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SERVICE MANUAL THEORY OF OPERATION

2007.04
Ver. 1.0
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THEORY OF OPERATION TOTAL CONTENTS

SAFETY AND IMPORTANT WARNING ITEMS ..............................................................S-1


IMPORTANT NOTICE ................................................................................................S-1
DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION .........................S-1
SAFETY WARNINGS .................................................................................................S-2
WARNING INDICATIONS ON THE MACHINE ........................................................S-18
MEASURES TO TAKE IN CASE OF AN ACCIDENT ....................................................S-19
Composition of the service manual ................................................................................. C-1
Notation of the service manual ....................................................................................... C-2

bizhub 163/211/220 main body


Outline ............................................................................................................................ 1
Composition/Operation ................................................................................................. 11

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

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Composition/Operation ................................................................................................... 3

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SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS


Read carefully the safety and important warning items described below to understand them
before doing service work.

IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this product as well as
the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
(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.

DESCRIPTION ITEMS FOR DANGER,


WARNING AND CAUTION
In this Service Manual, each of three expressions DANGER, WARNING, and
CAUTION is defined as follows together with a symbol mark to be used in a limited
meaning.
When servicing the product, the relevant works (disassembling, reassembling, adjustment,
repair, maintenance, etc.) need to be conducted with utmost care.

DANGER: Action having a high possibility of suffering death or serious injury

WARNING: Action having a possibility of suffering death or serious injury

CAUTION: Action having a possibility of suffering a slight wound, medium


trouble, and property damage

Symbols used for safety and important warning items are defined as follows:

:Precaution when servicing the


product. General Electric hazard High temperature
precaution

:Prohibition when servicing the


product. General Do not touch Do not
prohibition with wet hand disassemble

:Direction when servicing the


product. General Unplug Ground/Earth
instruction

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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.

Using any fuse or thermostat not specified by KMBT.


Safety will not be assured, leading to a risk of fire and
injury.

Disabling fuse functions or bridging fuse terminals with


wire, metal clips, solder or similar object.

Disabling relay functions (such as wedging paper between


relay contacts)

Disabling safety functions (interlocks, safety circuits, etc.)


Safety will not be assured, leading to a risk of fire and
injury.

Making any modification to the product unless instructed


by KMBT

Using parts not specified by KMBT

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SAFETY AND IMPORTANT WARNING ITEMS

[2] POWER PLUG SELECTION


In some countries or areas, the power plug provided with the product may not fit wall outlet
used in the area. In that case, it is obligation of customer engineer (hereafter called the CE)
to attach appropriate power plug or power cord set in order to connect the product to the
supply.

Power Cord Set or Power Plug

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.

Conductors in the power cable must be connected to ter-


minals of the plug according to the following order:
Black or Brown:L (line)
White or Light Blue:N (neutral)
Green/Yellow:PE (earth)
Wrong connection may cancel safeguards within the
product, and results in fire or electric shock.

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SAFETY AND IMPORTANT WARNING ITEMS

[3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE


KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all
applicable safety standards are met, in order to protect the customer and customer engi-
neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical
equipment may be subject to parts wear and eventual failure. In order to maintain safety
and reliability, the CE must perform regular safety checks.

1. Power Supply

Connection to Power Supply

WARNING
Check that mains voltage is as specified.
Connection to wrong voltage supply may result in fire or
electric shock.

Connect power plug directly into wall outlet having same


configuration as the plug.
Use of an adapter leads to the product connecting to kw
inadequate power supply (voltage, current capacity,
grounding), and may result in fire or electric shock.
If proper wall outlet is not available, advice the customer
to contact qualified electrician for the installation.

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.

If two or more power cords can be plugged into the wall


outlet, the total load must not exceed the rating of the wall
outlet.
If excessive current flows in the wall outlet, fire may
result.

Make sure the power cord is plugged in the wall outlet


securely.
Contact problems may lead to increased resistance,
overheating, and the risk of fire.

Check whether the product is grounded properly.


If current leakage occurs in an ungrounded product, you
may suffer electric shock while operating the product.
Connect power plug to grounded wall outlet.

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SAFETY AND IMPORTANT WARNING ITEMS

Power Plug and Cord

WARNING
When using the power cord set (inlet type) that came with
this product, make sure the connector is securely inserted
in the inlet of the product.
When securing measure is provided, secure the cord with
the fixture properly.
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.

Check whether the power cord is not stepped on or


pinched by a table and so on.
Overheating may occur there, leading to a risk of fire.

Check whether the power cord is damaged. Check


whether the sheath is damaged.
If the power plug, cord, or sheath is damaged, replace
with a new power cord (with plug and connector on each
end) specified by KMBT. Using the damaged power cord
may result in fire or electric shock.

Do not bundle or tie the power cord.


Overheating may occur there, leading to a risk of fire.

Check whether dust is collected around the power plug


and wall outlet.
Using the power plug and wall outlet without removing
dust may result in fire.

Do not insert the power plug into the wall outlet with a wet
hand.
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.

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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.

When an extension cord is required, use a specified one.


Current that can flow in the extension cord is limited, so
using a too long extension cord may result in fire.
Do not use an extension cable reel with the cable taken
up. Fire may result.

2. Installation Requirements

Prohibited Installation Places

WARNING
Do not place the product near flammable materials or vola-
tile materials that may catch fire.
A risk of fire exists.

Do not place the product in a place exposed to water such


as rain.
A risk of fire and electric shock exists.

When not Using the Product for a long time

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.

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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.

Inspection before Servicing

CAUTION
Before conducting an inspection, read all relevant docu-
mentation (service manual, technical notices, etc.) and
proceed with the inspection following the prescribed pro-
cedure in safety clothes, using only the prescribed tools.
Do not make any adjustment not described in the docu-
mentation.
If the prescribed procedure or tool is not used, the prod-
uct may break and a risk of injury or fire exists.

Before conducting an inspection, be sure to disconnect


the power plugs from the product and options.
When the power plug is inserted in the wall outlet, some
units are still powered even if the POWER switch is
turned OFF. A risk of electric shock exists.
The area around the fixing unit is hot.
You may get burnt.

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SAFETY AND IMPORTANT WARNING ITEMS

Work Performed with the Product Powered On

WARNING
Take every care when making adjustments or performing
an operation check with the product powered.
If you make adjustments or perform an operation check
with the external cover detached, you may touch live or
high-voltage parts or you may be caught in moving gears
or the timing belt, leading to a risk of injury.

