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Develop ineo+ 6500 Service Manual

Develop ineo+ 6500 Service Manual

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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 SAFETY INFORMATION ....................S-13 IMPORTANT NOTICE ....................S-13 INDICATION OF WARNING ON THE MACHINE .............S-14 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-16 Legal restrictions on copying ..................
Page 3 FD-501 OUTLINE ........................1 COMPOSITION/OPERATION..................15 * For particulars, see the contents of FD-501. LS-501/502 OUTLINE ........................1 COMPOSITION/OPERATION..................7 * For particulars, see the contents of LS-501/502. FS-503 OUTLINE ........................1 COMPOSITION/OPERATION..................7 * For particulars, see the contents of FS-503. FS-607 OUTLINE ........................
Page 4: Safety And Important Warning Items
SAFETY AND IMPORTANT WARNING ITEMS SAFETY AND IMPORTANT WARNING ITEMS Read carefully the Safety and Important Warning Items described below to understand them before doing service work. 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.
Page 5: Safety Warnings
SAFETY AND IMPORTANT WARNING ITEMS 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 CE from the risk of injury.
Page 8 SAFETY AND IMPORTANT WARNING ITEMS Connection to Power Supply WARNING • Check whether the product is grounded properly. If current leakage occurs in an ungrounded product, you may suffer electric shock while operating the product. Connect power plug to grounded wall outlet. Power Plug and Cord WARNING •...
Page 9 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • Check whether dust is collected around the power plug and wall outlet. Using the power plug and wall outlet without removing dust may result in fire. • Do not insert the power plug into the wall outlet with a wet hand.
Page 10 SAFETY AND IMPORTANT WARNING ITEMS Installation Requirements Prohibited Installation Places WARNING • Do not place the product near flammable materials or vol- atile materials that may catch fire. A risk of fire exists. • Do not place the product in a place exposed to water such as rain.
Page 11 SAFETY AND IMPORTANT WARNING ITEMS Servicing Inspection before Servicing CAUTION • Before conducting an inspection, read all relevant docu- mentation (service manual, technical notices, etc.) and proceed with the inspection following the prescribed pro- cedure in safety clothes, using only the prescribed tools. Do not make any adjustment not described in the docu- mentation.
Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When taking a report of problems from a user, check each part and repair properly. A risk of product trouble, injury, and fire exists. • Check the exterior and frame for edges, burrs, and other damages.
Page 13 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Do not remove the cover of the write unit. Do not supply power with the write unit shifted from the specified mount- ing position. The laser light can enter your eye, leading to a risk of loss of eyesight.
Page 14: Handling Of Consumables
SAFETY AND IMPORTANT WARNING ITEMS Handling of Consumables WARNING • Toner and developer are not harmful substances, but care must be taken not to breathe excessive amounts or let the substances come into contact with eyes, etc. It may be stimulative.
Page 15 SAFETY AND IMPORTANT WARNING ITEMS Fuse Fuse CAUTION • CAUTION Double pole / neutral fusing • ATTENTION Double pôle / Fusible sur le neutre Used Batteries Precautions Handling of batteries CAUTION • ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer.
Page 16: Safety Information
SAFETY INFORMATION SAFETY INFORMATION IMPORTANT NOTICE The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Admin- istration implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This copier is certified as a "Class 1"...
Page 17: Indication Of Warning On The Machine
SAFETY INFORMATION INDICATION OF WARNING ON THE MACHINE Caution labels shown below are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. a03up0e001ca S-14...
Page 18 SAFETY INFORMATION a03up0e002ca CAUTION: • You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. And also, when the caution label is peeled off or soiled and cannot be seen clearly, replace it with a new caution label.
Page 19: 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 20: Legal Restrictions On Copying
Legal restrictions on copying Certain types of originals must never be copied with the purpose or intent to pass copies of such originals off as the originals. The following is not a complete list, but is meant to be used as a guide to responsible copy- ing.
Page 21: Composition Of The Service Manual
Composition of the service manual This service manual consists of the following sections and chapters: <Theory of Operation section> OUTLINE: System configuration, product specifications, unit configuration, and paper path COMPOSITION/OPERATION: Configuration of each unit, explanation of the operating system, and explanation of the control system This section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.
Page 22: Notation Of The Service Manual
Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) IC board: Standard printer (2) bizhub PRO 920: Main body (3) PS-502 PostScript3 Option: PS3 Option (4) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...
Page 23 Classification Load symbol Ex. of signal name Description Power to drive the motor CONT Drive signal DRV1 Motor DRV2 Drive signals of two kinds Drive signals (control signals) of three kinds DRV1 DRV2 DRV3 DRV A DRV A DRV B Drive signals (control signals) of four kinds Motor, phases A and B control signals DRV B...
Page 24 Classification Load symbol Ex. of signal name Description SG, S.GND, S_GND Signal ground Ground PG, P.GND Power ground Data carrier detection Serial input SOUT Serial output Data terminal operation available Signal ground (earth) Serial com- DSR, DSET Data set ready munication Transmission request signal Consent transmission signal...
Page 25 Blank Page...
Page 26: Main Body
Theory of Operation SERVICE MANUAL C6500 Main body 2006.09 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 Ver1.0 Sep.2006 CONTENTS CONTENTS bizhub PRO C6500 OUTLINE 1. SYSTEM CONFIGURATION ............1 2.
Page 29 CONTENTS Theory of Operation Ver1.0 Sep.2006 Operation ..............43 9.3.1 Image creation control .
Page 30 Theory of Operation Ver1.0 Sep.2006 CONTENTS 15.3.3 Paper feed control ............69 15.3.4 Remaining paper detection control.
Page 31 CONTENTS Theory of Operation Ver1.0 Sep.2006 21.3.5 Fusing roller/Lw cooling control ..........108 22.
Page 32: Outline
Theory of Operation Ver1.0 Sep.2006 1. SYSTEM CONFIGURATION OUTLINE 1. SYSTEM CONFIGURATION A. System configuration [20] [19] [18] [10] [21] [17] [11] [14] [16] [13] [15] [12] a03ut1c001ca Main body [12] Saddle stitching staple finisher (FS-607) Dehumidifier fan heater (HT-503) [13] Punch kit (PK-512/513) Large capacity paper feed tray (LU-202)
Page 33 1. SYSTEM CONFIGURATION Theory of Operation Ver1.0 Sep.2006 B. Configuration for optional device connection Note • Any combination other than those listed below is not available. Paper feeding option Combinations for finishing AC power to be connected to PF-601 RU-504 FS-503 External (RU-504) PF-601...
Page 34: Product Specifications
Theory of Operation Ver1.0 Sep.2006 2. PRODUCT SPECIFICATIONS 2. PRODUCT SPECIFICATIONS A. Type Type Console type (floor-mounted type) Copying method Four-drum tandem laser electrostatic method Original stand Fixed Original alignment Left rear standard Photo conductor Writing method Two-beam laser scanning method Paper capacity Three trays (500 sheets x 3, 80g/m Multi bypass (250 sheets, 80g/m...
Page 35 2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 Magnification Fixed magnifi- Inch: x 1.000, x 2.000, x 1.545, x 1.294, x 1.214, cation x 0.785, x 0.772, x 0.647, x 0.500 Metric: x 1.000, x 2.000, x 1.414, x 1.224, x 1.154, x 0.866, x 0.816, x 0.707, x 0.500 Zoom magnifi- x 0.25 to x 4.00 (at the step of 0.1%)
Page 36 Theory of Operation Ver1.0 Sep.2006 2. PRODUCT SPECIFICATIONS C. Available types of paper and ranges of paper weight Type of paper Tray1, 2, 3 Bypass feed Plain paper A4 / 8 x 11 or larger : 64 to 256 g/m 64 to 300g/m A4 / 8 x 11 or smaller : 64 to 209 g/m...
Page 37 2. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 D. Materials Parts name Useful life Type name Toner bottle /Y 24,000 prints TN610Y Toner bottle /M 24,000 prints TN610M Toner bottle /C 24,000 prints TN610C Toner bottle /K 35,000 prints TN610K Drum cartridge 200,000 prints DU-102...
Page 38 Theory of Operation Ver1.0 Sep.2006 2. PRODUCT SPECIFICATIONS Machine data Power source Inch: AC208 to 240V 16A, 60Hz Metric: AC230V 15A, 50Hz Maximum power consump- Inch: 4,550W or less (B. When the type of the optional unit connection con- tion figuration (P2) is No.
Page 39: Unit Configuration
3. UNIT CONFIGURATION Theory of Operation Ver1.0 Sep.2006 3. UNIT CONFIGURATION Operation panel DF-609 (option) Fusing section Scanner section OT-502 (option) Toner supply section Developing section Write section Reverse/exit section Paper feed section ADU section Vertical convey- ance section Paper feed section Toner collection section Photo conductor section...
Page 40: Paper Path
Theory of Operation Ver1.0 Sep.2006 4. PAPER PATH 4. PAPER PATH Straight paper exit Paper exit (common) Transfer/Fusing conveyance Paper feed (common) Bypass tray Reversed paper paper feed exit Reverse conveyance ADU conveyance PF paper feed, LU paper feed Tray /1 paper feed Vertical conveyance Tray /2 paper feed...
Page 41 4. PAPER PATH Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 42: Configuration/Operation
Theory of Operation Ver1.0 Sep.2006 5. CONTROL BLOCK DIAGRAM CONFIGURATION/OPERATION 5. CONTROL BLOCK DIAGRAM RS232C Parallel OACB IMCB Write Section PRCB Fusing ACDB SCDB DCPS Unit M MC Image bus Clock SYN UART bus Other buses Individual signal line a03ut2c001ca Board name Functions Overall control board (OACB)
Page 43: Image Creating Process
6. IMAGE CREATING PROCESS Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS Flow and functions Steps Processes Functions Step 1 Charging process Distributes electrostatic charges uniformly over the surface of the four photoconductor drums. Step 2 Laser exposure process Forms an electrostatic latent image on each photoconductor drum.
Page 44: Charging Process (Step 1)
Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS Charging process (Step 1) A negative high DC voltage is applied to the gold-plate tungsten wire of the charging corona which is provided for each Y, M, C, and K photoconductor drums. Then the wire discharges toward the drum in order to charge the entire drum surface with the negative electrostatic charge.
Page 45: Image Development Process (Step 3)
As the toner is negatively charged, it is attracted to the image points on the drum and as a result, a visible toner image is created on the drum. This operation is referred to as "develop- ment."...
Page 46: First Transfer Process (Step 4)
Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS First transfer process (Step 4) The toner images created on each of the Y, M, C, and K photoconductor drums are transferred to the transfer belt one by one in the order of Y, M, C, and K. As a result, the four toner images are overlaid and a complete toner image is formed on the belt.
Page 47: Second Transfer Process (Step 5)
6. IMAGE CREATING PROCESS Theory of Operation Ver1.0 Sep.2006 Second transfer process (Step 5) Transferring the complete toner image formed on the transfer belt to paper is called as "second transfer." For the second transfer, the second transfer roller/Lw located at the back side of the transfer belt rotates to transport paper applying a pressure on the belt, while a high negative DC bias is applied to the second transfer roller/Up inside the belt.
Page 48: Separation Process (Step 6)
Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS Separation process (Step 6) For the second transfer, the paper is negatively charged by the second transfer roller/Up so that the paper makes intimate contact with the transfer belt. Once the toner is transferred to the paper, the paper must be sep- arated from the belt.
Page 49: Drum Cleaning (Sub Step 1)
6. IMAGE CREATING PROCESS Theory of Operation Ver1.0 Sep.2006 Drum cleaning (Sub step 1) The toner remains slightly on the drum after the first transfer. The process that cleans the remaining toner off is called "drum cleaning." The cleaning is made by the cleaning blade provided for each drum. Its edge made of urethane rubber scrapes the toner off the drum surface.
Page 50: Transfer Belt Cleaning (Sub Step 3)
Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS 6.10 Transfer belt cleaning (Sub step 3) The toner remains slightly on the transfer belt after the second transfer. The process that cleans the remaining toner off is called "Transfer belt cleaning". The transfer belt cleaning is made by the cleaning blade.
Page 51: Second Transfer Roller/Lw Cleaning (Sub Step 4)
6. IMAGE CREATING PROCESS Theory of Operation Ver1.0 Sep.2006 6.11 Second transfer roller/Lw cleaning (Sub step 4) Since the second transfer roller/Lw directly contacts with the toner on the transfer belt, the roller is contaminated with the toner. To clean the roller, a negative and positive high DC bias is applied to the second transfer roller/Up alternately so that the toner on the second transfer roller/Lw is attracted to the transfer belt.
Page 52: Toner Collection (Sub Step 5)
Theory of Operation Ver1.0 Sep.2006 6. IMAGE CREATING PROCESS 6.12 Toner collection (Sub step 5) The toner removed from the drums and the transfer belt is collected to the toner collection box through the toner collection screw. a03ut2c013ca Toner collection box Toner collecting port (Drum/M) Toner collecting port (Transfer belt) Toner collecting port (Drum/C)
Page 53: Process Speed
6. IMAGE CREATING PROCESS Theory of Operation Ver1.0 Sep.2006 6.13 Process speed The printer has three process speed settings to accommodate with various types of paper. One of the three set- tings is used according to the paper thickness/weight and whether the paper is coated or not. Paper weight Plain paper Glossy photo paper...
Page 54: Scanner Section
Theory of Operation Ver1.0 Sep.2006 7. SCANNER SECTION 7. SCANNER SECTION Configuration Exposure unit CCD board Shading correc- tion plate CCD unit Mirror unit a03ut2c014ca Drive FRONT a03ut2c015ca Exposure unit Scanner wire/Rr Scanner wire/Fr Scanner motor (M1) V mirror unit...
Page 55: Operation
7. SCANNER SECTION Theory of Operation Ver1.0 Sep.2006 Operation 7.3.1 Scanner/Exposure lamp control A. Home position search of the exposure unit • When the sub power switch (SW2) is turned on, the exposure unit starts to search the home position after the specified time passed.
Page 56 Theory of Operation Ver1.0 Sep.2006 7. SCANNER SECTION (2) The reading operation when the start button is turned on • After finishing the movement for the shading correction, the exposure unit shifts to scanning operation auto- matically. • The other movements of the exposure unit are the same as when the SW2 is turned on. C.
Page 57 7. SCANNER SECTION Theory of Operation Ver1.0 Sep.2006 (2) When selecting the AE density setting a03ut2c019ca Home position White correction (Second time) AE scan Platen APS position Exposure scan White correction (First time) Home position search D. Original reading control •...
Page 58 Theory of Operation Ver1.0 Sep.2006 7. SCANNER SECTION E. Original reading timing • When AE/ACS is not set, the exposure unit movement is the same in the platen mode and the DF. • When AE/ACS is set, the exposure unit movement differs between the platen mode and the DF mode. (1) When AE/ACS is not set a03ut2c020ca Home position...
Page 59 7. SCANNER SECTION Theory of Operation Ver1.0 Sep.2006 (3) When AE/ACS is set (DF mode) [10] [11] [12] [13] [14] a03ut2c022ca Home position AE/ACS scan for the second page (409 mm/s) Platen APS position [10] Exposure scan for the second page (270 mm/s) White correction (First time) White correction (Second time)
Page 60: Original Size Detection Control
Theory of Operation Ver1.0 Sep.2006 7. SCANNER SECTION 7.3.2 Original size detection control A. Detection method • The detection method differs between in the platen mode and in the DF mode. (1) DF mode • Refer to DF-609. (2) Platen mode •...
Page 61: Original Reading Area
7. SCANNER SECTION Theory of Operation Ver1.0 Sep.2006 7.3.3 Original reading area • The original reading area for both in platen mode and DF mode is determined as described below. A. When the automatic "Erase outside of original" is turned ON Out of original auto-reading area equals to the max.
Page 62: Write Section
Theory of Operation Ver1.0 Sep.2006 8. WRITE SECTION 8. WRITE SECTION Configuration Write unit /Y Write unit /M Write unit /C Write unit /K CY2 lens fθ lens Index mirror Dust-proof glass Laser correction Laser drive board motor (LASDB) Index board (INDEXB) Collimator lens unit...
Page 63: Operation
8. WRITE SECTION Theory of Operation Ver1.0 Sep.2006 Operation 8.2.1 Laser beam path [10] a03ut2c026ca Laser diode Index lens Collimator lens Index board (INDEXB) CY1 lens Drum Polygon mirror Dust-proof glass fθ lens [10] CY2 lens...
Page 64: Write Unit Control
Theory of Operation Ver1.0 Sep.2006 8. WRITE SECTION 8.2.2 Write unit control • The read data converted into digital data in the CCD board is sent to the image process board (IPB). • The RGB signals are converted to the YMCK signals in the IPB. •...
Page 65: Color Registration Control
8. WRITE SECTION Theory of Operation Ver1.0 Sep.2006 8.2.3 Color registration control In a black-and-white copier, a toner image formed on its drum can be directly transferred onto paper. In a color copier, the process is much complicated. This machine uses four photoconductor drums correspond to yellow, magenta, cyan, and black colors.
Page 66 Theory of Operation Ver1.0 Sep.2006 8. WRITE SECTION B. Overview of the color registration control In the color registration control, the color registration marks of each color are formed on the transfer belt (outside of the largest paper area). The color registration sensors; /Fr (PS8) and /Rr (PS9) detect the marks to know how much they are shifted from each other.
Page 67 8. WRITE SECTION Theory of Operation Ver1.0 Sep.2006 C. Procedure for the color registration control operation Transferring the color registration mark The color registration mark " " of each black, cyan, magenta, and yellow colors are transferred on the transfer belt in that order forming two marks per line, one each on the left and right sides on the belt.
Page 68 Theory of Operation Ver1.0 Sep.2006 8. WRITE SECTION Detecting the color registration marks The PS8 and PS9 detect the edges of the color registration mark " " of each color and convert the detected result into digital signals. The edge detection is performed at four points (edges) per mark. a03ut2c110ca Detecting direction (transferring direction) Color registration sensor /Fr and /Rr (PS8...
Page 69 8. WRITE SECTION Theory of Operation Ver1.0 Sep.2006 Calculating and correcting the color drift amount The interval between the detection of one edge of the registration mark and the next edge with the PS8 and PS9 sensors are recorded. As shown below, each time interval between the edge detections is determined with the counts of clock signal, and the counts with the PS8 and those with the PS9 are recorded separately.
Page 70: Front/Back Sides Skew Correction In Main Scan Direction
Theory of Operation Ver1.0 Sep.2006 8. WRITE SECTION D. Operation condition of the color registration control The color registration control is performed when: • Operation condition 1 The color registration automatic correction is executed in the service mode. Be sure to perform the above operation when replacing components listed in "9. LIST OF ADJUSTMENT ITEMS"...
Page 71: Image Stabilization Control
8. WRITE SECTION Theory of Operation Ver1.0 Sep.2006 8.2.6 Image stabilization control To achieve stable image quality, the following controls are provided. Refer to "23. IMAGE STABILIZATION CONTROL" for details. (See P.110) • MPC (maximum power control) • APC (automatic power control) •...
Page 72: Configuration
Theory of Operation Ver1.0 Sep.2006 9. PHOTOCONDUCTOR SECTION 9. PHOTOCONDUCTOR SECTION Configuration Drum /Y Drum /M Drum /C Drum /K Drum Transfer belt unit Developing unit Lubricant applying roller Erase lamp Lubrication Cleaning blade Toner collection screw a03ut2c028ca...
Page 73: Drive
9. PHOTOCONDUCTOR SECTION Theory of Operation Ver1.0 Sep.2006 Drive a03ut2c026ca Drum motor /Y (M14), /M (M15), /C (M16) Drum and /K (M17)
Page 74: Image Creation Control
Theory of Operation Ver1.0 Sep.2006 9. PHOTOCONDUCTOR SECTION Operation 9.3.1 Image creation control • The image creation process starts when the drum motor /K (M17) turns on [1], though transferring each color toner image to the transfer belt is made in the order of yellow, magenta, cyan, and black. •...
Page 75 9. PHOTOCONDUCTOR SECTION Theory of Operation Ver1.0 Sep.2006 [1][2] [3] [4] [11] [12] [15] Drum motor /Y (M14) Developing motor /Y (M20) Toner supply motor /Y (M49) Erase lamp /Y (EL/Y) Charging corona /Y (HV/1) Laser drive board /Y (LASDB/Y) Developing bias /Y (DC) (HV/1) Developing bias /Y (AC) (HV/1) 1st transfer /Y (HV/2)
Page 76: Erase Lamp (El) Control
Theory of Operation Ver1.0 Sep.2006 9. PHOTOCONDUCTOR SECTION 9.3.2 Erase lamp (EL) control A. Purposes • To eliminate remained electric potential on the drum surface • To distribute the electric potential uniformly on the drum surface • To light when the drum is in the position before charging B.
Page 77: Charging Section
10. CHARGING SECTION Theory of Operation Ver1.0 Sep.2006 10. CHARGING SECTION 10.1 Configuration Charging wire Charging plate Charging corona /Y Charging corona /M Charging corona /C Charging corona /K a03ut2c031ca...
Page 78: Operation
Theory of Operation Ver1.0 Sep.2006 10. CHARGING SECTION 10.2 Operation 10.2.1 Charging control A. Charging wire • The high voltage unit /1 (HV/1) boosts 24 VDC and apply a negative DC voltage to the charging wire. The wire discharges the negative voltage. •...
Page 79: Intermidiate Transfer Section
11. INTERMIDIATE TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 11. INTERMIDIATE TRANSFER SECTION 11.1 Configuration Color registration sensor shutter /Fr Belt cleaning blade Color registration sensor shutter /Rr Toner guide roller First transfer roller /Y Toner collection screw First transfer roller /M PGC sensor shutter Second transfer roller /Lw Image correction unit...
Page 80: Drive
Theory of Operation Ver1.0 Sep.2006 11. INTERMIDIATE TRANSFER SECTION 11.2 Drive 11.2.1 Transfer belt conveyance/pressure drive [16] [15] [14] [13] [12] [11] [10] a03ut2c033ca First transfer roller /Y Belt driving roller Drum [10] Standby (all released) First transfer roller /M [11] Black-and-white mode (Only first transfer rollers /K is pressed)
Page 81: Second Transfer Pressure/Release Drive
11. INTERMIDIATE TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 11.2.2 Second transfer pressure/release drive a03ut2c026ca Second transfer pressure/release motor Second transfer roller /Lw (M34) Pressure arm Transfer belt...
Page 82: Operation
Theory of Operation Ver1.0 Sep.2006 11. INTERMIDIATE TRANSFER SECTION 11.3 Operation 11.3.1 First transfer roller pressure/release mechanism • During first transfer, the transfer belt [9] is pressed against and released from the drums /Y [8], /M [10], /C [11] and /K [12]. •...
Page 83: First Transfer Control
11. INTERMIDIATE TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 11.3.2 First transfer control A. First transfer operation • Toner on the drum is transferred onto the transfer belt by a DC bias applied to the first transfer roller that presses the transfer belt from its inside. B.
Page 84: Second Transfer Mechanism
Theory of Operation Ver1.0 Sep.2006 11. INTERMIDIATE TRANSFER SECTION 11.3.3 Second transfer mechanism • The cam [5] is rotated by the second transfer pressure/release motor (M34). • When the cam pushes the pressure arm [6], the second transfer roller /Lw [7] is pushed up and pressed to the transfer belt unit [4].
