Konica Minolta magicolor 5550 Service Manual

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SERVICE MANUAL
magicolor 5550
magicolor 5550
magicolor 5570
magicolor 5570
THEORY OF OPERATION
®
®
2006.11
Ver. 1.0

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Summary of Contents for Konica Minolta magicolor 5550

  • Page 1 SERVICE MANUAL THEORY OF OPERATION magicolor 5550 magicolor 5550 ® magicolor 5570 magicolor 5570 ® 2006.11 Ver. 1.0...
  • Page 2: Table Of Contents

    WARNING INDICATIONS ON THE MACHINE ............S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-21 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 magicolor 5550/5570 main body Outline ..........................1 Composition/Operation ....................9 Duplex option Outline ..........................
  • Page 3 Blank Page...
  • Page 4: Safety And Important Warning Items

    IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.
  • Page 5: Safety Warnings

    [1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 6 SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.
  • Page 7: Connection To Power Supply

    SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS Work Performed with the Product Powered On WARNING • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.
  • Page 13: Handling Of Consumables

    SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...
  • Page 15 SAFETY AND IMPORTANT WARNING ITEMS [4] Used Batteries Precautions ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie.
  • Page 16: Internal Laser Radiation

    SAFETY AND IMPORTANT WARNING ITEMS [5] Laser Safety • This is a digital machine certified as a Class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class 1 Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 18 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 15 mW aallonpituus 770-800 nm VARNING!
  • Page 19: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. A011P0E504DA Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. A011P0C503DA S-16...
  • Page 20: Precautions For Handling The Laser Equipment

    SAFETY AND IMPORTANT WARNING ITEMS PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. • When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the printer OFF.
  • Page 21: Warning Indications On The Machine

    SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. High voltage •...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an elec- tric shock. High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an elec-...
  • Page 23 SAFETY AND IMPORTANT WARNING ITEMS WARNING • Do not burn used Imaging Units. Toner expelled from the fire is dangerous. WARNING • Do not burn used Waste Toner Bottle. Toner expelled from the fire is dangerous. WARNING • Do not burn used Toner Cartridge. Toner expelled from the fire is dangerous.
  • Page 24: Measures To Take In Case Of An Accident

    MEASURES TO TAKE IN CASE OF AN ACCIDENT MEASURES TO TAKE IN CASE OF AN ACCIDENT 1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.
  • Page 25 MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-22...
  • Page 26: Composition Of The Service Manual

    Composition of the service manual This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.
  • Page 27: Notation Of The Service Manual

    Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) PCRB: Print control board (2) magicolor 5550/5570: Main body (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...
  • Page 28: Main Body

    SERVICE MANUAL THEORY OF OPERATION magicolor 5550 ® magicolor 5570 ® Main body 2006.11 Ver. 1.0...
  • Page 29: Revision History

    Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 30 Theory of operation Ver. 1.0 Nov. 2006 CONTENTS magicolor 5550/5570 main body Outline System configuration....................1 Product specifications ..................... 2 Section configuration....................5 Media path ......................6 Image creation process................... 7 Composition/Operation Overall composition....................9 Timing chart at main body powerup ..............9 Control block diagram ..................
  • Page 31 Theory of operation Ver. 1.0 Nov. 2006 Composition ....................... 23 Operation......................24 9.2.1 Print unit life detection ................24 9.2.2 Print unit life control ..................24 Print unit section (photo conductor) ..............25 10.1 Composition ....................... 25 10.2 Drive ........................25 10.3 Operation......................
  • Page 32 Theory of operation Ver. 1.0 Nov. 2006 13.3.8 1st transfer belt backward rotation control ..........44 13.3.9 Toner collecting port shutter mechanism ............ 45 Transfer section (2nd transfer)................46 14.1 Composition......................46 14.2 Drive ........................47 14.3 Operation ......................47 14.3.1 2nd transfer roller pressure mechanism............
  • Page 33 Theory of operation Ver. 1.0 Nov. 2006 17.3 Operation......................66 17.3.1 Media lift plate mechanism ................. 66 17.3.2 Media separation mechanism..............67 17.3.3 Media feed control ..................67 17.3.4 Media supply level detection control ............68 17.3.5 Media empty condition detection control ............ 68 17.3.6 Edge guide plate..................
  • Page 34 Theory of operation Ver. 1.0 Nov. 2006 20.3.3 Fusing temperature control ................. 93 20.3.4 Fusing temperature control management ........... 94 20.3.5 Warm-up control..................95 20.3.6 Post-warm-up control .................. 97 20.3.7 Wait control ....................97 20.3.8 Proactive control ..................98 20.3.9 Print control....................
  • Page 35 Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 36: Outline

    Theory of operation Ver. 1.0 Nov. 2006 1. System configuration Outline System configuration System front view A011F1C501DA Main body Lower feeder unit Duplex option Lower feeder unit Hard disk kit Staple finisher...
  • Page 37: Product Specifications

    Average: 45 sec. or less Warm-up time (Power on to ready, at ambient temperature of 23° C/73.4° F and rated source voltage) Process speed magicolor 5550 152 mm/sec (plain paper, full-color mode) magicolor 5570 185 mm/sec (plain paper, full-color mode) First-page-out-time magicolor 5550 14.2 second (Full-color mode, A4S/Letter, 1-sided mode, plain paper)
  • Page 38 • Parallel (IEEE 1284) Support only an ECP mode • 10 Base-T/100 Base-TX/1000 Base-T (IEEE 802.3) Ethernet • USB 2.0 (High-Speed) • Host USB (PictBridge 1.0) magicolor 5550 Freescale PowerPC 7448, 733 MHz magicolor 5570 Freescale PowerPC 7448, 866 MHz...
  • Page 39 2. Product specifications Theory of operation Ver. 1.0 Nov. 2006 Memory Standard memory DDR-SDRAM 133 MHz 184 pin non ECC 256 MB (Expandable up to a 1024 MB) Hard disk Optional: 40 GB Compact flash card Commercially available compact flash cards of 256 MB, 512 MB, 1 GB or more storage capacity are supported.
  • Page 40: Section Configuration

    Theory of operation Ver. 1.0 Nov. 2006 3. Section configuration Section configuration Toner supply section Fusing section Transfer section Conveyance section Waste toner collecting section Media feed section (Tray 1) Write section Media feed section A011T1C500AA (Tray 2) Print unit section...
  • Page 41: Media Path

    4. Media path Theory of operation Ver. 1.0 Nov. 2006 Media path A011T1C001DA 1-sided media path 2-sided media path 1-sided media path from the tray 1...
  • Page 42: Image Creation Process

    Theory of operation Ver. 1.0 Nov. 2006 5. Image creation process Image creation process [8] Media separation [7] 2nd image transfer [9] Transfer belt cleaning [6] 1st image transfer [10] PC drum cleaning [2] PC drum [5] Developing [3] PC drum charging [1] Printer processing [4] LD exposure Printer processing...
  • Page 43 5. Image creation process Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 44: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2006 6. Overall composition Composition/Operation Overall composition Timing chart at main body powerup Conditions: A4S plain paper, 2 printed pages/job Polygon motor (M8) Intermediate transport motor (M3) Color PC drum motor (M2) Developing motor/YMC (M1) Developing motor/K (M5) Charge K...
  • Page 45: Control Block Diagram