Take every care when servicing with the external cover


detached.
High-voltage exists around the drum unit. A risk of elec-
tric shock exists.

Safety Checkpoints

WARNING
Check the exterior and frame for edges, burrs, and other
damage.
The user or CE may be injured.

Do not allow any metal parts such as clips, staples, and


screws to fall into the product.
They can short internal circuits and cause electric shock
or fire.

Check wiring for squeezing and any other damage.


Current can leak, leading to a risk of electric shock or
fire.

Carefully remove all toner remnants and dust from electri-


cal parts and electrode units such as a charging corona
unit.
Current can leak, leading to a risk of product trouble or
fire.

Check high-voltage cables and sheaths for any damage.


Current can leak, leading to a risk of electric shock or
fire.

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.

Before disassembling or adjusting the write unit (P/H unit)


incorporating a laser, make sure that the power cord has
been disconnected.
The laser light can enter your eye, leading to a risk of
loss of eyesight.

Do not remove the cover of the write unit. Do not supply


power with the write unit shifted from the specified mount-
ing position.
The laser light can enter your eye, leading to a risk of
loss of eyesight.

When replacing a lithium battery, replace it with a new lith-


ium battery specified in the Parts Guide Manual. Dispose
of the used lithium battery using the method specified by
local authority.
Improper replacement can cause explosion.

After replacing a part to which AC voltage is applied (e.g.,


optical lamp and fixing lamp), be sure to check the installa-
tion state.
A risk of fire exists.

Check the interlock switch and actuator for loosening and


check whether the interlock functions properly.
If the interlock does not function, you may receive an
electric shock or be injured when you insert your hand in
the product (e.g., for clearing paper jam).

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.

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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.

Never throw the used cartridge and toner into fire.


You may be burned due to dust explosion.

Handling of Service Materials

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.

Do not replace the cover or turn the product ON before


any solvent remnants on the cleaned parts have fully
evaporated.
A risk of fire exists.

S-10
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SAFETY AND IMPORTANT WARNING ITEMS

Handling of Service Materials

CAUTION
Use only a small amount of cleaner at a time and take
care not to spill any liquid. If this happens, immediately
wipe it off.
A risk of fire exists.

When using any solvent, ventilate the room well.


Breathing large quantities of organic solvents can lead to
discomfort.

S-11
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SAFETY AND IMPORTANT WARNING ITEMS

[4] Used Batteries Precautions


ALL Areas
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type recommended by the manufacturer.
Dispose of used batteries according to the manufacturers instructions.

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

[5] Laser Safety


This is a digital machine certified as a Class 1 laser product. There is no possibility of
danger from a laser, provided the machine is serviced according to the instruction in this
manual.

5.1 Internal Laser Radiation

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

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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

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SAFETY AND IMPORTANT WARNING ITEMS

5.2 Laser Safety Label


A laser safety label is attached to the inside of the machine as shown below.

A09AP0E505DA

5.3 Laser Caution Label


A laser caution label is attached to the outside of the machine as shown below.

A09AP0C503DA

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SAFETY AND IMPORTANT WARNING ITEMS

5.4 PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT


When laser protective goggles are to be used, select ones with a lens conforming to the
above specifications.
When a disassembly job needs to be performed in the laser beam path, such as when
working around the printerhead and PC drum, be sure first to turn the printer OFF.
If the job requires that the printer be left ON, take off your watch and ring and wear laser
protective goggles.
A highly reflective tool can be dangerous if it is brought into the laser beam path. Use
utmost care when handling tools on the users premises.
The Print head is not to be disassembled or adjusted in the field. Replace the unit or
Assembly including the control board. Therefore, remove the laser diode, and do not per-
form control board trimmer adjustment.

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SAFETY AND IMPORTANT WARNING ITEMS

WARNING INDICATIONS ON THE MACHINE


Caution labels shown are attached in some areas on/in the machine.
When accessing these areas for maintenance, repair, or adjustment, special care should
be taken to avoid burns and electric shock.

High voltage

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.

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MEASURES TO TAKE IN CASE OF AN ACCIDENT

MEASURES TO TAKE IN CASE OF AN


ACCIDENT
1. If an accident has occurred, the distributor who has been notified first must immediately
take emergency measures to provide relief to affected persons and to prevent further
damage.
2. If a report of a serious accident has been received from a customer, an on-site evalua-
tion must be carried out quickly and KMBT must be notified.
3. To determine the cause of the accident, conditions and materials must be recorded
through direct on-site checks, in accordance with instructions issued by KMBT.
4. For reports and measures concerning serious accidents, follow the regulations speci-
fied by every distributor.

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MEASURES TO TAKE IN CASE OF AN ACCIDENT

Blank Page

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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.

<Theory of Operation section>

OUTLINE: Explanation of system configuration,


product specifications, unit configuration, and paper path
COMPOSITION/OPERATION: Explanation of configuration of each unit,
operating system, and control system

<Field Service section>

GENERAL: Explanation of system configuration, and product


specifications
MAINTENANCE: Explanation of service schedule, maintenance steps, ser-
vice tools, removal/reinstallation methods of major parts,
and firmware version up method etc.
ADJUSTMENT/SETTING: Explanation of utility mode, service mode, and mechanical
adjustment etc.
TROUBLESHOOTING: Explanation of lists of jam codes and error codes, and
their countermeasures etc.
APPENDIX: Parts layout drawings, connector layout drawings, timing
chart, overall layout drawing are attached.