Page 85: Image Correction Unit Shutter Mechanism
11. INTERMIDIATE TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 11.3.5 Image correction unit shutter mechanism • The image correction unit is provided with a shutter mechanism that covers the sensors while they are not used to prevent them from contamination. •...
Page 86: Developing Section
Theory of Operation Ver1.0 Sep.2006 12. DEVELOPING SECTION 12. DEVELOPING SECTION 12.1 Configuration Developing unit /Y Developing unit /M Developing unit /C Developing unit /K Developer conveyance guide Feed magnet Developing roller roller Conveyance screw TRC sensor /Y (TCRS/Y) Agitator screw TRC sensor /M (TCRS/M) TRC sensor /C (TCRS/C) TRC sensor /K (TCRS/K)
Page 87: Drive
12. DEVELOPING SECTION Theory of Operation Ver1.0 Sep.2006 12.2 Drive a03ut2c102ca Agitator screw Conveyance screw Developing coupling /2 Developing coupling /1 Developing motor /Y (M20), /M (M21), /C Developing roller (M22), /K (M23) Feed roller...
Page 88: Operation
Theory of Operation Ver1.0 Sep.2006 12. DEVELOPING SECTION 12.3 Operation 12.3.1 Developer conveyance • The developer in the developing unit is agitated by the agitator screw [1] and conveyed to the conveyance screw [2]. • The developer around the conveyance screw is conveyed to the developing roller [4] by the feed roller [7] and the developer conveyance guide [6].
Page 89: Developing Suction Control
12. DEVELOPING SECTION Theory of Operation Ver1.0 Sep.2006 12.3.3 Developing suction control • The machine intakes the external air to effectively cool down the heat around the developing unit. • The developing fans /1 (M45) [1] and /2 (M46) [2] are provided to cool down the rear of the developing unit. The fresh-air brought by the M45 and M46 is sent to the rear of the developing unit via the duct [4].
Page 90: Toner Supply Section
Theory of Operation Ver1.0 Sep.2006 13. TONER SUPPLY SECTION 13. TONER SUPPLY SECTION 13.1 Configuration Toner supply door open/ close sensor (PS54) Interlock switch /2 (MS2) Piezoelectric sensor /Y (PZS/Y) Piezoelectric sensor /M (PZS/M) Toner bottle clutch /Y (MC14) Toner supply motor /Y (M49) Toner bottle clutch /M (MC15) Toner supply motor /M (M50) Toner bottle motor (M53)
Page 91: Drive
13. TONER SUPPLY SECTION Theory of Operation Ver1.0 Sep.2006 13.2 Drive [11] [12] [10] [13] a03ut2c042ca Toner supply gear /A (same shaft as C) Toner supply motor /C (M51) Toner bottle clutch /Y (MC14) Toner bottle motor (M53) Toner bottle clutch /M (MC15) [10] Toner supply motor /M (M50) Toner bottle clutch /C (MC16)
Page 92: Operation
Theory of Operation Ver1.0 Sep.2006 13. TONER SUPPLY SECTION 13.3 Operation 13.3.1 Toner conveyance control A. Toner supply control to the toner hopper • When toner level in the toner hopper becomes about 50g, the bottle motor (M53) and the toner bottle clutch /Y (MC14), /M (MC15), /C (MC16) and /K (M52) are turned on.
Page 93: Toner Collection Section
14. TONER COLLECTION SECTION Theory of Operation Ver1.0 Sep.2006 14. TONER COLLECTION SECTION 14.1 Configuration Belt waste toner socket Drum /Y waste toner socket Belt collection pipe Drum /M waste toner socket Drum /C waste toner socket Vertical conveyance pipe Drum /K waste toner socket Waste toner door sensor (PS60) Horizontal con-...
Page 94: Drive
Theory of Operation Ver1.0 Sep.2006 14. TONER COLLECTION SECTION 14.2 Drive a03ut2c044ca Drum waste toner inlet Vertical conveyance pipe Horizontal conveyance screw Belt collection screw Horizontal conveyance pipe Transfer belt motor (M18) Paper feed motor (M41) Belt collection cam...
Page 95: Operation
14. TONER COLLECTION SECTION Theory of Operation Ver1.0 Sep.2006 14.3 Operation 14.3.1 Toner collection control • Toner collection section is driven by the transfer belt motor (M18) and the paper feed motor (M41). • Collecting toner is performed by the M18 that drives the transfer belt and the paper feed operation driven by the M41.
Page 96: Paper Feed Section
Theory of Operation Ver1.0 Sep.2006 15. PAPER FEED SECTION 15. PAPER FEED SECTION 15.1 Configuration Paper feed Pre-registration roller roller Separation roller Pick-up roller Lift plate Tray /2 Tray /1 Tray /3 a03ut2c045ca...
Page 97: Drive
15. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 15.2 Drive [17] [19][18] [27] [21][20] [15] [16] [23] [24] [26] [22] [25] [14] [13] [12] [11] [10] [7] [5] a03ut2c046ca Pre-registration roller /3 [15] Lift wire Pre-registration clutch /3 (MC12) [16] Paper lift motor /1 (M38) Drive coupling /3...
Page 98: Operation
Theory of Operation Ver1.0 Sep.2006 15. PAPER FEED SECTION 15.3 Operation 15.3.1 Plate up/down control A. Plate-up operation • The lift plate [7] lies on the both left and right shaft [6]. • The lift wires [8] are connected to each shaft and the plate is kept in a horizontal position by the drive pulley [4], one for each of the lift drive shaft [5] via each pulley [9].
Page 99 15. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 B. Plate-down operation • When each tray is pulled out, the each lift drive shaft is disengaged from the couplings of the lift motors /1 (M38), /2 (M39), /3 (M40). • The disengagement cuts off the drive force from the M38, M39 and M40 to the lift plate, and the plate goes down by its own weight.
Page 100: Paper Feed Control
Theory of Operation Ver1.0 Sep.2006 15. PAPER FEED SECTION 15.3.3 Paper feed control A. Pick-up control • The paper feed motor (M41) starts to rotate upon receiving a print start signal [1]. • After the specified time passed from when the start signal is received [1], the pick-up solenoids /1 (SD7), /2 (SD8) and /3 (SD9) and the paper feed clutches /1 (MC7), /2 (MC9) and /3 (MC11) are turned on.
Page 101 15. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 B. Separation mechanism • The separation roller [4] is driven in the opposite direction [2] to the paper feed direction [10] via the torque limiter [1]. • The separation roller is pressed against the paper feed roller [8] by means of the spring [3] force [9] and the pressure applied from the torque limiter.
Page 102 Theory of Operation Ver1.0 Sep.2006 15. PAPER FEED SECTION C. Loop formation mechanism • The paper passed between the paper feed roller [5] and the separation roller [3] is conveyed to the pre-reg- istration roller [7]. • The paper pushes the actuator [1] and the actuator turns on the paper feed sensors /1 (PS29), /2 (PS35) and /3 (PS41).
Page 103 15. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 D. Pre-registration control • The pre-registration roller is driven by the paper feed motor (M41) via the pre-registration clutch /1 (MC8), / 2 (MC10) and /3 (MC12). • When paper feeding is started with the pick-up roller, the MC8, MC10 and MC12 do not transmit the drive force from the motor to the pre-registration roller so as not to rotate the roller.
Page 104: Remaining Paper Detection Control
Theory of Operation Ver1.0 Sep.2006 15. PAPER FEED SECTION 15.3.4 Remaining paper detection control • Remaining amount of papers in the tray is detected by the paper near empty sensor /1 (PS32), /2 (PS38), / 3 (PS44) [2]. • As the papers get lower, the actuator [6] on the front side of the tray is gradually rotated. •...
Page 105: Bypass Feed Tray Section
16. BYPASS FEED TRAY SECTION Theory of Operation Ver1.0 Sep.2006 16. BYPASS FEED TRAY SECTION 16.1 Configuration Paper feed roller Pick-up roller Lift plate Separation roller Paper size sensor /BP2 (PS49) Paper size sensor /BP1 (PS48) Paper empty sensor /BP (PS47) a03ut2c053ca...
Page 106: Drive
Theory of Operation Ver1.0 Sep.2006 16. BYPASS FEED TRAY SECTION 16.2 Drive a03ut2c054ca Lift gear Drive coupling Pick-up roller Paper feed roller Separation roller Paper feed clutch /BP (MC6) Paper feed motor (M41) Paper lift motor /BP (M35)
Page 107: Operation
16. BYPASS FEED TRAY SECTION Theory of Operation Ver1.0 Sep.2006 16.3 Operation 16.3.1 Plate up/down control A. Plate-up operation • The paper lift motor /BP (M35) drives the lift gear to lift the lift plate. B. Plate-down operation • The paper lift motor /BP (M35) drives the lift gear to lower the lift plate. C.
Page 108: Paper Feed Control
Theory of Operation Ver1.0 Sep.2006 16. BYPASS FEED TRAY SECTION 16.3.3 Paper feed control A. Pick-up control • The paper feed motor (M41) starts to rotate upon receiving a print start signal [1]. • After the specified time passed from when the start signal is received [1], the pick-up solenoid /BP (SD5) and the paper feed clutch /BP (MC6) are turned on [2].
Page 109: Paper Empty Detection Control
16. BYPASS FEED TRAY SECTION Theory of Operation Ver1.0 Sep.2006 B. Separation mechanism • The separation roller [4] is driven in the opposite [1] to the paper feed direction [8] via the torque limiter [6]. • The separation roller is pressed against the paper feed roller [10] by means of the spring [5] force [9] and the pressure applied from the torque limiter.
Page 110: Vertical Conveyance Section
Theory of Operation Ver1.0 Sep.2006 17. VERTICAL CONVEYANCE SECTION 17. VERTICAL CONVEYANCE SECTION 17.1 Configuration Intermediate conveyance roller /1 Intermediate conveyance roller /1 Vertical conveyance sensor (PS50) Vertical conveyance door sensor (PS51) Vertical conveyance door a03ut2c056ca...
Page 111: Drive
17. VERTICAL CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 17.2 Drive a03ut2c057ca Intermediate conveyance clutch /1 (MC13) Drive coupling Paper feed motor (M41) Intermediate conveyance roller /1...
Page 112: Operation
Theory of Operation Ver1.0 Sep.2006 17. VERTICAL CONVEYANCE SECTION 17.3 Operation 17.3.1 Vertical conveyance control • Paper that is fed from trays /1, /2 and /3 is conveyed to the intermediate conveyance section of ADU. • Paper that is fed from the tray /1 is conveyed to the intermediate conveyance roller /2 of the intermediate conveyance section (ADU) by the pre-registration roller.
Page 113: Registration Section
18. REGISTRATION SECTION Theory of Operation Ver1.0 Sep.2006 18. REGISTRATION SECTION 18.1 Configuration Registration tempera- Leading edge sensor ture sensor (TEMS1) (PS63) Registration driven roller Leading edge Registration sensor (PS63) sensor (PS22) Registration roller Registration Loop roller Loop roller driven roller Registration temperature sensor (TEMS1) Registration sensor (PS22) a03ut2c058ca...
Page 114: Drive
Theory of Operation Ver1.0 Sep.2006 18. REGISTRATION SECTION 18.2 Drive a03ut2c059ca Loop motor (M31) Registration roller Loop roller Registration motor (M30)
Page 115: Operation
18. REGISTRATION SECTION Theory of Operation Ver1.0 Sep.2006 18.3 Operation 18.3.1 Loop control • All papers are passed through the loop roller and conveyed to the registration roller. • Loop motor (M31) that drives the loop roller stops after specified time passed from when the registration sensor (PS22) turns ON upon detecting the leading edge of paper.
Page 116: Registration Operation
Theory of Operation Ver1.0 Sep.2006 18. REGISTRATION SECTION 18.3.2 Registration operation • After the specified time passed from when the print start signal is received [1], the loop motor (M31) starts to turn to rotate the loop roller. • The paper conveyed from the intermediate conveyance section or the ADU is conveyed to the registration roller by the loop roller.
Page 117: Adu Section
19. ADU SECTION Theory of Operation Ver1.0 Sep.2006 19. ADU SECTION 19.1 Configuration ADU conveyance ADU pre-registration roller Intermediate conveyance roller /2 ADU conveyance roller /2 roller /1 Intermediate Intermediate conveyance ADU conveyance conveyance sensor /1 ADU conveyance roller /3 sensor /2 (PS28) sensor (PS61) (PS27)
Page 118: Drive
Theory of Operation Ver1.0 Sep.2006 19. ADU SECTION 19.2 Drive [14] [15] [16][17] [18] [19][20] [21] [1][2] [11] [10] [13] [12] a03ut5c062ca Intermediate conveyance roller /2 [12] ADU loop motor (M57) Intermediate conveyance clutch /2 (MC4) [13] ADU reverse motor (M32) Paper feed motor (M41) [14] ADU conveyance roller /1...
Page 119: Operation
19. ADU SECTION Theory of Operation Ver1.0 Sep.2006 19.3 Operation 19.3.1 Paper reverse control A. Paper conveyance • During paper conveyance, the ADU gate [1] is open. • Paper conveyed from the reverse roller /Lw [2] is conveyed to the ACU reverse roller [3] through the ADU gate.
Page 120 Theory of Operation Ver1.0 Sep.2006 19. ADU SECTION B. Loop formation • When the ADU stop sensor (PS20) [3] detects the rear end of paper and turns OFF, ADU loop roller [5] stops after the specified time passed. • While the paper is stopped with its leading edge nipped by the ADU loop roller, the ADU reverse roller [4] continues to rotate.
Page 121 19. ADU SECTION Theory of Operation Ver1.0 Sep.2006 C. Paper reverse • When the ADU reverse roller [6] stops, the ADU gate [4] closes. • After the specified time passed from when the ADU reverse roller stops, the ADU loop roller [8] and ADU reverse roller rotate reversely at the same time.
Page 122: Adu Conveyance Control
Theory of Operation Ver1.0 Sep.2006 19. ADU SECTION 19.3.2 ADU conveyance control • When the front side of the first sheet is fixed [2], after receiving a print start signal [1], the ADU loop motor (M57) and the ADU reverse motor (M32) start to rotate in the normal direction. •...
Page 123: Reverse/Paper Exit Section
20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 20. REVERSE/PAPER EXIT SECTION 20.1 Configuration Reverse gate Reverse gate Decurler sensor (PS62) Reverse decurler roller Reverse paper exit sensor (PS19) Small size roller Reverse decurler roller Reverse roller/Lw: Paper exit decurler roller Paper exit roller Paper exit...
Page 124: Drive
Theory of Operation Ver1.0 Sep.2006 20. REVERSE/PAPER EXIT SECTION 20.2 Drive 20.2.1 Reverse/paper exit drive a03ut2c070ca Decurler motor (M55) Reverse paper exit motor (M33) Reverse decurler roller Paper exit solenoid (SD4) Small size roller Reverse gate Reverse roller /Lw...
Page 125: Paper Exit Drive/Ot-502 Drive
20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 20.2.2 Paper exit drive/OT-502 drive a03ut2c071ca Paper exit motor (M54) OT-502 Paper exit decurler roller OT paper exit roller Paper exit roller...
Page 126: Operation
Theory of Operation Ver1.0 Sep.2006 20. REVERSE/PAPER EXIT SECTION 20.3 Operation 20.3.1 Conveyance control A. Reverse/paper exit switch control • The paper exit path for paper conveyed from the fusing section is switched by the paper exit gate. • The paper exit gate is driven by the paper exit solenoid (SD4). •...
Page 127 20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 (2) ADU conveyance path • This paper path is used to exit paper face down after printing the one side for one-side printing or double- side printing. a03ut2c073ca Fusing section Reverse paper exit sensor (PS19) Reverse decurler roller OT-502 (Option) Fusing paper exit sensor (PS17)
Page 128 Theory of Operation Ver1.0 Sep.2006 20. REVERSE/PAPER EXIT SECTION C. Reverse/paper exit • This paper path is used to exit paper face down after printing on the backside in one-side printing or dou- ble-side printing. [10] [11] [12] [13] a03ut2c074ca Fusing section Paper exit pressure sensor (PS10) Reverse decurler roller...
Page 129: Reverse/Paper Exit Timing Control
20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 20.3.2 Reverse/paper exit timing control • In face down paper exit, paper conveyed from the fusing section to the reverse decurler roller passing under the reverse gate. • The reverse decurler roller conveys the paper to the small size roller by the normal rotation of the decurler motor (M55).
Page 130: Paper Exit Decurler Roller Pressure Control
Theory of Operation Ver1.0 Sep.2006 20. REVERSE/PAPER EXIT SECTION 20.3.3 Paper exit decurler roller pressure control A. Paper exit decurler roller pressure mechanism • The paper exit decurler roller [1] that faces to the paper exit roller is pressed by the rotation of the cam [2]. •...
Page 131: Reverse Decurler Roller Rotation Control
20. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 20.3.4 Reverse decurler roller rotation control A. Purpose • To prevent the reverse decurler roller from deformation when the roller has not been used for certain period of time. • To minimize unevenness in temperature on the decurler roller surface, which can cause unevenness in color of printed images, after a continuous printing is carried out.
Page 132: Fusing Section
Theory of Operation Ver1.0 Sep.2006 21. FUSING SECTION 21. FUSING SECTION 21.1 Configuration Fusing belt Fusing lamp /Up (L2, L3, L4) Fusing roller /1 Fusing paper exit roller /Up Fusing roller /2 Fusing roller /Lw Fusing heater lamp /4 (L5) a03ut2c077ca...
Page 133: Drive
21. FUSING SECTION Theory of Operation Ver1.0 Sep.2006 21.2 Drive a03ut2c078ca Fusing motor (M29) Fusing roller /1 Cam (fusing roller /Lw for applying pressure) Fusing belt Same gear Fusing roller /2 Fusing exit roller /Lw Fusing roller /Lw...
Page 134: Operation
Theory of Operation Ver1.0 Sep.2006 21. FUSING SECTION 21.3 Operation 21.3.1 Fusing roller drive control A. Fusing process speed table • There are three types of fusing process speed 1/1 speed (300mm/s), 2/3 speed (207mm/s), 1/2 speed (150mm/s). • The fusing process speed is selected according to the paper weight (thickness) and whether the glossy mode or not as shown in the table below.
Page 135 21. FUSING SECTION Theory of Operation Ver1.0 Sep.2006 B. Fusing process speed correction control • This control is carried out to avoid improper slack in paper when the paper comes to the fusing section from the second transfer section. • If the fusing process speed differs from the process speed of the second transfer section (difference in speed between the fusing roller /Lw [8] and the second transfer roller /Lw [4]) when the leading edge of the paper is nipped [1] by the fusing roller /Lw, the paper loop amount becomes increase.
Page 136: Pressure/Release Control
Theory of Operation Ver1.0 Sep.2006 21. FUSING SECTION 21.3.2 Pressure/release control • The fusing roller /Lw is pressed against the fusing belt during performing a print job. • When the fusing paper exit sensor (PS17) detects paper (the last page of the job) after completion of fusing, the fusing roller /Lw moves to stop pressing the fusing belt.
Page 137: Fusing Temperature Control
21. FUSING SECTION Theory of Operation Ver1.0 Sep.2006 21.3.3 Fusing temperature control A. Fusing temperature detection • The fusing roller /1 is heated by the fusing heater lamp /1 (L2), /2 (L3), /3 (L4). • The fusing belt is heated by the heated fusing roller /1. •...
Page 138: Protection Against Abnormality
Theory of Operation Ver1.0 Sep.2006 21. FUSING SECTION 21.3.4 Protection against abnormality • When the temperature sensor /1 (TEMS/1), /2 (TEMS/2), /3(TEMS/3), /4 (TEMS/4) is over the prescribed temperature for a specified time period, it is judged as a high temperature error and the main relay (RY1) is turned off, then the product is stopped after the first transfer, second transfer and fusing pressure are stopped/released.
Page 139: Fusing Roller/Lw Cooling Control
21. FUSING SECTION Theory of Operation Ver1.0 Sep.2006 21.3.5 Fusing roller/Lw cooling control • When the temperature of the fusing roller /Lw [2] detected by the temperature sensor /2 (TEMS/2) rises higher than a specified temperature, and the difference between the detected and the specified tempera- tures exceeds a predetermined level, the fusing fan /Lw (M65) [4] turns on and cools down the fusing roller /Lw.
Page 140: Interface Section
Theory of Operation Ver1.0 Sep.2006 22. INTERFACE SECTION 22. INTERFACE SECTION 22.1 Configuration CN493 CN495 CN1000 USB port (USB TypeB) Connector for printer controller RJ45 Ethernet connector Serial port (RS-232C) Service port Parallel port (IEEE1284 com- pliant) a03ut2c084ca 22.2 Application Type Application Connector for printer controller...
Page 141: Image Stabilization Control
23. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Sep.2006 23. IMAGE STABILIZATION CONTROL 23.1 Outline • This unit carries out various image stabilizing controls in order to achieve stable high print quality. • The image stabilizing controls carried out during printing are different from those carried out when the sub power switch (SW2) is turned on.
Page 142 Theory of Operation Ver1.0 Sep.2006 23. IMAGE STABILIZATION CONTROL A. Drum rotation control (1) Purpose • To prevent uneven electrostatic charges on the drum, which causes improper images under high humidity conditions. • To prevent unevenness in density caused by the difference in sensitivity between the part that the cleaner or the developer is applied to and other parts when leaving them in low/normal humidity conditions.
Page 143 23. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Sep.2006 C. Color registration adjustment (1) Purpose • Performed in order to correct the misalignment in main or sub scanning direction, entire horizontal magnifi- cation, and skew. (2) Operation • The color registration sensors /Fr and /Rr reads a patch image created on the transfer belt. •...
Page 144 Theory of Operation Ver1.0 Sep.2006 23. IMAGE STABILIZATION CONTROL E. Maximum density correction control (1) Purpose • To keep the maximum density constant regardless of the ambient condition and the number of printed pages. (2) Operation • The maximum density correction method differs in each color of Y, M, C, and K. •...
Page 145 23. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Sep.2006 G. Vm adjustment (1) Purpose • To achieve stabilized intermediate exposure potential regardless of a drop in sensitivity of photosensitive materials or the stain of the writing system. (2) Operation • While the drums are irradiated with a PWM128 intensity laser beam, the electric potential on the drums are detected by the drum potential sensor /Y (DPRS/Y), /M (DPRS/M), /C (DPRS/C), and /K (DPRS/K).
Page 146: Image Stabilizing Controls When Selecting The "Stability" In Expert Settings
Theory of Operation Ver1.0 Sep.2006 23. IMAGE STABILIZATION CONTROL 23.2.2 Image stabilizing controls when selecting the “Stability“ in expert settings The image stabilizing controls described below is only executed when "Stability" is selected in "Expert adjust- ment" → "Quality adjustment" → "Image Quality stability". A.
Page 147: Other Image Stabilizing Controls
23. IMAGE STABILIZATION CONTROL Theory of Operation Ver1.0 Sep.2006 23.2.3 Other Image stabilizing controls The image stabilizing controls described below is only executed when selecting "Stability" on the "Expert adjust- ment" → "Quality adjustment" → "Image Quality stability" screen. A. Toner refresh mode control a03ut2c113ca A.