    6. Overall composition Theory of operation Ver. 1.0 Nov. 2006 Control block diagram Operation board (OB) Print control board (PRCB) MFP board (MFPB) Media feed and conveyance Image processing Process Fusing Leser drive board (LASDB) TC/Y TC/M TC/C TC/K PU/Y PU/M PU/C PU/K...
  • Page 46: Write Section

    Theory of operation Ver. 1.0 Nov. 2006 7. Write section Write section Composition A011T2C500AA 4138to2001c0 G2 lens Return mirror/2nd Separation mirror SOS lens Return mirror/1st Index board G1 lens Synthetic mirror 4138to2002c0 Polygon mirror Semiconductor laser...
  • Page 47: Operation

    7. Write section Theory of operation Ver. 1.0 Nov. 2006 Operation 7.2.1 Overview • Four semiconductor lasers provided, one for each of the four different colors. A single polygon motor is used to make a scan motion. • Each photo conductor is irradiated with a laser light so that an electrostatic latent image is formed on it.
  • Page 48: Laser Emission Timing

    Theory of operation Ver. 1.0 Nov. 2006 7. Write section 7.2.3 Laser emission timing • When a ready signal is detected after the lapse of a given period of time after the print cycle has been started, a laser ON signal is output from the MFP board. •...
  • Page 49: Laser Light Intensity Control

    7. Write section Theory of operation Ver. 1.0 Nov. 2006 7.2.5 Laser light intensity control • The laser light intensity control corrects the target level of fluctuations in fine line repro- duction and reverse image (white on black) reproduction that occur due to variations in photo conductor electrostatic characteristics, developing characteristics, and transfer characteristics (part-to-part variations, environment, durability).
  • Page 50: Toner Supply Section

    Theory of operation Ver. 1.0 Nov. 2006 8. Toner supply section Toner supply section Composition A011T2C501AA A011T2C005DA TC detection board (CSIC) A011T2C006DA Toner collecting port Conveyance screw Agitating blade A011T2C007DA Conveyance screw...
  • Page 51: Drive

    8. Toner supply section Theory of operation Ver. 1.0 Nov. 2006 Drive Front view Toner supply motor/C, K (M7) Toner supply motor/Y, M (M6) 4138to2599c0 3D view Toner supply motor/C, K (M7) Toner supply motor/Y, M (M6) Agitating blade Conveyance screw 4138to2019c0...
  • Page 52: Operation

    Theory of operation Ver. 1.0 Nov. 2006 8. Toner supply section Operation 8.3.1 Toner cartridge capacity • There are three different types of toner cartridges which contain a different toner amount. • Toner cartridges shipped with main body: Quantity equivalent to 3,000 printed pages (Not equipped with TC detection board) •...
  • Page 53: Toner Collecting Port Shutter Mechanism

    8. Toner supply section Theory of operation Ver. 1.0 Nov. 2006 8.3.3 Toner collecting port shutter mechanism • The toner collecting port is equipped with a shutter mechanism that prevents toner from being spilled out when the toner cartridge is removed from the main body. •...
  • Page 54: Toner Replenishing Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 8. Toner supply section 8.3.4 Toner replenishing mechanism • The toner supply motor is energized according to the condition of the toner level sensor for each color of toner. Toner is then supplied from the toner cartridge to the print unit as necessary.
  • Page 55: Toner Level Detection

    8. Toner supply section Theory of operation Ver. 1.0 Nov. 2006 8.3.5 Toner level detection • The toner level is determined by the accumulated time of rotation of the toner supply motor. • The toner level can be checked through MENU/PRINT MENU/STATISTICS PAGE. 8.3.6 Toner near-empty condition detection •...
  • Page 56: Toner Empty Condition Detection

    Theory of operation Ver. 1.0 Nov. 2006 8. Toner supply section 8.3.7 Toner empty condition detection A. Toner empty condition detection mechanism • The print unit has a toner empty condition detecting mechanism. Based on the amount of toner conveyed from the toner cartridge to the print unit, a toner empty condition is detected.
  • Page 57: Toner Cartridge Life Control

    8. Toner supply section Theory of operation Ver. 1.0 Nov. 2006 8.3.9 Toner cartridge life control • Each toner cartridge is provided with a TC detection board that detects state of a toner cartridge placement, a new TC, a toner near-empty condition, and a toner empty condi- tion.
  • Page 58: Print Unit Section (Overall Composition)

    Theory of operation Ver. 1.0 Nov. 2006 9. Print unit section (overall composition) Print unit section (overall composition) Composition A011T2C508AA A011T2C012DA PC motor PU detection board (CSIC) Developing motor A011T2C013DA Photo conductor Replenishing screw Cleaning blade Agitating screw Supply roller Charge corona Developing roller Toner collecting...
  • Page 59: Operation

    9. Print unit section (overall composition) Theory of operation Ver. 1.0 Nov. 2006 Operation 9.2.1 Print unit life detection • Based on the photo conductor driving time, the cartridge life is determined. • When the photo conductor driving time reaches its near life, the near life warning mes- sage appears.
  • Page 60: Print Unit Section (Photo Conductor)

    Theory of operation Ver. 1.0 Nov. 2006 10. Print unit section (photo conductor) 10. Print unit section (photo conductor) 10.1 Composition Photo conductor A011T2C508AA A011T2C012DA Photo conductor Charge transport layer Aluminum base Charge corona Charge generating layer Direction of 4138to2018c4 4138to2505c1 rotation 10.2 Drive...
  • Page 61: Operation

    10. Print unit section (photo conductor) Theory of operation Ver. 1.0 Nov. 2006 10.3 Operation 10.3.1 Photo conductor drive mechanism • Motors are used for the drive mechanism independently of the developing system to sup- press incorrect color registration and uneven pitch. •...
  • Page 62: Photo Conductor Post-Exposure Control

    Theory of operation Ver. 1.0 Nov. 2006 10. Print unit section (photo conductor) 10.3.2 Photo conductor post-exposure control • The entire surface of the photo conductor is exposed to light before the photo conductor stops rotating during the stop sequence or color change sequence (from the color print to monochrome print) after a print cycle.
  • Page 63: Print Unit Section (Charge Corona)

    11. Print unit section (charge corona) Theory of operation Ver. 1.0 Nov. 2006 11. Print unit section (charge corona) 11.1 Composition Charge corona A011T2C508AA Grid mesh Electrode A011T2C018DA Charge corona A011T2C017DA...
  • Page 64: Operation

    Theory of operation Ver. 1.0 Nov. 2006 11. Print unit section (charge corona) 11.2 Operation 11.2.1 Charge corona unit ON/OFF control Polygon motor (M8) semiconductor laser Intermediate transport motor (M3) Color PC drum motor (M2) Developing motor/ Y, M, C (M1) Developing motor/ K (M5) Charge K...
  • Page 65: Ozone Ventilation Mechanism

    11. Print unit section (charge corona) Theory of operation Ver. 1.0 Nov. 2006 11.2.4 Ozone ventilation mechanism • Ozone stagnant in areas near the charge corona unit reduces sensitivity of the photo conductor, causing white bands to occur in the image. •...
  • Page 66: Print Unit Section (Developing)