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:

(1) bizhub 163/211/220: Main body


(2) Microsoft Windows 98: Windows 98
Microsoft Windows Me: Windows Me
Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT
Microsoft Windows 2000: Windows 2000
Microsoft Windows XP: Windows XP
When the description is made in combination of the OSs mentioned above:
Windows 98/Me
Windows NT 4.0/2000
Windows NT/2000/XP
Windows 98/Me/ NT/2000/XP

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>

Paper size Feeding direction Notation


Long edge feeding A4
A4
Short edge feeding A4S
A3 Short edge feeding A3

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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Theory of Operation Ver. 1.0 Apr. 2007

12.1 Composition ....................................................................................................... 29


bizhub 163/211/220

12.2 Drive ................................................................................................................... 29


12.3 Operation............................................................................................................ 30
12.3.1 Developing Roller........................................................................................ 30
12.3.2 Developing Bias .......................................................................................... 30
12.3.3 TCR Sensor ................................................................................................ 31
12.3.4 TCR Sensor Automatic Adjustment ............................................................ 31
13. Toner replenishing................................................................................................. 32
13.1 Composition ....................................................................................................... 32
Outline

13.2 Drive ................................................................................................................... 32


13.3 Operation............................................................................................................ 33
13.3.1 Toner Replenishing Mechanism.................................................................. 33
13.4 Toner Replenishing Control ................................................................................ 34
13.4.1 T/C Recovery Mode.................................................................................... 35
Composition/Operation

13.4.2 Toner Bottle Home Position Detection ........................................................ 36


14. Image transfer and paper separation section........................................................ 37
14.1 Composition ....................................................................................................... 37
14.2 Drive ................................................................................................................... 37
14.3 Operation............................................................................................................ 38
14.3.1 Image Transfer Section ............................................................................... 38
14.3.2 Paper Separation Section ........................................................................... 38
15. Toner recovery ...................................................................................................... 39
15.1 Composition ....................................................................................................... 39
15.2 Drive ................................................................................................................... 39
15.3 Operation............................................................................................................ 40
16. Paper feed............................................................................................................. 41
16.1 Composition ....................................................................................................... 41
16.2 Drive ................................................................................................................... 42
16.3 Operation............................................................................................................ 43
16.3.1 Paper Separating Mechanism..................................................................... 43
16.3.2 Drawer in Position Detection....................................................................... 43
16.3.3 Paper Empty Detection Mechanism............................................................ 44
16.3.4 Paper Lifting Plate....................................................................................... 44
16.3.5 Universal Tray Paper Size Detection Mechanism ....................................... 45
16.3.6 ON/OFF Positions of Paper Size Detecting Switches and
Corresponding Paper Size Detected .......................................................... 46
16.3.7 Paper feed Control...................................................................................... 47
16.3.8 Paper feed Retry Control ............................................................................ 47
17. Manual bypass section.......................................................................................... 48

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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

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Theory of Operation Ver. 1.0 Apr. 2007
bizhub 163/211/220
Outline
Composition/Operation

Blank Page

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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] bizhub 163/211/220 *1 [8] Paper feed unit (PF-502)


[2] Original cover (OC-504) *2 [9] Desk (DK-703)
[3] Automatic document feeder (DF-502) [10] Desk (DK-702)
[4] Reverse automatic document feeder [11] Desk (DK-701)
(DF-605) *3
[5] Shift tray (SF-501) [12] Job separator (JS-503)
[6] Automatic duplex unit (AD-504) *3 *5 [13] Key counter mount kit 1
(previous models for minolta.)
Key counter mount kit 2
(previous models for konica)
[7] Multi bypass tray (MB-501) *4 [14] Mechanical counter (MC-503)
*1: The standard bizhub 220 configuration is the main body plus 1-drawer paper feed unit.
*2: Standard only on the bizhub 163 and bizhub 211/220 for china
*3: To be mountable only on bizhub 211/220
*4: Standard only the main body for china (but separately packaged upon shipment from
factory)
*5: Standard only on bizhub 220 (but separately packaged upon shipment from factory)

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1. System configuration Theory of Operation Ver. 1.0 Apr. 2007

2/2 System rear view


bizhub 163/211/220

[4] [3] [1]

[2]
Outline

A08EE502AA

[1] Expanded memory unit (EM-103) [3] Image controller (IC-206) *


[2] Fax kit (FK-506) [4] Network interface card (NC-503) *
* It is not possible to mount these units at the same time.

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Theory of Operation Ver. 1.0 Apr. 2007 2. Product specification

2. Product specification

bizhub 163/211/220
A. Copier

Type Console/desktop type


Platen Stationary
Original scanning system CCD line sensor
Photoconductor Organic photoconductor
Copying system Electrostatic dry powdered image transfer to plain paper with a laser
Resolution 600 600 dpi
Paper feeding system Max. six-way system

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

Types of original Sheets, books, and three-dimensional objects


Max. original size A3 or 11 17
Multiple copies 1 to 99
15 sec. or less: bizhub 211/bizhub 220
30 sec. or less: bizhub 163
Warming-up time (when the auxiliary power switch is turned ON from a stabilized state, in which
the main power switch is ON and auxiliary power switch is OFF, with the rated
power source voltage and at a room temperature of 23C)
Leading edge: 4 mm (1/4 inch), trailing edge: 4 mm (1/4 inch),
Image loss
Rear edge: 4 mm (1/4 inch), front edge: 4 mm (1/4 inch)
Scan through glass: 7 sec. or less
First copy time ADF scan: 11 sec. or less
(A4, full size) (Values in conditions of paper fed from tray 1 at a room temperature of 23C
and with a rated power source)
Processing speed 93 mm/s
21 cpm or more (bizhub 211: metric areas)
Copying speed for 22 cpm or more (bizhub 220)
multi-copy cycle
(A4, 8-1/2 x 11) 20 cpm or more (bizhub 211: inch areas)
16 cpm or more (bizhub 163)
Full size x 1.00
Fixed zoom ratios
Reduction x 0.250, x 0.500. x 0.700, x 0.810
(Europe, china)
Enlargement x 1.150, x 1.410, x 2.000, x 4.000

Fixed zoom ratios Full size x 1.00


(Latin america areas Reduction x 0.250, x 0.500, x 0.640, x 0.780
for inch) Enlargement x 1.210, x 1.290, x 2.000, x 4.000

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2. Product specification Theory of Operation Ver. 1.0 Apr. 2007

Full size x 1.00


bizhub 163/211/220
Fixed zoom ratios
(Latin america area for Reduction x 0.250, x 0.500, x 0.700, x 0.780
metric) Enlargement x 1.150, x 1.410, x 2.000, x 4.000
Variable zoom ratios 0.250 to 4.000 in 0.001 increments
Tray 1 A3 to A5S, Letter, LedgerS, 11 x 14,
Paper size used
Manual bypass LegalS, Invoice, 8K, 16K, FLS
Plain paper/recycled paper 250 sheets
Special paper (thick paper, overhead
Paper capacity
projector transparencies, postcards, 20 sheets
(Tray 1)
label sheets)
Outline

Envelopes 10 sheets
Paper capacity Plain paper/recycled paper/special
1 sheets
(Manual bypass) paper

C. Paper

Tray1 Paper feed unit Manual bypass


Plain paper (60 to 90 g/m2) (250 sheets) *1
Transparencies (20 sheets) *1
Thick Paper (91 to 157 g/m2) (20 sheets) *1
Type
Postcards (20 sheets) *1
Labels (20 sheets) *1
Envelopes (10 sheets) *1
Width 90 to 297 mm *2 182 to 297 mm *2 90 to 297 mm *2
Size
Length 140 to 432 mm *2

*1: Capacity of manual bypass: 1 sheet


*2: If the width set 297 mm, the max. length is to 420 mm.
If the length set 432 mm, the max. width is to 279 mm.