Page 148: Image Processing
Theory of Operation Ver1.0 Sep.2006 24. IMAGE PROCESSING 24. IMAGE PROCESSING 24.1 Operation flow 3 line CCD sensor / A/D convert • Shading correction • Shading • RGB gap correction correction • Brightness/Density conversion • Image distinction • Scanner gamma correction •...
Page 149: Image Type Classification
24. IMAGE PROCESSING Theory of Operation Ver1.0 Sep.2006 24.2 Image type classification A. OUTLINE • A scanned image type is classified as text, dots, solid or chroma. • After the classification, gamma curve used for writing the image is changed to the appropriate one for the image type.
Page 150 Theory of Operation Ver1.0 Sep.2006 24. IMAGE PROCESSING B. Writing bit and resolution Relations between number of write bit and the resolution by the combination of the display and the image quality is shown in the figure below. Display of operation panel Enhance Mode Writing bit and resolution Line1...
Page 151 24. IMAGE PROCESSING Theory of Operation Ver1.0 Sep.2006 (1) Print image using 8bit, 1bit ED Original image Print image (2) Print image using 200lpi or 140lpi screen Original image Print image Print image Line screen Dot screen...
Page 152: Other Controls
Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS 25. OTHER CONTROLS 25.1 Power On control 25.1.1 Parts that operate when the main power switch (SW1) is turned on A. Configuration CBR/1 5VDC IMCB OACB DCPS/1 CBR/2 DCPS/2 RY/2 LU/PF(OPTION) HTR1 HTR2 ACDB a03ut2c091ca...
Page 153: Parts That Operate When The Sub Power Switch (Sw2) Is Turned On
25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 25.1.2 Parts that operate when the sub power switch (SW2) is turned on A. Configuration CBR/1 5VDC OACB IMCB 3.3VDC DCPS/1 24VDC 12VDC CBR/2 24VDC 12VDC PRCB 5VDC 24VDC DCPS/2 24VDC 24VDC 24VDC 24VDC 24VDC...
Page 154: Fan Control
Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS 25.2 Fan control 25.2.1 Configuration [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [15] [14] [13] [12] [11] [10] a03ut2c095ca Main unit fan (M47) [14] ADU fan /2 (M67) Developing fan /1 (M45) [15] ADU fan /1 (M66)
Page 155: Operation
25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 25.2.2 Operation A. Scanner fan (M2) control (1) Purpose • To cool the scanner section. (2) ON timing • Starts to operate upon starting of scanning. During DF scan, however, the fan keeps operating. (3) OFF timing •...
Page 156 Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS E. IPB fan /1 (M24), /2 (M25) control (1) Purpose • To cool around the image processing board (IPB). (2) ON timing • Rotates at low speed during standby. • Starts to operate upon starting of printing. •...
Page 157 25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 Power supply fan (M42) control (1) Purpose • To cool the DC power unit /1 (DCPS/1), /2 (DCPS/2). (2) Low/high speed switching timing • Rotates at low speed during standby. • Switches to high speed upon starting of printing. •...
Page 158 Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS M. Charging air suction fan (M48) control (1) Purpose • To cool around the charging coronas. (2) ON timing • Starts to operate upon starting of charging. • Starts to operate upon starting of image stabilization control. (3) OFF timing •...
Page 159 25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 Q. ADU fan /2 (M67) control (1) Purpose • To cool the ADU loop motor (M57) and the ADU reverse motor (M32). (2) ON timing • Starts to operate upon starting of printing in double side or reverse paper exit mode. (3) OFF timing •...
Page 160: Counter Control
Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS 25.3 Counter control 25.3.1 Structure of counter TCT/1 PRCB TCT/2 IMCB OACB OB/3 a03ut2c096ca...
Page 161: Counter Operation
25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 25.3.2 Counter operation Item Specification/mechanism Total counter /1 (TCT/1) • Display the total number of printed sheets in all print modes. • Mechanical counter driven by electrical signals. • Counts up by paper exit signal. Total counter /2 (TCT/2) •...
Page 162: Dehumidifier Heater Control
Theory of Operation Ver1.0 Sep.2006 25. OTHER CONTROLS 25.4 Dehumidifier heater control A. Configuration CBR/1 CBR/2 RY/2 LU/PF(OPTION) HTR1 HTR2 ACDB a03ut2c098ca B. Operation • The dehumidifier heater switch (SW3) supplies AC power to the sub relay (RY/2) inside the AC drive board (ACDB).
Page 163: Acs Control
25. OTHER CONTROLS Theory of Operation Ver1.0 Sep.2006 25.5 ACS control 25.5.1 Switching from the color mode to the black-and-white mode A. OUTLINE • If more than 5 black-and-white sheets are fed consecutively from the DF in which both the color sheets and the black-and-white sheets are stored, the pressure on the first transfer rollers /Y/M/C are released and it shifts to the black-and-white mode.
Page 164 Theory of Operation SERVICE MANUAL DF-609 2006.09 Ver. 1.0...
Page 165 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 166 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS DF-609 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 167 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 168: Outline
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Belt conveyance type original auto feeder B. Functions Original size A3, B4, A4, A4S, B5, B5S, A5, A5S, B6S 11 x 17, 8 x 14, 8 x 11, 8 x 11S, 5 x 13, 8...
Page 169 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 Scan speed Single-sided mode (including thin-paper mode): 39 sheets/min. x 11) Double-sided mode (including thin-paper mode): 26 sheets/min. Single-sided mode (thick-paper mode): 28 sheets/min. Double-sided mode (thick-paper mode): 14 sheets/min. Scanning system After the original that is conveyed on the belt stops, the scanner moves and scans the original.
Page 170: Unit Configuration Diagram
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION DIAGRAM 2. UNIT CONFIGURATION DIAGRAM a052t1c001ca Reverse/paper exit section Paper feed section Conveyance section...
Page 171: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Single-sided mode a052t1c003ca Reverse/paper exit Swing-back Conveyance to the reverse stacker Paper feeding...
Page 172: Double-Sided Mode
Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Double-sided mode A. Double-sided mode (front side scan) a052t1004ca Reverse conveyance/back side Paper feeding Position shift in front side scanning (swing-back) B. Double-sided mode (back side scan) a052t1c005ca Paper exiting Conveyance to the back side scanning posi- tion...
Page 173 3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 174: Configuration/Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION CONFIGURATION/OPERATION 4. PAPER FEED SECTION Configuration a052t2c001ca Pick-up roller Separation roller Paper feed roller Registration roller No paper sensor...
Page 175: Drive
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Drive a052t2c002ca Registration clutch (MC301) Separation roller (with torque limiter) Registration roller Paper feed roller (with one-way clutch) Paper feed motor (M301) Pick-up roller...
Page 176: Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION Operation 4.3.1 Paper feed control • The pick-up roller [7], paper feed roller [6], and registration roller [3] are driven by the paper feed motor (M301). • M301 drives in both directions, forward and reverse. When it drives in forward, the pick-up roller and the paper feed roller rotate to transfer papers, while the registration roller does not rotate.
Page 177 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 A. Single-sided mode The paper feed motor (M301) switches to high speed [1] and the pick-up roller is pressed against the origi- nals set to the original feed tray. The pick-up roller conveys the originals to the paper feed roller and the separation roller. The paper feed roller conveys a piece of original at the top, and the separation roller keeps the rest of the originals from being transferred.
Page 178 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION B. Double-sided mode The first sheet of original is conveyed in the same manner as in single-sided mode. [1] While front side of the first sheet is being scanned [2], the second sheet is conveyed from the tray and is formed a loop to corrected its skew [3], and the registration roller nips the original [4].
Page 179: Original Size Detection
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.2 Original size detection • Original size detection signal is detected by scanning in the main direction and sub direction. • The original size detection method differs between normal copy mode and mixed original copy mode. A.
Page 180: No Paper Detection
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION For inch area Other Standard originals (max. original size detected by guide plate) originals 11 x 17 — — — — x 11 — — — — x 14 — Thick Thick paper paper...
Page 181: Conveyance Section
5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION Configuration a052t2c006ca Conveyance belt Conveyance roller...
Page 182: Drive
Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION Drive a052t2c007ca Conveyance belt Conveyance motor (M302) Conveyance roller...
Page 183: Operation
5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 Operation 5.3.1 Scanning and conveyance control • The conveyance belt is driven by the conveyance motor (M302). • In single-sided mode, a swing-back to position the original for scanning is performed after the original is conveyed from the paper feed section to the conveyance belt.
Page 184 Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION (2) Control After the registration roller nips the original [1], the original is conveyed [2] from the paper feed section. After the specified time has elapsed from when the timing sensor (PS302) has turned off (Rear end detec- tion), M302 is turned off and the original is conveyed to the point that the rear end of the original comes over the positioning plate, and then the conveyance stops [3].
Page 185 5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 B. Double-sided mode (1) Operation • The paper path of the reverse paper exit section is created by the paper exit gate [1] and the reverse gate [8]. Both gates are set by turning off the paper exit solenoid (SD301) and turning on the reverse solenoid (SD302).
Page 186 Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION While operating the reverse conveyance [2], the original is conveyed at low speed [4] after a short pause [3] and the original is stuck [5] against the positioning plate [1]. The back side scan is performed. a052t2c011ca Stuck position Pushing at low speed (Reverse conveyance)
Page 187 5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 (2) Control The front side scan is performed [1] in the same operating method as in the single-sided mode. M302 starts driving forward at the same time as M303 is turned on. Then the original is conveyed to the reverse/conveyance section [2].
Page 188: Reverse/Paper Exit Section
Theory of Operation Ver1.0 Sep.2006 6. REVERSE/PAPER EXIT SECTION 6. REVERSE/PAPER EXIT SECTION Configuration a052t2c013ca Paper exit sensor (PS306) Reverse gate Paper exit gate Reverse stacker Reverse sensor (PS305) Paper exit stacker Reverse roller Paper exit roller...
Page 189: Drive
6. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 Drive a052t2c014ca Paper exit gate Reverse/paper exit motor (M303) Reverse solenoid (SD302) Paper exit roller (with one-way clutch) Reverse gate Paper exit solenoid (SD301) Reverse roller...
Page 190: Operation
Theory of Operation Ver1.0 Sep.2006 6. REVERSE/PAPER EXIT SECTION Operation • The reverse roller and the paper exit roller are driven by the reverse/paper exit motor (M303). • One-way clutch rotates the paper exit roller only in the paper exit direction when M303 drives both forward and reverse.
Page 191: Paper Exit Control
6. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 6.3.1 Paper exit control A. Straight paper exit (1) Operation • When the paper exit solenoid (SD301) is turned on, the paper exit gate [1] is set in the straight paper exit path [3].
Page 192 Theory of Operation Ver1.0 Sep.2006 6. REVERSE/PAPER EXIT SECTION (2) Control When the paper exit solenoid (SD301) is turned on [2] after the scanning [1] is completed, the paper exit gate is set in the straight paper exit path. The reverse/paper exit motor (M303) is turned on at the same time as the conveyance motor (M302), and the original conveyed by the conveyance belt is conveyed to the paper exit roller of the reverse/paper exit section.
Page 193 6. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 B. Reverse/paper exit (1) Operation • The paper exit solenoid (SD301) and the reverse solenoid (SD302) are off in this mode. The original [4] from the conveyance section is fed around the reverse roller [3] through the paper exit gate [1], and conveyed to the reverse stacker [5] by the reverse gate [7].
Page 194 Theory of Operation Ver1.0 Sep.2006 6. REVERSE/PAPER EXIT SECTION a052t2c019ca Original Paper exit roller Reverse/paper exit...
Page 195 6. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 (2) Control The original from the conveyance section is conveyed to the path of the reverse stacker [1] that is set by paper exit gate and the reverse gate. When the reverse sensor (PS305) detects the rear end of the original [2] and turns off, M303 reduces its speed.
Page 196: Reverse Paper Exit Control
Theory of Operation Ver1.0 Sep.2006 6. REVERSE/PAPER EXIT SECTION 6.3.2 Reverse paper exit control (1) Operation • In reverse conveyance mode, the paper exit solenoid (SD301) is set to OFF while the reverse solenoid (SD302) is set to ON. • The original [3] from the conveyance section wraps around the reverse roller [2] by the paper exit gate [1].
Page 197 6. REVERSE/PAPER EXIT SECTION Theory of Operation Ver1.0 Sep.2006 (2) Control After the front side scan is performed [1], the conveyance motor (M302) [2] conveys the original from the conveyance section, and then the reverse/paper exit motor (M303) conveys it to the reverse path that is set the paper exit solenoid (SD301) OFF and the original is fed around the reverse roller [3].
Page 198 Theory of Operation SERVICE MANUAL PF-601/HT-504 2006.09 Ver. 1.0...
Page 199 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 200 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS PF-601/HT-504 OUTLINE 1. PRODUCT SPECIFICATIONS............1 PF-601 .
Page 201 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 202: Outline
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS PF-601 A. Type Type Front loading type two-tray paper feeder B. Functions Number of trays Two trays (All trays universal) Tray capacity 6,000 sheets (80 g/m standard paper) = 3,000 sheets x 2 trays C.
Page 203 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 HT-504 A. Type Type Fan heater type dehumidifier heater B. Maintenance Machine service life Same as the main body. C. Machine data Power source 24/5VDC (supplied from the main body), 200 to 240VAC Maximum power consump- DC: 6W or less, AC: 580W or less tion...
Page 204: Unit Configuration Diagram
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION DIAGRAM 2. UNIT CONFIGURATION DIAGRAM a03xt1c001ca Paper feed section HT-504 (Optional) Conveyance section...
Page 205: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH a03xt1c002ca From tray/4 From tray/4 and /5 to the main body From tray/5...
Page 206: Configuration/Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION CONFIGURATION/OPERATION 4. PAPER FEED SECTION Configuration Pick-up roller Paper feed roller Separation roller Paper empty sensor /1 (PS3), /2 (PS11) Paper feed assist fans Paper size VR/1 (VR1) and VR/2 (VR3) (Main scan direction) Paper size sensors /Rt1 (PS5), /Lt1 Remaining paper VR/1 (PS6), /Rt2 (PS13), and /Lt2 (PS14)
Page 207: Drive
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Drive 4.2.1 Tray lift drive a03xt2c002ca Lift wire/Fr2 and /Rr2 Paper lift plate Lift wire/Fr1 and /Rr1 Paper lift motor/1 (M2) and /2 (M3)
Page 208: Paper Feed Drive
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.2.2 Paper feed drive [10] [11] a03xt2c003ca Paper feed roller Separation clutch /1 (MC2) Pick-up roller Paper feed clutch /2 (MC4) Separation roller Coupling (transmission of driving force to the tray/5) Torque limiter Paper feed clutch/1 (MC1) [10]...
Page 209: Pick-Up Drive
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.2.3 Pick-up drive a03xt2c004ca Pick-up solenoid/1 (SD1) and /2 (SD5) [2] Pick-up roller...
Page 210: Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION Operation 4.3.1 Plate up/down control A. Plate-up mechanism • The paper lift motors/1 (M2) and /2 (M3) drive the pulley to wind up the lift wires in order to lift the paper lift plate.
Page 211: Paper Size Detection Control
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.2 Paper size detection control A. Main scan/Sub scan direction detection • The detection methods differ between main scanning direction and sub-scanning direction. (1) Main scan direction • The size in the main scan direction is detected by the paper size VR/1 (VR1) and /2 (VR3) that move together with the paper guide.
Page 212 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION Paper size Paper size sensor /Lt1 (PS5) and /Lt2 (PS14) /Rt1 (PS5) and /Rt2 (PS13) A6S, B6S, A4S, B5, A3, OFF (light blocking) 11 x 17, 13 x 19 x 11S, 8K, 16KS A5S, B5S, A4, SRA4, B4, ON (exposure) S, 8...
Page 213 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 B. Assist guide detection control • The paper size sensors /Fr1 (PS7), /Fr2 (PS15) [2], /Rr1 (PS8), and /Rr2 (PS16) [3] detect opening or clos- ing of the auxiliary guide [1] when A6S size paper are set. •...
Page 214: Pick-Up Mechanism
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.3 Pick-up mechanism • Paper is picked up when the pick-up solenoids/1 (SD1) and /2 (SD5) are turned off. • When the solenoids SD1and SD5 are turned off, the pick-up roller goes down to press paper by its own weight.
Page 215: Separation Mechanism
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.4 Separation mechanism • Papers are separated by the separation roller [5]. • The separation roller [5] rotates in the direction [10] opposite to the paper conveyance direction [9] by means of the torque limiter [8]. The roller is pressed against the paper feed roller by force exerted by the spring [7] and the torque limiter.
Page 216: Air Assist Mechanism
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.5 Air assist mechanism • The paper feed assist fans that are provided on the paper guides in the trays/4 and /5 blow air [7] onto paper [9] in order to assist the separation of paper. •...
Page 217 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 A. Operation timing • When the coated paper is selected in the paper setting, the paper feed assist fans/Fr11 (FM1), /Fr12 (FM3), /Rr11 (FM2) and /Rr12 (FM4) or the paper feed assist fans/Fr21 (FM5), /Fr22 (FM7), /Rr21 (FM6) and /Rr22 (FM8) of corresponding tray start to operate when the START button is pressed.
Page 218: Paper Empty Detection Control
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.6 Paper empty detection control • Paper empty detection on the tray is made according to on/off statuses of the upper limit sensors/1 (PS1) and /2 (PS9) [6], and the paper empty sensors/1 (PS3) and /2 (PS11) [1]. •...
Page 219: Remaining Paper Detection Control
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.7 Remaining paper detection control • Remaining paper detection is made by the remaining paper VR/1 (VR2) and /2 (VR4) that are interlocked with the up/down operation of the paper lift plate via the pulley and the gear. •...
Page 220: Conveyance Section
Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION 5. CONVEYANCE SECTION Configuration Vertical conveyance roller/2 Vertical conveyance roller/1 Vertical conveyance roller/3 Small size roller Horizontal conveyance roller/2 Multi feed Horizontal conveyance roller/1 detection board /R (MFDTB/R), /S (MFDTB/S) Pre-registration roller Centering sen- sor (PS25) a03xt2c014ca...
Page 221: Drive
5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 Drive [13] [12] [11] [10] [14] [15] a03xt2c015ca Coupling (transmission of driving force to Vertical conveyance clutch/3 (MC9) the tray/4) Vertical conveyance roller/3 Coupling (transmission of driving force to [10] Horizontal conveyance clutch/1 (MC10) the tray/5) [11] Horizontal conveyance roller/1...
Page 222: Operation
Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION Operation 5.3.1 Pre-registration control • In order to correct skew of paper, paper fed from the tray strikes against the pre-registration roller that is stopping at that time. • The pre-registration clutch (MC12) is turned on, the driving force of the paper feed motor (M1) is transmitted to the pre-registration roller to feed paper inside the main body.
Page 223: Conveyance Control
5. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 5.3.2 Conveyance control • For the vertical conveyance, the driving force of the paper feed motor (M1) [1] is transmitted by turning on and off the vertical conveyance clutches /1 (MC7) [4], /2 (MC8) [7], and /3 (MC9) [8]. •...
Page 224: Multi Feed Detection Control
Theory of Operation Ver1.0 Sep.2006 5. CONVEYANCE SECTION 5.3.3 Multi feed detection control • The multi feed sensor is provided in the horizontal conveyance section to detect multi feed. • The multi feed sensor is a ultrasonic sensor consisted of a sending and receiving section. The ultrasonic waves sent from the multi feed detection board/S (MFDTB/S) are received at the multi feed detection board/R (MFDTB/R).
Page 225: Others
6. OTHERS Theory of Operation Ver1.0 Sep.2006 6. OTHERS Dehumidifier heater control • Dehumidifier heaters /1 (HTR1) and /2 (HTR2) are provided under the trays /4 and /5, one for each tray, to prevent paper from damping. • When the sub power switch (SW2) is turned off, the HTR1 and HTR2 are turned on. a03xt2c016ca Dehumidifier heater/1 (HTR1) Dehumidifier heater/2 (HTR2)
Page 226: Tray Damper Mechanism
Theory of Operation Ver1.0 Sep.2006 6. OTHERS Tray damper mechanism • The damper [1] is provided in the tray to prevent the pile of paper from becoming misaligned due to the vibration caused when inserting the tray. a03xt2c017ca Damper...
Page 227: Main Body Assist Mechanism
6. OTHERS Theory of Operation Ver1.0 Sep.2006 Main body assist mechanism 6.3.1 Filter replacement assy retaining mechanism • When PF is installed to the main body, the filter replacement assy retaining mechanism [1] of PF presses down the filter replacement assy of the main body to prevent the filter replacement assy from coming loose. a03xt2c018ca Filter replacement assy retaining mechanism...
Page 228: Filter Replacement Assy Ventilation Mechanism
Theory of Operation Ver1.0 Sep.2006 6. OTHERS 6.3.2 Filter replacement assy ventilation mechanism • When PF is installed to the main body, the ventilation fan/1 (FM10) [1] and /2 (FM9) [2] operate to exhaust heated air around the writing section of the main body. •...
Page 229: Optional)
7. HT-504 (OPTIONAL) Theory of Operation Ver1.0 Sep.2006 7. HT-504 (OPTIONAL) Configuration a03xt2c020ca Dehumidifier fan heater unit/Up Dehumidifier fan/1 (FM13) and /3 (FM11) Dehumidifier fan heater unit/Lw Dehumidifier fan/2 (FM14) and /4 (FM12) Power unit Fan heater/Up (HTR3) and /Lw (HTR4)
Page 230: Operation
Theory of Operation Ver1.0 Sep.2006 7. HT-504 (OPTIONAL) Operation 7.2.1 Dehumidifier fan heater control A. Dryness preparation control • When the Dryness preparation control is set to [On] in the user settings, preliminary drying operation is per- formed before printing after opening/closing the tray. •...
Page 231: Ac Power Control
7. HT-504 (OPTIONAL) Theory of Operation Ver1.0 Sep.2006 7.2.2 AC power control • When the temperature sensor in the dehumidifier fan heater unit detects an error, a relay in the AC board [3] is cut off to prevent abnormal temperature from occurring. •...
Page 232 Theory of Operation SERVICE MANUAL LU-202/HT-503 2006.09 Ver. 1.0...
Page 233 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 234 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS LU-202/HT-503 OUTLINE 1. PRODUCT SPECIFICATIONS............1 LU-202 .
Page 235 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 236: Product Specifications
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS LU-202 A. Type Type Side mount type large volume paper feed tray B. Functions Max. tray capacity 2500 sheets (80 g/m Stacked height 275 mm C. Paper type Paper size SRA3, A3, B4, SRA4, SRA4S, A4, A4S, B5 13 x 19, 12 x 18, 11 x 17, 8...
Page 237 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 HT-503 A. Type Type Fan heater type dehumidifier device B. Maintenance Machine service life Same as the main body. C. Machine data Power source 24/5VDC, 200 to 240VAC (supplied both from the main body) Maximum power consump- DC: 4W or less, AC: 290W or less tion...
Page 238: Unit Configuration Diagram
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION DIAGRAM 2. UNIT CONFIGURATION DIAGRAM a03wt1c001ca Up/down section Paper feed section HT-503 (Optional)
Page 239: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH a03wt1c002ca Separation roller Pick-up roller Pre-registration roller Paper lift plate Paper feed roller...
