Professional Documents
Culture Documents
2007.04
Ver. 1.0
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THEORY OF OPERATION TOTAL CONTENTS
DF-605/MK-501
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 5
DF-502
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
AD-504
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
PF-502
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
MB-501
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
JS-503
Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................... 3
SF-501
Outline ............................................................................................................................ 1
i
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Composition/Operation ................................................................................................... 3
ii
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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.
Changes may have been made to this product to improve its performance after this Service
Manual was printed. Accordingly, KMBT does not warrant, either explicitly or implicitly, that
the information contained in this service manual is complete and accurate.
The user of this service manual must assume all risks of personal injury and/or damage to
the product while servicing the product for which this service manual is intended.
Therefore, this service manual must be carefully read before doing service work both in the
course of technical training and even after that, for performing maintenance and control of
the product properly.
Keep this service manual also for future service.
Symbols used for safety and important warning items are defined as follows:
S-1
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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. For this reason, unauthorized modifications involve
a high risk of degradation in performance and safety. Such modifications are therefore
strictly prohibited. the points listed below are not exhaustive, but they illustrate the reason-
ing behind this policy.
Prohibited Actions
DANGER
Using any cables or power cord not specified by KMBT.
S-2
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SAFETY AND IMPORTANT WARNING ITEMS
WARNING
Use power supply cord set which meets the following
criteria:
- provided with a plug having configuration intended for
the connection to wall outlet appropriate for the prod-
kw
uct's rated voltage and current, and
- the plug has pin/terminal(s) for grounding, and
- provided with three-conductor cable having enough cur-
rent capacity, and
- the cord set meets regulatory requirements for the area.
Use of inadequate cord set leads to fire or electric shock.
Attach power plug which meets the following criteria:
- having configuration intended for the connection to wall
outlet appropriate for the product's rated voltage and
current, and
- the plug has pin/terminal(s) for grounding, and
- meets regulatory requirements for the area.
Use of inadequate cord set leads to the product connect-
ing to inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
S-3
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SAFETY AND IMPORTANT WARNING ITEMS
1. Power Supply
WARNING
Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.
Plug the power cord into the dedicated wall outlet with a
capacity greater than the maximum power consumption.
If excessive current flows in the wall outlet, fire may
result.
S-4
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SAFETY AND IMPORTANT WARNING ITEMS
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.
If the power cord (inlet type) is not connected to the prod-
uct securely, a contact problem may lead to increased
resistance, overheating, and risk of fire.
Do not insert the power plug into the wall outlet with a wet
hand.
The risk of electric shock exists.
When unplugging the power cord, grasp the plug, not the
cable.
The cable may be broken, leading to a risk of fire and
electric shock.
S-5
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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.
2. Installation Requirements
WARNING
Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.
WARNING
When the product is not used over an extended period of
time (holidays, etc.), switch it off and unplug the power
cord.
Dust collected around the power plug and outlet may
cause fire.
S-6
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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. When the product is used in a poorly ventilated room
b. When taking a lot of copies
c. When using multiple products at the same time
Stability
CAUTION
Be sure to lock the caster stoppers.
In the case of an earthquake and so on, the product may
slide, leading to a injury.
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.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.
S-7
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SAFETY AND IMPORTANT WARNING ITEMS
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.
Safety Checkpoints
WARNING
Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.
S-8
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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.
Make sure the wiring cannot come into contact with sharp
edges, burrs, or other pointed parts.
Current can leak, leading to a risk of electric shock or
fire.
S-9
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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.
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.
If the substances get in the eye, rinse with plenty of water
immediately. When symptoms are noticeable, consult a
physician.
CAUTION
Unplug the power cord from the wall outlet.
Drum cleaner (isopropyl alcohol) and roller cleaner (ace-
tone-based) are highly flammable and must be handled
with care. A risk of fire exists.
S-10
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SAFETY AND IMPORTANT WARNING ITEMS
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.
S-11
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SAFETY AND IMPORTANT WARNING ITEMS
Germany
VORSICHT!
Explosionsgefahr bei unsachgemem Austausch der Batterie.
Ersatz nur durch denselben oder einen vom Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
France
ATTENTION
Il y a danger dexplosion sil y a remplacement incorrect de la batterie.
Remplacer uniquement avec une batterie du mme type ou dun type quivalent recom-
mand par le constructeur.
Mettre au rebut les batteries usages conformment aux instructions du fabricant.
Denmark
ADVARSEL!
Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.
Udskiftning m kun ske med batteri af samme fabrikat og type.
Levr det brugte batteri tilbage til leverandren.
Finland, Sweden
VAROlTUS
Paristo voi rjht, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.
Hvit kytetty paristo valmistajan ohjeiden mukaisesti.
VARNING
Explosionsfara vid felaktigt batteribyte.
Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-
tillverkaren.
Kassera anvnt batteri enligt fabrikantens instruktion.
Norway
ADVARSEL
Eksplosjonsfare ved feilaktig skifte av batteri.
Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.
Brukte batterier kasseres i henhold til fabrikantens instruksjoner.
S-12
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SAFETY AND IMPORTANT WARNING ITEMS
semiconductor laser
Maximum power of the laser diode 5 mW
Maximum average radiation power (*) 6.32 W
Wavelength 770-795 nm
*at laser aperture of the Print Head Unit
This product employs a Class 3B laser diode that emits an invisible laser beam. The
laser diode and the scanning polygon mirror are incorporated in the print head unit.
The print head unit is NOT A FIELD SERVICEABLE ITEM. Therefore, the print head unit
should not be opened under any circumstances.
Laser Aperture of
the Print Head Unit
A09AP0C501DA
S-13
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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. Food and Drug Administration of
the U.S. Department of Health and Human Services (DHHS). This means that the device
does not produce hazardous laser radiation.
The label shown on page S-16 indicates compliance with the CDRH regulations and
must be attached to laser products marketed in the United States.
.
CAUTION
Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
All Areas
CAUTION
Use of controls, adjustments or performance of procedures other than those
specified in this manual may result in hazardous radiation exposure.
semiconductor laser
Maximum power of the laser diode 5 mW
Wavelength 770-795 nm
Denmark
ADVARSEL
Usynlig laserstrling ved bning, nr sikkerhedsafbrydere er ude af funktion.
Undg udsttelse for strling. Klasse 1 laser produkt der opfylder IEC60825-1
sikkerheds kravene.
halvlederlaser
Laserdiodens hjeste styrke 5 mW
blgelngden 770-795 nm
S-14
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SAFETY AND IMPORTANT WARNING ITEMS
Finland, Sweden
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
VAROITUS!
Laitteen kyttminen muulla kuin tss kyttohjeessa mainitulla tavalla saat-
taa altistaa kyttjn turvallisuusluokan 1 ylittvlle nkymttmlle laser-
steilylle.
puolijohdelaser
Laserdiodin suurin teho 5 mW
aallonpituus 770-795 nm
VARNING!
Om apparaten anvnds p annat stt n i denna bruksanvisning specificerats,
kan anvndaren utsttas fr osynlig laserstrlning, som verskrider grnsen fr
laserklass 1.
halvledarlaser
Den maximala effekten fr laserdioden 5 mW
vglngden 770-795 nm
VARO!
Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttomlle laser-
steilylle. l katso steeseen.
VARNING!
Osynlig laserstrining nr denna del r ppnad och sprren r urkopplad.
Betrakta ej strien.
Norway
ADVERSEL
Dersom apparatet brukes p annen mte enn spesifisert i denne bruksanvisn-
ing, kan brukeren utsettes fr unsynlig laserstrlning, som overskrider grensen
for laser klass 1.
halvleder laser
Maksimal effekt till laserdiode 5 mW
blgelengde 770-795 nm
S-15
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SAFETY AND IMPORTANT WARNING ITEMS
A09AP0E505DA
A09AP0C503DA
S-16
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SAFETY AND IMPORTANT WARNING ITEMS
S-17
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SAFETY AND IMPORTANT WARNING ITEMS
High voltage
High temperature
High voltage
A09AP0C504DA
CAUTION:
You may be burned or injured if you touch any area that you are advised not to
touch by any caution label. Do not remove caution labels. If any caution label has
come off or soiled and therefore the caution cannot be read, contact our service
office.