D. Maintenance

300,000 prints or 5 years, whichever is earlier


Machine durability (bizhub 211/bizhub 220)
240,000 prints or 5 years, whichever is earlier (bizhub 163)

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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

Temperature 10 to 30C (with a fluctuation of 10C or less per hour)


Humidity 15 to 85% (with a fluctuation of 10%/h)

G. Built-in controllers

Printing Speed bizhub 211: 21 printed pages/min (A4, 300 dpi)


12 printed pages/min (A4, 600 dpi)
bizhub 163: 16 printed pages/min (A4, 300 dpi)
12 printed pages/min (A4, 600 dpi)
Memory Shared with the copier
Interface USB revision 2.0 compatible
Printer language GDI
Font Windows
Complying OS Windows XP (SP2 or later), Windows 2000 (SP4 or later), Windows ME,
Windows 98 SE

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2. Product specification Theory of Operation Ver. 1.0 Apr. 2007

2.1 Fax kit (FK-506): (Option)


bizhub 163/211/220

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.

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Theory of Operation Ver. 1.0 Apr. 2007 3. Cross sectional view

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

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4. Paper path Theory of Operation Ver. 1.0 Apr. 2007

4. Paper path
bizhub 163/211/220
Outline

4034G503BA

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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

[2] IR Image [14] Paper Exit


Processing

[3] PH Image [13] Fusing


Processing
[11] Cleaning

[12] Main Erase [4] PC Drum

Outline
[6] Laser Exposure
[5] Drum Charging [10] Paper Separation

[7] Developing [9] Image Transfer

[8] Paper Feed

A08EE568AA

A CCD sensor is used to convert the image data represented by light


Photoelectric
[1] reflected off the original to a corresponding electric signal which, in turn,
Conversion
is output to the IR image processing section.
The analog electric signal is converted to an 8-bit digital image
IR Image signal (A/D conversion) which, in turn, goes through appropriate
[2]
Processing corrections before being output to the PH image processing
section.
After going through corrections, the digital image signal is con-
PH Image
[3] verted to a corresponding electric signal (D/A conversion), with
Processing
which the laser is turned ON or OFF as necessary.
Made up of an aluminum pipe coated with a photoconductive
[4] PC Drum
layer, on which an electrostatic latent image is formed.
A uniform negative DC charge is deposited across the entire
[5] Drum Charging
surface of the PC Drum.
The laser beam strikes the surface of the PC Drum, forming an
[6] Laser Exposure
electrostatic latent image.
Toner negatively charged in the Developer Mixing Chamber is
attracted onto the electrostatic latent image changing it to a vis-
ible, developed image.
[7] Developing
A developing bias (Vb) is applied to the Developing Roller to
prevent toner from being attracted onto those areas of the PC
Drum which correspond to the background areas of the original.
[8] Paper Feed Paper is supplied from the paper feed tray.
A DC positive charge is applied to the Image Transfer Roller to
[9] Image Transfer transfer the visible image on the surface of the PC Drum onto
the paper.

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5. Copy process Theory of Operation Ver. 1.0 Apr. 2007

The PC Drum Paper Separator Fingers remove paper from the


bizhub 163/211/220

surface of the PC Drum.


[10] Paper Separation
The Charge Neutralizing Plate neutralizes any charge left on
the paper.
Residual toner on the surface of the PC Drum is scraped off.
[11] Cleaning
The toner is then recycled back to the Developing Unit.
The surface of the PC Drum is irradiated with light and any sur-
[12] Main Erase
face potential remaining there after cleaning is neutralized.
The developed image is permanently fused to the paper by the
[13] Fusing
combination of heat and pressure applied by the Fusing Roller.
Outline

The paper is fed out onto the Exit Tray.


The optional Job Separator (JS-503), when mounted on the
[14] Paper Exit
copier, allows a specific tray, in which paper is fed, to be
selected according to the operating mode.

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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)

Power unit cooling


fan motor (FM2)
A08EE569AA

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6. Overall configuration Theory of Operation Ver. 1.0 Apr. 2007

6.2 Control Block Diagram


bizhub 163/211/220

Operation
Panel IR CCD

MFP board (MFPB) Document related


option
EM-103
FAXB
NC-503 or
IC-206
Composition/Operation

NCUB

Paper Exit
Source Option
PH
Printer control board
High voltage unit
(PRCB)

Paper Source PU
Option

Process (Motor, Sensor, DC Power)

Control System Line

Image Bus Line


A08EC506AA

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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

Original size sensor 1 (PS101)


Original cover sensor Scanner motor (M5)
(PS8) CCD board (CCDB)

Scanner home
position sensor
(PS100)
Original
cover set
switch (S6)

Scanner
Assy

Exposure Lamp
2nd/3rd Mirrors Carriage
A08EC514AA

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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

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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

1. The Scanner generally stands by at the shading position.


When the Original Cover or ADF is raised to an angle of 15 or more, the Scanner
moves to the original size detection position.
2. When the Original Cover or ADF is raised to an angle of less than 15 with an orig-
inal placed on the Original Glass (when the Original Cover Sensor is activated), the
lamp turns ON and the original size is detected.
3. When the Size Reset Switch is turned ON with the Original Cover or ADF fully low-
ered, the Scanner moves to the shading position to carry out shading.
4. If the Start key is not immediately pressed, the lamp goes out after the lapse of 11
sec. after it has turned ON.
5. If the Start key is pressed immediately and the lamp remains ON, the Scanner
starts a scan motion immediately.
6. After the original has been scanned, the Scanner makes a return motion and its
home position is detected. Then, the Scanner moves to, and stops at, the home
position.

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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007

<Making copiers using DF-502>


bizhub 163/211/220
Composition/Operation

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.