    Theory of operation Ver. 1.0 Nov. 2006 12. Print unit section (developing) 12. Print unit section (developing) 12.1 Composition Photo conductor Replenishing screw Cleaning blade Charge corona Agitating screw Supply roller A011T2C508AA Developing roller Toner collecting A011T2C014DA screw Developing motor/Y, M, C (M1) Developing motor/K (M5) A011T2C512AA A011T2C019DA...
  • Page 67: Operation

    12. Print unit section (developing) Theory of operation Ver. 1.0 Nov. 2006 12.2 Operation 12.2.1 Developing drive control Polygon motor (M8) Intermediate transport motor (M3) Color PC drum motor (M2) Developing motor/Y, M, C (M1) Developing motor/K (M5) Charge K Charge YMC Developing Y Developing M...
  • Page 68: Toner Collecting Port Shutter Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 12. Print unit section (developing) 12.2.2 Toner collecting port shutter mechanism • The toner collecting port is equipped with a shutter mechanism that prevents toner from being spilled out when the print unit is removed from the main body. •...
  • Page 69: Toner Flow

    12. Print unit section (developing) Theory of operation Ver. 1.0 Nov. 2006 12.2.3 Toner flow 1. Toner stored in the toner cartridge is agitated by the agitating blade and conveyed onto the front side of the toner cartridge by the conveyance screw. 2.
  • Page 70: Developing System

    Theory of operation Ver. 1.0 Nov. 2006 12. Print unit section (developing) 12.2.4 Developing system • Two types of developing systems are used, a non-contact developing system and an alternating current application system. 1. A negative charge (supply bias voltage Vr) is applied the supply roller to regulate the amount of toner sticking to the developing roller.
  • Page 71: Cleaning Mechanism

    12. Print unit section (developing) Theory of operation Ver. 1.0 Nov. 2006 12.2.5 Cleaning mechanism A. Cleaning operation 1. The cleaning blade is pressed against the surface of the photo conductor to remove toner left off the surface (fixed blade system). 2.
  • Page 72: Transfer Section (1St Transfer)

    Theory of operation Ver. 1.0 Nov. 2006 13. Transfer section (1st transfer) 13. Transfer section (1st transfer) 13.1 Composition A011T2C503AA A011T2C031DA Retraction position sensor/1 (PS9) Sliding plate Transfer belt drive roller Retraction lever/Y, M, C Transfer belt 1st transfer roller/C 1st transfer roller/Y 1st transfer roller/K Driven roller...
  • Page 73: Drive

    13. Transfer section (1st transfer) Theory of operation Ver. 1.0 Nov. 2006 13.2 Drive Pressure/retraction clutch/1 (CL4) Intermediate transport motor (M3) 4138to2038c0 Mechanism for driving the belt Pressure/retraction clutch/1 (CL4) Transfer belt drive roller Intermediate transport motor (M3) Transfer belt Driven roller 4138to2041c1 Mechanism for driving the pressure/retraction motion...
  • Page 74: Operation

    Theory of operation Ver. 1.0 Nov. 2006 13. Transfer section (1st transfer) 13.3 Operation 13.3.1 1st transfer output control • To transfer the toner image from the photo conductor to the transfer belt, the transfer volt- age is applied to the 1st transfer roller. •...
  • Page 75: 1St Transfer Roller Pressure Operation

    13. Transfer section (1st transfer) Theory of operation Ver. 1.0 Nov. 2006 13.3.3 1st transfer roller pressure operation 1. Rotation of the intermediate transport motor is transmitted by a gear train to the pressure/retraction clutch/1. 2. Rotation of the pressure/retraction clutch/1 turns the pressure cam, which moves the sliding plate.
  • Page 76: 1St Transfer Roller Retraction Operation

    Theory of operation Ver. 1.0 Nov. 2006 13. Transfer section (1st transfer) 13.3.4 1st transfer roller retraction operation 1. Rotation of the intermediate transport motor is transmitted by a gear train to the pressure/retraction clutch/1. 2. Rotation of the pressure/retraction clutch/1 turns the pressure cam, which moves the sliding plate.
  • Page 77: 1St Transfer Roller Pressure/Retraction Position Control

    13. Transfer section (1st transfer) Theory of operation Ver. 1.0 Nov. 2006 13.3.5 1st transfer roller pressure/retraction position control A. Pressure position control • The pressure and retraction operation of the 1st transfer roller is controlled as the retrac- tion position sensor/1 detects the movement of the sliding plate. 1.
  • Page 78: Transfer Belt Cleaning Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 13. Transfer section (1st transfer) 13.3.6 Transfer belt cleaning mechanism • To scrape residual toner off the surface of the transfer belt, the transfer belt is provided with a cleaning blade. • The cleaning blade is in pressed contact with the transfer belt at all times. That is, it cleans the surface of the transfer belt as long as the belt turns.
  • Page 79: 1St Transfer Belt Cleaning Control

    13. Transfer section (1st transfer) Theory of operation Ver. 1.0 Nov. 2006 13.3.7 1st transfer belt cleaning control • If there is a possibility of the main body being stopped with toner left on the surface of the transfer belt between the cleaning blade position and the 2nd transfer position (due to a media misfeed or malfunction), the intermediate transport motor is energized to turn the transfer belt.
  • Page 80: Toner Collecting Port Shutter Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 13. Transfer section (1st transfer) 13.3.9 Toner collecting port shutter mechanism • A shutter mechanism is provided to prevent waste toner from being spilled from the toner collecting port when the waste toner box is removed and reinstalled. •...
  • Page 81: Transfer Section (2Nd Transfer)

    14. Transfer section (2nd transfer) Theory of operation Ver. 1.0 Nov. 2006 14. Transfer section (2nd transfer) 14.1 Composition 2nd transfer roller A011T2C503AA 4138to2096c0 2nd transfer roller 2nd transfer roller Pre-transfer guide plate Pre-transfer guide plate Retraction lever 4138to2061c0 Retraction cam Pressure/retraction clutch/2 (CL5) Retraction position 4138to2048c0...
  • Page 82: Drive

    Theory of operation Ver. 1.0 Nov. 2006 14. Transfer section (2nd transfer) 14.2 Drive Pressure/retraction clutch/ 2 (CL5) Transfer belt drive roller Transfer belt drive roller Retraction cam Retraction position Pressure/retraction sensor/2 (PS10) clutch/2 (CL5) Retraction position 4138to2585c0 4138to2048c0 sensor/2 (PS10) Retraction cam 14.3 Operation 14.3.1...
  • Page 83 14. Transfer section (2nd transfer) Theory of operation Ver. 1.0 Nov. 2006 C. Pressure/retraction operation 1. Rotation of the intermediate transport motor is transmitted to the drive roller of the intermediate transfer belt unit. 2. Rotation of the drive roller is transmitted to the pressure/retraction clutch/2. 3.
  • Page 84: 2Nd Transfer Roller Pressure Position Deviation Preventive Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 14. Transfer section (2nd transfer) D. Pressure/retraction operation Retraction position sensor/2 (PS10) blocked Retraction position sensor/2 (PS10) unblocked 2nd transfer roller pressed 2nd transfer roller retracted IDC sensor cover open IDC sensor cover closed 4138to2586c0 Pressure cam angle 4138to2585c1...
  • Page 85: 2Nd Transfer Voltage Control