S-18
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MEASURES TO TAKE IN CASE OF AN ACCIDENT
S-19
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MEASURES TO TAKE IN CASE OF AN ACCIDENT
Blank Page
S-20
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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.
Field Service section gives, as information required by the CE at the site (or at the cus-
tomers premise), a rough outline of the service schedule and its details, maintenance
steps, the object and role of each adjustment, error codes and supplementary information.
The basic configuration of each section is as follows. However some options may not be
applied to the following configuration.
C-1
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Notation of the service manual
A. Product name
In this manual, each of the products is described as follows:
B. Brand name
The company names and product names mentioned in this manual are the brand name or
the registered trademark of each company.
C. Feeding direction
When the long side of the paper is parallel with the feeding direction, it is called short
edge feeding. The feeding direction which is perpendicular to the short edge feeding is
called the long edge feeding.
Short edge feeding will be identified with [S (abbreviation for Short edge feeding)] on the
paper size. No specific notation is added for the long edge feeding.
When the size has only the short edge feeding with no long edge feeding, [S] will not be
added to the paper size.
<Sample notation>
C-2
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
bizhub 163/211/220
bizhub 163/211/220 main body
Outline
1. System configuration............................................................................................... 1
2. Product specification ............................................................................................... 3
2.1 Fax kit (FK-506): (Option) ..................................................................................... 6
Outline
3. Cross sectional view................................................................................................ 7
4. Paper path............................................................................................................... 8
5. Copy process .......................................................................................................... 9
Composition/Operation
Composition/Operation
6. Overall configuration ............................................................................................. 11
6.1 Timing Chart at Power ON.................................................................................. 11
6.2 Control Block Diagram ........................................................................................ 12
7. Scanner (IR) .......................................................................................................... 13
7.1 Composition........................................................................................................ 13
7.2 Drive ................................................................................................................... 14
7.3 Operation ............................................................................................................ 15
7.3.1 Scanner Moving Mechanism/Control .......................................................... 15
7.3.2 Original Size Detection ............................................................................... 16
7.3.3 Determination of Original Size .................................................................... 17
7.3.4 For Metric, China and Latin America (Metric) areas ................................... 20
8. PH (Writing section) .............................................................................................. 21
8.1 Composition........................................................................................................ 21
8.2 Drive ................................................................................................................... 22
9. Imaging unit........................................................................................................... 23
9.1 Construction ....................................................................................................... 23
9.2 Operation ............................................................................................................ 24
10. PC Drum ............................................................................................................... 25
10.1 Composition........................................................................................................ 25
10.2 Drive ................................................................................................................... 25
10.3 Operation ............................................................................................................ 26
10.3.1 Grounding of the PC Drum ......................................................................... 27
11. PC Drum charging................................................................................................. 28
11.1 Composition........................................................................................................ 28
11.2 Operation ............................................................................................................ 28
12. Developing ............................................................................................................ 29
i
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Theory of Operation Ver. 1.0 Apr. 2007
ii
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Theory of Operation Ver. 1.0 Apr. 2007
17.1 Composition........................................................................................................ 48
bizhub 163/211/220
17.2 Drive ................................................................................................................... 48
17.3 Operation ............................................................................................................ 49
17.3.1 Paper Detection Mechanism ....................................................................... 49
17.3.2 Manual Feed Take Up Control..................................................................... 50
18. Registration roller section...................................................................................... 51
18.1 Composition........................................................................................................ 51
18.2 Drive ................................................................................................................... 51
18.3 Operation ............................................................................................................ 52
Outline
18.3.1 Paper Dust Remover................................................................................... 52
19. Fusing unit section ................................................................................................ 53
19.1 Composition (for bizhub 163).............................................................................. 53
19.2 Composition (for bizhub 211/220)....................................................................... 54
19.3 Drive ................................................................................................................... 55
Composition/Operation
19.4 Operation ............................................................................................................ 55
19.4.1 Fusing Roller Pressure Mechanism ............................................................ 55
19.4.2 Fusing Temperature Control (for bizhub 163) ............................................. 56
19.4.3 Fusing Temperature Control (for bizhub 211/220) ...................................... 57
19.4.4 PPM Control (bizhub 163 Only) .................................................................. 58
20. Paper exit (for bizhub 163) .................................................................................... 59
20.1 Composition........................................................................................................ 59
20.2 Drive ................................................................................................................... 59
21. Paper exit (for bizhub 210/220) ............................................................................. 60
21.1 Construction ....................................................................................................... 60
21.2 Operation ............................................................................................................ 60
22. Image stabilization system .................................................................................... 61
22.1 Composition........................................................................................................ 61
23. Others ................................................................................................................... 62
23.1 Fan Control ......................................................................................................... 62
23.1.1 Composition ................................................................................................ 62
23.1.2 Operation .................................................................................................... 63
iii
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Theory of Operation Ver. 1.0 Apr. 2007
bizhub 163/211/220
Outline
Composition/Operation
Blank Page
iv
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Theory of Operation Ver. 1.0 Apr. 2007 1. System configuration
Outline
bizhub 163/211/220
1. System configuration
1/2 System front view
[3] [4]
[2]
[5]
Outline
[12]
[6]
[1]
[7]
[13]
[8]
[14]
[11]
[9]
[10]
A08EE501AA
1
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1. System configuration Theory of Operation Ver. 1.0 Apr. 2007
[2]
Outline
A08EE502AA
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Product specification
2. Product specification
bizhub 163/211/220
A. Copier
Outline
Exposure system Mirror scanning
Developing system HMT system
Charging system Comb electrode DC negative corona with scorotron system
Image transfer system Roller image transfer
Paper separating system Paper separator fingers and charge neutralizing plate
Fusing system Heat roller
Paper discharging system Charge neutralizing brush
B. Functions
3
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2. Product specification Theory of Operation Ver. 1.0 Apr. 2007
Envelopes 10 sheets
Paper capacity Plain paper/recycled paper/special
1 sheets
(Manual bypass) paper
C. Paper
D. Maintenance
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Product specification
E. Machine specifications
bizhub 163/211/220
Voltage AC100 V, AC120V, AC220-240V
Power requirements
Frequency 50/60 Hz
100/110/120 area 1000 W 10% or less
127/230 area 1050 W 10% or less
bizhub 163
220 area 940 W 10% or less
Max power consump-
240 area 1100 W 10% or less
tion
110/120/220 area 1200 W 10% or less
bizhub 211/220 127/240 area 1350 W 10% or less
Outline
230 area 1250 W 10% or less
599 (W) x 620 (D) x 520 (H) mm *1
Dimensions 760 (W) x 620 (D) x 604 (H) mm *2 (bizhub 220 for China)
760 (W) x 620 (D) x 520 (H) mm *2 (bizhub 163 for China)
998 (W) x 665 (D) mm (bizhub 211/220)
Space requirements
998 (W) x 620 (D) mm (bizhub 161)
Mass 89 kg (when fully equipped)
*1: Including the original cover
*2: Including MB-501 and original cover
F. Operating environment
G. Built-in controllers
5
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2. Product specification Theory of Operation Ver. 1.0 Apr. 2007
Transmission mode G3
Compatible wiring General subscriber telephone line, NCC each line
Connection method Direct connection (using a modular jack)
Transmission speed 33.6, 31.2, 28.8, 26.4, 24.0, 21.6, 19.2, 16.8, 14.4, 12.0, 9.6, 7.2, 4.8, 2.4
kbps (automatic switching)
Transmission time 3 seconds *1
Scanning density 8 dots/mm x 3.85/7.7/15.4 lines/mm, 16 dots/mm x 15.4 lines/mm *2
Document size Maximum A3 (Ledger), banner documents (maximum 1000 mm (39-1/4
Outline
inches)) possible
Print paper size Metric: A3, B4, A4, B5, A5
Inch: Invoice (8-1/2 x 5-1/2), Letter, Legal (8-1/2 x 14), Ledger (11 x 17)
Scanning storage With built in memory (5 MB): 280 pages
With expanded memory (64 MB): 1,024 pages
*With standard A4-size documents
Compression encoding MH / MR / MMR / JBIG
format
*1: This is the speed for transmitting an A4-size, or Letter-size document containing approx-
imately 700 characters at high-speed (33.6 kbps) using the standard resolution (8 dots/mm
x 3.85 lines/mm (200 dpi x 100 lpi)). The transmission time for only the image information
and the communication control time are not included. In addition, the actual transmission
time differs depending on the contents of the document, the recipients fax machine and the
condition of the wiring.