7.3.2 Original Size Detection


Original Size Sensor 1 and the CCD mounted in the optical section are used to detect
the size of the original.

PS102 (Option)

PS101

A08EE570AA

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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)

7.3.3 Determination of Original Size

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.

(1) Size Detection (Standard)


<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 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.

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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007

<For Metric, China and Latin America (Metric) areas>


bizhub 163/211/220

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.

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Theory of Operation Ver. 1.0 Apr. 2007 7. Scanner (IR)

(2) Size Detection (When FLS/LEGAL Change is selected)

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.

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7. Scanner (IR) Theory of Operation Ver. 1.0 Apr. 2007

7.3.4 For Metric, China and Latin America (Metric) areas


bizhub 163/211/220

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)

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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
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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

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Theory of Operation Ver. 1.0 Apr. 2007 9. Imaging unit

9. Imaging unit

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9.1 Construction

A08EC581AA

Composition/Operation
A08EC509AA
Cleaning Blade

PC Drum
Paper Separa-
tor Fingers

PC Drum
PC Drum Charge
Corona

Developing Roller

3rd Toner Conveying Roller 1st Toner Conveying Roller


2nd Toner Conveying Roller A08EC517AA

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9. Imaging unit Theory of Operation Ver. 1.0 Apr. 2007

9.2 Operation
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The Main Motor provides drive for the PC Drum, Developing Roller, and other mechani-
cal components.

Main motor (M1)

Recycled Toner Conveying Screw

Developing Roller

Recycled Toner
Recycling Coil
Composition/Operation

2nd Toner Conveying Roller

A08EC562AA

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Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum

10. PC Drum

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10.1 Composition

A08EC582AA

Composition/Operation
A08EC509AA

10.2 Drive

A08EC563AA

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10. PC Drum Theory of Operation Ver. 1.0 Apr. 2007

10.3 Operation
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The PC Drum used in this copier is the organic photoconductor (OPC).


The drum is a lamination of the Charge Transport Layer and Charge Generating Layer
coating an aluminum alloy base.

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.

(PC Drum Cross-Section)

Charge Generation Layer


PC Drum Charge Transport Layer
Aluminum Base
Composition/Operation

A08EC527AA

26
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Theory of Operation Ver. 1.0 Apr. 2007 10. PC Drum

10.3.1 Grounding of the PC Drum

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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

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11. PC Drum charging Theory of Operation Ver. 1.0 Apr. 2007

11. PC Drum charging


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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

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Theory of Operation Ver. 1.0 Apr. 2007 12. Developing

12. Developing

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12.1 Composition

A08EC584AA

Composition/Operation
A08EC509AA

12.2 Drive

A08EC518AA

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12. Developing Theory of Operation Ver. 1.0 Apr. 2007

12.3 Operation
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12.3.1 Developing Roller


The Developing Roller consists of an outer sleeve roller and an inner magnet roller.
The roller conveys developer to the point of development.
The developer (carrier and toner) in the Developer Mixing Chamber is conveyed onto the
point of development by the Toner Conveying Rollers and the Developing Roller.

Toner/Carrier PC Drum

1st Toner Conveying Roller Point of Development

Toner
2nd Toner Conveying Roller
Carrier

Developing Roller
Composition/Operation

A08EC519AA

12.3.2 Developing Bias


Vb (-DC, AC) is applied to the Developing Roller.
Vb (-DC) is applied to prevent toner from sticking to the background of the image.
Vb (AC) is applied to enhance good separation of toner from carrier.
The amount of toner sticking to the surface of the PC Drum is varied according to the dif-
ference in potential between the voltage (Vi) on the surface of the PC Drum and
Vb (-DC).
Large difference = A greater amount of toner sticks.
Small difference = A smaller amount of toner sticks.

PC Drum

Developing Roller

Developing Bias
Terminal

A08EC520AA

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Theory of Operation Ver. 1.0 Apr. 2007 12. Developing

12.3.3 TCR Sensor

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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

TCR Sensor 1st Toner Conveying Roller


A08EC521AA

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 developer is mixed.

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.

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13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007

13. Toner replenishing


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13.1 Composition
Composition/Operation

A08EC585AA

A08EC510AA

13.2 Drive

A08EC564AA

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Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing

13.3 Operation

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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).

Coupling Toner Bottle

Composition/Operation
Metering
Chamber

A08ET2C522AA

Toner replenishing
motor (M2)

Toner Conveying Screw

Developer Mixing Chamber

A08EC561AA

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13. Toner replenishing Theory of Operation Ver. 1.0 Apr. 2007

13.4 Toner Replenishing Control


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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 %.

T/C ratio (%) B/W ratio toner replenishing


More than 14 not supplied
13.5 to 14 More than 2000 supplied
13 to 13.5 More than 1000 supplied
12.5 to 13 More than 500 supplied
12 to 12.5 More than 500 supplied
10 to 12 More than 0 supplied
Less than 7 Proceeds to the T/C recovery mode

The greater the value of B/W in the table, the higher the B/W ratio (high image density
Composition/Operation

original).

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Theory of Operation Ver. 1.0 Apr. 2007 13. Toner replenishing

13.4.1 T/C Recovery Mode

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The machine enters the T/C recover mode when a T/C of 10 % or less is detected.

Toner is replenished for 90 sec.

T/C is recovered by 1 % or more. T/C is not recovered by 1 % or more,


or T/C is less than 12 %.

Toner is replenished for 60 sec.

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 %.

Toner is replenished for 30 sec. to A toner-empty condition is detected.


complete the T/C recovery mode.

T/C is less than 8 %.

A toner-empty-stop condition results and the initiation of


any new copy cycle is prohibited.

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

13.4.2 Toner Bottle Home Position Detection


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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.