    14. Transfer section (2nd transfer) Theory of operation Ver. 1.0 Nov. 2006 14.3.3 2nd transfer voltage control • The transfer voltage is applied to the 2nd transfer roller in order to transfer the toner image from the transfer belt to the media. •...
  • Page 86: 2Nd Transfer Roller Cleaning Control

    Theory of operation Ver. 1.0 Nov. 2006 14. Transfer section (2nd transfer) 14.3.5 2nd transfer roller cleaning control • DC positive and negative transfer bias voltages are alternately applied to the 2nd transfer roller. This allows toner residue on the surface of the 2nd transfer roller to be transferred back to the transfer belt, thus cleaning the 2nd transfer roller.
  • Page 87: Waste Toner Collecting Section

    15. Waste toner collecting section Theory of operation Ver. 1.0 Nov. 2006 15. Waste toner collecting section 15.1 Composition A011T2C504AA A011T2C059DA Waste toner transport unit Toner collecting screw (Print unit) Developing motor/K (M5) Waste toner collecting bottle Suction transport unit A011T2C037DA...
  • Page 88: Drive

    Theory of operation Ver. 1.0 Nov. 2006 15. Waste toner collecting section 15.2 Drive Developing motor/K (M5) Waste toner collecting screw (Waste toner transport unit) Waste toner collecting screw 2nd conveyance screw (Suctiion transport unit) (Waste toner bottle) 1st conveyance screw A011T2C038DA (Waste toner bottle)
  • Page 89: Operation

    15. Waste toner collecting section Theory of operation Ver. 1.0 Nov. 2006 15.3 Operation 15.3.1 Toner flow at the 1st transfer section 1. Toner scraped off by the cleaning blade in the print unit is conveyed to the toner col- lecting port by the toner collecting screw.
  • Page 90: Toner Flow At The 2Nd Transfer Section

    Theory of operation Ver. 1.0 Nov. 2006 15. Waste toner collecting section 15.3.2 Toner flow at the 2nd transfer section 1. Toner scraped off by the cleaning blade provided in the transfer belt unit is collected onto the middle of the transfer belt unit by the toner collecting screw. 2.
  • Page 91: Toner Collecting Port Shutter Mechanism At The Suction Transport Unit

    15. Waste toner collecting section Theory of operation Ver. 1.0 Nov. 2006 15.3.3 Toner collecting port shutter mechanism at the suction transport unit • A dual-shutter is used to prevent waste toner from being spilled from the toner collecting port when the waste toner box is removed and reinstalled. •...
  • Page 92: Waste Toner Box Locking Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 15. Waste toner collecting section 15.3.5 Waste Toner Box locking mechanism • When the box lock lever is in the unlocked position (the 12 o'clock position), the protru- sion provided at the toner collecting port interferes with the main body frame, thus pre- venting the waste toner box from being removed.
  • Page 93: Waste Toner Box-In-Position Detection Mechanism

    15. Waste toner collecting section Theory of operation Ver. 1.0 Nov. 2006 15.3.7 Waste toner box-in-position detection mechanism • The waste toner box set detection lever is provided to detect a waste toner box loaded in position. • When the waste toner box is not loaded, the set detection lever lowers by its own weight to plug the set detection window.
  • Page 94: Waste Toner Near-Full Condition Detection Control

    Theory of operation Ver. 1.0 Nov. 2006 15. Waste toner collecting section 15.3.9 Waste toner near-full condition detection control • A waste toner near-full condition is detected when the waste toner sensor continuously blocks for a predetermined period of time. •...
  • Page 95: Media Feed Section (Tray 1)

    16. Media feed section (Tray 1) Theory of operation Ver. 1.0 Nov. 2006 16. Media feed section (Tray 1) 16.1 Composition A011T2C507AA A011T2C510AA Empty sensor actuator Feed roller Media lift plate Media empty sensor/2 (PS3) Edge guide plate A011T2C050DA Separation roller Empty sensor actuator Media empty sensor/2 (PS3)
  • Page 96: Drive

    Theory of operation Ver. 1.0 Nov. 2006 16. Media feed section (Tray 1) 16.2 Drive Media feed clutch/1 (CL1) Feed roller Intermediate transport motor (M3) 4138T2C002DB 16.3 Operation 16.3.1 Media lift plate mechanism • The media lift plate will be locked under the media lift plate lock lever by pressing it down (in which the media is loaded in position).
  • Page 97: Media Separation Mechanism

    16. Media feed section (Tray 1) Theory of operation Ver. 1.0 Nov. 2006 16.3.2 Media separation mechanism • Drive from the intermediate transport motor is transmitted through the media feed clutch/ 1 to turn the feed roller. • The feed roller rotates to take up and feed media into the main body. •...
  • Page 98: Media Empty Condition Detection Control

    Theory of operation Ver. 1.0 Nov. 2006 16. Media feed section (Tray 1) 16.3.4 Media empty condition detection control • A media empty condition is detected when the empty sensor actuator unblocks the media empty sensor/2. • No mechanism is provided for detecting a media near-empty condition. The media sup- ply level indicator serves this purpose.
  • Page 99: Edge Guide Plate

    16. Media feed section (Tray 1) Theory of operation Ver. 1.0 Nov. 2006 16.3.5 Edge guide plate • The edge guide plate can be slid to the exact size in the width direction of the media to be loaded. • No mechanism is provided for detecting a media size. Edge guide plate 4138to2621c0 16.3.6...
  • Page 100: Media Feed Section (Tray 2)

    Theory of operation Ver. 1.0 Nov. 2006 17. Media feed section (Tray 2) 17. Media feed section (Tray 2) 17.1 Composition A011T2C506AA A011T2C509AA Feed roller Empty sensor actuator Separation roller 4138to2603c0 Edge guide plate Trailing edge guide plate Media feed clutch/2 (CL3) Media empty sensor/1 (PS1)
  • Page 101: Drive

    17. Media feed section (Tray 2) Theory of operation Ver. 1.0 Nov. 2006 17.2 Drive Intermediate transport motor (M3) Media feed clutch/1 (CL1) Feed roller 4138to2058c0 17.3 Operation 17.3.1 Media lift plate mechanism • The media lift plate is pressed down into the locked position (in which the media is loaded in position).
  • Page 102: Media Separation Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 17. Media feed section (Tray 2) 17.3.2 Media separation mechanism • Drive from the intermediate transport motor is transmitted through the media feed clutch/ 2 to turn the feed roller. • The feed roller rotates to take up and feed media into the main body. •...
  • Page 103: Media Supply Level Detection Control

    17. Media feed section (Tray 2) Theory of operation Ver. 1.0 Nov. 2006 17.3.4 Media supply level detection control • There is a window in the front cover of the cassette for indicating the media supply level. • When the media lift plate goes up, a red lever appears in the window. The lower the level of the media stack, the more the red portion is visible.
  • Page 104: Edge Guide Plate

    Theory of operation Ver. 1.0 Nov. 2006 17. Media feed section (Tray 2) 17.3.6 Edge guide plate • Set the appropriate edge guide plate which corresponds to the width of the media to be loaded (A4 or 81/2). • No mechanism is provided for detecting the media size. Lock plate Lock plate Edge guide plate...
  • Page 105: Tray Open/Close Detection Control