*2: Real-time transmission is supported only with the document feeder.
6
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Theory of Operation Ver. 1.0 Apr. 2007 3. Cross sectional view
bizhub 163/211/220
1
Outline
3
12
4
11
5
10 6
4034G502BA
[1] Automatic document feeder DF-502 [7] Paper feed unit PF-502 (Option)
(Option)
[2] Scanner [8] Copy table DK-703 (Option)
[3] Job separator JS-503 (Option) [9] Paper feed tray/1
[4] Fusing unit [10] PH unit
[5] Image transfer section [11] Imaging unit
[6] Multiple bypass MB-501 (Option) [12] Exit section
7
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4. Paper path Theory of Operation Ver. 1.0 Apr. 2007
4. Paper path
bizhub 163/211/220
Outline
4034G503BA
8
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Theory of Operation Ver. 1.0 Apr. 2007 5. Copy process
5. Copy process
bizhub 163/211/220
[1] Photoelectric
Conversion
Outline
[6] Laser Exposure
[5] Drum Charging [10] Paper Separation
A08EE568AA
9
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5. Copy process Theory of Operation Ver. 1.0 Apr. 2007
10
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Theory of Operation Ver. 1.0 Apr. 2007 6. Overall configuration
Composition/Operation
bizhub 163/211/220
6. Overall configuration
6.1 Timing Chart at Power ON
Fusing cooling
Composition/Operation
fan motor (FM1)
11
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6. Overall configuration Theory of Operation Ver. 1.0 Apr. 2007
Operation
Panel IR CCD
NCUB
Paper Exit
Source Option
PH
Printer control board
High voltage unit
(PRCB)
Paper Source PU
Option
12
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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)
7. Scanner (IR)
bizhub 163/211/220
7.1 Composition
A08EC579AA
Composition/Operation
A08EC508AA
Scanner home
position sensor
(PS100)
Original
cover set
switch (S6)
Scanner
Assy
Exposure Lamp
2nd/3rd Mirrors Carriage
A08EC514AA
13
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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007
7.2 Drive
bizhub 163/211/220
Composition/Operation
A08EC515AA
14
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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)
7.3 Operation
bizhub 163/211/220
7.3.1 Scanner Moving Mechanism/Control
The Scanner is moved by the Scanner Motor at a given speed.
The Scanner Home Position Sensor detects the Scanner at its home position.
The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner. It thereby keeps
constant the optical path length between the original and the PC Drum.
A. Operation
<Marking copies through the Original Glass>
Composition/Operation
A08EE572AA
15
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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007
A08EE578AA
1. When the original is loaded and the Start key pressed, the Scanner performs shad-
ing.
2. The Scanner then moves to the scanning position under the ADF glass.
The original is scanned as it is moved.
3. After the original has been scanned, the home position of the Scanner is detected.
Then, the Scanner moves to, and stops at, the home position.
PS102 (Option)
PS101
A08EE570AA
16
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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)
bizhub 163/211/220
The Original Size Sensor is used to determine the size of the original.
Two size conversion patterns are available depending on the applicable marketing area.
Refer to the Field Service (CCD APS SIZE) for setting.
Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
PS101 *PS102
OFF Invoice S Letter S Letter
ON Legal S Legal S 1117 S
Pattern 2
Composition/Operation
Original Size
~143.9 ~153.0 ~187.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm~
PS101 *PS102
Invoice
OFF OFF A5 S B5 S A4 S Letter S B5 B5 Letter A4
S
1117
ON OFF FLS S FLS S FLS S FLS S FLS S FLS S B4 S A3
S
1117
OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S A3
S
1117
ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S A3
S
*: PS102 is an option.
17
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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007
Pattern 1
Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
Sensor mm mm mm mm mm mm mm mm~
PS101 *PS102
OFF A5 S B5 S 16K S A4 S B5 B5 16K A4
ON FLS S FLS S FLS S FLS S FLS S B4 S 8K S A3
Pattern 2
Original
Size
~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm mm mm~
PS *PS
101 102
Composition/Operation
Invoice Letter
OFF OFF A5 S B5 S 16K S A4 S B5 B5 16K Letter A4
S S
1117
ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S A3
S
Legal Legal Legal Legal Legal Legal 1117
OFF ON B4 S B4 S 8K S A3
S S S S S S S
Legal Legal Legal Legal Legal Legal 1117
ON ON B4 S B4 S 8K S A3
S S S S S S S
*: PS102 is an option.
18
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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)
bizhub 163/211/220
For Inch and Latin America (Inch) areas
Pattern 1
Original Size
~144.7 ~220.9 ~221.0
Sensor mm mm mm
PS101 *PS102
OFF Invoice S Letter S Letter
ON FLS S FLS S 1117 S
Pattern 2
Original Size
~143.9 ~153.0 ~187.0 ~213.0 ~220.9 ~225.0 ~262.0 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm~
PS101 *PS102
Invoice
OFF OFF A5 S B5 S A4 S Letter S B5 B5 Letter A4
Composition/Operation
S
1117
ON OFF FLS S FLS S FLS S FLS S FLS S FLS S B4 S A3
S
1117
OFF ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S A3
S
1117
ON ON Legal S Legal S Legal S Legal S Legal S B4 S B4 S A3
S
*: UN3 is an option.
19
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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007
Pattern 1
Original Size
~153.0 ~187.0 ~200.0 ~215.0 ~225.0 ~262.0 ~275.0 275.1
Sensor mm mm mm mm mm mm mm mm~
PS101 *PS102
OFF A5 S B5 S 16K S A4 S B5 B5 16K A4
ON Legal S Legal S Legal S Legal S Legal S B4 S 8K S A3
Pattern 2
Original
Size
~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5
Sensor mm mm mm mm mm mm mm mm mm mm mm~
PS *PS
101 102
Composition/Operation
Invoice Letter
OFF OFF A5 S B5 S 16K S A4 S B5 B5 16K Letter A4
S S
1117
ON OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S B4 S 8K S A3
S
Legal Legal Legal Legal Legal Legal 1117
OFF ON B4 S B4 S 8K S A3
S S S S S S S
Legal Legal Legal Legal Legal Legal 1117
ON ON B4 S B4 S 8K S A3
S S S S S S S
*: PS102 is an option.
20
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Theory of Operation Ver. 1.0 Apr. 2007 8. PH (Writing section)
8. PH (Writing section)
bizhub 163/211/220
8.1 Composition
A08EC580AA
Composition/Operation
A08EC508AA
Polygon Motor
f Lens
LD Board
SOS Sensor
A08EC516AA
21
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8. PH (Writing section) Theory of Operation Ver. 1.0 Apr. 2007
8.2 Drive
bizhub 163/211/220
When a laser beam strikes the Polygon Mirror, light reflected off the Polygon Mirror is
directed at the PC Drum by way of the lens and return mirror.
The Polygon Mirror has seven faces, being turned at high speeds by the Polygon Motor.
The SOS Mirror and SOS Sensor keep constant the timing, at which emission of a laser
beam is started for each main scanning line.
Polygon
Motor f Lens
SOS Mirror
PC Drum
Composition/Operation
LD Board
SOS Sensor
A08EC526AA
22
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Theory of Operation Ver. 1.0 Apr. 2007 9. Imaging unit
9. Imaging unit
bizhub 163/211/220
9.1 Construction
A08EC581AA
Composition/Operation
A08EC509AA
Cleaning Blade
PC Drum
Paper Separa-
tor Fingers
PC Drum
PC Drum Charge
Corona
Developing Roller
23
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9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2007
9.2 Operation
bizhub 163/211/220
The Main Motor provides drive for the PC Drum, Developing Roller, and other mechani-
cal components.