Toner Supply Port


Composition/Operation

Toner bottle home position


sensor (PS6)

A08EC530AA

36
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Theory of Operation Ver. 1.0 Apr. 2007 14. Image transfer and paper separation section

14. Image transfer and paper separation section

bizhub 163/211/220
14.1 Composition

A08EC591AA

Composition/Operation
A08EC511AA

14.2 Drive

A08EC565AA

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14. Image transfer and paper separation section Theory of Operation Ver. 1.0 Apr. 2007

14.3 Operation
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14.3.1 Image Transfer Section


A positive charge is applied to the Image Transfer Roller to transfer the toner image
formed on the surface of the PC Drum onto the paper.
The charge applied to the Image Transfer Roller is varied according to the following con-
ditions to ensure that image transfer efficiency is stabilized.
1. Paper Type: The amount of charge is made less for OHP film.
2. Paper width: The smaller the paper width, the greater the amount of charge.
3. B/W ratio of image: The lower the B/W ratio, the greater the amount of charge.
A negative charge is applied to the Image Transfer Roller to return toner sticking to the
Image Transfer Roller to the PC Drum. It is performed in the following timings:
(At the start and end of a copy cycle; when the Power Switch is turned ON; when a mis-
feed or malfunction is reset)

14.3.2 Paper Separation Section


Paper separation is accomplished through the curvature separation system that works
on the diameters of the PC Drum and the Image Transfer Roller.
Composition/Operation

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 Paper Separator Fingers

PC Drum

Charge Neutralizing Plate

Image Transfer Roller


A08EC531AA

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Theory of Operation Ver. 1.0 Apr. 2007 15. Toner recovery

15. Toner recovery

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15.1 Composition

Composition/Operation
A08EC585AA

A08EC509AA

15.2 Drive

A08EC567AA

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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

Spent Toner Conveying Screw 1

Spent Toner Conveying Screw 2

Spent Toner Recycling Coil

Spent Toner Recycling Duct

Cleaning Blade

Developer Mixing Chamber


A08EC532AA

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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed

16. Paper feed

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16.1 Composition

A08EC587AA

Composition/Operation
A08EC557AA Paper empty sensor/1 (PS4)
Paper size detect board (PSDTB) Feed Roller/1

Paper size sensor (S5)


Separation Roller/1

Paper Lifting Plate

A08EC533AA

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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007

16.2 Drive
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The Main Motor (M1) provides the drive for paper feed operations.
The drive is transmitted through the Paper feed solenoid/1.

Main motor (M1)

Paper feed solenoid/1 (SD1)

Feed Roller
Composition/Operation

A08EC534AA

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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed

16.3 Operation

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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.

When one sheet of paper is taken up:


The coefficient of friction on the front side of the sheet of paper taken up and fed through
the space between the Feed Roller and Separation Roller is the same as that on the back-
side of the sheet of paper, allowing the paper to be properly fed into the machine.

When two or more sheets of paper are taken up:


The coefficient of friction between the paper and the Separation Roller is greater than that
between the sheets of paper, which allows only the top sheet of paper to be fed into the
machine.

Feed Roller

Composition/Operation
Paper

Separation Roller

A08EC535AA

16.3.2 Drawer in Position Detection


When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor.
The copier then knows that the drawer has been slid in position.

Tray set sensor (PS5)

A08EC536AA

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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007

16.3.3 Paper Empty Detection Mechanism


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The Paper Empty Sensor detects a paper-empty condition in the drawer.

Paper empty sensor/1 (PS4)


Composition/Operation

A08EC537AA

16.3.4 Paper Lifting Plate


The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked
when the tray is slid into the unit.
The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.

Spring

Paper Lifting Plate

A08EC538AA

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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed

16.3.5 Universal Tray Paper Size Detection Mechanism

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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.

Paper size sensor (S5)


Paper size detect board (PSDTB)

1 2 3 4

Composition/Operation
A08EC539AA

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16. Paper feed Theory of Operation Ver. 1.0 Apr. 2007

16.3.6 ON/OFF Positions of Paper Size Detecting Switches and Corresponding


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Paper Size Detected


<For Metric>

Paper Size Detect Board (PSDTB)


Paper size sensor (S5) Paper Size
SW1 SW2 SW3 SW4
B4
ON Activated A3
ON ON A5 S
ON ON Activated A4
ON A5, postcards
ON ON ON A5 S
ON ON ON Activated A4
ON ON B5
ON ON ON A4 S
Composition/Operation

ON ON ON ON B5 S

<For Inch>

Paper Size Detect Board (PSDTB)


Paper size sensor (S5) Paper Size
SW1 SW2 SW3 SW4
B4, Legal

Activated B4, 1114
B5 S, Invoice S
ON
Activated A3, 1117
ON ON A5 S, Invoice S
ON ON Activated A4, Letter
ON A5, Invoice
ON ON ON A5 S, Invoice S
ON ON ON Activated A4, Letter
ON ON B5, Invoice
ON ON ON A4 S, Letter S
ON ON ON ON B5 S, Letter S

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Theory of Operation Ver. 1.0 Apr. 2007 16. Paper feed

16.3.7 Paper feed Control

bizhub 163/211/220
A08EE588AA

16.3.8 Paper feed Retry Control


To minimize the occurrence of a paper misfeed, the paper take-up sequence is tempo-

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.

No. of Paper Feed Retry Sequences


Paper Feed Retry 2

A08EE589AA

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17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007

17. Manual bypass section


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17.1 Composition

A08EC590AA
Composition/Operation

A08EC512AA

17.2 Drive

Main motor (M1)

Paper set sensor/bypass (PS2)

Paper feed solenoid/bypass (SD2)

A08EC566AA

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Theory of Operation Ver. 1.0 Apr. 2007 17. Manual bypass section

17.3 Operation

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Drive for bypass paper feed is provided by the Main Motor (M1).
The drive is transmitted through the Paper feed solenoid/bypass.

Main motor (M1)

Paper set sensor/bypass (PS2)

Composition/Operation
Paper feed solenoid/bypass (SD2)

A08EC542AA

17.3.1 Paper Detection Mechanism


The Sensor detects a sheet of paper on the Manual Bypass.

<When Paper is Present> <When Paper is not Present>

Paper set sensor/bypass (PS2)

Paper

A08EC543AA

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17. Manual bypass section Theory of Operation Ver. 1.0 Apr. 2007

17.3.2 Manual Feed Take Up Control


bizhub 163/211/220

A08EE573AA
Composition/Operation

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Theory of Operation Ver. 1.0 Apr. 2007 18. Registration roller section

18. Registration roller section

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18.1 Composition

A08EC586AA

Composition/Operation
A08EC558AA

18.2 Drive

Registration roller
clutch (CL1)

Registration roller

Registration sensor
(PS1)

Paper Dust Remover


A08EC545AA

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18. Registration roller section Theory of Operation Ver. 1.0 Apr. 2007

18.3 Operation
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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).