Page 240: Configuration/Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION CONFIGURATION/OPERATION 4. PAPER FEED SECTION Configuration Centering sensor (PS1) Separation roller Pre-registration roller Pick-up roller Paper feed roller Paper feed assist fans Paper empty sensor (PS108) Paper size detection mechanism Paper size detection mechanism (Main scan direction) (Sub scan direction) Remaining paper detection mechanism a03wt2c001ca...
Page 241: Drive
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Drive 4.2.1 Paper feed drive [10] a03wt2c002ca Paper feed motor (M1) Separation roller Paper feed clutch (MC101) Front side Pick-up roller Torque limitter Paper feed roller Pre-registration roller One-way mechanism [10] Pre-registration clutch (MC102)
Page 242: Pick-Up Drive
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.2.2 Pick-up drive a03wt2c003ca Pick-up roller Front side Pick-up solenoid (SD100) Paper feed roller...
Page 243: Operation
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Operation 4.3.1 Paper feed control A. Pick-up control (1) Outline • Paper is picked up when the pick-up solenoid (SD100) is turned off. • The pick-up roller rotates with the paper feed roller. (2) Operation At the time printing is started [1], SD100 is off and the pick-up roller presses against loaded paper with its own weight.
Page 244 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION B. Separation mechanism • The separation roller [5] rotates in the direction [10] opposite to the paper conveyance direction [9] by means of the torque limiter [8]. • The separation roller is pressed against the paper feed roller [1] by the force [6] exerted by the spring [7] and the torque generated by the torque limiter.
Page 245 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 C. Pre-registration control (1) Outline • The pre-registration roller [3] is driven by the paper feed motor (M1) via the pre-registration clutch (MC102). M1 drive force is transmitted/shut off by MC102 to rotate/stop the roller. •...
Page 246 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION (2) Control for small-sized paper Paper fed by the paper feed roller hits against the pre-registration roller that is stopping due to the off-status [1] of MC102, and the skew of paper is corrected. Then, after a predetermined time period has elapsed, MC102 turns on [2] to rotate the pre-registration roller to convey the paper.
Page 247 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 (3) Control for large-sized paper The pre-registration for the 1st sheet of paper is carried out in the same manner as that for small-sized paper. MC102 turns on again [1] after the 2nd paper hits against the pre-registration roller, and turns off [2] when a predetermined time period has elapsed after the LU exit sensor (PS107) detects the leading edge of paper, then keeps the off-status until the rear end of the 1st paper is detected by PS27 in the main body.
Page 248 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION D. Air assist control • The paper feed assist fan/Fr (FM1) and /Rr (FM2) are mounted to the side guide/Fr and /Rr respectively in order to assist the separation of paper. •...
Page 249: Paper Empty Detection Control
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.2 Paper empty detection control • A paper empty status can be detected by on/off statuses of the upper limit sensor (PS109) [6] and the paper empty sensor (PS108) [1]. • When paper is loaded on the tray, the paper pushes the actuator [2] up as the paper lift plate [4] moves upward and PS108 [1] turns on.
Page 250: Remaining Paper Detection Control
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.3 Remaining paper detection control • The remaining amount of paper is detected by the position of the remaining paper detection gear [6] moved together with the shaft [5] of the paper lift motor (M100) which drives the paper lift plate. •...
Page 251 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 (1) Sensor detection and remaining paper • The remaining amount of paper is detected in eight levels according to on/off statuses of the four sensors. • The number of horizontal lines, or an arrow mark appear on the tray mark displayed on the touch panel of the main unit in order to indicate the remaining amount of paper in the tray.
Page 252: Paper Size Detection Control
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.4 Paper size detection control A. Outline • The detection method differs between main scan direction and sub scan direction. • Paper size in main scan direction is detected by the position of the gear of the paper size VR (VR1) [1] which is rotated by the detection guide plate/Rr [2] mounted on the side guide/Fr [6].
Page 253: Centering Detection Control
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 B. Sensor detection and paper size • The tables below lists how paper sizes are detected by the paper size VR (VR1), the paper size sensor/Rr (PS110) and /Fr (PS111). Main scan direction Sub scan direction PS110 PS111...
Page 254 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION B. Detection area • The detection range [5] of the centering sensor (PS1) [6] is 216 mm in the main scan direction. • The gap between the center [4] of paper [1] in the main scan direction and the origin point [2] of PS1 is 21.85 mm [3].
Page 255: Up/Down Section
5. UP/DOWN SECTION Theory of Operation Ver1.0 Sep.2006 5. UP/DOWN SECTION Configuration Upper limit sensor (PS109) Paper lift plate Lower limit sensor Paper (PS101) lift motor (M100) Lift wire a03wt2c015ca...
Page 256 Theory of Operation Ver1.0 Sep.2006 5. UP/DOWN SECTION Drive [10] FRONT a03wt2c016ca Lift wire/Rr1 Lift wire/Fr2 Lift wire /Rr2 Lift wire/Fr1 Lift wire/Rr3 Paper lift plate Drive shaft Paper lift motor (M100) Lift wire/Fr3 [10] Remaining paper detection gear...
Page 257: Operation
5. UP/DOWN SECTION Theory of Operation Ver1.0 Sep.2006 Operation 5.3.1 Plate up/down control A. Mechanism • Moving the paper lift plate up/down is made by winding/releasing the lift wires with the pulleys driven by the paper lift motor (M100). • Six lift wires are connected to the paper lift plate (three each on front and back).
Page 258: Others
Theory of Operation Ver1.0 Sep.2006 6. OTHERS 6. OTHERS Dehumidifier heater control • The LU is equipped with the dehumidifier heater (HTR1) to reduce the moisture inside the LU. • HTR1 is powered with 220 VAC supplied from the main body, and activated by turning on the dehumidifier heater switch (SW3) on the main body and turning off the sub power switch (SW2) a03wt2c018ca Dehumidifer heater (HTR1)
Page 259: Interlock Control
6. OTHERS Theory of Operation Ver1.0 Sep.2006 Interlock control • The interlock switch/1 (MS1) and the front door sensor (PS115) are mounted on the front door, and the interlock switch/2 (MS2) and the upper door sensor (PS100) are mounted on the upper door. •...
Page 260: Optional)
Theory of Operation Ver1.0 Sep.2006 7. HT-503 (OPTIONAL) 7. HT-503 (OPTIONAL) Configuration Dehumidifier Dehumidifier Dehumidifier Temperature sensor (TEMS) fan/1 (FM3) fan/2 (FM4) heater/3(HTR/2) AC drive board (ACDB) a03wt2c019ca...
Page 261: Operation
7. HT-503 (OPTIONAL) Theory of Operation Ver1.0 Sep.2006 Operation 7.2.1 Dehumidifier fan heater control A. Outline • The fan heater (HTR3) and the dehumidifier fan/1 (FM3) and /2 (FM4) generate hot airflow inside the LU and reduce moisture in order to prevent jam of coated paper due to dampness. •...
Page 262 Theory of Operation SERVICE MANUAL RU-503/504 2006.09 Ver. 1.0...
Page 263 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 264 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS RU-503/504 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 265 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 266: Product Specifications
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Conveyance unit with paper cooling and decurler functions B. Functions (1) Functions Accelerated conveyance To accelerate for the finisher standard line speed. mode Decurler conveyance mode Reduces paper curl and conveys at an accelerating rate with posttreatment lin- ear velocity.
Page 267 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 E. Machine data Power source RU-503 24/5V DC (supplied from the main body) RU-504 AC100 to 240V/5V DC (supplied from the main body) Maximum power consump- 90VA or less tion Dimensions Including main body: 175 (W) x 723 (D) x 1 (H) mm Weight RU-503 Approx.
Page 268: Unit Configuration Diagram
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION DIAGRAM 2. UNIT CONFIGURATION DIAGRAM Conveyance section Power source section (RU-504 only) a04kt1c001ca...
Page 269: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH A. Accelerated conveyance mode (Normal mode) a04kt1c002ca Decurler gate /1 Intermediate roller /3 Intermediate roller /1 Paper exit roller Entrance roller /2 Decurler gate /2 Entrance roller /1 Intermediate roller /2...
Page 270 Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH B. Decurler conveyance mode (straightening the upward curling) [11] [10] a04kt1c003ca Decurler gate /1 Decurler gate /2 Intermediate roller /1 Intermediate roller /2 Entrance roller /2 Decurler belt /1 Entrance roller /1 [10] Decurler roller /1 Intermediate roller /3...
Page 271 3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 C. Decurler conveyance mode (straightening the downward curling) [11] [10] a04kt1c004ca Decurler gate /1 Intermediate roller /3 Intermediate roller /1 Paper exit roller Decurler belt /2 Decurler roller /2 Decurler roller /3 [10] Decurler gate /2 Entrance roller /2...
Page 272: Configuration/Operation
Theory of Operation Ver1.0 Sep.2006 4. CONVEYANCE SECTION CONFIGURATION/OPERATION 4. CONVEYANCE SECTION Configuration Decurler gate /1 Decurler roller /2 Decurler roller /1 Decurler belt /1 Decurler gate /2 Decurler belt /2 Decurler roller /3 Decurler roller /4 Paper fan /1, /2, /3 (M2, M3, M4) a04kt2c001ca...
Page 273: Drive
4. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 Drive 4.2.1 Conveyance drive [14] [13] [12] [16] [11] [15] [10] a04kt2c002ca Decurler gate solenoid /1 (SD2) Entrance conveyance motor (M1) Decurler gate /1 [10] Paper exit roller Gear [11] Intermediate roller /3 Paper exit motor (M5) [12] Intermediate roller /2...
Page 274: Operation
Theory of Operation Ver1.0 Sep.2006 4. CONVEYANCE SECTION Operation 4.3.1 Conveyance control • The entrance conveyance motor (M1) controls the rotation of the entrance rollers /1 [6] and /2 [5]. • The paper exit motor (M5) controls the rotation of the intermediate rollers /1 [2], /2 [12], /3 [1] and the paper exit roller [9].
Page 275 4. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 A. Straight mode The entrance conveyance motor (M1) and the paper exit motor (M5) turn ON when a start-printing signal is sent from the main body. Then, M1 rotates at the same rate as the line speed of the main body while M5 rotates at high speed.
Page 276 Theory of Operation Ver1.0 Sep.2006 4. CONVEYANCE SECTION B. Reverse paper exit mode • Each control timing is the same as in the straight mode. [1] [2] Entrance sensor (PS1) Entrance Middle conveyance motor (M1) High Paper exit motor Middle (M5) (speed) a04kt2c005ca...
Page 277: Decurler Control
4. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 4.3.2 Decurler control • The paper exit motor (M5) controls the rotation of the decurler rollers /1 [15] and /3 [14] • Conveys paper into between the decurler belt /1 [7], /2 [10], and decurler roller /2 [8], /4 [12] and gives pressure to remove the curl of the paper.
Page 278 Theory of Operation Ver1.0 Sep.2006 4. CONVEYANCE SECTION [16] [10] [11] [14] [12] [19] [17] [18] [13] a04kt2c006ca Decurler gate solenoid /1 (SD2) ON [11] Decurler /Lw Decurler gate solenoid /1 (SD2) [12] Decurler roller /4 Switching paper through path [13] Paper exit sensor (PS3) Paper through path (normal path)
Page 279 4. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 A. Decurler /Up control • When the upward paper curl straightening ON in the service mode and Adjustment Menu-Finisher Adjust- ment setting, a start-printing signal is sent form the main body and the decurler gate solenoid /1 (SD2) starts operating.
Page 280: Fan Control
Theory of Operation Ver1.0 Sep.2006 4. CONVEYANCE SECTION 4.3.3 Fan control • There are five fans: Paper fan /1, /2 and /3 (M2, M3 and M4) [2] [4] [5] Ventilation assist fan /1 and /2 (M6 and M7) [3] [1] •...
Page 281 4. CONVEYANCE SECTION Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 282 Theory of Operation SERVICE MANUAL FD-501 2006.09 Ver. 2.0...
Page 283 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 284 Theory of Operation Ver2.0 Sep.2006 CONTENTS CONTENTS FD-501 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 285 CONTENTS Theory of Operation Ver2.0 Sep.2006 9. PI SECTION ............... 48 Composition .
Page 286: Product Specifications
Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Multi folding device with punch and PI functions B. Functions (1) Functions Normal paper exit function Transfer paper exited from the main body is exited into the main tray/sub tray. Punching function Transfer paper that is exited by the main body or fed to the PI is punched for each sheet of paper and exited into the main tray/sub tray.
Page 287 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 (2) Maximum tray capacity Main tray 2,500 sheets: A4, A4S, B5, B5S (weighing 50 to 244 g/m x 11, 8 x 11S , 16KS 1,500 sheets: SRA3 , A3, B4, SRA4 , SRA4S 13 x 19 ,12 x 18, 11 x 17, 8 x 14...
Page 288 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS C. Type of paper (1) Punching function Paper size 2 holes: A3, B4, SRA4S , A4, A4S, B5, B5S, A5, A5S 12 x 18 , 11 x 17, 8 x 14, 8 x 11, 8 x 11S, 5 x 13, 8...
Page 289 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 (3) PI functions Paper size SRA3 , A3, B4, SRA4 , SRA4S , A4, A4S, B5, B5S, A5 13 x 19 , 12 x 18, 11 x 17, 8 x 14, 8 x 11, 8 x 11S, 5 x 13, 8...
Page 290: Unit Composition
Theory of Operation Ver2.0 Sep.2006 2. UNIT COMPOSITION 2. UNIT COMPOSITION fd501to1001c PI section Folding conveyance section Conveyance section Main tray section Punch section Sub tray section...
Page 291: Paper Path
3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH A. Straight mode fd501to1002c Paper through from the PI Paper through from the main body paper exit...
Page 292 Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH B. Sub tray mode fd501to1003c Paper through from the PI Paper through from the main body paper exit...
Page 293 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 C. Punch mode (L and S sizes) fd501to1004c Paper through from the PI Paper exit to the main tray, paper through to the next option Paper through from the main body paper exit In the case of a L size Paper exit to the sub tray In the case of a S size...
Page 294 Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH D. Z-fold mode fd501to1005c Paper through from the PI Paper exit to the main tray, paper through to the next option Paper through from the main body paper exit 1st folding Paper exit to the sub tray 2nd folding...
Page 295 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 E. Letter fold-out mode fd501to1006c Paper through from the PI Paper exit to the main tray, paper through to the next option Paper through from the main body paper exit 1st folding Paper exit to the sub tray 2nd folding...
Page 296 Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH Letter fold-in/double parallel fold mode fd501to1007c Paper through from the PI Paper exit to the main tray, paper through to the next option Paper through from the main body paper exit 1st folding Paper exit to the sub tray 2nd folding...
Page 297 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 G. Gate fold mode fd501to1008c Paper through from the PI 3rd folding Paper through from the main body paper exit Paper exit to the main tray, paper through to the next option 1st folding 2nd folding Paper exit to the sub tray...
Page 298 Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH H. Folding mode fd501to1009c Paper through from the PI Paper exit to the main tray, paper through to the next option Paper through from the main body paper exit Folding Paper exit to the sub tray...
Page 299 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 Blank page...
Page 300: Composition/Operation
Theory of Operation Ver2.0 Sep.2006 4. CONVEYANCE SECTION COMPOSITION/OPERATION 4. CONVEYANCE SECTION Composition Entrance gate Sub tray gate Alignment plate /Fr, S size gate L size gate fd501to2001c...
Page 301: Drive
4. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive 4.2.1 Conveyance drive fd501to2002c Main tray paper exit motor (M17) Entrance conveyance motor (M1) Intermediate conveyance motor (M3) Punch conveyance motor (M2)
Page 302: Gate Drive
Theory of Operation Ver2.0 Sep.2006 4. CONVEYANCE SECTION 4.2.2 Gate drive [18] [17] [16] [15] [14] [13] [12] [10] [11] fd501to2003c Entrance gate [10] Vertical conveyance roller /4 Entrance gate solenoid (SD1) [11] L size gate solenoid (SD4) Vertical conveyance roller /1 [12] L size gate Roller solenoid /1 (SD5)
Page 303: Alignment Drive
4. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 4.2.3 Alignment drive fd501to2004c Alignment motor (M12) Alignment plate /Rr Belt Alignment plate /Fr...
Page 304: Operation
Theory of Operation Ver2.0 Sep.2006 4. CONVEYANCE SECTION Operation 4.3.1 Conveyance path switching The conveyance path of the paper that has been conveyed to the entrance guide plate varies according to the presence of a punch or folding, the tray into which paper is exited, and the paper size. The switching of the con- veyance path is made by the entrance gate, the sub tray gate, the S size gate, the L size gate and the folding gate.
Page 305 4. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 B. Sub tray gate Switching is made between the main tray paper exit and the sub tray paper exit by the sub tray gate solenoid (SD9). In the case of the main tray paper exit, the SD9 remains OFF. When exiting the 1st sheet of paper into the sub tray, switch the SD9 a specified period of time after the start button is turned ON.
Page 306 Theory of Operation Ver2.0 Sep.2006 4. CONVEYANCE SECTION C. S size gate Switching is made according to the paper size and the presence of folding. The drive of the gate is made by S size gate solenoid (SD3). In the punch mode with no folding and in the case of the S size paper, SD3 remains OFF.
Page 307 4. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 D. L size gate When folding the paper, the conveyance path is switched back and forth for each paper conveyance to prevent the succeeding paper from coming into contact with the trailing edge of the L size paper that is in folding pro- cess.
Page 308: Conveyance Line Speed Control
Theory of Operation Ver2.0 Sep.2006 4. CONVEYANCE SECTION For the control of the L size gate, SD4 stands by at the OFF position (outer path) for the 1st sheet of paper to pass through. The 1st sheet of paper turns ON SD4 a specified period of time after the punch registration sensor (PS6) turns ON, and makes the switch to the inner path.
Page 309: Alignment Control
4. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 4.3.3 Alignment control On paper conveyed to the punching position, an alignment operation is made by the 2 alignment plates to improve the accuracy of the punch hole positioning and the folding. And its home position is detected by the alignment plate home sensor (PS10).
Page 310: Punch Section
Theory of Operation Ver2.0 Sep.2006 5. PUNCH SECTION 5. PUNCH SECTION Composition Punch rear claw Punch hole switching Punch scraps box mechanism fd501to2009c...
Page 311: Drive
5. PUNCH SECTION Theory of Operation Ver2.0 Sep.2006 Drive 5.2.1 Rear registration drive fd501to2010c Punch registration motor (M13) Punch rear claw Paper...
Page 312: Punch Drive
Theory of Operation Ver2.0 Sep.2006 5. PUNCH SECTION 5.2.2 Punch drive [10] fd501to2011c Rotation when punching 3 holes (as seen from the front) Eccentric cam Rotation when punching 2 holes (as seen from the front) Front direction Punch motor (M10) 3-hole punch edge 2-hole punch edge Eccentric cam...
Page 313 5. PUNCH SECTION Theory of Operation Ver2.0 Sep.2006 C. Punch scraps box control The setting of the punch scraps box is detected by the punch scraps box set sensor (PS12), and the full condi- tion of the punch scraps box is detected by the punch scraps full sensor (PS26).
Page 314: Folding Conveyance Section
Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION 6. FOLDING CONVEYANCE SECTION Composition 3rd folding mechanism 2nd folding mechanism Folding gate 1st folding mechanism Registration roller fd501to2012c...
Page 315: Drive
6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive 6.2.1 Conveyance drive fd501to2013c Coupling Folding gate The pulley operates as an idler due to the Folding gate solenoid (SD15) bearing...
Page 316: Folding Drive
Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION 6.2.2 Folding drive fd501to2014c 3rd folding roller /1 mounting board 2nd folding guide 3rd folding guide 1st folding roller /1 mounting board 2nd folding roller /1 mounting board 1st folding guide...
Page 317: Operation
6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Operation 6.3.1 Registration control The paper that has passes through the punch registration sensor (PS6) and arrives at the folding conveyance section is pressed against the registration roller to make adjustments for skew. A specified period of time after the PS6 turns ON, the 1st folding motor (M4) resumes the conveyance of paper.
Page 318: Conveyance Path Switching
Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION 6.3.2 Conveyance path switching Switching is made between the 2nd folding conveyance path and the 3rd folding conveyance path by the fold- ing gate solenoid (SD15). In the case of other than the Z-fold, a specified period of time after the 1st folding conveyance sensor (PS51) turns ON, SD15 turns ON to convey the paper to the 2nd folding after the 1st folding.
Page 319 6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Timing chart of the 1st folding roller /1 (Other folding rollers are also controlled in the same manner.) Punch registration sensor (PS6) Roller solenoid /4 (SD8) 1st folding conveyance sensor (PS51) 1st folding motor (M4) Conveyance 1st folding roller /1...
Page 320: 1St Folding Control
Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION 6.3.3 1st folding control A. Conveyance/folding switching control The switching between conveyance and folding is made by moving the 1st folding roller /1. This switching is made when the eccentric cam is driven by the 1st folding release motor (M14). After the 1st folding conveyance sensor (PS51) turns ON, the paper is conveyed by a specified number of steps.
Page 321 6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 And in parallel with this, when the 1st folding release motor (M14) starts up, the winding-up of the wire that pulls the folding guide [2] to the right side is loosened to allow the folding guide [2] to push out the paper in the clear- ance between the 1st folding rollers /1 [1] and /2 [3].
Page 322: 2Nd Folding Control
Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION 6.3.4 2nd folding control A. Conveyance/folding switching control The switching between conveyance and folding is made by moving the 2nd folding roller /1. This switching is made when the eccentric cam is driven by the 2nd folding release motor (M15). After the 2nd folding conveyance sensor (PS53) turns ON, the paper is conveyed by a specified number of steps.
Page 323 6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 And in parallel with this, when the 2nd folding release motor (M15) starts up, the winding-up of the wire that pulls the folding guide [2] to the right side is loosened to allow the folding guide [2] to push out the paper in the clear- ance between the 2nd folding rollers /1 [1] and /2 [3].
Page 324 Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION B. Gate fold assist control In the case of the Gate fold, the 2nd folding roller solenoid (SD18) turns ON a specified period of time after the 1st folding motor (M14) starts folding. When SD18 starts up, the 2nd roller is pressed firmly. This is a measure taken to avoid a multiple fold that is apt to occur at the folding section of paper when the 2nd folding is made.
Page 325: 3Rd Folding Control
6. FOLDING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 6.3.5 3rd folding control A. Conveyance/folding switching control The switching between conveyance and folding is made by moving the 3rd folding roller /1. This switching is made when the eccentric cam is driven by the 3rd folding release motor (M16). After the 3rd folding conveyance sensor (PS54) turns ON, the paper is conveyed by a specified number of steps.
Page 326 Theory of Operation Ver2.0 Sep.2006 6. FOLDING CONVEYANCE SECTION And in parallel with this, when the 3rd folding release motor (M16) starts up, the winding-up of the wire that pulls the folding guide [2] to the left side is loosened to allow the folding guide [2] to push out the paper in the clear- ance between the 3rd folding rollers /1 [1] and /2 [3].
Page 327: Main Tray Section
7. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 7. MAIN TRAY SECTION Composition Main tray Main tray paper exit sensor (PS18) Main tray upper limit sensor (PS20) Main tray paper full sensor (PS7) Main tray lower limit sensor (PS22) fd501to2035c...