    17. Media feed section (Tray 2) Theory of operation Ver. 1.0 Nov. 2006 17.3.8 Tray open/close detection control • Whether tray is opened or closed is detected with the tray 2 switch. 1. Closing the tray will make the detecting plate press and turn ON the actuator for the tray 2 switch mounted on the main body frame.
  • Page 106: Conveyance Section (Idc Sensor)

    Theory of operation Ver. 1.0 Nov. 2006 18. Conveyance section (IDC sensor) 18. Conveyance section (IDC sensor) 18.1 Composition A011T2C503AA 4138to2060c0 IDC sensor/Re IDC sensor (IDCSB/R) IDC sensor/Fr (IDCSB/F) sensor lever 4138to2082c0 IDC sensor cover Pressure/retraction Retraction cam clutch/2 (CL5) 4138to2083c0...
  • Page 107: Drive

    18. Conveyance section (IDC sensor) Theory of operation Ver. 1.0 Nov. 2006 18.1.1 Drive IDC sensor lever IDC sensor cover Pressure/ retraction clutch/2 (CL5) Retraction cam 4138to2083c0 18.2 Operation 18.2.1 Toner density detection control • A reflective sensor is used for the IDC sensor that detects the amount of toner sticking to the surface of the transfer belt.
  • Page 108: Idc Sensor Calibration Control

    Theory of operation Ver. 1.0 Nov. 2006 18. Conveyance section (IDC sensor) 18.2.2 IDC sensor calibration control • Changes in various types of characteristics due to change with time of the IDC sensor (deteriorated LED, dirty sensor surface), part-to-part variations in the sensors, and change of environment affect the IDC sensor output corresponding to the clear transfer belt surface.
  • Page 109: Conveyance Section (Registration Roller)

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) 19.1 Composition A011T2C503AA 4138to2096c0 Media loop sensor (PS6) Charge neutralizing cloth 2nd transfer roller Registration roller Registration roller clutch (CL2) OHP sensor (PS7) Registration sensor (PS4) Temperature/humidity sensor (TEM/HUMS)
  • Page 110: Operation

    Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) 19.3 Operation 19.3.1 Conveyance speed control • The intermediate transport motor provides drive for the conveyance section. • The conveyance speed is variable in four steps and the appropriate one is selected according to the media type and print mode as detailed below.
  • Page 111: Control Of Loop Formed Before Registration Roller

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19.3.3 Control of loop formed before registration roller • Media conveyance is stopped after the lapse of a predetermined period of time after the leading edge of the media fed from the feed roller has reached the registration roller. This forms a loop in the media.
  • Page 112: Control Of Loop Formed Before 2Nd Transfer

    Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) B. Registration roller clutch control • In synchronization with the leading edge of the image [the sub scan print start signal (/ TOD) of the controller] after the leading edge of the media has reached the registration roller and a loop has been formed in the media, the registration roller clutch is energized to start turning the registration roller.
  • Page 113: Control Of Loop Formed Before Fusing Section

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19.3.5 Control of loop formed before fusing section • The difference between the fusing speed and media conveyance speed is corrected to prevent double transferred images and brush effects from occurring. •...
  • Page 114: Media Neutralization

    Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) 19.3.6 Media neutralization • The charge neutralizing cloth neutralizes any charge left in the media after the 2nd trans- fer process. • The charge residue is grounded through the charge neutralizing cloth to the main body frame.
  • Page 115: Ohp Transparencies Detection Control

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19.3.7 OHP transparencies detection control • To prevent incorrect prints on OHP transparencies, the type of the media being conveyed is detected by the OHP sensor. • The OHP detection is made after the loop has been formed in the media before the reg- istration roller.
  • Page 116: Media Size Error Detection Control

    Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) 19.3.8 Media size error detection control • To prevent incorrect printed pages, the size of the media being conveyed is detected using the registration sensor and media feed sensor. •...
  • Page 117: Conveyance System Media Misfeed Detection Control

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19.3.9 Conveyance system media misfeed detection control • In the feeding section, a specific sensor is assigned for each media source. Based on the time elapsed before the sensors become activated, misfeed is detected. •...
  • Page 118 Theory of operation Ver. 1.0 Nov. 2006 19. Conveyance section (Registration roller) Misfeed type Misfeed detection starting point Misfeed detection condition Tray 1 Feed clutch/1 (CL1) ON Registration sensor (PS4) not acti- vated within a predetermined time Tray 2 Feed clutch/2 (CL3) ON Media feed sensor (PS2: Tray 3) not Tray 3 Feed clutch (CL1: Tray 3) ON...
  • Page 119: Remaining Media Detection Control When The Main Power Switch Is Turned On

    19. Conveyance section (Registration roller) Theory of operation Ver. 1.0 Nov. 2006 19.3.10 Remaining media detection control when the main power switch is turned • Any sheet of media left inside the main body is checked when the power switch is turned ON or a door is opened and closed.
  • Page 120: Fusing Section

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section 20. Fusing section 20.1 Composition A011T2C511AA A011T2C056DA Media exit roller Media full sensor (PS12) Fusing media size sensor (PS15) Exit sensor (PS8) Thermistor/2 (TH2) Fusing pad Fusing belt Thermostat/1 (TS1) Fusing heater lamp/2 (FH2) Thermistor/1 (TH1)
  • Page 121: Drive

    20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 20.2 Drive Exit roller Fusing pressure roller Fusing belt Heating roller Fusing motor (M4) 4138to2105c0 Fusing pressure roller Fusing motor (M4) Fusing belt Heating roller 4138to2068c0 Media exit roller Fusing motor (M4) 4138to2074c0...
  • Page 122: Operation

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section 20.3 Operation 20.3.1 Fusing pressure roller pressure selection mechanism • The pressure applied by the fusing pressure roller is selected appropriately to prevent media wrinkles during printing of envelopes. • A pressure selection mechanism is provided to vary the pressure in two steps. •...
  • Page 123: Fusing Pressure Roller Drive Control

    (mm/s) (mm/s) Full-color 61.7 Monochrome 61.7 Printing Monochrome mode 61.7 low PPM Glossy 61.7 61.7 • magicolor 5550 Thick stock 1/ Envelopes/Glossy Thick stock 2/ Plain paper Glossy paper 2 Media paper 1/OHP Postcards (mm/s) (mm/s) transparencies (mm/s) (mm/s) Full-color 61.7...
  • Page 124 Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section B. Fusing speed control (control of loop before fusing) • To prevent double transferred images and brush effects from occurring, the difference between the fusing speed and the media conveyance speed during image transfer is cor- rected.
  • Page 125 20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 E. Fusing pressure roller deformation prevention control • To prevent the fusing pressure roller from being deformed, the fusing pressure roller is forcibly turned if it is left idle for a predetermined period of time. •...
  • Page 126 Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section G. Media width detection control • The fusing media size sensor detects the width of the media being conveyed. • If the width of the media that has moved past the fusing media size sensor is 210 mm (A4 width) or more, the leading edge of the media pushes up the actuator of the sensor, thus blocking the sensor.
  • Page 127 20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 H. Detection of media full in the exit tray • The media full sensor detects the load capacity of output media in the exit tray. • When the media holding plate is low, the edge of the media holding plate shades the media full sensor.
  • Page 128: Fusing Temperature Control

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section Proactive control • To shorten the time period that begins when a print request is accepted and ends when the fusing sequence starts, the fusing motor is turned beforehand. • Control start timing •...
  • Page 129: Fusing Temperature Control Management