Main motor (M1)

Registration roller
clutch (CL1)
Composition/Operation

A08EC546AA

18.3.1 Paper Dust Remover


The Paper Dust Remover collects paper dust on the paper.

Paper Dust Remover

A08EC547AA

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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section

19. Fusing unit section

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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

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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007

19.2 Composition (for bizhub 211/220)


bizhub 163/211/220

Sub Heater Lamp) Heater Lamp

Fusing Roller/rt

Fusing Roller

Thermostat
Pressure Lever
Composition/Operation

A08EE571AA

Thermistor (TH1)
Thermistor (TH2)

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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section

19.3 Drive

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The main motor (M1) provides the drive for the fusing unit.

Main motor (M1)

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

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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007

19.4.2 Fusing Temperature Control (for bizhub 163)


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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.

<Temperature Control in Standby State>

Warm-up completed
Composition/Operation

A08EE574AA

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3


Standby 180 C 180 C 170 C 170 C
Plain paper (width: 250 mm or more;
190 C 190 C 170 C 170 C
length: less than 360 mm)
Plain paper (width: less than 250 mm) 180C 180 C 165 C 165 C
Thick paper (width: 250 mm or more) 210 C 210 C 190 C 190 C
Thick paper (width: less than 250 mm) 200 C 200 C 190 C 190 C
OHP film (width: 250 mm or more) 180 C 180 C 165 C 165 C
OHP film (width: less than 250 mm) 155 C 155 C 155 C

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Theory of Operation Ver. 1.0 Apr. 2007 19. Fusing unit section

19.4.3 Fusing Temperature Control (for bizhub 211/220)

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.

<Temperature Control in Standby State>

Warm-up completed

Composition/Operation
A08EE576AA

Machine Condition or Paper Type Mode 1 Mode 2 Mode 3


Standby 180 C 180 C 165 C 165 C
Plain paper (width: 221 mm or more) 180 C 180 C 180 C
Plain paper (width: 220 mm or less) 180 C 180 C 180 C
Thick paper (width: 201 mm or more) 200 C 200 C 200 C
Thick paper (width: 200 mm or less) 200 C 200 C 200 C
OHP film (width: 201 mm or more) 165 C 165 C 165 C
OHP film (width: 200 mm or less) 165 C 165 C 165 C

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19. Fusing unit section Theory of Operation Ver. 1.0 Apr. 2007

19.4.4 PPM Control (bizhub 163 Only)


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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

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Theory of Operation Ver. 1.0 Apr. 2007 20. Paper exit (for bizhub 163)

20. Paper exit (for bizhub 163)

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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

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21. Paper exit (for bizhub 210/220) Theory of Operation Ver. 1.0 Apr. 2007

21. Paper exit (for bizhub 210/220)


bizhub 163/211/220

21.1 Construction
Composition/Operation

A08EC593AA

A08EC560AA

21.2 Operation
The exit rollers are driven by the switchback motor (M3).

Exit Roller

Switchback motor (M3)


A08EE575AA

60
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Theory of Operation Ver. 1.0 Apr. 2007 22. Image stabilization system

22. Image stabilization system

bizhub 163/211/220
22.1 Composition
The following image stabilization controls are provided to ensure stabilized copy image.

Purpose Means Control


The Vg/Vb control voltage is varied to bring Vg/Vb
to an appropriate level according to the following
settings.
To stabilize image Grid voltage (Vg) and devel- Tech. Rep. Choice: ID Adjustment
density. oping bias (Vb) control Tech. Rep. Choice: VG Adjustment
User's Choice: Print Density
SUPPLIES LIFE COUNT.
Paper type
The image transfer output is varied to bring the
image transfer current to an appropriate level
To stabilize image Image transfer output con- according to the following conditions.
transfer. trol Paper type

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

23.1 Fan Control


23.1.1 Composition
Composition/Operation

Power unit cooling fan motor (FM2)


A08EC555AA

Fusing cooling fan motor (FM1)

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

Motor Name Control Conditions


A fan motor draws air from the area around the Fusing Unit to the out-
side to prevent the machine interior temperature from running high. In
addition, the fan motor pulls paper being transported up through suc-
tion force to help stabilize paper transport.
Fusing cooling
Ozone produced from the PC Drum Charge Corona is absorbed by
fan motor (FM1)
the Ozone Filter from the air drawn by a fan motor to the outside.
The fan motor is turned at full speed during a print cycle and at a
speed reduction during other timings, thereby making the machine
quieter without sacrificing cooling performance.
A cooling fan motor draws air from the area around the Power Supply
Unit to the outside to prevent the Power Supply Unit temperature from
Power unit cooling running high.
fan motor (FM2) The cooling fan motor is turned at full speed when the Main Motor

Composition/Operation
turns and at a speed reduction during other timings, thereby making
the machine quieter without sacrificing cooling performance.

B. Fan control

Motor Name Control Control Conditions


During a print cycle (full speed rotation after the lapse
Full speed of a given period of time after the start of the print
cycle)
Half speed rotation after the lapse of a given period of
Fusing cooling
time after the end of the print cycle
fan motor (FM1) Half speed
Half speed rotation at any timing other than the full
speed and stop control
When a malfunction occurs
Stop
When the right door is open
Full speed When power is turned ON or Sleep is canceled
Power unit cooling Half speed rotation if the main motor (M1) is deener-
fan motor (FM2) Stop gized after the lapse of a given period of time after the
full speed rotation

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23. Others Theory of Operation Ver. 1.0 Apr. 2007
bizhub 163/211/220
Composition/Operation

Blank Page

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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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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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

Name Reverse automatic document feeder


Paper feed Paper feed from top of stack
Type Turnover Switch back system
Paper exit Straight exit system
Installation Screw cramp to the main unit

Outline
Document alignment Center
Document loading Left image side up

B. Functions

Modes 1-sided mode / 2-sided mode

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

D. Paper feed prohibited originals


If fed, trouble occurrence will be highly possible.
DF-605/MK-501

Type of original Possible trouble


Feed failure, damage to the original, or drive
Original that is stapled or clipped.
failure due to clip clogging
Feed failure, damage to the original, or drive
Book original
failure
Original weighing less than 35g/m2 or
Feed failure
129g/m2 or more
Torn original Feed failure, damaged sheet
Outline

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

E. Paper feed not guaranteed originals


If fed, paper feed will be possible to some extent but trouble occurrence will be possible.

