 1.0...
  • Page 123 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 124 Theory of operation ver. 1.0 July. 2006 CONTENTS Lower feeder unit Outline Product specifications ..................... 1 Composition/operation Composition ......................3 Drive ........................4 Mechanical operation ....................5 Conveyance drive mechanism................5 Paper empty detection..................6 Tray set detection....................7...
  • Page 125 Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 126: Outline

    Theory of operation ver. 1.0 July. 2006 1. Product specifications Outline Product specifications A. Type Name Add-on 500-sheet paper feed cassette Type Front-loading type Installation Desk type Document Alignment Center B. Paper type Paper size A4/Letter Paper type Plain paper: 60 to 90 g/m (16 to 24 lb) Capacity 500 sheets...
  • Page 127 1. Product specifications Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 128: Composition/Operation

    Theory of operation ver. 1.0 July. 2006 2. Composition Composition/operation Composition 4056T2C501AA 4056T2C509AA Tray set detecting switch (SW1) PF drive board (PFDB) Paper empty sensor (PS1) Paper pick-up solenoid (SD1) 4056T2C502AA...

  • Page 129: Drive

    3. Drive Theory of operation ver. 1.0 July. 2006 Drive 4056T2C510AA...

  • Page 130: Mechanical Operation

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operation cal operation Mechani Conveyance drive mechanism • The lower feeder unit is not provided with any drive motor. The driving force for paper feeding and conveyance (drive from main motor) is transmitted through a coupling gear from the printer.

  • Page 131: Paper Empty Detection

    4. Mechanical operation Theory of operation ver. 1.0 July. 2006 Paper empty detection • The paper empty sensor of the PF drive board detects a paper empty condition in the lower feeder unit. • When there is paper loaded in the lower feeder unit, the actuator is raised, which unblocks the sensor.

  • Page 132: Tray Set Detection

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operation Tray set detection • The lower feeder unit is provided with a tray set detecting switch that is attached with a segment lever. • When tray 2 is inserted, the switch actuator on the right-hand side of tray 2 pushes the lever.
  • Page 133 4. Mechanical operation Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 134: Duplex Option

    SERVICE MANUAL THEORY OF OPERATION Duplex Option 2006.07 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 July. 2006 CONTENTS Duplex option Outline Product specifications ..................... 1 Composition/Operation Composition ......................3 Drive ........................4 Mechanical operations .................... 5 Switchback mechanism ..................5 4.1.1 Switchback operation ..................5 4.1.2 Paper exit roller drive coupling mechanism........... 6 4.1.3 Switchback motor control ................
  • Page 137 Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 138: Outline

    Theory of operation ver. 1.0 July. 2006 1. Product specifications Outline Product specifications A. Type Name Duplex option Type Switchback and circulating duplex unit Installation Mounted on the right side door of main unit Reversing system Exit roller switchback Conveyance system Rubber roller + driven rolls Document alignment Center...
  • Page 139 1. Product specifications Theory of operation ver. 1.0 July. 2006 Blank Page...

  • Page 140: Composition/Operation

    Theory of operation ver. 1.0 July. 2006 2. Composition Composition/Operation Composition 4057T2C509AA Transport roller 1 4057T2C501AA Registration roller Transport roller 2 4057T2C502AA Reverse motor (M2) Cooling fan motor (FM1) Transport motor (M1) Transport sensor (PS3) Door sensor (PS2) Registration solenoid (SD1) AD drive board (ADDB) Paper loop sensor (PS1) Registration roller...

  • Page 141: Drive

    3. Drive Theory of operation ver. 1.0 July. 2006 Drive Reverse motor (M2) Transport roller 1 Transport motor (M1) Registration roller Transport roller 2 4057T2C504AA...

  • Page 142: Mechanical Operations

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Mechanical operations Switchback mechanism 4.1.1 Switchback operation • The paper exit roller of the main unit is used to subject the 1-sided print to a switchback sequence so that the 1-sided print is to be transported through the duplex option. Feeding the paper into duplex option Exit sensor (PS7) Paper exit roller...

  • Page 143: Paper Exit Roller Drive Coupling Mechanism

    4. Mechanical operations Theory of operation ver. 1.0 July. 2006 4.1.2 Paper exit roller drive coupling mechanism • When the duplex option is mounted, the gear assy of the fusing unit is raised by the lead- ing edge of the duplex option lever, thereby disconnecting drive from the machine (fusing roller).

  • Page 144: Transport And Duplex Paper Take-Up Mechanism

    Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Transport and duplex paper take-up mechanism 4.2.1 Transport and duplex paper take-up operation • Drive for the duplex option is provided by the transport motor. Transport roller 1 Transport motor (M1) Registration roller Transport roller 2 4057to2509c0...

  • Page 145: 2-Sided Printing Method

    4. Mechanical operations Theory of operation ver. 1.0 July. 2006 2-sided printing method • The following two types of 2-sided printing methods are available. 2-sided printing with a single sheet of paper resident in the system 2-sided printing method 2-sided printing with two sheets of paper resident in the system (when the FD length is no less than 276 mm, no more than 297 mm).
  • Page 146 Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Operation 4 • The main unit carries out the second print cycle to produce the print image of the first page of the original on the other side of the 1-sided print. Operation 5 •...

  • Page 147: Operations In 2-Sided Printing With Two Sheets Of Paper Resident In The System

    4. Mechanical operations Theory of operation ver. 1.0 July. 2006 4.3.2 Operations in 2-sided printing with two sheets of paper resident in the sys- Operation 1 Paper Exit Roller • The first sheet of paper is taken up and fed in from the main unit drawer and the main unit starts the first print cycle to produce the print image of the second page of the original.
  • Page 148 Theory of operation ver. 1.0 July. 2006 4. Mechanical operations Operation 5 • While feeding the first 2-sided print out, main unit produces the print image of the 6th page of the original on the third sheet of paper. • The second sheet of paper waits at the duplex take-up position until the third sheet of paper is subjected to a switchback sequence.
  • Page 149 4. Mechanical operations Theory of operation ver. 1.0 July. 2006 • 2-sided printing of two A4 originals with two sheets of paper resident in the sys- Belt Positioning Sensor (PS4) Registration Sensor (PS1) Exit Sensor (PS7) Forward Backward Forward Backward Forward Backward Forward...
  • Page 150 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Printed in Japan Use of this manual should be strictly supervised to Use of this manual should be strictly supervised to DD4139-A-TE1 DD4139-A-TE1 avoid disclosure of confidential information.

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