Page 328: Drive
Theory of Operation Ver2.0 Sep.2006 7. MAIN TRAY SECTION Drive fd501to2036c Main tray Tray up/down motor (M11) Up/down wire...
Page 329: Operation
7. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 Operation 7.3.1 Main tray up/down control The up/down operation of the main tray is controlled by rotating the tray up/down motor (M11) in the normal or reverse direction. A. Main tray paper detection A specified period of time after the main tray paper exit sensor (PS18) turns ON, M11 starts up to bring down the main tray until the main tray upper limit sensor (PS20) turns OFF, and then bring it up again until PS20 turns After the paper is exited, PS20 maintains the distance between the upper surface of the paper exited in the main...
Page 330: Sub Tray Section
Theory of Operation Ver2.0 Sep.2006 8. SUB TRAY SECTION 8. SUB TRAY SECTION Composition Sub tray paper full sensor (PS17) fd501to2024c...
Page 331: Drive
8. SUB TRAY SECTION Theory of Operation Ver2.0 Sep.2006 Drive fd501to2025c Paper exit solenoid (SD12) Sub tray paper exit roller Sub tray paper exit roller...
Page 332: Operation
Theory of Operation Ver2.0 Sep.2006 8. SUB TRAY SECTION Operation 8.3.1 Sub tray full detection control When the paper that has been exited in the sub tray gets to a specified thickness, the sub tray paper full sensor (PS17) [2] turns OFF, and the "sub tray paper full" information is sent to the main body. Upon receipt of this infor- mation, the main body displays the message on the operation LCD.
Page 333: Pi Section
9. PI SECTION Theory of Operation Ver2.0 Sep.2006 9. PI SECTION Composition Paper pick-up mechanism Manual operation Paper separation mechanism Multi feed sensor Paper set sensor Paper size VR (main scan direc- tion) Paper size sensor (sub scan direc- tion) Lift plate fd501to2027c...
Page 334: Drive
Theory of Operation Ver2.0 Sep.2006 9. PI SECTION Drive 9.2.1 Tray lift drive fd501to2028c Paper lift motor /Up (M8) PI lift plate /Lw Paper lift motor /Lw (M9) PI lift plate /Up...
Page 335: Paper Feed Drive
9. PI SECTION Theory of Operation Ver2.0 Sep.2006 9.2.2 Paper feed drive [10] [11] fd501to2029c Separation roller /Up Pick-up roller /Lw PI registration clutch /Up (CL1) PI conveyance motor (M7) PI registration clutch /Lw (CL2) Rotational direction of separation roller /Up Separation roller /Lw [10] Pick-up roller /Up...
Page 336: Pick-Up Drive
Theory of Operation Ver2.0 Sep.2006 9. PI SECTION 9.2.3 Pick-up drive fd501to2030c Spring PI pick-up solenoids /Up (SD13) and /Lw (SD14) Direction of spring force Release arm Pick-up rollers /Up and /Lw...
Page 337: Operation
9. PI SECTION Theory of Operation Ver2.0 Sep.2006 Operation 9.3.1 Size detection control For the size detection of a paper, there are the following two directions for each of the tray /Up and the tray /Lw: that is, the main scan direction and the sub scan direction. The size detection in the sub scan, when the PI paper set sensors /Up (PS44) and /Lw (PS45) [6] turn ON, is made by the following 3 sensors: PI maximum size sensors /Up (PS47) and /Lw (PS48) [1], L size sensors /Up (PS35) and /Lw (PS41) [2] and S size sensors /Up (PS36) and /Lw (PS42) [3].
Page 338: Up/Down Control
Theory of Operation Ver2.0 Sep.2006 9. PI SECTION 9.3.2 Up/down control For the up/down of the tray, when the paper lift motors /Up (M8) [1] and /Lw (M9) [7] rotate in the normal and reverse directions, the lift arms /Up [11] and /Lw [9] start up to bring up and down the PI lift plates /Up [12] and /Lw [10].
Page 339: Pick-Up Mechanism
9. PI SECTION Theory of Operation Ver2.0 Sep.2006 9.3.3 Pick-up mechanism The picking-up of the paper [6] is made when the PI pick-up solenoids /Up (SD13) and /Lw (SD14) [5] turn ON. The release arm that is pressed down by the spring [1] in the direction of [2] presses down the paper feed arm [4] to place the pick-up rollers /Up and /Lw [7] in the release condition.
Page 340: Separation Mechanism
Theory of Operation Ver2.0 Sep.2006 9. PI SECTION 9.3.4 Separation mechanism The separation roller [4] is driven in the direction opposite to the paper conveyance [2]. However, when no paper is conveyed or only one sheet of paper is conveyed, the frictional force generating between the paper feed roller [1] and the separation roller [4] or the paper and the separation roller is greater than the frictional force of the torque limiter [3].
Page 341: Multi Feed Detection Control
9. PI SECTION Theory of Operation Ver2.0 Sep.2006 9.3.5 Multi feed detection control To detect a multi feed while in the PI paper feed, the PI conveyance path is provided with the multi feed sensor. The multi feed sensor is a ultrasonic sensor made up of a pair of a sender and a receiver. This sensor receives ultrasonic waves sent from the multi feed detection board /1 (MFDB1) [1] by the multi feed detection board /2 (MFDB2) [2].
Page 342 Theory of Operation SERVICE MANUAL LS-501/502 2006.09 Ver. 2.0...
Page 343 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 344 Theory of Operation Ver2.0 Sep.2006 CONTENTS CONTENTS LS-501/502 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 345 CONTENTS Theory of Operation Ver2.0 Sep.2006 Blank page...
Page 346: Product Specifications
Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Grip conveyance type horizontal stacker Conveyance method Entrance convey- Roller conveyance method ance Stacker tray con- Grip conveyance method veyance Sub tray convey- Roller conveyance method ance Coupling convey- Roller conveyance (LS-501 only)
Page 347 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 C. Type of paper Paper size Stacker tray • When 5,000 sheets loaded SRA3* , A3, B4, SRA4* , SRA4S* , A4, A4S 13 x 19* , 12 x 18, 11 x 17, 8 x 14, 8 x 11, x 11S...
Page 348 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS D. Maintenance Maintenance Same as the main body. Machine service life Same as the main body. E. Machine data Power source LS-501 AC100 to 240V (DC5V is supplied from the main body) LS-502 24V DC (supplied from the main body) Maximum power consump-...
Page 349: Unit Composition
2. UNIT COMPOSITION Theory of Operation Ver2.0 Sep.2006 2. UNIT COMPOSITION [10] ls502to1001c Shift unit Stacker tray conveyance section 1st gate Coupling conveyance section Entrance conveyance section Sub tray Stacker tray Sub tray conveyance section Hand cart [10] 2nd gate...
Page 350: Paper Path
Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH 3. PAPER PATH ls502to1002c Stacker tray non-sort/sort mode Sub tray mode Coupling mode...
Page 351 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 Blank page...
Page 352: Composition/Operation
Theory of Operation Ver2.0 Sep.2006 4. COUPLING CONVEYANCE SECTION COMPOSITION/OPERATION 4. COUPLING CONVEYANCE SECTION Composition Entrance convey- Coupling conveyance ance lock solenoid lock solenoid (SD11) (SD5) (LS-501 only) Front door lock solenoid (SD4) ls502to2001c Drive ls502to2002c Entrance conveyance lock solenoid (SD5) Coupling jam release lever Entrance jam release lever Coupling conveyance lock solenoid (SD11)
Page 353: Operation
4. COUPLING CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Operation 4.3.1 Door open/close mechanism While the LS is in operation, the front door is locked by the front door lock solenoid (SD4), thus making it impos- sible to open and close it. However, while in the coupling conveyance (coupling mode) or while exiting paper into the sub tray (sub tray mode), the front door can be opened and closed.
Page 354: Entrance Conveyance Section
Theory of Operation Ver2.0 Sep.2006 5. ENTRANCE CONVEYANCE SECTION 5. ENTRANCE CONVEYANCE SECTION Composition Paper cooling fan motor (FM4) Paper cooling fan 2nd gate motor /2 (FM6) Paper cooling fan motor /1 (FM2) 1st gate Paper cooling fan motor /Rr (FM5) Paper cooling fan motor /Fr (FM1) Paper cooling fan...
Page 355: Drive
5. ENTRANCE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive ls502to2004c 2nd gate solenoid (SD10) Entrance roller Coupling conveyance roller /2 1st gate Conveyance motor (M2) Coupling conveyance roller /1 1st gate solenoid (SD1) 2nd gate...
Page 356: Operation
Theory of Operation Ver2.0 Sep.2006 5. ENTRANCE CONVEYANCE SECTION Operation 5.3.1 Path switching The path along which paper conveyed to the entrance guide plate is conveyed varies according to the operation mode. The switching of the conveyance path is made by the 1st gate and the 2nd gate. A.
Page 357 5. ENTRANCE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 B. 2nd gate The conveyance path is switched between the sub tray paper exit (sub tray mode) and the coupling conveyance (coupling mode). ls502to2006c Coupling mode 2nd gate Sub tray mode...
Page 358: Conveyance Line Speed Control
Theory of Operation Ver2.0 Sep.2006 5. ENTRANCE CONVEYANCE SECTION 5.3.2 Conveyance line speed control The conveyance process speed of the entrance roller and the coupling conveyance rollers 1/ and 2/ that are driven by the conveyance motor (M2) varies according to the conveyance process speed of the main body. These operations are common to all the modes.
Page 359: Paper Cooling Mechanism
5. ENTRANCE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 5.3.3 Paper cooling mechanism Paper conveyed to the LS is likely to curl up due to fusing heat. Heat storage accumulated in paper stacked during continuous printing may cause tacking (sheets of paper sticking hard each other by toner) when toner that has been fused is re-fused and adheres.
Page 360: Conveyance Section
Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION 6. CONVEYANCE SECTION Composition Paper press sole- noid /3 (SD8) Decurler roller Paper empty Paper press arm sensor (PS6) Grip belt Paper empty Paddler Job partition Front stopper detection actuator plate solenoid (SD9) Sub tray full sensor (PS9) Conveyance sen-...
Page 361: Drive
6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive 6.2.1 Stacker tray/sub tray conveyance drive ls502to2010c Sub tray paper exit motor (M3) Paddler Conveyance motor (M2) Sub tray conveyance roller Decurler roller Sub tray paper exit roller...
Page 362: Coupling Conveyance/Grip Belt/Paper Press Arm Drive
Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION 6.2.2 Coupling conveyance/grip belt/paper press arm drive [10] [11] [12] [13] [14] [15] ls502to2011c : LS-501 only Paper press arm /1 Coupling conveyance roller /5 : LS-501 only Stacker tray paper empty detection actuator [10] Paper press solenoid /2 (SD7) Grip belt...
Page 363: Stacker Tray Up Down Drive
6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 6.2.3 Stacker tray up down drive ls501t2c001a Wire Stacker tray Belt Stacker tray up down arm Stacker tray up down motor (M1)
Page 364: Shift Unit/Alignment Plate Drive
Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION 6.2.4 Shift unit/alignment plate drive LS drawing as seen from above. On the right side is the main body. ls502to2013c Guide rail Shift unit Alignment plate Shift unit motor (M5) Alignment motor (M7) Guide rail...
Page 365: Rear Stopper/Job Partition Plate Drive
6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 6.2.5 Rear stopper/job partition plate drive ls502to2014c Rear stopper Rear stopper solenoid (SD3) Job partition plate Job partition solenoid (SD2)
Page 366: Front Stopper/Paper Press Arm Drive
Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION 6.2.6 Front stopper/paper press arm drive ls502to2015c Spring Spring Paper press solenoid /3 (SD8) Front stopper Paper press arm /3 Front stopper solenoid (SD9)
Page 367: Operation
6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Operation 6.3.1 Stacker tray conveyance While in the stacker tray non-sort mode and the stacker tray sort mode, paper is conveyed into the stacker tray. A. Decurler Paper that has passed through the 1st gate is conveyed to the grip belt by the decurler roller. At this time, the correction of curled paper is made by the decurler roller.
Page 368 Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION C. Front stopper control Paper conveyed by the grip strikes against the front stopper equipped to the shift unit and is released from the grip. At this time, the shift unit has been moved to the position specified in advance for each paper size. Two types of the front stoppers, more specifically, a movable type and a stationary type, are employed.
Page 369 6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 (1) Stacker tray non-sort mode Entrance sensor (PS4) Shift unit motor (M5) Latch ON signal Front stopper solenoid (SD9) Latch OFF signal ls502to2018c Main body paper exit sensor (PS3) ON 2nd sheet of paper The shift unit starts to move 3rd sheet of paper 1st sheet of paper...
Page 370 Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION D. Job partition plate In stacker tray sort mode, the trailing edge of the shift paper is restricted by the job partition plate and the paper is exited onto the stacker tray 20 mm shifted from the non-shift paper. At this time, the upper surface of the non- shift paper does not come to the same level as the lower edge of the job partition plate and the 1st sheet of the shift paper is in possibility of getting into the lower side of the job partition plate.
Page 371 6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 (1) Stacker tray non-sort mode Ex.: Letter 4 sheets Entrance sensor (PS4) Latch ON signal Job partition solenoid (SD2) Latch OFF signal ls502to2021c Main body paper exit sensor (PS3) ON 3rd sheet of paper 1st sheet of paper Job partition plate close Job partition plate close...
Page 372 Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION E. Rear stopper control While in the stacker tray sort mode is in shifting, the rear stopper is left open and this plays as a guide for the trailing edge of paper. To assist the separation of paper released from the grip, the paddle is rotated at a high speed.
Page 373 6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 (1) Stacker tray non-sort mode Ex.: Letter 4 sheets [11] Entrance sensor (PS4) Latch ON signal Rear stopper solenoid (SD3) Latch OFF signal [13] [10] [12] ls502to2029c Main body paper exit sensor (PS3) ON 3rd sheet of paper 1st sheet of paper Rear stopper open...
Page 374 Theory of Operation Ver2.0 Sep.2006 6. CONVEYANCE SECTION Paper press arm The paper that has been released from the grip is pressed one at a time onto the stacker tray by the paper pres- sure arms /1, /2 and /3 to be loaded on the stacker tray. However, the operation of the paper pressure arm /2 is limited only to the paper size larger than B4.
Page 375: Coupling Conveyance
6. CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 H. Stacker tray up down control The detection of the upper surface of paper loaded on the stacker tray is made by the paper empty sensor (PS6) through the paper press arm /3. When PS6 is turned off by loading paper that has been exited, the stacker tray up down motor (M1) turns on to lower the stacker tray down to the position at which PS6 turns on.
Page 376 Theory of Operation SERVICE MANUAL FS-503 2006.09 Ver. 2.0...
Page 377 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 378 Theory of Operation Ver2.0 Sep.2006 CONTENTS CONTENTS FS-503 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 379 CONTENTS Theory of Operation Ver2.0 Sep.2006 8.3.1 Paper exit opening control ........... . 38 8.3.2 Main tray up/down control .
Page 380: Product Specifications
Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Staple-cut type multi staple device B. Functions (1) Functions Straight mode Exited into the main tray with no processing made. Shift mode Exited into the main tray after being shifted. Sub tray mode Exited into the sub tray with no processing made.
Page 381 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 (3) Maximum number of sheets loadable Main tray Straight/Shift 3,000 sheets: A4, A4S, B5, B5S (Weighing 50 to 244 g/ x 11, 8 x 11S 16K* , 16KS* 1,500 sheets: SRA3* , A3, B4, SRA4* , SRA4S* 13 x 19* (straight only), 12 x 18, 11 x 17, 8...
Page 382 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS Sub tray SRA3* , A3, B4, SRA4* , SRA4S* A4, A4S, B5, B5S, A5, A5S* , B6S* , A6S* (Weighing 50 to 300 g/ 13 x 19* , 12 x 18, 11 x 17, 8 x 14, 8 x 11, 8 x 11S, 5...
Page 383 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 E. Machine data Power source 24/5V DC (supplied from the main body) Maximum power consump- 110VA tion Dimensions When the main tray is pulled out: 915 (W) x 656 (D) x 1020 (H) mm When the main tray is set in: 798 (W) x 656 (D) x 1020 (H) mm When the main tray is removed:...
Page 384: Unit Composition
Theory of Operation Ver2.0 Sep.2006 2. UNIT COMPOSITION 2. UNIT COMPOSITION fs503to1001c Paper conveyance section Main tray section Stapler section Sub tray section Stacker section...
Page 385: Paper Path
3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH fs503to1002c Sub tray paper path Main tray paper path (only while in stapling) Main tray paper path (straight/sort/staple)
Page 386: Composition/Operation
Theory of Operation Ver2.0 Sep.2006 4. PAPER CONVEYANCE SECTION COMPOSITION/OPERATION 4. PAPER CONVEYANCE SECTION Composition Tray gate Bypass gate fs503to2001c...
Page 387: Drive
4. PAPER CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive fs503to2002c Conveyance motor (M1) Bypass solenoid (SD5) Gate solenoid (SD2)
Page 388: Operation
Theory of Operation Ver2.0 Sep.2006 4. PAPER CONVEYANCE SECTION Operation 4.3.1 Conveyance path switching A. Tray gate control The tray gate switches the paper conveyance path between the main tray and the sub tray. The tray gate is normally set to the conveyance path to the main tray. When paper is exited to the sub tray, how- ever, the gate is switched to the path to the sub tray through the drive of the solenoid (SD2).
Page 389 4. PAPER CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 (2) In the case of the 2nd and subsequent copies A specified period of time after the FNS entrance sensor (PS4) detects the trailing edge of the 1st page of the 2nd copy, the bypass solenoid (SD5) turns ON to draw the 2nd page of the 2nd copy into the bypass route.
Page 390: Sub Tray Section
Theory of Operation Ver2.0 Sep.2006 5. SUB TRAY SECTION 5. SUB TRAY SECTION Composition Sub tray Sub tray paper exit roller Sub tray paper full sensor (PS30) fs503to2004c Drive fs503to2005c Sub tray paper exit motor (M6) Sub tray paper exit roller...
Page 391: Operation
5. SUB TRAY SECTION Theory of Operation Ver2.0 Sep.2006 Operation A. Sub tray paper full detection control When paper that has been exited into the sub tray gets to the specified thickness, the sub tray paper full sensor (PS30) turns ON to send the "sub tray paper full" information to the main body. Then, the main body displays the massage on the operation panel.
Page 392: Stacker Section
Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION 6. STACKER SECTION Composition Alignment plate Stack assist plate Paddle Stacker entrance belt Swing roller Rear stopper Flat-stapling Paper exit stopper fs503to2007c...
Page 393: Drive
6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 Drive 6.2.1 Stacker entrance roller/paddle drive fs503to2008c Stacker entrance belt Stacker entrance motor (M13) Swing roller Paddle Stacker entrance roller Paddle motor (M2)
Page 394: Stack Assist Plate/Rear Stopper Drive
Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION 6.2.2 Stack assist plate/rear stopper drive fs503to2009c Stack assist home sensor (PS32) Rear stopper home sensor (PS35) Stack assist plate Rear stopper motor (M26) Rear stopper Stack assist motor (M24)
Page 395: Intermediate Roller/Paper Exit Arm Drive
6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 6.2.3 Intermediate roller/paper exit arm drive [10] [10] fs503to2010c Intermediate roller release solenoid (SD7) Paper exit arm motor (M23) Intermediate roller open close motor (M25) Paper exit arm home sensor (PS9) Eccentric cam Intermediate roller /Lw Intermediate roller home sensor (PS33) Coupling...
Page 396: Alignment Drive
Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION 6.2.4 Alignment drive fs503to2011c Alignment plate /Rr Alignment motor /Fr (M22) Alignment motor /Rr (M5) Alignment home sensor /Fr (PS31) Alignment home sensor /Rr (PS8) Alignment plate /Fr...
Page 397: Operation
6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 Operation 6.3.1 Stacker conveyance speed control Paper conveyed by the conveyance motor (M1) is sent to the stacker when the stacker entrance motor (M13) is decelerated a specified period of time after the stacker entrance sensor (PS5) turns ON and before it runs through the stacker entrance roller.
Page 398 Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION While in the print operation, the pressure/release of the intermediate roller /Up [1] onto the intermediate roller /Lw [2] is made by the intermediate roller release solenoid (SD7) [3]. When paper is being conveyed to the stacker, SD7 turns ON to release the nip, and paper that passes through the opening between the intermediate roller /Up [1] and the intermediate roller /Lw [2] is conveyed to the stacker.
Page 399 6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 B. Staple mode control While in the staple mode operation, through the initial operation made when the start signal is turned ON, the intermediate roller /Up [1] is moved to the evacuation position by the eccentric cam [2] that is driven by the inter- mediate roller open close motor (M25).
Page 400: Stack Assist Control
Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION 6.3.3 Stack assist control The stack assist plate is a paper pressure plate that is used to increase the speed to put paper in the stacker for an increased productivity. The stack assist plate [1] is driven by the stack assist motor (M24). When being conveyed to the stacker section, each sheet of paper is pressed at the position near the rear end of the paper [2] to be stacked at a speed faster than a free fall.
Page 401: Alignment Control
6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 6.3.5 Alignment control A. Horizontal alignment The horizontal alignment is made by the 2 alignment plates, that is, alignment plate /Fr and alignment plate /Rr. These 2 alignment plates are driven independently by each of the alignment motor /Fr (M22) and the alignment motor /Rr (M5).
Page 402 Theory of Operation Ver2.0 Sep.2006 6. STACKER SECTION (2) Shift mode In the shift mode, each time a sheet of paper is sent to the stacker, the alignment plate /Fr [1] and the alignment plate /Rr [2] shift to the rear to convey the paper [3] to the shift position before exiting it. fs503to2015c Alignment plate /Fr Paper...
Page 403: Stacker Paper Exit
6. STACKER SECTION Theory of Operation Ver2.0 Sep.2006 (3) Staple mode In the staple mode, the alignment operation is made by the alignment plates /Fr and /Rr for each sheet of paper that has been sent to the stacker. After the last sheet of paper of the copy is conveyed to the stacker section, the alignment operation for the staple is made for stapling.
Page 404: Stapler Section
Theory of Operation Ver2.0 Sep.2006 7. STAPLER SECTION 7. STAPLER SECTION Composition Stapler /Rr Stapler /Fr Staple scraps box fs503to2016c...
Page 405: Drive
7. STAPLER SECTION Theory of Operation Ver2.0 Sep.2006 Drive 7.2.1 Stapler movement/rotation fs503to2017c Stapler /Fr Stapler rotation home sensor (PS14) Stapler movement motor (M11) Stapler rotation motor (M4) Stapler movement home sensor (PS11) Stapler /Rr Belt...
Page 406: Stapler
Theory of Operation Ver2.0 Sep.2006 7. STAPLER SECTION 7.2.2 Stapler fs503to2018c Staple cut/bending arm Stapling arm Stapler motors /Rr (M30), /Fr (M31) Pressure plate Eccentric cam...
Page 407: Operation
7. STAPLER SECTION Theory of Operation Ver2.0 Sep.2006 Operation 7.3.1 Stapler movement control For stapler movements, there are two types, that is, the horizontal movement of the stapler intervals and the rotation of the stapler /Rr. Movement is made according to the staple mode. The horizontal movement of the stapler is made by the stapler movement motor (M11).