Developing Roller
Recycled Toner
Recycling Coil
Composition/Operation
A08EC562AA
24
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Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum
10. PC Drum
bizhub 163/211/220
10.1 Composition
A08EC582AA
Composition/Operation
A08EC509AA
10.2 Drive
A08EC563AA
25
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10. PC Drum Theory of Operation Ver. 1.0 Apr. 2007
10.3 Operation
bizhub 163/211/220
Handling Precaution
The PC Drum of this type exhibits light fatigue after being exposed to light for a
long time, which results in its sensitivity being changed. Always, therefore, wrap
the drum in the PC Drum Cloth or a soft cloth immediately after it has been
removed from the copier. Utmost care should also be used when handling the PC
Drum to ensure that its surface is not contaminated.
A08EC527AA
26
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Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum
bizhub 163/211/220
The ground contact (Ground Plate) of the PC Drum is located on the inside on its left-
hand side. It remains in contact with the drum shaft at all times. When the Imaging Unit is
loaded in the copier, the drum shaft comes into contact with the Ground Plate of the PC
Drum. The potential on the surface of the PC Drum exposed to the laser beam is then
grounded through the Ground Plate to the frame of the copier.
PC Drum
Composition/Operation
Frame
Ground Plate
A08EC528AA
27
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11. PC Drum charging Theory of Operation Ver. 1.0 Apr. 2007
11.1 Composition
A08EC583AA
Composition/Operation
A08EC509AA
11.2 Operation
The surface of the PC Drum is deposited with charge through corona discharge from the
PC Drum Charge Corona.
The grid mesh interposed between the corona wire and the PC Drum ensures that a uni-
form charge is deposited across the entire surface of the PC Drum.
The corona unit has a comb electrode that discharges only toward the grid mesh. This
results in the amount of ozone produced being smaller than with the wire electrode.
Comb Electrode
Grid Mesh
A08EC529AA
28
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Theory of Operation Ver. 1.0 Apr. 2007 12. Developing
12. Developing
bizhub 163/211/220
12.1 Composition
A08EC584AA
Composition/Operation
A08EC509AA
12.2 Drive
A08EC518AA
29
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12. Developing Theory of Operation Ver. 1.0 Apr. 2007
12.3 Operation
bizhub 163/211/220
Toner/Carrier PC Drum
Toner
2nd Toner Conveying Roller
Carrier
Developing Roller
Composition/Operation
A08EC519AA
PC Drum
Developing Roller
Developing Bias
Terminal
A08EC520AA
30
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Theory of Operation Ver. 1.0 Apr. 2007 12. Developing
bizhub 163/211/220
The TCR Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer
Mixing Chamber.
3rd Toner Conveying Roller
2nd Toner Conveying Roller Developing Roller
Composition/Operation
12.3.4 TCR Sensor Automatic Adjustment
The reference value for the TCR Sensor is automatically adjusted as detailed below
using the TCR Sensor Automatic Adjustment mode.
With the copier set in the TCR Sensor Automatic Adjustment mode, press the Start key.
The TCR Sensor converts the reference T/C (14 %) to a corresponding voltage
value and outputs it.
Does the output voltage fall within the range from 2.28 to 2.36 V?
YES NO
The voltage input to the TCR Sensor The voltage input to the TCR Sensor from
from the Master Board at this time is fixed the Master Board is varied.
as the reference voltage. 2.37 V or more: Decrease the voltage.
2.29 V or less: Increase the voltage.
31
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13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007
13.1 Composition
Composition/Operation
A08EC585AA
A08EC510AA
13.2 Drive
A08EC564AA
32
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Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing
13.3 Operation
bizhub 163/211/220
13.3.1 Toner Replenishing Mechanism
Toner is supplied from the Toner Bottle to the Developer Mixing Chamber.
1. The Toner Replenishing Motor (M2) turns the coupling, which turns the Toner Bot-
tle.
2. To regulate the amount of toner supplied from the Toner Bottle, there is a Metering
Chamber provided in the outer race of the coupling.
3. When the Toner Bottle turns, toner in the Metering Chamber drops.
4. Toner from the metering chamber is conveyed by the Toner Conveying Screw into
the Developer Mixing Chamber.
5. The Toner Conveying Screw is turned by the Toner Replenishing Motor (M2).
Composition/Operation
Metering
Chamber
A08ET2C522AA
Toner replenishing
motor (M2)
A08EC561AA
33
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13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007
Replenishing of the supply of toner is determined based on the T/C ratio and B/W ratio.
If T/C is 14 % or more, toner replenishing is not carried out regardless of the B/W value.
If T/C is less than 14 %, toner replenishing is determined according to the B/W value.
Toner is replenished until T/C becomes 14 %.
The greater the value of B/W in the table, the higher the B/W ratio (high image density
Composition/Operation
original).
34
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Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing
bizhub 163/211/220
The machine enters the T/C recover mode when a T/C of 10 % or less is detected.
Composition/Operation
T/C is recovered by 2 % or more, T/C is not recovered by 2 % or more,
or is 12 % or more. or T/C is less than 12 %.
A toner-empty condition is reset when the Front Cover is opened and closed after a T/C
of 10 % or more is detected with the supply of toner replenished.
A toner-empty-stop condition is reset when the Front Cover is opened and closed after a
T/C of 8 % or more is detected with the supply of toner replenished. A toner-empty con-
dition results, however, if T/C falls within the range between 8 % and 10 % when the
Front Cover is opened and closed.
35
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13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007
The toner supply port is on the upper side whenever the toner bottle is at its home posi-
tion. The toner bottle home position sensor (PS6) detects the toner bottle at its home
position.
A08EC530AA
36
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Theory of Operation Ver. 1.0 Apr. 2007 14. Image transfer and paper separation section
bizhub 163/211/220
14.1 Composition
A08EC591AA
Composition/Operation
A08EC511AA
14.2 Drive
A08EC565AA
37
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14. Image transfer and paper separation section Theory of Operation Ver. 1.0 Apr. 2007
14.3 Operation
bizhub 163/211/220
Since the PC Drum has a small diameter, there is no likelihood that the paper will be
wound around the PC Drum. The paper is separated by its own weight.
The Charge Neutralizing Plate neutralizes any charge left on the paper after image trans-
fer, thereby preventing discharge noise that could otherwise occur when the paper is
separated.
The PC Drum Paper Separator Fingers properly separate from the surface of the PC
Drum thin paper or other type of paper that is hard to separate.
PC Drum
38
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Theory of Operation Ver. 1.0 Apr. 2007 15. Toner recovery
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15.1 Composition
Composition/Operation
A08EC585AA
A08EC509AA
15.2 Drive
A08EC567AA
39
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15. Toner recovery Theory of Operation Ver. 1.0 Apr. 2007
15.3 Operation
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The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum.
The spent toner is conveyed through the Recycling Duct and eventually back to the
Developer Mixing Chamber.
The following control is provided to prevent paper dust from being wedged between the
Cleaning Blade and the PC Drum. When the cumulative period of time through which the
PC Drum has been driven reaches a predetermined value, the PC Drum is turned back-
ward (by turning the Main Motor backward). Shoulder gears comprising two different
parts are provided on the copier. This ensures that the drive is transmitted only to the
Imaging Unit, but not any other parts, during backward rotation.
Cumulative Time Through Which PC Drum Has Been Driven PC Drum Backward Rotation Time
Approx. 330 sec. 50 ms
PC Drum
Composition/Operation
Cleaning Blade
40
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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed
bizhub 163/211/220
16.1 Composition
A08EC587AA
Composition/Operation
A08EC557AA Paper empty sensor/1 (PS4)
Paper size detect board (PSDTB) Feed Roller/1
A08EC533AA
41
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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007
16.2 Drive
bizhub 163/211/220
The Main Motor (M1) provides the drive for paper feed operations.
The drive is transmitted through the Paper feed solenoid/1.