    20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 20.3.4 Fusing temperature control management • The appropriate type of temperature control is provided according to the main body sta- tus. Reset Heater OFF Warm-up control Post-warm-up control Wait control Proactive control Print control Post-print cycle control...
  • Page 130: Warm-Up Control

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section G. Condition enabling shift to heater OFF control • A malfunction or media misfeed occurs. • A power save mode signal is received. 20.3.5 Warm-up control • Control is provided until the heating roller reaches the predetermined level. •...
  • Page 131 20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 E. Ordinary start control 1. The temperature adjustment is started with the target temperature of the fusing heater lamp/1 set at 170°C. At the same time, the temperature adjustment is started with the target temperature of the fusing heater lamp/2 set at 150°C.
  • Page 132: Post-Warm-Up Control

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section 20.3.6 Post-warm-up control • After the warm-up cycle has been completed, the fusing pressure roller and fusing belt are turned to achieve a uniform temperature. • If the heating roller and the fusing pressure roller have reached their respective required temperatures, the main body considers that the fusing unit rollers and belt have reached the specified temperatures.
  • Page 133: Proactive Control

    20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 20.3.8 Proactive control • To shorten the time period that begins when a print request is accepted and ends when a copy is printed out, the proactive rotation of the fusing motor is controlled. A.
  • Page 134: Post-Print Control

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section 20.3.10 Post-print control • To prevent the fusing temperature from rising after the print cycle has been run, a step- wise control is provided using an intermediate temperature between the print tempera- ture and the wait temperature.
  • Page 135: Ppm Control

    20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 20.3.12 PPM control • The PPM control is performed to prevent the fusing pressure roller and the fusing belt temperatures from going down during a multi-print cycle as well as to prevent the tem- peratures of the roller and belt edges from going up.
  • Page 136: Protection Against Abnormally High Temperature

    Theory of operation Ver. 1.0 Nov. 2006 20. Fusing section 20.3.13 Protection against abnormally high temperature • The main body provides protection at three different stages to prevent abnormally high temperature of the fusing unit. 1. Soft protection 2. Hard protection 3.
  • Page 137 20. Fusing section Theory of operation Ver. 1.0 Nov. 2006 C. 3rd stage: Thermostat protection • If neither the soft protection nor hard protection can detect an abnormally high tempera- ture due to a defective thermistor, the thermostat/1 and thermostat/2 operate at the spec- ified temperature.
  • Page 138: Image Stabilization Control

    Theory of operation Ver. 1.0 Nov. 2006 21. Image stabilization control 21. Image stabilization control • To ensure that a stabilized output image is produced at all times, a comprehensive con- trol is provided for the developing bias voltage, laser light intensity, registration correction, gamma characteristics detection, and other parameters.
  • Page 139: Simplified Correction Control

    21. Image stabilization control Theory of operation Ver. 1.0 Nov. 2006 21.1.2 Simplified correction control • If the simplified correction control is not effective in making a good correction, the com- plete correction control is executed. Control name Purpose To check the low gain output value and offset voltage value of 1 IDC sensor offset value check the IDC sensor when the shutter is closed.
  • Page 140: Image Stabilization Control Execution Request

    Theory of operation Ver. 1.0 Nov. 2006 21. Image stabilization control 21.1.4 Image stabilization control execution request • A request for execution of the complete correction control, simplified correction control, or individual registration control is made at the following timing. Stabilization request Stabilization request timing Execution processing...
  • Page 141: Combination And Execution Sequence Of Different Sub-Controls

    21. Image stabilization control Theory of operation Ver. 1.0 Nov. 2006 21.1.6 Combination and execution sequence of different sub-controls Simplified Complete individual Control name image image registration stabilization stabilization control ➀ ➀ IDC sensor Check calibration control ➁ Correction See P.73 IDC sensor reflection ➁...
  • Page 142: Miscellaneous

    Theory of operation Ver. 1.0 Nov. 2006 22. Miscellaneous 22. Miscellaneous 22.1 Fan control 22.1.1 Composition Fusing fan motor (FM2) DC power supply DC power supply fan motor (FM1) fan motor (FM1) Fusing fan motor (FM2) 4138to2111c0 Ozone ventilation Ozone ventilation fan motor (FM3) fan motor (FM3) A011T2C058DA...
  • Page 143: Control

    22. Miscellaneous Theory of operation Ver. 1.0 Nov. 2006 22.1.3 Control A. DC power supply fan motor control <Full speed rotation conditions> • For the period of time that begins when the warm-up cycle is started and ends when a predetermined period of time elapses after the warm-up cycle has been completed.
  • Page 144 Theory of operation Ver. 1.0 Nov. 2006 22. Miscellaneous C. Ozone ventilation fan motor <Full speed rotation conditions> • At the start of a warm-up cycle • During a print cycle • During when the image stabilization control is performed •...
  • Page 145 22. Miscellaneous Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 146: Duplex Option

    SERVICE MANUAL THEORY OF OPERATION Duplex Option 2006.11 Ver. 1.0...
  • Page 147 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 148 Theory of operation Ver. 1.0 Nov. 2006 CONTENTS Duplex option Outline Product specifications ..................... 1 Composition/Operation Overall composition....................3 Center cross section ....................4 Drive system ......................5 Mechanical operations .................... 6 Reversing mechanism ..................6 5.1.1 Reversing operation ..................6 5.1.2 Media exit roller drive coupling mechanism ..........
  • Page 149 Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 150: Outline

    Theory of operation Ver. 1.0 Nov. 2006 1. Product specifications Outline Product specifications A. Type Name Duplex unit Type Switchback and circulating duplex unit Installation Mounted on the right side door of main body Reversing system Exit roller switchback Tracfer system Rubber roller + driven rolls Document alignment Center...
  • Page 151 1. Product specifications Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 152: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2006 2. Overall composition Composition/Operation Overall composition Duplex option door 4538T2C001DA...
  • Page 153: Center Cross Section

    3. Center cross section Theory of operation Ver. 1.0 Nov. 2006 Center cross section Transport roller 1 Transport roll 1 Transport roll 2 Transport roller 2...
  • Page 154: Drive System

    Theory of operation Ver. 1.0 Nov. 2006 4. Drive system Drive system Reversing drive mechanism Transport drive mechanism...
  • Page 155: Mechanical Operations

    5. Mechanical operations Theory of operation Ver. 1.0 Nov. 2006 Mechanical operations Reversing mechanism 5.1.1 Reversing operation • The 1-sided printed page is subjected to a reversing operation performed by the exit roller in the main body and conveyed into the duplex option. Conveyed into the duplex option Exit roller 5.1.2...
  • Page 156: Conveyance And Duplex Media Feed Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Mechanical operations Conveyance and duplex media feed mechanism 5.2.1 Conveyance and duplex media feed operation • The transport motor provides the drive for the duplex option. Transport roller 1 Transport motor (M1) Transport roll 1 Transport roll 2 Transport roller 2...
  • Page 157: 2-Sided Printing Method