Page 408: Staple Control
Theory of Operation Ver2.0 Sep.2006 7. STAPLER SECTION 7.3.2 Staple control The staple control is made by the stapler motors /Rr (M30) and /Fr (M31) to drive the eccentric cam. The inside [2] of the eccentric cam [1] is provided with the cam groove [4] of the pressure arm [3] and the pin [6] of the staple cut/clinch arm [5].
Page 409 7. STAPLER SECTION Theory of Operation Ver2.0 Sep.2006 A. Paper pressure When the eccentric cam rotates 90° from the home position, the cam groove [1] on the inside drives the pin [3] provided on the pressure arm [2] in the arrow-marked direction. The pressure arm [2] drives the pressure plate [4] and presses the clinch side hard against the staple side [5] to press the paper [6].
Page 410 Theory of Operation Ver2.0 Sep.2006 7. STAPLER SECTION B. Stapling control When the eccentric cam rotates from 90° to 180°, the cam groove [1] on the outside drives the pin [3] provided on the stapling arm [2] in the arrow-marked direction. The pin at the tip [4] of the stapling arm pushes up the sta- pling blade [5] to push out the staple [6], punch out the paper [7] and staple it.
Page 411 7. STAPLER SECTION Theory of Operation Ver2.0 Sep.2006 C. Staple cut/clinch control When the eccentric cam rotates from 180° to 270°, the pin [1] provided on the inside drives the staple cut/clinch arm [2] in the arrow-marked direction. At the start of rotation, the lever operation of the staple cut/clinch arm [2] rotates the coupling metal fitting [3] to pull the pin [4] in the arrow-marked direction and the staple [7] inserted into the round hole [6] of the staple cut blade [5] is cut.
Page 412 Theory of Operation Ver2.0 Sep.2006 7. STAPLER SECTION D. Cartridge detection The presence of a cartridge or the incorrect setting of a cartridge is detected by the cartridge set sensors /Rr (PS42), /Fr (PS43). When there is no cartridge or the cartridge is set incorrectly, an error message is displayed on the operation section.
Page 413: Main Tray Section
8. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 8. MAIN TRAY SECTION Composition Paper exit opening unit Main tray paper exit roller Paper pressure Main tray Lift wire fs503to2023c...
Page 414: Drive
Theory of Operation Ver2.0 Sep.2006 8. MAIN TRAY SECTION Drive 8.2.1 Tray up/down drive fs503to2024c Counter reset sensor (PS15) Lift wire Tray lower limit sensor (PS3) Main tray Tray up down motor (M3) Lift pulley /Up Lift pulley /Lw...
Page 415: Main Tray Paper Exit Drive
8. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 8.2.2 Main tray paper exit drive fs503to2025c Main tray paper exit motor (M7) Main tray paper exit roller Coupling Paper exit opening solenoid (SD9) Paper pressure arm...
Page 416: Paper Exit Opening Drive
Theory of Operation Ver2.0 Sep.2006 8. MAIN TRAY SECTION 8.2.3 Paper exit opening drive fs503to2026c Main tray paper exit roller Paper exit opening motor (M8) Paper exit opening unit Paper exit opening home sensor (PS12) Drive bar...
Page 417 8. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 Operation 8.3.1 Paper exit opening control When paper is too long and protruding, the paper exit opening is opened and closed for alignment. There are 3 opening positions available according to the mode and the paper length. For paper shorter than the following length, the paper exit opening is opened neither in the non-staple mode nor the staple mode.
Page 418 Theory of Operation Ver2.0 Sep.2006 8. MAIN TRAY SECTION B. Staple control When the paper length is less than 219 mm, paper exit unit is not opened. When the paper length is 219 mm or longer and less than 400 mm, paper exit unit is opened by 55°. When the paper length is 400 mm or longer, paper exit unit is opened by 44°.
Page 419 8. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 8.3.2 Main tray up/down control The driving force of the tray up down motor (M3) rotates the lift pulley by the belt and the gear to wind up the lift wire. The main tray goes up or down according to the direction in which the up/down wire is wound up. When the lift pulley /Lw rotates clockwise as seen from the front, the main tray goes up and when it rotates counter- clockwise, the tray goes down.
Page 420 Theory of Operation Ver2.0 Sep.2006 8. MAIN TRAY SECTION C. Main tray paper detection The tray upper limit sensor (PS2) and the stapler paper exit upper limit sensor (PS7) maintain the distance between the upper surface of the paper exited in the main tray (or the main tray upper surface when no paper is exited) and the paper exit opening at a specified distance to prevent any uneven paper exit from occurring.
Page 421 8. MAIN TRAY SECTION Theory of Operation Ver2.0 Sep.2006 Blank page...
Page 422: Operation
Theory of Operation SERVICE MANUAL FS-607 2006.09 Ver. 1.0...
Page 423 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 424 Theory of Operation Ve1.0 Sep.2006 CONTENTS CONTENTS FS-607 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 425 CONTENTS Theory of Operation Ve1.0 Sep.2006 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION ........51 Composition .
Page 426: Product Specifications
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Multi folding multi stapling device B. Functions (1) Functions Non-sort mode Exited to the main tray with no processing made. Sort/group mode Exited to the main tray after being shifted for every copy. Sub tray mode Exited to the sub tray with no processing made.
Page 427 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 (4) Max. paper capacity Main tray Non-sort mode, 2500 sheets: A4, A4S, B5, B5S (Weighing 80g/m sort/group mode x 11, 8 x 11S 16K, 16KS 1500 sheets: A3, B4, SRA4S, 12 x 18, 11 x 17, 8 x 14, x 13, 8 x 13, 8...
Page 428 Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS C. Type of paper (1) Stapling mode Paper size A3, B4, SRA4S, A4, A4S, B5, B5S, A5 12 x 18, 11 x 17, 8 x 14, 8 x 11, 8 x 11S x 13, 8 x 13, 8 x 13...
Page 429 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 E. Machine data Power source 24/5VDC (supplied from the main body) Maximum power consump- 80W or less tion Dimensions When the main tray is pulled out: 790.5 (W) x 656 (D) x 990 (H) mm When the main tray is set in: 674.5 (W) x 656 (D) x 990 (H) mm Weight Approx.
Page 430: Unit Configuration
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION 2. UNIT CONFIGURATION Transfer section Main tray section Stapler section Stacker section Folding/saddle stitching/tri-folding section a04dt1c001ca...
Page 431: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Non-sort/sort/group mode a04dt1c002ca Paper path from PI (PI-502 installed) Main tray Paper path from the main body Paper exit unit Gate Shift unit (sort/group mode only)
Page 432: Sub Tray Mode
Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Sub tray mode a04dt1c003ca Paper path from PI (PI-502 installed) Gate Paper path from the main body Sub tray...
Page 433: Stapling Mode
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 Stapling mode a04dt1c004ca Paper path from PI (PI-502 installed) Flat-stapling stopper Paper path from the main body Stapler Gate Main tray Clincher Paper exit unit...
Page 434: Folding/Saddle Stitching Mode
Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Folding/saddle stitching mode 15jmt1c001na Paper path from PI (PI-502 installed) Folding knife Paper path from the main body Saddle stitching stopper Gate Booklet tray Clincher Stapler...
Page 435: Tri-Folding Mode
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 Tri-folding mode 15jmt1c002na Paper path from PI (PI-502 installed) Saddle stitching stopper Paper path from the main body Booklet tray Gate Tri-folding stopper Folding knife...
Page 436: Composition/Operation
Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION COMPOSITION/OPERATION 4. TRANSFER SECTION Composition Sub tray paper full Shift unit sensor (PS19) Sub tray paper exit sensor (PS1) Shift roller Gate Paper exit unit PI transfer roller Main tray exit paper sensor (PS6) Entrance roller FNS entrance sensor...
Page 437: Drive
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 Drive [15] [16] [17] [18] [19] [20] [21] [14] [13] [12] [11] [10] a04dt2c001ca FNS transfer motor (M1) [12] Shift roller PI transfer roller [13] Main tray exit roller Entrance roller [14] Paper exit opening solenoid (SD4) Transfer roller /A [15]...
Page 438: Operation
Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION Operation 4.3.1 Punch registration control (available only when PK is installed) The FNS conveyance motor (M1) turns OFF temporarily to stop conveyance of paper when the specified time has passed since paper exit sensor (PS37) detected the leading edge of the paper. Thus the paper is pressed against the entrance roller forming a loop to correct the bend.
Page 439: Fs Transfer Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.2 FS transfer control The FS transfer is conducted by the 24V DC motor controlled by the FNS control board (FNSCB). A. Door switch control The FS transfer drive control is started when transmitting the start signal from the main body. However, en error message is transmitted to the main body PRCB and the control is not started if the door switch (MS1) turns OFF.
Page 440: Gate Drive Control
Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION 4.3.3 Gate drive control The gate switches among the paper transfer path to the main tray, the one to the sub tray, and the one to the stacker. A. Gate operation The gate motor (M12) drives the gate cam [2], and then 2 cams /UP [3] and /Lw [4] of the gate cum drive the 2 gates /UP [5] and /Lw [6] respectively.
Page 441: Bypass Gate Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.4 Bypass gate control The bypass gate is located in the paper path to the stacker section. The bypass gate is the gate to transfer the subsequent paper during the stapling operation for eliminating the time loss and increasing the productivity. A.
Page 442 Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION B. Bypass gate control The bypass gate only operates for the small size paper (A4, B5, and 8 x 11) in the stapling mode. The FNS control board (FNSCB) controls the bypass gate solenoid (SD5). When stapling 2 sheets of paper for 3 copies, SD5 operates as follows.
Page 443: Shift Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.5 Shift control The FNS transfer motor (M1) drives the shift roller. The shift roller moves itself backward to shift the paper while transferring the paper to the main tray. A. Shift operation During conveying the paper to the main tray [1], the crank mechanism [3] shifts the shift movable section [5] including the shift roller [4] approximately 30 mm backward [6] to shift and exit the paper when shift roller motor (M2) [2] rotates.
Page 444 Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION B. Shift control In the sort/group mode, the shift roller motor (M2) turns ON [2] and shifts the shift movable section after a spec- ified period of time since the FNS entrance sensor (PS4) detects the trailing edge of the paper [1]. The FNS transfer motor (M1) drives the shift roller.
Page 445: Paper Exit Roller Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.6 Paper exit roller control The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the main tray paper exit roller and the paper exit belt. A. Non-sort/sort/group mode The paper exit roller motor (M7) rotates in high speed when the FNS entrance sensor (PS4) detects the leading edge of the paper [1].
Page 446: Paper Exit Opening Solenoid Control
Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION 4.3.7 Paper exit opening solenoid control The paper exit roller is usually releasing the nip except when exiting the paper because its rotation is slower than the transfer roller. However, the nip movable section moves to nip the paper when the paper reaches to the paper exit opening.
Page 447: Paper Exit Opening Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.8 Paper exit opening control In the stapling mode (when the paper length is B5S or longer in the sub scan direction) and the folding/saddle stitching/tri-folding mode, the paper exit opening is opened from the beginning of the printing operation to the end of the stapling operation because the paper protrudes.
Page 448 Theory of Operation Ver1.0 Sep.2006 4. TRANSFER SECTION B. Paper exit opening/closing control (1) Stapling mode (when the paper length is B5S or longer in the sub scan direction) Transmitting the FNS signal [1] from the main body, the paper exit motor (M8) rotates [2] to open the paper exit opening.
Page 449: Sub Tray Paper Exit Control
4. TRANSFER SECTION Theory of Operation Ver1.0 Sep.2006 4.3.9 Sub tray paper exit control The sub tray paper exit motor (M21) controlled by the FNS control board (FNSCB) drives the sub tray paper exit roller. A. Sub tray paper exit motor (M21) control The sub tray paper exit motor (M21) rotates in high speed when the sub tray paper exit sensor (PS1) detects the leading edge of the paper.
Page 450: Main Tray Section
Theory of Operation Ver1.0 Sep.2006 5. MAIN TRAY SECTION 5. MAIN TRAY SECTION Composition Paper exit unit Main tray exit roller Main tray Lift wire a04dt2c004ca...
Page 451: Drive
5. MAIN TRAY SECTION Theory of Operation Ver1.0 Sep.2006 Drive 15jkt2c015na Lift pulley /Up Lift pulley /Lw Lift wire Main tray Main tray lift motor (M3)
Page 452: Operation
Theory of Operation Ver1.0 Sep.2006 5. MAIN TRAY SECTION Operation 5.3.1 Tray lift control A. Tray lift operation The worm gear installed in the shaft of the main tray lift motor (M3) [6] winds up the lift wire. It lifts up or down the main tray [9] depending on the winding direction. Rotating the lift pulley /Lw clockwise and counterclockwise in view of front, the main tray is lifted up and down respectively.
Page 453 5. MAIN TRAY SECTION Theory of Operation Ver1.0 Sep.2006 C. Tray lift control The main tray lift motor (M3) lifts up and down the main tray by rotating in the forward and reverse direction respectively. The FNS control board (FNSCB) controls M3. (1) Non-sort/sort/group mode Transmitting the FNS signal from the main body, the tray lift motor (M3) lifts up the tray until the main tray upper limit sensor (PS2) turns ON.
Page 454: Stacker Section
Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION 6. STACKER SECTION Composition Alignment home sensor /Up (PS8) Alignment plate /Up Paper exit belt home sensor (PS9) Paper exit arm Stacker entrance motor (M13) Paper exit belt Alignment motor /Up (M5) Stacker empty sensor Stacker entrance roller (PS20)
Page 455: Drive
6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 Drive [12] [13] [14] [15] [11] [10] 15jmt2c001na Coupling (from M7) Alignment plate /Lw Alignment motor /Up (M5) [10] Flat-stapling stopper release solenoid /Fr (SD8), Flat-stapling stopper release solenoid /Rr (SD7) Stacker entrance motor (M13) Stacker entrance roller [11] Paper assist roller...
Page 456: Operation
Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION Operation 6.3.1 Alignment /Up control In the stapling/saddle stitching/tri-folding mode, the alignment motor /Up (M5) rotates in the forward/reverse direction to open/close the alignment plate /Up to perform the alignment of the paper transferred to the stacker in the main scan direction.
Page 457: Alignment /Lw Control
6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 6.3.2 Alignment /Lw control In the saddle stitching/folding/tri-folding mode, the alignment plate /Up and the alignment plate /Lw move back and forth to align the paper in the main scan direction. The alignment motor /Lw (M16) performs the alignment operation by rotating in the forward and reverse direc- tion to move the alignment plate back and forth.
Page 458: Stopper Control
Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION 6.3.3 Stopper control The stopping position in vertical direction of paper conveyed to the stacker is different among the stapling mode, the saddle stitching mode, and the folding mode. 2 stoppers (the saddle stitching stopper and the flat-stapling stopper) control the stopping position of paper. A.
Page 459 6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 B. Stopper control (1) Folding mode Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor (M18) rotates [2] to move down the saddle stitching stopper to the stopping position in accordance with the paper size. After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching stopper to the folding position.
Page 460 Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION (2) Saddle stitching mode Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor (M18) rotates [2] to move down the saddle stitching stopper to the stopping position in accordance with the paper size. After completing the stapling operation [3], the alignment motors /Up (M5) and /Lw (M16) open the alignment plate and M18 rotates [4] to move down the saddle stitching stopper to the folding position.
Page 461 6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 (3) Tri-folding mode Transmitting the FNS signal from the main body [1], the saddle stitching stopper motor (M18) rotates [2] to move down the saddle stitching stopper to the stopping position in accordance with the paper size. After completing the alignment operation of the last paper [3], M18 rotates [4] to move down the saddle stitching stopper to the 1st folding position in the tri-folding.
Page 462 Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION 6.3.4 Stacker entrance transfer control The stacker entrance motor (M13) drives the stacker entrance roller, swing belt to transfer the paper to the stacker, align the trailing edge of the paper, and adjust the staple wait timing. A.
Page 463: Stacker Entrance Transfer Control
6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 B. Stacker entrance transfer control (1) Stapling mode (the paper size is not A4, B5, or 8 x 11, without the bypassing operation) Transmitting the FNS signal from the main body [1], the stacker entrance motor (M13) turns ON and rotates in high speed.
Page 464 Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION (2) Stapling mode (the paper size is A4, B5, or 8 x 11, with the bypassing operation) The 1st copy is transferred by the same operation for the paper whose size is other than A4, B5, or 8 x 11.
Page 465 6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 (3) Folding/saddle stitching mode Transmitting the FNS signal from the main body [1], the stacker entrance motor (M13) turns ON and rotates in high speed. M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects the trailing edge of the paper.
Page 466 Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION (4) Tri-folding mode Transmitting the FNS signal from the main body [1], the stacker entrance motor (M13) turns ON and rotates in high speed. M13 rotates in low speed [2] to transfer the paper in low speed when the stacker entrance sensor (PS5) detects the trailing edge of the paper.
Page 467: Stacker Paper Exit Control
6. STACKER SECTION Theory of Operation Ver1.0 Sep.2006 6.3.5 Stacker paper exit control The paper exit roller motor (M7) controlled by the FNS control board (FNSCB) drives the paper exit belt of the stacker via the coupling gear. A. Paper exit belt operation The paper exit arm [2] mounted on the paper exit belt [1] exits the paper to the main tray in the stapling mode.
Page 468 Theory of Operation Ver1.0 Sep.2006 6. STACKER SECTION B. Paper exit arm control (1) Stapling mode (when the paper length is shorter than B5S in the sub scan direction) Completing the stapling operation, the paper exit roller motor (M7) rotates to drive the paper exit belt in the stacker section.
Page 469: Stapler Section
7. STAPLER SECTION Theory of Operation Ver1.0 Sep.2006 7. STAPLER SECTION Composition Stapler rotation motor (M6) Stapler /Rr Stapler movement motor (M11) Stapler movement home sensor (PS11) Stapler /Fr Clincher rotation motor (M4) Stapler rotation home sen- sor (PS13) Clincher /Rr Clincher rotation home sensor (PS14) Clincher /Fr a04dt2c007ca...
Page 470: Drive
Theory of Operation Ver1.0 Sep.2006 7. STAPLER SECTION Drive [10] [10] [11] 15jmt2c014na Stapler movement motor (M11) Stapler /Fr Upper side of the timing belt Stapler movement home sensor (PS11) Clincher rotation motor (M4) Stapler /Rr Clincher /Rr [10] Stapler rotation motor (M6) Clincher /Fr [11] Timing belt...
Page 471: Operation
7. STAPLER SECTION Theory of Operation Ver1.0 Sep.2006 Operation 7.3.1 Stapler movement control The staplers move in the horizontal direction for adjusting their distance. The stapler at the rear also rotates. The movement is made according to the stapling mode. A.
Page 472 Theory of Operation Ver1.0 Sep.2006 7. STAPLER SECTION B. Rotational movement operation The stapler /Rr and the clincher /Rr rotate 45° for performing 1 staple/one-corner stapling at rear. The stapler rotation motor (M6) [10] rotates the stapler /Rr [9] and the clincher rotation motor (M4) [5] rotates the clincher /Rr [7].
Page 473: Stapler Movement Control
7. STAPLER SECTION Theory of Operation Ver1.0 Sep.2006 C. Stapler movement control (1) Size movement in 1 staple/front and 2 staples Transmitting the FNS signal from the main body, the stapler movement motor (M11) turns ON to widen the dis- tance between stapler and clincher.
Page 474: Stapler Control
Theory of Operation Ver1.0 Sep.2006 7. STAPLER SECTION 7.3.2 Stapler control The stapling operation is performed by the stapler motors /Rr (M9) and /Fr (M14) and the clincher motors /Rr (M10) and /Fr (M15). A. Stapling operation In the stapling operation, the stapler motors /Rr (M9) and /Fr (M14) in the staplers /Rr and /Fr [6] push out the paper press section [4] to the clinchers [2] by the cam mechanism [5] to hold the paper [1] and punch out the staples [3].
Page 475 7. STAPLER SECTION Theory of Operation Ver1.0 Sep.2006 B. Staple control (1) Stapling After completing the alignment operation of the alignment plate, the stapler motors /Rr (M9) and /Fr (M14) per- form the stapling operation. After a specified period of time, the clincher motors /Rr (M10) and /Fr (M15) bend the staples.
Page 476: Folding/Saddle Stitching/Tri-Folding Section
Theory of Operation Ver1.0 Sep.2006 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION Composition Tri-folding gate solenoid (SD6) Folding paper exit sensor (PS25) Folding knife home sensor (PS22) Tri-folding gate Folding transfer motor (M20) Folding full sensor (PS29) Tri-folding stopper Folding knifeg Folding roller Folding knife motor...
Page 477: Drive
8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION Theory of Operation Ver1.0 Sep.2006 Drive 15jmt2c019na Folding knife Tri-folding gate solenoid (SD6) Folding knife motor (M19) Tri-folding gate Folding transfer motor (M20) Folding roller Tri-folding roller...
Page 478: Operation
Theory of Operation Ver1.0 Sep.2006 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION Operation 8.3.1 Folding knife control The folding knife motor drives the folding knife. The folding knife is used in the folding/saddle stitching/tri-folding mode. In the tri-folding mode, it is used at the 1st folding. A.
Page 479: Folding Transfer Control
8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION Theory of Operation Ver1.0 Sep.2006 8.3.2 Folding transfer control The folding transfer motor (M20) drives the folding roller. Then, the folding roller drives the tri-folding roller. A. Folding transfer control The folding knife motor (M19) turns ON [2] after a specified period of time since the folding pass-through sensor (PS26) detects the paper and the saddle stitching stopper stops at the folding position.
Page 480 Theory of Operation Ver1.0 Sep.2006 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION 8.3.3 Tri-folding gate control The tri-folding gate switches between the folding/saddle stitching path and the tri-folding path. The tri-folding gate solenoid (SD6) drives the tri-folding gate. A. Tri-folding 2nd folding operation The tri-folding gate solenoid (SD6) [5] drives the tri-folding gate [6] to switch the paper path to the tri-folding path for leading the paper exited from the folding roller [1] to the tri-folding stopper [4].
Page 481 8. FOLDING/SADDLE STITCHING/TRI-FOLDING SECTION Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 482 Theory of Operation SERVICE MANUAL PI-502 2006.09 Ver. 1.0...
Page 483 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 484 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS PI-502 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 485 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 486: Product Specifications
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Torque limiter separation type seat feeding device B. Functions Auto sheet feeding (online Feeds the sheet to FS automatically under the instruction from the main body. operation) Manual sheet feeding Feeds the sheet to FS under the instruction from the operation panel of PI.
Page 487 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 D. Maintenance Maintenance Same as the main body. Machine service life Same as the main body. E. Machine data Power source 24/5V DC (supplied from the main body) Maximum power consump- 30W or less tion Dimensions 511 (W) x 620 (D) x 220 (H) mm...
Page 488: Unit Configuration Diagram
Theory of Operation Ver1.0 Sep.2006 2. UNIT CONFIGURATION DIAGRAM 2. UNIT CONFIGURATION DIAGRAM Tray /Up section Pick-up /Up section Separation /Up section Conveyance section Tray /Lw section Pick-up /Lw section Separation /Lw section 15jft2c001na...
Page 489: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH Auto sheet feeding (online operation) 15jft1c002na Paper path from the tray /Up Paper path from the tray /Lw Manual sheet feeding (offline operation) 15jft1c003na Paper path from the tray /Lw...