Feed Roller
Composition/Operation
A08EC534AA
42
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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed
16.3 Operation
bizhub 163/211/220
16.3.1 Paper Separating Mechanism
The coefficient of friction between the Feed Roller and Separation Roller is effectively
used to prevent double feed of paper.
Feed Roller
Composition/Operation
Paper
Separation Roller
A08EC535AA
A08EC536AA
43
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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007
A08EC537AA
Spring
A08EC538AA
44
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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed
bizhub 163/211/220
Both the width (in the crosswise direction) and length (in the feeding direction) of the
paper are detected and the copier CPU determines the paper size based on the combi-
nation of the two readings.
The width of the paper is detected when the lever that is operatively connected to the
Edge Guide activates or deactivates the Paper Size Detection Sensor.
The length of the paper is detected when the lever that is operatively connected to the
Trailing Edge Stop actuates or deactuates the switches on the Paper size detect board.
1 2 3 4
Composition/Operation
A08EC539AA
45
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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007
ON ON ON ON B5 S
<For Inch>
46
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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed
bizhub 163/211/220
A08EE588AA
Composition/Operation
rarily halted if the paper fails to reach the Synchronizing Roller Sensor within a given
period of time after the sequence has been started. The paper take-up sequence is then
performed again. These paper take-up sequences are repeated a given number of times.
A08EE589AA
47
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17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007
17.1 Composition
A08EC590AA
Composition/Operation
A08EC512AA
17.2 Drive
A08EC566AA
48
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Theory of Operation Ver. 1.0 Apr. 2007 17. Manual bypass section
17.3 Operation
bizhub 163/211/220
Drive for bypass paper feed is provided by the Main Motor (M1).
The drive is transmitted through the Paper feed solenoid/bypass.
Composition/Operation
Paper feed solenoid/bypass (SD2)
A08EC542AA
Paper
A08EC543AA
49
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17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007
A08EE573AA
Composition/Operation
50
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Theory of Operation Ver. 1.0 Apr. 2007 18. Registration roller section
bizhub 163/211/220
18.1 Composition
A08EC586AA
Composition/Operation
A08EC558AA
18.2 Drive
Registration roller
clutch (CL1)
Registration roller
Registration sensor
(PS1)
51
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18. Registration roller section Theory of Operation Ver. 1.0 Apr. 2007
18.3 Operation
bizhub 163/211/220
The Synchronizing Roller ensures that the paper is fed off from the transport section in
time with the exposure timing of the exposure section (PH).
Drive from the Main Motor (M1) is transmitted through a gear train to the Registration
roller clutch (CL1).
Registration roller
clutch (CL1)
Composition/Operation
A08EC546AA
A08EC547AA
52
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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section
bizhub 163/211/220
19.1 Composition (for bizhub 163)
Heat and pressure from the Fusing Roller permanently fuse toner onto the paper.
Composition/Operation
A08EC592AA
A08EC559AA
Heater Lamp
Fusing Roller/rt
Fusing Roller
Thermistor (TH1)
Pressure Lever
A08EC548AA
Thermostat
53
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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007
Fusing Roller/rt
Fusing Roller
Thermostat
Pressure Lever
Composition/Operation
A08EE571AA
Thermistor (TH1)
Thermistor (TH2)
54
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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section
19.3 Drive
bizhub 163/211/220
The main motor (M1) provides the drive for the fusing unit.
Fusing Roller/Rt
Fusing roller
Composition/Operation
A08EC549AA
19.4 Operation
19.4.1 Fusing Roller Pressure Mechanism
To provide a nip width between the rollers, a Pressure Spring is used functioning to press
the Fusing Roller/Rt up against the Fusing Roller.
Fusing Roller/Rt
Pressure Lever
Fusing Roller
Pressure Spring
A08EC550AA
55
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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007
The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
surface of the Fusing Roller.
The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.
Warm-up completed
Composition/Operation
A08EE574AA
56
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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section
bizhub 163/211/220
The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the
surface of the Fusing Roller.
The Fusing Roller surface temperature is detected by using a thermistor that translates
the temperature to a corresponding electrical signal.
If the Fusing Roller temperature becomes excessively high, the Fusing Roller Heater
Lamp is shut down.
Warm-up completed
Composition/Operation
A08EE576AA
57
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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007
If paper of a small size (width of 250 mm or less) or thick paper is used to run a multi-
copy cycle, the temperature on the edges of the Fusing Rollers tends to run high, mean-
ing that the temperature of the Fusing Rollers varies among different spots of the rollers.
When the cumulative number of copies made through continuous copy cycles * exceeds
30, the paper take-up interval is made longer, thereby allowing the temperatures of the
Fusing Rollers at different spots to be uniform.
* Continuous copy cycle: Continuous copy cycles run with an interval of 2 min. or less
between cycles.
Composition/Operation
58
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Theory of Operation Ver. 1.0 Apr. 2007 20. Paper exit (for bizhub 163)
bizhub 163/211/220
20.1 Composition
Composition/Operation
A08EC593AA
A08EC560AA
20.2 Drive
The main motor (M1) provides the drive for the exit section.
Exit Roller
Main motor (M1)
A08EC553AA
59
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21. Paper exit (for bizhub 210/220) Theory of Operation Ver. 1.0 Apr. 2007
21.1 Construction
Composition/Operation
A08EC593AA
A08EC560AA
21.2 Operation
The exit rollers are driven by the switchback motor (M3).
Exit Roller
60
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Theory of Operation Ver. 1.0 Apr. 2007 22. Image stabilization system
bizhub 163/211/220
22.1 Composition
The following image stabilization controls are provided to ensure stabilized copy image.
Composition/Operation
Paper width
B/W ratio of image
A08EE577AA
61
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23. Others Theory of Operation Ver. 1.0 Apr. 2007
23. Others
bizhub 163/211/220
Ozone Filter
A08EC556AA
62
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Theory of Operation Ver. 1.0 Apr. 2007 23. Others
23.1.2 Operation
bizhub 163/211/220
A. Function
Composition/Operation
turns and at a speed reduction during other timings, thereby making
the machine quieter without sacrificing cooling performance.
B. Fan control
63
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23. Others Theory of Operation Ver. 1.0 Apr. 2007
bizhub 163/211/220
Composition/Operation
Blank Page
64
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
DF-605/MK-501
DF-605/MK-501
Outline
1. Product specifications ............................................................................................. 1
2. Paper Feed Path ..................................................................................................... 4
2.1 In 1-sided mode .................................................................................................... 4
Outline
2.2 In 2-sided mode .................................................................................................... 4
Composition/Operation
3. Composition ............................................................................................................ 5
4. Drive ........................................................................................................................ 6
Composition/Operation
5. Operation ................................................................................................................ 7
5.1 Document pick-up mechanism ............................................................................. 7
5.1.1 Pick-up operation .......................................................................................... 7
5.2 Document feed/transport mechanism................................................................... 8
5.3 Raised/lowered position detecting mechanism................................................... 12
5.3.1 Document size detection............................................................................. 12
5.3.2 Raised/lowered position detection .............................................................. 12
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Theory of Operation Ver. 1.0 Apr. 2007
DF-605/MK-501
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications
Outline
DF-605/MK-501
1. Product specifications
A. Type
Outline
Document alignment Center
Document loading Left image side up
B. Functions
C. Paper
1-Sided mode
Standard mode 35 to 128 g/m2 (9.25 to 34 lb)
Plain paper 2-Sided mode
50 to 128 g/m2 (13.25 to 34 lb)
Mixed original detection
1-Sided / 2-Sided Mode
Type of document mode
50 to 128 g/m2 (13.25 to 34 lb)
Plain paper
1-Sided mode
FAX mode 35 to 128 g/m2 (9.25 to 34 lb)
Plain paper 2-Sided mode
50 to 128 g/m2 (13.25 to 34 lb)
Metric area
Detectable document B6S to A3
size*1 Inch area
5 1/2 8 1/2S / 5 1/2 8 1/2 to 11 17
Capacity 80 sheets (80 g/m2) or load height of 11 mm or less.
*1: For the combined original detection mode, refer to the mixed original detection enabled
size combination table.