    5. Mechanical operations Theory of operation Ver. 1.0 Nov. 2006 2-sided printing method • The following two types of 2-sided printing methods are available. 2-sided printing with a single sheet of media resident in the system 2-sided printing method 2-sided printing with two sheets of media resident in the system (for letter and smaller sizes) 5.3.1 Process of 2-sided printing with a single sheet of media resident in the...
  • Page 158 Theory of operation Ver. 1.0 Nov. 2006 5. Mechanical operations Operation 4 • The image of the first page of the print job is printed on the 1-sided printed page fed out of the duplex option. Operation 5 • As the 2-sided printed page is being fed out of the main body, the image of the fourth page of the print job is printed on the second sheet of media.
  • Page 159: Process Of 2-Sided Printing With Two Sheets Of Media Resident In The System

    5. Mechanical operations Theory of operation Ver. 1.0 Nov. 2006 5.3.2 Process of 2-sided printing with two sheets of media resident in the sys- Operation 1 Exit roller • The first sheet of media is fed in and the image of the second page of the print job is printed.
  • Page 160 Theory of operation Ver. 1.0 Nov. 2006 5. Mechanical operations Operation 4 • Immediately before the second sheet of media exits the feed roller, the rotating direc- tion of the feed roller changes and the second sheet of media is transported into the duplex option.
  • Page 161 5. Mechanical operations Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 162: Lower Feeder Unit

    SERVICE MANUAL THEORY OF OPERATION Lower Feeder Unit 2006.11 Ver. 1.0...
  • Page 163 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 164 Theory of operation Ver. 1.0 Nov. 2006 CONTENTS Lower feeder unit Outline Product specifications ..................... 1 Composition/Operation Overall composition....................3 Drive ........................4 Operations....................... 4 Media feed control ....................4 4.1.1 Media lift plate mechanism ................4 4.1.2 Feed roller/vertical transport roller control ............ 5 4.1.3 Media separation mechanism ...............
  • Page 165 Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 166: Outline

    Theory of operation Ver. 1.0 Nov. 2006 1. Product specifications Outline Product specifications A. Type Name Add-on 500-sheet media feed cassette Type Front-loading type Installation Desk type Media feeding system Media separation by a small-diameter roller with torque limiter Document Alignment Center B.
  • Page 167 1. Product specifications Theory of operation Ver. 1.0 Nov. 2006 Blank Page...
  • Page 168: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2006 2. Overall composition Composition/Operation Overall composition Media lift plate Lower feeder unit right door Media level indicator lever Auxiliary guide 4537T2C001DA Media feed clutch (CL1) Vertical transport roller Feed roller Transport motor (M1) Separation roller 4537to2502c2 Media empty sensor...
  • Page 169: Drive

    3. Drive Theory of operation Ver. 1.0 Nov. 2006 Drive Media feed clutch (CL1) Vertical transport roller Transport motor (M1) Feed roller Separation roller 4537T2C002DA Operations Media feed control 4.1.1 Media lift plate mechanism • The media lift plate is pressed down into the locked position (in which the media is loaded in position).
  • Page 170: Feed Roller/Vertical Transport Roller Control

    Theory of operation Ver. 1.0 Nov. 2006 4. Operations 4.1.2 Feed roller/vertical transport roller control • The feed roller and vertical transport roller are rotated, which feeds media from the lower feeder unit and conveys it further into the inside of the main body 1.
  • Page 171: Media Separation Mechanism

    4. Operations Theory of operation Ver. 1.0 Nov. 2006 4.1.3 Media separation mechanism • A separation roller provided with a torque limiter is used to prevent double feeding of media. Feed roller Separation roller 4138to2115c0 4.1.4 Media detection mechanism • The media feed sensor detects the media fed in by the feed roller. •...
  • Page 172: Media Supply Level Detection Control

    Theory of operation Ver. 1.0 Nov. 2006 4. Operations 4.1.5 Media supply level detection control • There is a window in the front cover of the cassette for indicating the media supply level. • When the media lift plate goes up, a red lever appears in the window. The lower the level of the media stack in the tray, the more red that is visible.
  • Page 173: Edge Guide Plate

    4. Operations Theory of operation Ver. 1.0 Nov. 2006 4.1.7 Edge guide plate • The edge guide plate can be slid to the exact size in the width direction of the media to be loaded (A4, B5, 8/12). Edge guide plate 4138to2120c0 4.1.8 Trailing edge guide plate...
  • Page 174: Media Size Detection Control

    Theory of operation Ver. 1.0 Nov. 2006 4. Operations 4.1.9 Media size detection control • The media size switch detects the length size (FD) of the media. 1. The size detection board turns as the trailing edge guide plate is moved. 2.
  • Page 175: Media Reference Position Adjustment Mechanism

    4. Operations Theory of operation Ver. 1.0 Nov. 2006 4.1.10 Media reference position adjustment mechanism • The edge guide plate can be moved to allow the print start reference position for the media to be adjusted. 1. Through a hole in the media lift plate on top of the tray, loosen two screws that secure the edge guide plate.
  • Page 176: Staple Finisher

    SERVICE MANUAL THEORY OF OPERATION Staple finisher 2006.11 Ver. 1.0...
  • Page 177 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 178 Theory of operation Ver. 1.0 Nov. 2006 CONTENTS Staple finisher Outline Product specifications ..................... 1 Media path ......................4 Feeding media to the main tray ................4 Feeding media to the sub tray ................4 Composition/Operation Composition ......................5 Drive ........................6 Operations.......................
  • Page 179 Theory of operation Ver. 1.0 Nov. 2006 5.5.3 Media holding mechanism ................31 5.5.4 Media full detection..................32 Staple section..................... 33 5.6.1 Stapling mechanism ................... 33 5.6.2 Stapling position ..................34 5.6.3 Staple sheet empty detection ..............34...
  • Page 180: Outline

    Theory of operation Ver. 1.0 Nov. 2006 1. Product specifications Outline Product specifications A. Type Type Staple finisher suspended on the main body Installation Suspended on the main body Document alignment Center Media ejection system Face down, Output from the back end Consumables Staples B.
  • Page 181 1. Product specifications Theory of operation Ver. 1.0 Nov. 2006 (2) Sort offset, group offset Max. Capacity (Main tray) Type Size Weight x 11S, A4S Media length: or less longer than 300 mm B5S, A4S x 11S, 8- x 14 Plain paper 60 to 90 g/m 500 sheets or 50...
  • Page 182 Theory of operation Ver. 1.0 Nov. 2006 1. Product specifications E. Machine specifications DC 24 V ± 10% (supplied from the main body) Power requirements Max. power 48 W or less consumption Stapling unit: 475 (W) × 462 (D) × 360 (H) mm 18.75 (W) ×...
  • Page 183: Media Path

    2. Media path Theory of operation Ver. 1.0 Nov. 2006 Media path Feeding media to the main tray Feeding media Transporting media to the media Transporting media to the main tray aligning section from the main body A01FT1C003AA Feeding media to the sub tray Feeding media Transporting media to the finisher Transporting media...
  • Page 184: Composition/Operation

    Theory of operation Ver. 1.0 Nov. 2006 3. Composition Composition/Operation Composition Sub tray section Sub tray transport section Transport unit Storage section Main tray section Staple section A01FT2C001DA Finisher Transport unit A01FT2C001AA A01FT2C002AA Main tray section Sub tray section A01FT2C002DA A01FT2C003AA...
  • Page 185: Drive

    4. Drive Theory of operation Ver. 1.0 Nov. 2006 Drive Aligning belt up/down drive section Transport unit drive section Finisher drive section Main tray drive section Media ejector drive section A01FT2C003DA...
  • Page 186: Operations