Page 490: Composition/Operation
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION COMPOSITION/OPERATION 4. PAPER FEED SECTION Composition Tray /Up Pick-up roller /Up Paper feed roller /Up Separation roller /Up Conveyance roller /Up Paper feed roller /Lw Conveyance Tray /Lw roller /Lw Pick-up roller /Lw Separation roller /Lw a04ht2c001ca...
Page 491: Drive
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Drive 4.2.1 Paper feed drive [10] [14] [13] [11] [12] [18] [15] [17] [16] 15jft2c002nb Pick-up roller /Lw [10] Paper feed roller /Lw Pick-up roller /Up [11] Conveyance roller /Lw Pick-up solenoid /Up (SD201) [12] Separation roller /Lw Paper feed roller /Up...
Page 492: Tray Lift Drive
Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.2.2 Tray lift drive 15jft2c003nb Front Tray lift motor /Up (M201) Tray lift motor /Lw (M202)
Page 493: Operation
4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 Operation 4.3.1 Tray lift mechanism The tray lift motors /Up (M201) [2] and /Lw (M202) [7] move up and down the trays /Up and /Lw by rotating in the forward and reverse direction to drive the lift arms /Up [10] and /Lw [4] and move up and down the lift plates /Up [8] and /Lw [6], respectively.
Page 494 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.2 Pick-up mechanism The pick-up solenoids /Up (SD201) [2] and /Lw (SD202) turn ON to pick up the paper. The release arm [5] held upward by the spring [1] lifts up the pick-up roller mounting plate [4] to release the pick-up roller [3]. When SD201 and SD202 turn ON, the release arm moves backward, and then the pick-up roller mounting plate and the pick-up roller fall down by their own weight.
Page 495 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.3 Separation mechanism The separation roller [4] is driven to rotate in the opposite direction from the paper transfer direction [2]. When transferring no or 1 sheet of paper, the separation roller rotates in the paper transfer direction to transfer the paper to the paper transfer section because the frictional force between the paper feed roller [1] or the paper and the separation roller [4] is stronger than the frictional force of the torque limiter [3].
Page 496 Theory of Operation Ver1.0 Sep.2006 4. PAPER FEED SECTION 4.3.4 Registration control Transmitting the FS start signal [1], the transfer motor (M203) rotates in low speed and the pick-up solenoids / UP (SD201) and /Lw (SD202) turn ON. At the time, the tray lift motors /Up (M201) and /Lw (M202) rotate in the forward direction to lift up the trays /Up and /Lw.
Page 497 4. PAPER FEED SECTION Theory of Operation Ver1.0 Sep.2006 4.3.5 Paper size detection control The paper size VRs /Up (VR201) [1] and /Lw (VR202) [3] coupled with the side guide [2] detects the paper size in the main scan direction. The paper set sensors /Up (PS203) [5] and /Lw (PS212) [4] and the L size sensor /Lw (PS208) [6] detects the paper size in the sub scan direction.
Page 498 Theory of Operation SERVICE MANUAL PK-512/513 2006.09 Ver. 1.0...
Page 499 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 500 Theory of Operation Ver1.0 Sep.2006 CONTENTS CONTENTS PK-512/513 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 501 CONTENTS Theory of Operation Ver1.0 Sep.2006 Blank page...
Page 502: Product Specifications
Theory of Operation Ver1.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type FS-integrated type punching operation device B. Functions Punching method Stops and punches every paper No. of holes PK-512: 2 holes/3 holes (inch) or 2 holes/4 holes (metric) PK-513: 4 holes φ...
Page 503 1. PRODUCT SPECIFICATIONS Theory of Operation Ver1.0 Sep.2006 D. Maintenance Maintenance Same as the main body. Machine service life Same as the main body. E. Machine data Power source 24/5V DC (supply from the main body) Maximum power 40 W or less consumption Dimensions 130 (W) x 470 (D) x 115 (H) mm...
Page 504: Unit Composition
Theory of Operation Ver1.0 Sep.2006 2. UNIT COMPOSITION 2. UNIT COMPOSITION Punch section Punch scraps box section 15kjt2e001na...
Page 505: Paper Path
3. PAPER PATH Theory of Operation Ver1.0 Sep.2006 3. PAPER PATH 15kjt1c002na Paper path from PI Paper path from the main body Punch unit Punch scraps box...
Page 506: Composition/Operation
Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION COMPOSITION/OPERATION 4. PUNCH SECTION Composition Paper size sensor (PS305) Punch blade Punch unit Punch blade Entrance roller a04et2e001ca...
Page 507: Drive
4. PUNCH SECTION Theory of Operation Ver1.0 Sep.2006 Drive 4.2.1 Punch shift drive 15kjt2c002na Punch unit Punch shift motor (M302) Guide shaft Rack Belt Punch shift home sensor (PS303) Front...
Page 508 Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION 4.2.2 Punch drive A. PK-512 (2 to 3 holes) [12] [13] [11] [10] [11] [10] 15kjt2e007nb Punch motor (M301) Groove of the switching cam Eccentric cam Projection of the punch blade Slide link [10] Projection of the switching cam Switching cam...
Page 509 4. PUNCH SECTION Theory of Operation Ver1.0 Sep.2006 B. PK-512 (2 to 4 holes) [12] [13] [11] [10] [11] [10] a04et2f002ca Punch motor (M301) Groove of the switching cam Eccentric cam Projection of the punch blade Slide link [10] Projection of the switching cam Switching cam [11] Punch blade...
Page 510 Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION C. PK-513 15kjt2c003nb Eccentric cam Punch blade Drive arm Punch motor (M301)
Page 511: Punch Standby Position Movement Control
4. PUNCH SECTION Theory of Operation Ver1.0 Sep.2006 Operation 4.3.1 Punch standby position movement control Turning ON the device, the punch shift motor (M302) rotates to move the punch unit [6] to the home position until the punch shift home sensor (PS303) turns ON. Selecting the punch mode, M302 rotates to move the punch unit [6] so that the paper size sensor (PS305) [1] of the punch unit [6] is positioned 5 mm inward [2] from the side edge of the paper.
Page 512: Punch Position Correction Control
Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION 4.3.2 Punch position correction control For the punch unit positioned from the side edge of the paper to the inside (see "4.3.1 Punch standby position movement control"), the punch position is adjusted in the following procedure so that punching is made sym- metrically to the center of paper at all times.
Page 513: Punch Control
4. PUNCH SECTION Theory of Operation Ver1.0 Sep.2006 4.3.3 Punch control A. Registration loop control The FNS conveyance motor (M1) turns OFF temporarily to stop conveyance of paper when the specified time has passed since paper exit sensor (PS13) detected the leading edge of the paper. Thus the paper is pressed against the entrance roller forming a loop to correct the bend.
Page 514 Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION B. Punch control (PK-512) The FNS transfer motor (M1) is driven by the main body start signal. In the punching mode, the motor M1 stops temporarily after the FNS entrance sensor (PS4) detects the rear edge of paper. At the same time, the punch motor (M301) [3] rotates in the direction according to the number of punched holes.
Page 515 4. PUNCH SECTION Theory of Operation Ver1.0 Sep.2006 (1) 2 to 3 holes mode In the 2 to 3 punched hole mode, the groove of the switching cam of the 3-hole punching blade is shaped so that the rear side is concentric with the rotating axis and the front side is curved toward the rotating axis. For this reason, when the switching cam is rotated clockwise, the punching blade is driven downward and when the cam is rotated counterclockwise, the punching blade is not driven.
Page 516 Theory of Operation Ver1.0 Sep.2006 4. PUNCH SECTION C. Punch control (PK-513) Transmitting the start signal from the main body, the FNS conveyance motor (M1) rotates. In the punch mode, M1 stops temporarily a specified period of time after the FNS entrance sensor (PS4) detects the trailing edge of the paper.
Page 517: Punch Scraps Box Section
5. PUNCH SCRAPS BOX SECTION Theory of Operation Ver1.0 Sep.2006 5. PUNCH SCRAPS BOX SECTION Composition Punch scraps box full sensor (PS302) Punch scraps box set sensor (PS304) Punch scraps box Front side 15kjt2e009nb Drive The punch scraps box section comprises no moving parts. Operation 5.3.1 Punch scraps box control...
Page 518 Theory of Operation SERVICE MANUAL SD-501 2006.09 Ver. 2.0...
Page 519 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improve- ment of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 520 Theory of Operation Ver2.0 Sep.2006 CONTENTS CONTENTS SD-501 OUTLINE 1. PRODUCT SPECIFICATIONS............1 2.
Page 521 CONTENTS Theory of Operation Ver2.0 Sep.2006 7.2.1 Saddle stitching alignment drive ..........51 7.2.2 Saddle stitching hold drive .
Page 522: Product Specifications
Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS OUTLINE 1. PRODUCT SPECIFICATIONS A. Type Type Saddle stitching unit with fore-edge trimming and multi-folding function B. Functions (1) Functions Subtray exit Exits paper to the subtray without any process. Coupling exit Conveys paper to the succeeding device without any process.
Page 523 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 C. Type of paper (1) Coupling/subtray mode Paper size SRA3* , A3, B4, SRA4* , SRA4S* , A4, A4S, B5, B5S, A5, A5S* , B6S* , A6S* 13 x 19* , 12 x 18, 11 x 17, 8 x 14, 8 x 11, 8 x 11S,...
Page 524 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS (2) Saddle stitching mode Paper size SRA3* , A3, B4, SRA4S* , A4S, B5S 12 x 18, 11 x 17, 8 x 14, 8 x 11S x 13, 8 x 13, 8 x 13 , 8 x 13 , 16K*...
Page 525 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 Folding height 15ant1c011na Folding sheets [1] Folding height 12 x 18 x 14 x 11S 11 x 17 (301 mm to 400 mm) (261 mm to 300 mm) (401 mm or more) 2 to 5 35 mm or less 40 mm or less...
Page 526 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS (3) Trimming mode Paper size SRA3* , A3, B4, SRA4S* , A4S, B5S 12 x 18, 11 x 17, 8 x 14, 8 x 11S x 13, 8 x 13, 8 x 13 , 8 x 13 , 16KS* Custom paper...
Page 527 1. PRODUCT SPECIFICATIONS Theory of Operation Ver2.0 Sep.2006 (4) Multi center folding mode Paper size SRA3* , A3, B4, SRA4S* , A4S, B5S 12 x 18, 11 x 17, 8 x 14, 8 x 11S x 13, 8 x 13, 8 x 13 , 8 x 13 , 16KS*...
Page 528 Theory of Operation Ver2.0 Sep.2006 1. PRODUCT SPECIFICATIONS (5) Multi letter folding mode Paper size A4S, 8 x 11S Paper weight 50 to 91 g/m Maximum folding Paper weight Sheets sheets 50 to 81 g/m 5 sheets 82 to 91 g/m 3 sheets Folding precision Original size...
Page 529: Unit Composition
2. UNIT COMPOSITION Theory of Operation Ver2.0 Sep.2006 2. UNIT COMPOSITION 15ant1c001na Folding section Trimmer section Right angle conveyance section Saddle stitching section Bundle process section Horizontal conveyance section Left side view...
Page 530: Paper Path
Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH 3. PAPER PATH A. Coupling exit/subtray exit mode 15ant1c002na Horizontal conveyance Coupling exit Subtray exit...
Page 531 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 B. Multi letter folding mode [4] [5] [10] 15ant1c003na Stack to the right angle conveyance section Paper exit Right angle conveyance Stack movement of the paper exit Conveyance to the folding section Front side view 1st folding Top side view...
Page 532 Theory of Operation Ver2.0 Sep.2006 3. PAPER PATH C. Multi center folding/saddle stitching mode (1) From the paper exit from the main body to the center folding 15ant1c004na Stack to the right angle conveyance section Release from the folding roller Right angle conveyance Front side view Conveyance to the folding section...
Page 533 3. PAPER PATH Theory of Operation Ver2.0 Sep.2006 (2) From the center folding to the paper exit 15ant1c005na Conveyance from the folding section to the Paper exit saddle stitching section Stack movement of the paper exit Movement by the bundle arm Front side view Movement by the clip Left side view...
Page 534: Composition/Operation
Theory of Operation Ver2.0 Sep.2006 4. HORIZONTAL CONVEYANCE SECTION COMPOSITION/OPERATION 4. HORIZONTAL CONVEYANCE SECTION Composition Horizontal convey- Horizontal Entrance Subtray paper full Sub tray ance gate conveyance conveyance sensor (PS12) Entrance gate 15ant2c001nb...
Page 535: Entrance Conveyance Drive
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Drive 4.2.1 Entrance conveyance drive 15ant2c002nb Entrance roller Front side view Entrance conveyance motor (M1) Conveyance roller Overlap assist roller 4.2.2 Horizontal conveyance drive 15ant2c003na Front side view Horizontal conveyance motor (M2) Exit roller Subtray exit roller Conveyance roller...
Page 536: Gate Drive/Subtray Pressure/Release Drive
Theory of Operation Ver2.0 Sep.2006 4. HORIZONTAL CONVEYANCE SECTION 4.2.3 Gate drive/subtray pressure/release drive 15ant2c004na Subtray exit roller Horizontal conveyance gate Roller release solenoid /4 (SD4) Entrance gate solenoid (SD1) Horizontal conveyance gate solenoid (SD3) Entrance gate...
Page 537: Operation
4. HORIZONTAL CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 Operation 4.3.1 Conveyance path switching operation A. Entrance gate solenoid control The entrance gate switches the path to the horizontal conveyance section and one to the right angle convey- ance section. The switch is conducted by the entrance gate solenoid (SD1). The right angle conveyance path is selected when SD1 turns OFF and the horizontal conveyance path is selected when it turns ON.
Page 538: Subtray Exit Control
Theory of Operation Ver2.0 Sep.2006 4. HORIZONTAL CONVEYANCE SECTION 4.3.3 Subtray exit control When exiting the paper to the subtray, the paper is prevented to be misaligned by releasing the nipping of the subtray exit roller by the roller release solenoid /4 (SD4) to nip the paper only at the trailing edge and slowing down the paper by the subtray exit roller that is rotating in low speed for every paper.
Page 539: Right Angle Conveyance Section
5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION Composition Right angle conveyance gate Alignment claws Alignment Right angle convey- section ance roller /1 Right angle convey- ance roller /2 Overlap section Overlap stopper Right angle conveyance Right angle conveyance 15ant2c008nb...
Page 540: Right Angle Conveyance Drive/Alignment Drive
Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION Drive 5.2.1 Right angle conveyance drive/alignment drive [11] [10] 15ant2c009na Alignment claws Right angle conveyance roller /4 Torque limiter Right angle conveyance roller /3 Roller release solenoid /1 (SD5) Right angle conveyance roller /2 Front side direction [10] Right angle conveyance motor (M6)
Page 541: Overlap Drive
5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 5.2.2 Overlap drive 15ant2c010nb Overlap stopper Front side view Overlap motor (M13) Right angle conveyance gate Right side view Right angle conveyance gate solenoid (SD2) Overlap home sensor (PS17) Overlap assist roller...
Page 542: Operation
Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION Operation 5.3.1 Paper overlap control A. Overlap mechanism When the folding operation is conducted for more than one sheet of paper, they are overlapped in the right angle conveyance section, and then conveyed to the folding section. The overlap mechanism is the mechanism to overlap the paper in adequate paper conveyance order.
Page 543 5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 The first stacked sheet of paper [5] is conveyed while the overlap stopper is located at the standby position [4]. Before conveying the second paper, right angle conveyance gate solenoid (SD2) turns ON to move the right angle conveyance gate [6] to the right [7].
Page 544 Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION B. Overlap control (1) Multi letter folding mode control In the multi letter folding mode, up to 5 sheets are stacked in the right angle conveyance section and conveyed to the folding section. The multi letter folding is available only with paper of 50 to 91 g/m in weight and is unavailable with others.
Page 545 5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 (2) Center folding/saddle stitching mode control In the center folding and saddle stitching modes, 1, 2, or 3 sheets of paper are stacked and conveyed to the folding section. The number of the stacked sheets is different depending on its paper weight and the convey- ance pattern.
Page 546 Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION 5.3.2 Alignment control A. Alignment mechanism The alignment is conducted by driving the alignment claws [2] by the right angle conveyance motor (M6) [5] through the belt [3] and the torque limiter [4]. The alignment claws move to the rear of the shelter direction [7] and are stopped by the mechanical stoppers [1] through the torque limiter when M6 is rotating toward the paper conveyance direction.
Page 547 5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 B. Alignment control The right angle conveyance motor (M6) rotates in the reverse direction when the main body start signal [1] turns ON and the alignment claws move to the standby position [2] in accordance with the paper size. No alignment operation is conducted for the 1st paper.
Page 548: Right Angle Conveyance Control
Theory of Operation Ver2.0 Sep.2006 5. RIGHT ANGLE CONVEYANCE SECTION 5.3.3 Right angle conveyance control A. Right angle conveyance mechanism In the right angle conveyance, the right angle conveyance motor (M6) and the roller release solenoids /1 (SD5) [5] and /2 (SD6) [10] convey the paper. When conveying the paper to the overlap section, the paper falls vertically [6] to the overlap stopper [7] by its own weight after conveyed by the overlap assist roller.
Page 549 5. RIGHT ANGLE CONVEYANCE SECTION Theory of Operation Ver2.0 Sep.2006 B. Conveyance control The roller release solenoid /1 (SD5) turns ON to press the right angle conveyance roller /1 [2] after a specified period of time since the entrance sensor (PS1) detects the trailing edge of last paper of the set [1]. After the alignment operation [3], the right angle conveyance motor (M6) rotates in the forward direction to convey the paper to the front side [4] by rotating 90°.
Page 550: Folding Section
Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION 6. FOLDING SECTION Composition Alignment claws /Fr Conveyance belt 2nd folding blade (main scan) (tri-folding) Folding roller /3 Folding roller /2 Alignment stop- per /Rr (main scan) 1st folding blade Folding roller /1 Folding alignment Folding exit Guide shaft...
Page 551: Drive
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 Drive 6.2.1 Folding entrance drive 15ant2c016na Folding entrance motor (M3) Folding entrance roller /1 Right side view Roller release solenoid /3 (SD7)
Page 552: Folding Conveyance Drive
Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION 6.2.2 Folding conveyance drive 15ant2c017na One way clutch Right side view Oscillation connecting gear Exit belt Folding conveyance motor (M4) Folding roller /3 Folding roller /2 Tri-folding exit clutch (CL1) Folding roller /1...
Page 553: Folding Blade Drive
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 6.2.3 Folding blade drive [10] [11] [12] [13] [14] 15ant2c018na 1st folding blade motor (M18) 2nd folding blade motor (M19) Folding roller /2 2nd folding blade home sensor /2 (PS23) 1st folding blade home sensor /2 (PS21) [10] 2nd folding blade home sensor /1 (PS22) 1st folding blade home sensor /1 (PS20)
Page 554: Folding Main Scan Alignment Drive
Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION 6.2.4 Folding main scan alignment drive 15ant2c019na Folding main scan alignment home sensor /Rr (PS19) Folding main scan alignment motor /Fr (M7) Alignment stoppers /Rr Folding main scan alignment home sensor /Fr1 (PS18) Right side view Folding main scan alignment home sensor /Fr2 (PS49) Alignment claws /Fr...
Page 555: Folding Sub Scan Alignment/Center Folding Exit Drive
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 6.2.5 Folding sub scan alignment/center folding exit drive 15ant2c020na Folding alignment stoppers /Rt Front side direction Home position stoppers /Rt Folding sub scan alignment home sensor (PS56) Folding exit home sensor (PS24) Folding exit claws Torque limiter Alignment stoppers /Lt...
Page 556: Guide Shaft Drive
Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION 6.2.6 Guide shaft drive 15ant2c021na Guide shaft home sensor (PS46) Front side view Guide shaft motor (M25) Guide shaft...
Page 557: Operation
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 Operation 6.3.1 Folding entrance conveyance control A. Mechanism The folding entrance motor (M3) and the roller release solenoid /3 (SD7) [5] conduct the folding entrance con- veyance operation. The paper [1] conveyed from the right angle conveyance section is conveyed to the folding entrance with the pressure of the folding entrance roller /1 [7] released.
Page 558 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION B. Control The roller release solenoid /3 (SD7) turns ON to nip the paper with the folding entrance roller [2] after a specified period of time since the right angle conveyance sensor /2 (PS6) detects the leading edge of paper [1], and then the roller release solenoid /2 (SD6) turns ON to release the nip of the right angle conveyance roller /4 [3] after a specified period of time.
Page 559: Folding Main Scan Alignment Control
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 6.3.2 Folding main scan alignment control A. Mechanism In the folding main scan alignment, the alignment stoppers /Rr [5] driven by the folding main scan alignment motor /Rr (M14) stop at the appropriate position in accordance with the paper size, and then the alignment claws /Fr [2] driven by the folding main scan alignment motor /Fr (M7) conduct the alignment operation.
Page 560 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION B. Control The folding main scan alignment motor /Rr (M14) drives the alignment stoppers /Rr to the appropriate position in accordance with the paper size [2] when the main body start signal [1] turns ON. The folding main scan alignment motor /Fr (M7) rotates in the forward direction to let [3] the alignment claws /Fr push the trailing edge of paper for conveyance after a specified period of time since the folding entrance sensor (PS60) detects the trailing edge of paper, and then M7 stops after a specified period of time [4].
Page 561: Folding Control
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 6.3.3 Folding control A. Mechanism Folding consists of the 1st folding and 2nd folding. The 1st folding is conducted in the multi letter folding mode, the multi center folding mode, and the saddle stitching mode.
Page 562 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION B. Tri-folding control (1) Operation After the initial operation, the 1st folding blade [8] is at the standby position /1 [5]. In the actuator [7], the 1st fold- ing blade home sensor /2 (PS21) [3] turns ON and the 1st folding blade home sensor /1 (PS20) [6] turns OFF. When the paper [9] is conveyed to the folding section and the 1st folding blade motor (M18) is rotated [2], the crank [4] rotates 90°...
Page 563 6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 (2) Control When the folding main scan alignment motor /Fr (M7) stops rotating at the completion of the paper alignment operation, the 1st folding blade motor (M18) turns ON and starts rotating in the reverse direction. The 1st folding blade folds and inserts the paper between the folding rollers /1 and /2.
Page 564 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION C. Tri-folding exit control (1) Operation In the multi letter folding exit, the driving force of the folding conveyance motor (M4) is transmitted via the tri-fold- ing exit clutch (CL1). CL1 turns ON and the exit belt [4] is driven approximately 7 mm to convey the paper to the front side for every paper exit.
Page 565 6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 D. Center folding control When the folding main scan alignment motor /Fr (M7) stops at the completion of the paper alignment operation, the 1st folding blade motor (M18) turns ON and rotates in the reverse direction [2] to let the 1st folding blade insert the paper between the folding rollers /1 and /2.
Page 566: Folding Sub Scan Alignment Control
Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION 6.3.4 Folding sub scan alignment control A. Mechanism The folding sub scan alignment operation is conducted in the multi letter folding mode and is conducted with the folding exit claws [13] and the folding alignment stoppers /Rt [3] driven by the folding sub scan alignment exit motor (M8) [8].
Page 567 6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 B. Folding sub scan alignment control The folding sub scan alignment exit motor (M8) rotates in the reverse direction to conduct the alignment opera- tion in the sub scan direction [2] after a specified period of time since the right angle conveyance sensor /2 (PS6) detects the trailing edge of paper and the alignment operation in the main scan direction is conducted [1].