1
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1. Product specifications Theory of Operation Ver. 1.0 Apr. 2007
Highly curled original (15 mm or more) Original misfeed due to dog-ear or skew
OHP transparencies Feed failure
Label Sheet Feed failure
Offset master Feed failure
Sheets clipped or notched Damaged sheet
Patched part folded or torn sheet, Sheets
Sheets patched
misfed
2
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications
DF-605/MK-501
Max. original size 297 mm 257 mm 210 mm 182 mm 148 mm
Mixed original size A3 A4 B4 B5 A4S A5 B5S A5S
A3 OK OK - - - - - -
297 mm
A4 OK OK - - - - - -
B4 OK OK OK OK - - - -
257 mm
B5 OK OK OK OK - - - -
A4S OK* OK* OK OK OK OK - -
210 mm
A5 NG NG OK OK OK OK - -
Outline
182 mm B5S NG NG OK* OK* OK OK OK -
148 mm A5S NG NG NG NG NG NG OK OK
128 mm B6S NG NG NG NG NG NG NG OK
For Inch
Max. original size 11 8.5 5.5
Mixed original size 11 x 17 8.5 x 11 8.5 x 14 8.5 x 11S 5.5 x 8.5 8.5 x 5.5S
11 x 17 OK OK - - - -
11
8.5 x 11 OK OK - - - -
8.5 x 14 OK* OK* OK OK OK -
8.5
8.5 x 11S OK* OK* OK OK OK -
8.5 x 5.5 NG NG OK OK OK -
5.5
8.5 x 5.5S NG NG NG NG NG OK
G. Machine specifications
H. Operating
Conforms to the operating environment of the main unit.
NOTE
These specifications are subject to change without notice.
3
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2. Paper Feed Path Theory of Operation Ver. 1.0 Apr. 2007
3: Exit
4344T1C501AA
4344T1C502AA
4
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Theory of Operation Ver. 1.0 Apr. 2007 3. Composition
Composition/Operation
DF-605/MK-501
3. Composition
Composition/Operation
Conveyance section Switchback section Document exit section
4344T2C501AA
5
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4. Drive Theory of Operation Ver. 1.0 Apr. 2007
4. Drive
DF-605/MK-501
4344T2C502AA
Transport motor (M2-ADF)
Composition/Operation
6
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Theory of Operation Ver. 1.0 Apr. 2007 5. Operation
5. Operation
DF-605/MK-501
5.1 Document pick-up mechanism
The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separa-
tion Roller, and this section is driven by the Paper Feed Motor.
Composition/Operation
Feed Roller Separation
Roller
4344T2C503AA
7
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5. Operation Theory of Operation Ver. 1.0 Apr. 2007
When the document reaches the Registration Sensor, the Feed Roller starts turning for-
ward and, at the same time that the Pickup Roller goes up, drive is then supplied to the
Registration Roller.
When the Transport Motor starts turning forward, the two Transport Rollers and the Exit/
Turnover Roller feed the document toward the exit direction.
Direction of
Parts Details
Rotation
Backward The Pickup Rollers lower and start turning and the Feed
Paper Feed Motor rotation Roller turns.
(M1-ADF) Forward
The Registration Roller turns.
rotation
Backward The Transport Roller and Exit/Turnover Roller turn in the
Transport Motor rotation direction to turn over the original.
(M2-ADF) Forward The Transport Roller and Exit/Turnover Roller turn in the
rotation direction to feed the original out.
Composition/Operation
Exit/Turnover Roller
Registration Roller
Transport Roller
4344T2C504AA
8
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Theory of Operation Ver. 1.0 Apr. 2007 5. Operation
DF-605/MK-501
Original Detection Sensor
Exit
4344T2C506AA
1. When the Start key is pressed, the Paper Feed Motor starts turning backward,
causing the Pick-Up Roller to lower and start a paper take-up sequence.
Composition/Operation
2. The scanning of the 1st side is started after the lapse of a given period of time after
the Original Detection Sensor has been activated by the leading edge of the origi-
nal.
3. The original is transported for a given period of time after the trailing edge of the
last page of the document has deactivated the Exit/Turnover Sensor. It is then fed
into the Exit Tray and the Transport Motor is deenergized.
9
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5. Operation Theory of Operation Ver. 1.0 Apr. 2007
causing the Pick-Up Roller to lower and start feeding the 1st page of the document.
The scanning of the 1st side is started after the lapse of a given period of time after
the Original Detection Sensor has been activated by the leading edge of the 1st
page.
The Transport Motor is deenergized to stop the original after the lapse of a given
period of time after the trailing edge of the 1st page has deactivated the Exit/Turn-
over Sensor.
Stop
Composition/Operation
4344T2C506AA
2. The Transport Motor is turned backward to turn over the original. After the Registra-
tion Roller, the Transport Motor is turned forward to allow the Scanner to scan the
backside of the 1st page.
3. After the transport sequence for turnover has been started, the Exit Roller Retrac-
tion Solenoid is energized so that the Exit/Turnover Roller is retracted.
Turnover
Stop
4344T2C505AA
10
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Theory of Operation Ver. 1.0 Apr. 2007 5. Operation
4. To ensure that pages of the document are in the proper order, the page is turned
over again before being ejected into the Exit Tray.
DF-605/MK-501
Turnover
Exit
4344T2C505AA
Composition/Operation
11
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5. Operation Theory of Operation Ver. 1.0 Apr. 2007
12
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
DF-502
DF-502
Outline
1. Product specification ............................................................................................... 1
Composition/Operation
Outline
2. Automatic Document Feeder (DF-502) ................................................................... 3
2.1 Composition.......................................................................................................... 3
2.2 Drive ..................................................................................................................... 4
2.3 Operation .............................................................................................................. 5
2.3.1 Document Pick-Up and Feed ........................................................................ 5
Composition/Operation
2.3.2 Document Transport...................................................................................... 6
2.3.3 Document Separating Mechanism ................................................................ 7
2.3.4 Document Exit Mechanism ........................................................................... 8
2.3.5 Document Size Detection Mechanism .......................................................... 9
2.3.6 Raised/Lowered Position Detection Mechanism ........................................... 9
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Theory of Operation Ver. 1.0 Apr. 2007
DF-502
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification
Outline
1. Product specification
DF-502
A. Type
Outline
B. Paper
D. Machine specifications
E. Operating environment
Conforms to the operating environment of the main unit.
NOTE
These specifications are subject to change without notice.
1
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1. Product specification Theory of Operation Ver. 1.0 Apr. 2007
DF-502
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)
Composition/Operation
2. Automatic Document Feeder (DF-502)
DF-502
2.1 Composition
Composition/Operation
4688C512AA
4688C502AA
Main Motor
Feed Clutch
Pick-Up Roller
Exit Rollers
Feed Roller
Registration Rollers
4688C501AA
3
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2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Drive
DF-502
Composition/Operation
4688C503AA
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)
2.3 Operation
2.3.1 Document Pick-Up and Feed
DF-502
The document is taken up as the Pick-Up Roller and Feed Roller turn.
The Pick-Up Roller transports the document up to the Feed Roller.
After a scan is completed, the Main Motor is turned backward to raise the Pick-Up Roller.
The Pick-Up Roller and the Feed Roller are turned through the Paper Feed Clutch and by
a gear train and a belt driven by the Main Motor.
The Paper Empty Sensor is used to detect a document loaded on the Document Loading
Tray.
The Document Stoppers determine the leading edge position of the document loaded on
the Document Loading Tray. They are in the lowered, swung-down position in the
standby state and swing upward when the document is to be taken up.
The swing-up and swing-down motion of the Document Stoppers is operatively con-
nected to the raising and lowering of the Pick-Up Roller.
Composition/Operation
Pick-Up Roller
4688C504AA
Feed Roller
Document Stoppers
5
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2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2007
Registration Rollers
4688C506AA
6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)
DF-502
used to prevent double feed of paper.
Since the friction coefficient on the top side of the paper is equal to that
When one sheet of paper is
on the underside of the paper, the Separation Roller is turned by the
taken up
Feed Roller. This feeds the paper forward.