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations Operations Transport unit section • The transport unit controls transport of media fed out from the main body, switchback operations for the media during 2-sided printing, and drive for feeding media out into the finisher section.
  • Page 187: Media Transport

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.1.1 Media transport • Transport rollers 1 and 2 transport 1-sided printed media and 2-sided printed media to be fed out of the main body to the finisher section. • The 1-sided printed media to be subjected to the second print process is not transported to the finisher section, but is switched back into the main body.
  • Page 188: Transport Roller Drive Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.1.2 Transport roller drive mechanism • For the 1-sided printed media and 2-sided printed media, the motor drive force rotates the transport rollers 1 and 2 in the forward direction via a torque limiter, thereby trans- porting the media in the forward direction.
  • Page 189: Transport Cover Open/Close Detection

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.1.4 Transport cover open/close detection • The transport unit is not provided with any sensors for detecting the open or closed posi- tion of the transport cover. The media full sensor located at the fusing section of the main body functions to detect the open or closed position of the transport cover.
  • Page 190: Sub Tray Transport Section

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations Sub tray transport section • The sub tray transport section controls drive for transporting media from the transport unit out onto the sub tray. • The media fed onto the sub tray does not undergo shift or stapling process. Sub tray A01FT2C014DA A01FT2C015DA...
  • Page 191: Entrance Switch

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.2.1 Entrance switch • The media path for the media transported from the transport unit is changed so that the media may be fed into the sub tray transport section. • The transport motor provides the drive for media transport. •...
  • Page 192: Media Transport

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.2.2 Media transport • Media transported from the transport unit is transported to the sub tray. • The transport motor provides the drive for transporting the media. • When the transport motor is energized, the transport roller and exit roller are driven to rotate.
  • Page 193: Media Full Detection

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.2.3 Media full detection • The media full sensor detects the load capacity of output media in the sub tray. • When the media holding plate is low, the edge of the media holding plate shades the media full sensor.
  • Page 194: Finisher Cover Open/Close Detection

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.2.4 Finisher cover open/close detection • The finisher cover sensor detects the open or closed position of the finisher cover. • Opening the finisher cover unblocks the finisher cover sensor. At this time, the finisher cover sensor detects that the finisher cover is opened.
  • Page 195: Main Tray Transport Section

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 Main tray transport section • The main tray transport section controls drive for transporting the media from the trans- port unit into the main tray and for shift and stapling operations performed on the media from the transport unit.
  • Page 196: Entrance Switch

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.3.1 Entrance switch • The media path for the media transported from the transport unit is changed so that the media may be fed into the storage section. • The transport motor provides the drive for media transport. •...
  • Page 197: Media Transport

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.3.2 Media transport • The media fed off from the transport unit is transported to the main tray section. • The transport motor and exit motor provide drive for media transport. •...
  • Page 198: Upper Exit Roller Up/Down Motion Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.3.3 Upper exit roller up/down motion mechanism • The upper exit roller is lowered when the media is fed straight into the main tray or stored in the finishing tray. • When a printed media stack/set is fed out, the upper exit roller is raised to be away from the lower exit roller, so that there is an unblocked media path between the upper and lower exit rollers.
  • Page 199: Storage Section

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 Storage section 5.4.1 Media aligning mechanism • The printed media stack/set is aligned and stapled together in the storage section before being fed out into the main tray. • The storage section sensor detects media in the finishing tray. •...
  • Page 200 Theory of operation Ver. 1.0 Nov. 2006 5. Operations A. Operation 1. The transport motor drives the align- Exit roller ing belt, so that the media is trans- ported up to the position of the exit roller. 2. When the trailing edge of the media moves past the aligning belt, the exit roller up/down motor starts rotating to lower the upper exit roller.
  • Page 201: Finishing Tray Media Full Detection On Staple Mode

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.4.2 Finishing tray media full detection on staple mode • The number of printed media that can be stored in the finishing tray on staple mode var- ies depending on the length of media. Media length Plain paper 300 mm or under...
  • Page 202: Aligning Belt Up/Down Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.4.3 Aligning belt up/down mechanism • When the aligning plate and media ejector are operated, the aligning belt is made to leave the media. • The aligning belt is moved up or down through drive from the transport motor. •...
  • Page 203: Aligning Plate Mechanism

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.4.4 Aligning plate mechanism • The aligning plate is moved to align media in the crosswise direction. • Media aligning is accomplished by the align motor and the aligning plate. A. Aligning plates •...
  • Page 204: Exit Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.4.5 Exit mechanism • The printed media stack/set aligned in the storage section is fed out into the main tray. • The aligning belt is moved up or down by the aligning belt up/down solenoid. •...
  • Page 205 5. Operations Theory of operation Ver. 1.0 Nov. 2006 A. Operation NOTE • The following describe the operation in the shift mode. The operation in the sta- pling mode basically follows the same steps with some performed in different orders. 1.
  • Page 206: Media Ejector Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.4.6 Media ejector mechanism • The printed media stack/set stored in the finishing tray is fed out into the main tray. • The media ejector is advanced or retracted by the drive from the media ejector motor. •...
  • Page 207: Main Tray Section

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 Main tray section • The main tray section controls the media level and detection of a media full condition in order to accommodate properly media fed out of the staple finisher. A01FT2C058DA A01FT2C002AA Media level...
  • Page 208: Main Tray Ascent/Descent

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.5.1 Main tray ascent/descent • Rotation of the tray up/down motor in either the forward or backward direction drives the tray up/down gear to move the main tray up or down. •...
  • Page 209: Media Level Detection Mechanism

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.5.2 Media level detection mechanism • The main tray moves up or down according to the amount of media fed onto it. • media level sensor/1 and media level sensor/2 control the media level each time a sheet of media is fed out, so that the level of the media fed onto the tray remains constant at all times.
  • Page 210: Media Holding Mechanism

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations 5.5.3 Media holding mechanism • The media level lever serves also for holding media down on the main tray while printed media stacks/sets are fed out (except for the stapling mode), thereby preventing the media stacks/sets which have previously been fed onto the main tray from being pushed out and dropped by a new media stack/set being fed out.
  • Page 211: Media Full Detection

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.5.4 Media full detection • The amount of media fed out into the main tray is detected by the media level sensor/1, media level sensor/2, and the tray lower sensor. • When the corresponding sensor detects either condition 1 or 2 described below, the sta- ple finisher determines that the maximum capacity of the printed media on the main tray has been reached, giving the following message on the control panel.
  • Page 212: Staple Section

    Theory of operation Ver. 1.0 Nov. 2006 5. Operations Staple section • The staple section controls the stapling unit for stapling the printed media stack/set aligned neatly and staple empty detection. A01FT2C067DA A01FT2C068DA 5.6.1 Stapling mechanism • Stapling is performed by the stapling unit. •...
  • Page 213: Stapling Position

    5. Operations Theory of operation Ver. 1.0 Nov. 2006 5.6.2 Stapling position • When the staple finisher is mounted on the main body, the printed media is fed out face down with its trailing edge first. • The staple is driven into the media stack/set at an angle of 49 degrees relative to the printed surface at the rear corner.
  • Page 214 © 2006 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Use of this manual should be strictly supervised to DDA011-A-TE1 avoid disclosure of confidential information.

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