Page 568 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION C. Center folding exit operation The folding sub scan alignment exit motor (M8) does not conduct the alignment operation in the sub scan direc- tion in the multi center folding/saddle stitching mode. It conducts the operation only when it exits the paper to the saddle stitching section.
Page 569: Guide Shaft Control
6. FOLDING SECTION Theory of Operation Ver2.0 Sep.2006 6.3.5 Guide shaft control A. Mechanism The guide shaft [2] holds the fold line [4] from the bottom and makes certain of the stack [3] in the saddle stitch- ing section when the folding exit claws [7] exit the folded paper [1] to the saddle stitching section. The guide shaft is projected [5] in sync with the paper exit only when the first folded paper for each set is exited and put away immediately to the folding section [6].
Page 570 Theory of Operation Ver2.0 Sep.2006 6. FOLDING SECTION B. Guide shaft control The guide shaft motor (M25) turns ON [2] and the guide shaft is projected after a specified period of time since the folding main scan alignment motor /Fr (M7) completes the realignment operation in the main scan direction [1] (after the folding operation).
Page 571: Saddle Stitching Section
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION Composition Saddle stitching Saddle stitching Saddle stitching Stapler hold /Up hold /Lw alignment plate Clip Bundle arm Bundle arm assist plate Clincher 15ant2c028nb...
Page 572: Drive
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION Drive 7.2.1 Saddle stitching alignment drive 15ant2c029na Saddle stitching alignment motor /Rt (M9) Saddle stitching alignment home sensor /Lt (PS29) Folding sensor /2 (PS44) Saddle stitching alignment motor /Lt (M16) Saddle stitching alignment home sensor /Rt (PS28) Saddle stitching alignment plate /Lt Front side view Saddle stitching alignment plate /Rt...
Page 573: Clincher Up Down Drive
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.2.3 Clincher up down drive 15ant2c031na Left side view Clincher up down motor (M20) Roller Spring Eccentric cam Clinchers /Rt, /Lt Clincher up down home sensor (PS26) Saddle stitching hold /Lw...
Page 574: Stapler/Clincher Movement Drive
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.2.4 Stapler/clincher movement drive 15ant2c032na Top side view Stapler movement home sensor (PS25) Stapler /Rt Stapler movement motor (M15) Clincher /Rt Clincher /Lt Front side view Stapler /Lt...
Page 575: Stapler/Clincher Drive
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.2.5 Stapler/clincher drive 15ant2c077na Stapling arm Staple Staple bending arm Left side view Clincher plate Eccentric cam Clincher solenoids /Rt (SD9) and /Lt (SD10) Stapler motors /Rt (M29), /Lt (M39)
Page 576: Bundle Arm Rotation Drive
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.2.6 Bundle arm rotation drive 15ant2c033na Bundle arm Guide shaft Slide guide Fulcrum shaft Left side view Bundle arm rotation home sensor (PS31) Bundle arm rotation motor (M22)
Page 577: Bundle Arm Movement Drive
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.2.7 Bundle arm movement drive 15ant2c034na Bundle arm Bundle arm motor (M10) Guide shaft Bundle arm home sensor (PS32) Folding sensor /2 (PS44) Fulcrum shaft...
Page 578: Bundle Arm Assist Drive
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.2.8 Bundle arm assist drive 15ant2c035na Bundle arm assist upper limit sensor (PS39) Bundle arm assist home sensor (PS38) Left side view Bundle arm assist motor (M26) Bundle arm assist plate...
Page 579: Bundle Clip Drive
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.2.9 Bundle clip drive [10] 15ant2c036nb Bundle clip upper limit sensor (PS33) Release roller Bundle clip motor (M11) Wire Left side view Spring Bundle clip lower limit motor (PS30) Release plate /Up Release plate /Lw [10] Clip...
Page 580: Operation
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION Operation 7.3.1 Saddle stitching alignment control A. Mechanism In the saddle stitching alignment, the saddle stitching alignment plates /Lt [2] and /Rt [8] align the center folded paper [5] in the sub scan direction. The saddle stitching alignment motor /Lt (M16) [3] drives the saddle stitching alignment plate /Lt [2] in the sub scan direction via the belt by rotating in the forward and reverse directions.
Page 581 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The saddle stitching alignment motor /Lt (M16) rotates in the reverse direction when the main body start signal [1] turns ON and the saddle stitching alignment plate /Lt moves to the position for the appropriate paper size [2]. The saddle stitching alignment motor /Rt (M9) rotates in the forward direction and the saddle stitching alignment plate /Rt conducts the preliminary alignment operation [4] when the folding sensor /2 (PS44) at the exit of the folding section detects the trailing edge of the paper [3].
Page 582: Stapler/Clincher Movement Control
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.3.2 Stapler/clincher movement control A. Mechanism The staplers/clinchers move to the stapling position in accordance with the paper size. The stapling position is different for every paper size to make the stapling distance half of the paper size. The staplers /Rt [10] and /Lt [8] are fixed to the belt /Up [9] and the clinchers /Rt [2] and /Lt [4] to the belt /Lw [1].
Page 583: Saddle Stitching Hold Control
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.3.3 Saddle stitching hold control A. Mechanism The saddle stitching hold is the mechanism to prevent the paper misalignment at stapling. The saddle stitching hold /Up [1] moves down to the saddle stitching hold /Lw [2] at its lower position and hold the center folded paper [3] at the fold line from both up and down.
Page 584 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION The saddle stitching hold /Up [6] is enforced by the spring [3] toward the saddle stitching hold /Lw [5]. When the saddle stitching press motor (M21) rotates the eccentric cam [2] via the gear [1], the arm [4] moves along with the shape of the eccentric cam and the saddle stitching hold /Up is lowered by the spring [3].
Page 585 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control (1) Saddle stitching mode At the end of the paper alignment operation [1], the saddle stitching press motor (M21) rotates to move the sad- dle stitching hold /Up downward [2] and hold the paper between the saddle stitching holds /Up and /Lw. Then, the clincher up down motor (M20) starts rotating and the saddle stitching hold /Up is pushed up by the saddle stitching hold /Lw while holding the paper [3].
Page 586: Clincher Up Down Control
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.3.4 Clincher up down control A. Mechanism The clincher shelters at the lower position to obtain space between the stapler and the clincher when the paper is conveyed between them. After the alignment operation, the saddle stitching hold /Up [7] moves down and holds the center folded paper [6].
Page 587 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 The clincher [7] moves down to the lower position by its own weight and moves upward by the clincher up down motor (M20). The roller [2] attached to the arm [5] is pushed up and the clincher is contacted with the stapler when M20 rotates the eccentric cam [3].
Page 588 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION B. Control The clincher moves up or down only in the saddle stitching mode. Once the saddle stitching press motor (M21) moves down the saddle stitching hold /Up [1], the clincher up down motor (M20) rotates in the forward direction to move up the clinchers /Rt and /Lt and the saddle stitching hold /Lw [2].
Page 589 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.3.5 Stapler control A. Mechanism The stapler operation is conducted by the stapler motors /Rt (M29) and /Lt (M30) [10] and the clincher solenoids /Rt (SD9) and /Lt (SD10) [5]. The stapler operation is detected by the stapler home sensors /Rt (HS1) and /Lt (HS3) [8] and the clincher start sensors /Rt (HS2) and /Lt (HS4) [11].
Page 590 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION B. Control (1) Stapling control The stapler motors /Rt (M29) and /Lt (30) start the stapling operation [2] when the clincher up down home sen- sor (PS26) detects that the clinchers /Rt and /Lt are contacted with the stapler unit [1]. The clincher solenoids /Rt (SD9) and /Lt (SD10) bend the staple and the stapling operation is completed when the clincher start sensors /Rt (HS1) and /Lt (HS3) in the stapler unit turn ON [3].
Page 591: Bundle Arm Control
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.3.6 Bundle arm control The bundle arm [4] rotates and moves in the sub scan direction. It rotates to convey the paper from the stapling section to the bundle clip section and moves in the sub scan direction to catch/release the paper.
Page 592 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION A. Bundle arm movement mechanism The bundle arm [5] is driven by the bundle arm motor (M10) [6] to catch/release the paper [4] in the sub scan direction via the belt. The bundle arm home sensor (PS32) [1] detects the home position of the bundle arm.
Page 593 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 B. Bundle arm rotation mechanism The bundle arm rotation motor (M22) [2] drives the bundle arm [8] via the belt, slide guide [5], and guide shaft [6]. When M22 drives the slide guide [5] in the main scan direction, the guide shaft [6] passing through the long hole of the slide guide is rotated, and then the bundle arm [8] is rotated around the fulcrum.
Page 594 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION In the rotation drive of the bundle arm [8], the slide guide [5] has to be overrun to be sure to make the ring [7] of the bundle arm contact with the guide plate [6]. To prevent any parts from damage due to the overrun, the guide shaft [3] can be moved by the shock absorbing guide [4] and the spring [2].
Page 595 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 C. Bundle arm control The bundle arm motor (M10) rotates in the reverse direction when the main body start signal [1] turns ON and moves the bundle arm to the appropriate position in accordance with the paper size. The bundle arm rotation motor (M22) rotates in the forward direction to rotate the bundle arm to the stapling section [3] after a specified period of time since the folding sensor /2 (PS44) detects the trailing edge of paper of the last set.
Page 596 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION [11] [12][13] [14] Folding sensor /2 (PS44) Bundle arm assist motor (M26) Clincher up down home sensor (PS26) Forward Bundle arm motor (M10) Reverse Bundle arm Forward rotation motor Reverse (M22) Bundle arm rotation home sensor (PS31) Bundle arm home sensor (PS32) Forward...
Page 597: Bundle Arm Assist Control
7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 7.3.7 Bundle arm assist control A. Mechanism The bundle arm assist mechanism is the mechanism to assist the paper conveyance of the bundle arm rotation drive to be conducted without fault. It pushes up the fore edge side of the paper [6] with the bundle arm assist plate [4] to tilt it to the front.
Page 598 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION B. Control (1) Small size paper (313 mm or less) For the small size paper, the bundle arm assist motor (M26) rotates in the forward direction when the main body start signal [1] turns ON to drive the bundle arm assist plate at the home position to the position at the bundle arm assist upper limit sensor (PS39) [2].
Page 599 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 (2) Large size paper (314 mm or more) For the large size paper, the bundle arm assist motor (M26) rotates in the forward direction when the main body start signal [1] turns ON to drive the bundle arm assist plate to the standby position in accordance with the paper size [2] and stands by for the paper.
Page 600: Bundle Clip Control
Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION 7.3.8 Bundle clip control A. Mechanism The bundle clip is the mechanism to hold the paper that the bundle arm conveyed to the slope and convey the paper to the bundle press stage with its fore edge side to the trimmer section. The bundle clip catches, releases, and conveys the paper.
Page 601 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 The bundle clip motor (M11) [5] drives the bundle clip [1] up [8] and down [7] via the gear and belt. The spring [9] provides the bundle clip the force to catch the paper, and the wire [2] and the winding shaft [3] open the bundle clip to release the paper.
Page 602 Theory of Operation Ver2.0 Sep.2006 7. SADDLE STITCHING SECTION The bundle clip is closed all the time except when it is located at the upper and lower limit position. When the bundle clip moves up [1], the release roller /Up [6] gets onto [7] the release plate /Up [8]. Then the wire winding shaft [4] rotates [3] and takes up the wire [5] to open the bundle clip.
Page 603 7. SADDLE STITCHING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The bundle clip motor (M11) rotates in the forward direction to move up the bundle clip until the bundle clip upper limit sensor (PS33) turns ON [2] after a specified period of time since the bundle assist motor (M26) starts the assisting operation [1].
Page 604: Bundle Processing Section
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8. BUNDLE PROCESSING SECTION Composition Bundle press Bundle press Trimmer scraps Up down wire stage plate removal fan (FM1) Exit claws Bundle regis- tration plate Bundle tray paper full sen- sor (PS61) Shutter Registration claws...
Page 605: Drive
8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 Drive 8.2.1 Bundle press stage lift drive [10] [11] [12] [13] 15ant2c051na Bundle registration plate Bundle press stage up down home sensor (PS35) Bundle registration plate wire Bundle press stage up down limit sensor (PS45) Lift wire [10] Bundle press stage up down motor (M24)
Page 606: Bundle Press Movement Drive
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8.2.2 Bundle press movement drive 15ant2c052na Bundle press Left side view Bundle press movement home sensor (PS36) Bundle press movement motor (M17) Bundle press stage 8.2.3 Bundle registration drive 15ant2c053na Exit claws Registration claws Left side view Bundle registration home sensor (PS34)
Page 607: Bundle Press Drive
8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 8.2.4 Bundle press drive 15ant2c054nb Bundle press plate /Up Front side direction Release wire /Rt Bundle press lower limit sensor (PS47) Wire winding shaft Bundle press home sensor (PS37) Bundle press motor (M23) Spring Release wire /Lt...
Page 608: Bundle Exit Drive
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8.2.5 Bundle exit drive [13] [12] [11] [10] 15ant2c055nb Bundle exit conveyance belt Trimmer scraps press plate Left side view Bundle exit drive belt [10] Trimmer scraps press claws Actuator [11] Scraps press home sensor (PS48) Belt [12]...
Page 609: Operation
8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 Operation 8.3.1 Bundle press stage up down control The bundle press stage conducts the up and down operation to convey and exit the paper by the switch back method. The bundle press stage is moved up [7] to decrease the angle difference when receiving the paper [8] conveyed by the bundle clip from the slope [1].
Page 610 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION A. Mechanism The bundle press stage up down motor (M24) [12] rotates the wire winding shaft [14] and winds up the lift wire [3]. During the initial phase, the wire is tightened and the wire arm [4] comes to the horizontal position but the bundle press stage [5] doesn't move up.
Page 611 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control (1) Trimming mode The bundle press stage up down motor (M24) rotates in the forward direction to move up the bundle press stage [2] when the main body start signal [1] turns ON. M24 stops while holding the bundle press stage in slant- ing position when the bundle press stage up down limit sensor (PS45) turns ON [3].
Page 612 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION (2) No trimming mode The bundle press stage up down motor (M24) rotates in the forward direction to move up the bundle press stage [2] when the main body start signal [1] turns ON. M24 stops while holding the bundle press stage in slant- ing position when the bundle press stage up down limit sensor (PS45) turns ON [3].
Page 613: Bundle Press Movement Control
8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 8.3.2 Bundle press movement control The bundle press movement is the mechanism to convey the paper to the trimmer section by pressing the paper with the press section to prevent the trimming skew at the trimmer operation after the paper registration operation.
Page 614 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION B. Control (1) Trimming mode The bundle press movement motor (M17) rotates in the reverse direction to move the bundle press section to the paper conveyance position [2] after specified period of time since the bundle clip motor (M11) starts convey- ing the paper [1].
Page 615 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 (2) No trimming mode The bundle press movement motor (M17) rotates in the reverse direction to move the bundle press section to the paper conveyance position [2] after a specified period of time since the bundle clip motor (M11) starts con- veying the paper [1].
Page 616: Bundle Press Control
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8.3.3 Bundle press control The bundle press is the mechanism to hold the paper during trim operation to prevent the trimming skew after the paper registration operation. A. Mechanism The bundle press plates /Up [1] and /Lw [15] hold the paper. The bundle press plate /Up is pulled to the bundle press plate /Lw [15] (to the direction to hold and press the paper) by the spring [13] via the press wires /Rt [2] and /Lt [12].
Page 617 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The bundle press motor (M23) rotates in the forward direction to conduct the paper press operation [2] to press the paper properly when the bundle press movement motor (M17) completes the press position search [1]. M23 rotates in the reverse direction to move up the bundle press plate /Up slightly to prevent the paper from becom- ing loose [4] when the bundle press lower limit sensor (PS47) detects the lower limit [3] and turns OFF.
Page 618: Bundle Registration Control
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8.3.4 Bundle registration control The paper registration operation reforms the skew at trimming. A. Mechanism The bundle registration motor (M12) drives the registration claws [4]. Two registration claws [4] conduct the registration by making the paper [14] contact [3] with the bundle registra- tion plate [13] from the gutter side.
Page 619 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The bundle registration motor (M12) rotates in the reverse direction when the main body start signal turns ON and the registration claws move to the standby position in accordance with the paper size [2]. The bundle registration motor (M12) rotates in the reverse direction to conduct the paper conveyance assisting operation [4] and the preregistration operation [5] after a specified period of time since the bundle clip motor (M11) starts conveying the paper [3].
Page 620: Bundle Exit Control
Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION 8.3.5 Bundle exit control A. Mechanism (1) Bundle exit mechanism The paper is exited to the bundle exit tray [12]. The paper exited to the bundle exit tray is conveyed to the front by the bundle exit conveyance belt [1] and stacked.
Page 621 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 (2) Bundle exit tray expanding mechanism The bundle exit tray is expandable. The folded bundle exit conveyance belt [6] is also expanded [1] when the bundle exit tray is expanded. At the time, it also moves the bundle exit conveyance belt drive shaft [5] for the bundle exit conveyance belt [1] and [6].
Page 622 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION (3) Trimmer scraps press mechanism Trimmer scraps press is executed by driving the bundle exit motor (M5). The M5 motor drives the pins [10] via the scraps press craws [4] on the belt [5] to move the scraps press plate [2] forward, then the trimmer scraps are pressed by the plate.
Page 623 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 (4) Shutter mechanism When the spring [10] pushes the scraps press plate [2] to its backmost position, the shutter arm [6] is pushed up and the shutter [9] is opened. On the other hand, the shutter is closed when the scraps press plate is moved for- ward from the back most position to the position [3] by the spring of the shutter arm.
Page 624 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION B. Trimmer scraps removal control The scraps removal fan (FM1) [3] blows air [4] to make sure to put the trimmer scraps to the scraps box. 15ant2c115na Left side view Bundle clip lower limit sensor (PS30) Bundle press Trimmer scraps removal fan (FM1) Bundle clip...
Page 625 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 C. Bundle exit control The bundle exit motor (M5) rotates in the forward direction and the bundle exit conveyance belt conveys the exit paper [2] after a specified period of time since the trimmer blade motor (M31) completes the trimming [1]. M5 stops after a specified period of time since the bundle exit sensor /2 (PS57) detects the trailing edge of paper[3].
Page 626 Theory of Operation Ver2.0 Sep.2006 8. BUNDLE PROCESSING SECTION D. Shutter / trimmer scraps press control When the trimming is executed with the shutter closed, the bundle exit motor (M5) starts rotating forward to exit paper [1]. Then the scraps press plate moves backward to drop the trimmer scraps with the shutter opened [2]. After a specified period of time since the paper exit is finished [3], the M5 motor rotates in reverse to move the scraps press plate frontward 50 mm and stops [4] with the shutter closed.
Page 627 8. BUNDLE PROCESSING SECTION Theory of Operation Ver2.0 Sep.2006 E. Bundle exit paper full control The bundle tray paper full sensor (PS61) [1] detects the bundle exit paper full. The main body displays the mes- sage on its operation panel when the paper full is detected. 15ant2c109na Bundle tray paper full sensor (PS61) Trimmer scraps full control...
Page 628: Trimmer Section
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9. TRIMMER SECTION Composition Trimmer press plate Front side direction Trimmer paddle Trimmer blade Trimmer board 15ant2c119na...
Page 629: Drive
9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 Drive 9.2.1 Trimmer press drive 15ant2c067na Trimmer board Press drive screw Press arm Trimmer press home sensor (PS53) Trimmer press motor (M32) Trimmer press upper limit sensor (PS52) Slide block Trimmer press plate...
Page 630: Trimmer Blade Drive
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9.2.2 Trimmer blade drive 15ant2c068na Trimmer blade drive screw Trimmer blade Drive plate Trimmer blade home sensor (PS50) Drive guide holes Trimmer blade upper limit sensor (PS51) Drive shafts Trimmer blade motor (M31)
Page 631: Trimmer Board Drive
9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 9.2.3 Trimmer board drive 15ant2c069na Trimmer board solenoid (SD11) Trimmer board Trimmer board replacement sensor (PS59) One-way clutch Pinion Front side direction Rack...
Page 632: Paddle Drive
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9.2.4 Paddle drive 15ant2c120na Trimmer paddle Trimmer paddle motor (M33)
Page 633: Operation
9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 Operation 9.3.1 Trimmer press control A. Mechanism The trimmer press is the mechanism to hold the paper at its fore-edge side to prevent the trimming misalign- ment. There is approximately 5 mm of opening at the home position. The press arms [4] press the paper with the trim- mer board [2] when the trimmer press motor (M32) [1] drives and the slide blocks [7] move to the closing direc- tion [8].
Page 634 Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION When changing the trimming position of the trimmer board or replacing the trimmer board via the I/O check mode, M32 rotates in the reverse direction to move up the press board higher than the position of the trimmer press upper limit sensor (PS52) and release the trimmer board [3] by pushing the trimmer board retaining spring [2] by the plate [1].
Page 635 9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 B. Control (1) The number of the print paper is 16 or more (32 or more for the saddle stitched paper) The trimmer press motor (M32) rotates in the reverse direction [2] when the bundle clip motor starts conveying the paper [1].
Page 636: Trimmer Blade Control
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9.3.2 Trimmer blade control A. Mechanism The trimming is conducted by the trimmer blade driven by the trimmer blade motor (M31) while the paper is pressed by the trimmer press. The drive shafts [4] moves up in a slanting direction along with the drive guide holes [2] when M31 pulls the trim- mer blade retaining plate [5] to the direction [1].
Page 637 9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The trimmer blade motor (M31) starts the trimming [2] when the trimmer press motor (M32) completes the press and stops [1]. M31 stops when the overcurrent is detected [3]. M31 starts the returning operation to the home position [5] when the bundle press motor (M23) starts releasing the press [4].
Page 638: Trimmer Board Control
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9.3.3 Trimmer board control A. Mechanism The trimmer operation may be conducted improperly due to the damage on the trimmer board if the trimmer board is subjected to the trimmer blade many times at the same position. For this reason, the trimmer board is slid 1 mm backward for sheet cutting each time a job of 700 times trimming is completed.
Page 639 9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 B. Control The trimmer press motor (M32) starts the returning operation [2] to the home position when the 700th trimmer operation [1] is completed. M32 does not stop by defection of the trimmer press home sensor (PS53) [3]. The opening keeps widening until the overcurrent of M32 is detected [4].
Page 640: Trimmer Paddle
Theory of Operation Ver2.0 Sep.2006 9. TRIMMER SECTION 9.3.4 Trimmer paddle A. Mechanism The trimmer paddle [2] is provided to prevent the saddle-stitched paper from creating trails with scraps by get- ting into the paper during the press operation, and to drop the scraps forcibly. The trimmer paddle is driven by the trimmer paddle motor (M33).
Page 641 9. TRIMMER SECTION Theory of Operation Ver2.0 Sep.2006 B. Control In trimming mode, the trimmer paddle motor (M33) starts forward/reverse rotation after paper clipping is oper- ated by the bundle clip motor (M11), and then the M33 motor stops when the trimming JOB is finished. If the trimming amount value is set in the "Trimming adjustment"...
Page 642 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to avoid CCA03U-M-TE1-0675 disclosure of confidential information.