The friction coefficient between the sheets of paper is smaller than that
When two or more sheets of between the paper and Separation Roller. This stops the Separation
paper are taken up Roller, allowing only the first sheet of paper to be transported by the
Feed Roller.
Composition/Operation
Feed Roller
Separation Roller
4688C507AA
7
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2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2007
The Exit Roller is driven by gears and a belt which are driven by the Main Motor.
Exit Rollers
Composition/Operation
4688C508AA
8
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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)
DF-502
detection and document length detection.
A. Document Width Detection
The width of an original is detected by the combination of Paper Width Sensors as
detected while the original is being taken up.
Each sensor is located as follows with reference to the Document Edge Guide in the rear.
Composition/Operation
Magnet
4688C509AA
9
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2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2007
DF-502
Composition/Operation
Blank Page
10
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
AD-504
AD-504
Outline
1. Product specifications ............................................................................................. 1
Composition/Operation
Outline
2. Duplex Unit (AD-504) .............................................................................................. 3
2.1 Composition.......................................................................................................... 3
2.2 Drive ..................................................................................................................... 4
2.3 Operation .............................................................................................................. 4
2.3.1 Switchback Operation ................................................................................... 4
Composition/Operation
2.3.2 2-sided Copying with a Single Sheet of Paper Resident in the Unit.............. 5
2.3.3 2-sided Copying with Two Sheets of Paper Resident in the Unit .................. 6
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Theory of Operation Ver. 1.0 Apr. 2007
AD-504
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications
Outline
1. Product specifications
AD-504
A. Type
Outline
B. Paper
Size A3, A4S/A4, A5S/A5, B4, B5S/B5, FLS, Ledger, Legal, Letter, InvoiceS/
Invoice
Type Plain paper (60 to 90 g/m2), recycled paper (60 to 90 g/m2)
Document alignment Center
C. Machine specifications
D. Operating environment
Conforms to the operating environment of the main body.
NOTE
These specifications are subject to change without notice.
1
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1. Product specifications Theory of Operation Ver. 1.0 Apr. 2007
AD-504
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Duplex Unit (AD-504)
Composition/Operation
2. Duplex Unit (AD-504)
AD-504
2.1 Composition
Composition/Operation
4532C516AA
4532C515AA
4532C503AA
3
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2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Drive
The Duplex Unit Transport Motor provides the drive for the Duplex Unit.
AD-504
Transport Roller 1
Transport Roll 1
Transport Roller 2
Transport Roll 2
Composition/Operation
4532C502AA
2.3 Operation
2.3.1 Switchback Operation
The paper printed on one side is switched back by the exit rollers on copier to transport it
into the duplex unit.
The switchback operation of transport rollers is carried out by the Switchback Motor.
4532C504AA
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Duplex Unit (AD-504)
2.3.2 2-sided Copying with a Single Sheet of Paper Resident in the Unit
A. Operation
AD-504
1. The first sheet of paper is taken up
and the image of page 2 of the origi-
nal is printed.
4532C505AA
Composition/Operation
4532C506AA
4532C507AA
4532C508AA
4532C509AA
5
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2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2007
2.3.3 2-sided Copying with Two Sheets of Paper Resident in the Unit
A. Operation
AD-504
4532C505AA
4532C511AA
4532C513AA
6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Duplex Unit (AD-504)
AD-504
image of page 6 of the original is
printed.
4532C514AA
Composition/Operation
7
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2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2007
AD-504
Composition/Operation
Blank Page
8
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
PF-502
PF-502
Outline
1. Product specification ............................................................................................... 1
Composition/Operation
Outline
2. Paper Feed Unit (PF-502) ....................................................................................... 3
2.1 Composition.......................................................................................................... 3
2.2 Drive ..................................................................................................................... 4
2.3 Operation .............................................................................................................. 5
2.3.1 Edge Guide and Trailing Edge Stop .............................................................. 5
Composition/Operation
2.3.2 Paper Lifting Plate......................................................................................... 5
2.3.3 Tray-in-Position Detection ............................................................................. 6
2.3.4 Paper Empty Detection ................................................................................. 6
2.3.5 Paper Size Detecting Mechanism ................................................................. 7
2.3.6 Paper Separating Mechanism....................................................................... 8
2.3.7 Paper Feed Control ....................................................................................... 8
2.3.8 Paper Feed Retry Control ............................................................................. 9
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Theory of Operation Ver. 1.0 Apr. 2007
PF-502
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification
Outline
1. Product specification
PF-502
A. Type
B. Paper
Outline
Recycled paper (60 to 90 g/m2)
Metric areas: A3, A4S, A4, A5, B4, B5S, and B5
Sizes Inch areas: Ledger (11 x 17), 11 x 14, Legal (8-1/2 x 14), LetterS (8-1/2 x 11S),
and Invoice (5-1/2 x 8-1/2)
C. Machine specifications
D. Operating environment
Conforms to the operating environment of the main body.
NOTE
These specifications are subject to change without notice.
1
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1. Product specification Theory of Operation Ver. 1.0 Apr. 2007
PF-502
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)
Composition/Operation
2. Paper Feed Unit (PF-502)
PF-502
2.1 Composition
Composition/Operation
4686C512AA
4686C502AA
Side Door
4686C501AA
3
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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Drive
Drive from the Main Motor (M1) is transmitted via a gear train to the paper feed mecha-
PF-502
4686C503AA
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)
2.3 Operation
2.3.1 Edge Guide and Trailing Edge Stop
PF-502
The Edge Guide and Trailing Edge Stop can be slid into any desired position.
Composition/Operation
4686C504AA
4686C505AA
5
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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007
6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)
PF-502
paper are detected and the copier CPU determines the paper size based on the combi-
nation of the two readings.
The width of the paper is detected when the lever that is operatively connected to the
Edge Guide activates or deactivates the Paper Size Detect switch.
The length of the paper is detected when the lever that is operatively connected to the
Trailing Edge Stop actuates or deactuates the switches on the Paper Size Detect Board.
Composition/Operation
Paper size detect switch (SW1)
4686C508AA
Trailing Edge Stop Edge Guide
7
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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007
the top sheet of paper to ride over the fingers and be fed out of the tray into the copier.
When there are only two sheets of left in the tray and if the friction force of the Paper Lift-
ing Plate is low, the bottom sheet of paper is taken up and fed into the copier with the top
sheet of paper. To prevent this situation from occurring, there is a Friction Plate provided
on top of the Paper Lifting Plate.
Before the Feed Roller contacts the paper, the Feed Roller holds the paper down so that
the paper remains stationary before its being taken up by the Feed Roller.
Feed Roller
Paper
Composition/Operation
Separator Finger
Roll
8
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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)
PF-502
second time to carry out a paper feed retry sequence if a sheet of paper fails to reach the
Registration sensor (for the 2nd Tray) or the Paper feed sensor (for the 3rd to 5th Tray)
within a given period of time after a paper feed sequence has been initiated. This
sequence is repeated a predetermined number of times.
Composition/Operation
4686C511AA
9
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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007
PF-502
Composition/Operation
Blank Page
10
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
MB-501
MB-501
Outline
1. Product specification ............................................................................................... 1
Composition/Operation
Outline
2. Multiple Bypass (MB-501) ....................................................................................... 3
2.1 Composition.......................................................................................................... 3
2.2 Drive ..................................................................................................................... 4
2.3 Operation .............................................................................................................. 5
2.3.1 Paper Feed Mechanism ................................................................................ 5
Composition/Operation
2.3.2 Paper Empty Detection Mechanism.............................................................. 6
2.3.3 Paper Feed Control ....................................................................................... 6
2.3.4 Paper Feed Retry Control ............................................................................. 7
i
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Theory of Operation Ver. 1.0 Apr. 2007
MB-501
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification
Outline
1. Product specification
MB-501
A. Type
B. Paper
Outline
OHP film
Thick paper (91 to 157 g/m2) 20 sheets
Type
Postcards and labels
Envelopes 10 sheets
Recycled paper (60 to 90 g/m ) 2 100 sheets
Width 90 X 297 mm
Size
Length 140 X 432 mm
A3, A4S, A4, A5, A5S, B4, B5S, B5, FLS, Ledger, 11 x 14, Legal, LetterS, Letter,
Sizes
InvoiceS, Invoice, 8K, 16KS, and 16K
C. Machine specifications
Registration Center
Capacity 100 sheets (80 g/m2)
Power requirements DC24 V, DC5 V (supplied from the copier)
Power consumption 9 W or less
439 mm (W) x 435 mm (D) x 137 mm (H)
Dimensions
17.25 inch (W) x 17.25 inch (D) x 5.5 inch (H)
Mass 3.1 kg (6.75 lb)
D. Operating environment
Conforms to the operating environment of the main body.
NOTE
These specifications are subject to change without notice.
1
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1. Product specification Theory of Operation Ver. 1.0 Apr. 2007
MB-501
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Multiple Bypass (MB-501)
Composition/Operation
2. Multiple Bypass (MB-501)
MB-501
2.1 Composition
Composition/Operation
4687C509AA
4687C502AA
Feed Roller
Paper feed
solenoid (SD1)
3
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2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Drive
Drive for bypass paper feed is provided by the Main Motor (M1).
MB-501
Feed Roller
Composition/Operation
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Multiple Bypass (MB-501)
2.3 Operation
2.3.1 Paper Feed Mechanism
MB-501
The Paper Lifting Plate is raised to press the paper stack on the tray up against the Feed
Roller.
The Paper Lifting Plate is raised and lowered in time with a paper feed sequence.
The ascent and descent motion of the Paper Lifting Plate is accomplished when the drive
from the motor is transmitted to the cam through a solenoid to rotate the cam.
Feed Roller
Composition/Operation
Cam
4687C504AA
<Ascent/Descent Motion>
Main Motor (M1) is energized.
Feed Roller is turned.
Feed Roller
Paper
Cam: Rotates
Tray: Raised
Paper take-up
Cam: Rotates
Tray: Lowered
4687C505AA
Paper feed solenoid (SD1): Deenergized
5
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2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2007
Paper
4687C506AA
Composition/Operation
4687E507AA
6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Multiple Bypass (MB-501)
MB-501
halted if the paper fails to reach the Registration Roller Sensor within a given period of
time after the sequence has been started. The paper feed sequence is then performed
again. These paper feed sequences are repeated a given number of times.
Composition/Operation
7
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2. Multiple Bypass (MB-501) Theory of Operation Ver. 1.0 Apr. 2007
MB-501
Composition/Operation
Blank Page
8
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
JS-503
JS-503
Outline
1. Product specification ............................................................................................... 1
Composition/Operation
Outline
2. Job Separator (JS-503) ........................................................................................... 3
2.1 Construction ......................................................................................................... 3
2.2 Operation .............................................................................................................. 4
2.2.1 Tray Selecting Mechanism ............................................................................ 5
2.2.2 Tray-Full Detecting Mechanism..................................................................... 6
Composition/Operation
2.2.3 Job Tray Paper Detecting Mechanism........................................................... 6
i
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Theory of Operation Ver. 1.0 Apr. 2007
JS-503
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification
Outline
1. Product specification
JS-503
A. Type
B. Paper
Outline
Upper drawer Lower drawer
100 sheets (A4S),
150 sheets (A4S),
Plain paper (60 to 90 g/m2) 50 sheets (other than A4S)
75 sheets (other than A4S)
Load height up to 22 mm
OHP film
Thick paper (91 to 157 g/m2)
10 sheets 20 sheets
Postcards, labels, and enve-
lopes
100 sheets (A4S),
150 sheets (A4S),
Recycled paper (60 to 90 g/m2) 50 sheets (other than A4S)
75 sheets (other than A4S)
Load height up to 22 mm
C. Machine specifications
D. Operating environment
Conforms to the operating environment of the main body.
NOTE
These specifications are subject to change without notice.
1
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1. Product specification Theory of Operation Ver. 1.0 Apr. 2007
JS-503
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. Job Separator (JS-503)
Composition/Operation
2. Job Separator (JS-503)
JS-503
2.1 Construction
Composition/Operation
4689C507AA
4689C501AA
Job Tray
Paper detecting
board (PSDB)
3
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2. Job Separator (JS-503) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Operation
The Main Motor (M1) provides drive for the Job Separator.
JS-503
Job Tray
Composition/Operation
4689C502AA
4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Job Separator (JS-503)
JS-503
is selected according to the operating mode (either the fax, copier, or printer mode).
The Exit Tray of the copier is for the copier. The Job Tray is, on the other hand, for the fax
and printer.
The corresponding tray is selected through the operation of the motor and sensor as
shown below.
Composition/Operation
4021M046AB
Paper 4689C503AA
Paper
Job Tray
4689C504AA
5
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2. Job Separator (JS-503) Theory of Operation Ver. 1.0 Apr. 2007
A tray-full condition is detected when the sensor is blocked for a continuous given period
of time (approx. 20 sec.).
Job Tray
Exit Roller
Composition/Operation
4689C505AA
Job Tray
4689C506AA
6
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SERVICE MANUAL THEORY OF OPERATION
2007.04
Ver. 1.0
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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.
Revision mark:
To indicate clearly a section revised, show 1 to the left of the revised section.
A number within 1 represents the number of times the revision has been made.
To indicate clearly a section revised, show 1 in the lower outside section of the correspond-
ing page.
A number within 1 represents the number of times the revision has been made.
NOTE
Revision marks shown in a page are restricted only to the latest ones with the old ones deleted.
When a page revised in Ver. 2.0 has been changed in Ver. 3.0:
The revision marks for Ver. 3.0 only are shown with those for Ver. 2.0 deleted.
When a page revised in Ver. 2.0 has not been changed in Ver. 3.0:
The revision marks for Ver. 2.0 are left as they are.
CONTENTS
SF-501
SF-501
Outline
1. Product specifications ............................................................................................. 1
Composition/Operation
Outline
2. SHIFTING UNIT (SF-501) ....................................................................................... 3
2.1 Composition.......................................................................................................... 3
2.2 Operation .............................................................................................................. 4
2.2.1 Exit Position Shifting Mechanism .................................................................. 4
Composition/Operation
i
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Theory of Operation Ver. 1.0 Apr. 2007
SF-501
Outline
Composition/Operation
Blank Page
ii
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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications
Outline
1. Product specifications
SF-501
A. Machine specifications
Shifting amount 28 mm
Paper capacity 250 sheets
Power consumption Less than 63 W
B. Operating environment
Outline
Conforms to the operating environment of the main body.
NOTE
These specifications are subject to change without notice.
1
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1. Product specifications Theory of Operation Ver. 1.0 Apr. 2007
SF-501
Outline
Blank Page
2
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Theory of Operation Ver. 1.0 Apr. 2007 2. SHIFTING UNIT (SF-501)
Composition/Operation
2. SHIFTING UNIT (SF-501)
SF-501
2.1 Composition
Composition/Operation
4690C505AA
4690C502AA
4690C501AA
3
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2. SHIFTING UNIT (SF-501) Theory of Operation Ver. 1.0 Apr. 2007
2.2 Operation
2.2.1 Exit Position Shifting Mechanism
SF-501
Paper is fed into the Shifting Unit along a straight path or shifted from the reference
straight path position. This exit position shifting mechanism allows different finishing
functions offered by the machine (Non-Sort, Sort, and Group) to be effected.
<Straight Feeding>
The paper that travels along a straight path is fed straight into the Shifting Unit without
being shifted sideways as the Exit Roller turns.
Exit Roller
Paper
Composition/Operation
4690C503AA
<Shifted Feeding>
When the trailing edge of the paper transported to the exit section moves past the Fusing
Roller, the Shift Motor is energized to move the Transport Roller sideways.
The paper is fed into the Shifting Unit as it is shifted sideways.
The Exit Roller is moved sideways by turning the motor forward or backward.
The Exit Roller is detected at its home position by a sensor.
Exit Roller
4690C504AA
4
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2007.04 Ver.1.0