Type of original Possible trouble


Sheets lightly curled (Curled amount: 10 - 15 mm) Dog-eared, exit failure
Heat sensitive paper Edge folded, exit failure, transport failure
Coated paper (Ink Jet paper) Take-up failure, transport failure
Translucent paper Take-up failure, transport failure
Paper immediately after paper exit from the main unit Take-up failure, transport failure
Paper with many punched holes (e.g., loose leaf) limited
Multi-page feed due to flashes from holes
to vertical feeding
Sheets with 2 to 4 holes Transport failure
Sheets two-folded or Z-folded Transport failure, image deformation
Sheets with rough surface (e.g., letterhead) Take-up failure
Image deformation, multi-page feed, take-up
Sheets folded
failure

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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications

F. Mixed original feed chart


For Metric

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

Mixed original feed available


OK
(Tilted with in 1.5% or less)
NG NO. mixed original feed
- Can not set original
* Tilted with in 2% or less is 80%

G. Machine specifications

DC 24 V (supplied from the main unit)


Power Requirements DC 5 V (generated within the Automatic Document Feeder)
DC 3.3 V (supplied from the main unit)
Max. Power Con-
48 W or less
sumption
582 (W) x 558 (D) x 145 (H) mm
Dimensions
23 inch (W) x 20.5 inch (D) x 5.75 inch (H)
Weight 10 kg (22 lb) or less

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

2. Paper Feed Path


DF-605/MK-501

2.1 In 1-sided mode


Outline

3: Exit

2: Transport and turnover

1: Feed (scanning the 1st side)

4344T1C501AA

2.2 In 2-sided mode

2: Transport and switchback


6: Exit

4: Transport and switchback

1: Feed (scanning the 1st side)


3: Transport and turnover (scanning the 2nd side)
5: Transport

4344T1C502AA

4
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Theory of Operation Ver. 1.0 Apr. 2007 3. Composition

Composition/Operation

DF-605/MK-501
3. Composition

Document feed section

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

Paper feed motor (M1-ADF)

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.

5.1.1 Pick-up operation


When the Start key is pressed, the Paper Feed Motor starts turning backward, causing
the Pick-Up Roller to lower and start turning at the same time. At the same time, the
Feed Roller starts turning.
The Pick-Up Rollers are in the raised position when in the standby state and in the low-
ered position during feeding.

Paper feed motor (M1-ADF)


Pick-Up Roller

Composition/Operation
Feed Roller Separation
Roller

4344T2C503AA

7
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5. Operation Theory of Operation Ver. 1.0 Apr. 2007

5.2 Document feed/transport mechanism


DF-605/MK-501

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

Paper feed motor (M1-DF)


Transport motor (M2-DF)

Exit/Turnover Roller

Registration Roller

Transport Roller

4344T2C504AA

8
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Theory of Operation Ver. 1.0 Apr. 2007 5. Operation

A. Operation flow in the 1-sided mode

DF-605/MK-501
Original Detection Sensor

Exit

Scanning the 1st side Exit/Turnover Sensor

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

B. Operation flow in the 2-sided mode


1. When the Start key is pressed, the Paper Feed Motor starts turning backward,
DF-605/MK-501

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.

Original Detection Sensor

Stop
Composition/Operation

Scanning the 1st side Exit/Turnover Sensor

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

Scanning the 2nd side

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

Scanning the 2nd side

4344T2C505AA

Composition/Operation

11
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5. Operation Theory of Operation Ver. 1.0 Apr. 2007

5.3 Raised/lowered position detecting mechanism


DF-605/MK-501

5.3.1 Document size detection


The 15 degree Open Detection Mechanism enables the main unit to detect the document
size when the DF is used as the Original Cover of the main unit, there is the Lever Actu-
ator provided in the DF body that blocks or unblocks a sensor to initiate a reconfirmation
of the original size as read by the original size detection sensors.

5.3.2 Raised/lowered position detection


The Raised/Lowered Position Detection Mechanism uses a magnet installed in the DF
body to allow the main unit to know that the DF is raised or lowered. This magnet actu-
ates the Original cover set switch on the main unit to perform this operation.
Composition/Operation

Original cover set switch (S6) 4344T2C508AA

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

Name Automatic document feeder


Installation Inserted in top portion of the copier
Modes Standard = 1-sided original
Mixed original = 1-sided original
Document loading Left-hand side, face up

Outline
B. Paper

Standard Mixed original


Type Plain paper (50 to 110 g/m ) 2 Plain paper (60 to 90 g/m2)
A3, A4S, A4, A5S, B4, B5S, B5, A3 and A4, B4 and B5, 11 x 17 and
Sizes 11 x 17, 11 x 14, Legal, LetterS, Letter, Letter, Legal and LetterS, Legal and
InvoiceS, and Invoice Invoice, LetterS and Invoice

C. Paper feed prohibited originals

Type of original Possible problems


Take-up failure, damaged sheet, defective drive
Sheets stapled or clipped together
mechanism due to jammed staples or clips
Sheets glued together Take-up failure, damaged sheet
Sheets folded, torn, or wrinkled Take-up failure, damaged sheet
Sheet misfed due to its being dog-eared or fed in
Sheets severely curled
askew

D. Machine specifications

Document alignment Center


Capacity 50 sheets max. (80 g/m2)
Power requirements DC24 V, DC5 V (supplied from the copier)
Power consumption 36 W or less
Dimensions 598 mm (W) x 483 mm (D) x 102 mm (H)
Mass 6.3 kg

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

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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.

Paper feed clutch (CL1) Main motor (M1)

Composition/Operation
Pick-Up Roller

Paper empty sensor (PS2)

4688C504AA

Feed Roller
Document Stoppers

5
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2. Automatic Document Feeder (DF-502) Theory of Operation Ver. 1.0 Apr. 2007

2.3.2 Document Transport


The document taken up is transported to the document scanning position of the copier
DF-502

by the Registration Rollers.


The Registration Rollers are turned by a gear train and belts which are driven by the
Main Motor.

Main motor (M1)


Composition/Operation

Registration Rollers

4688C506AA

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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)

2.3.3 Document Separating Mechanism


The coefficient of friction between the Feed Roller and Separation Roller is effectively

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

2.3.4 Document Exit Mechanism


The document is fed out of the ADF by the Exit Roller.
DF-502

The Exit Roller is driven by gears and a belt which are driven by the Main Motor.

Main motor (M1)

Exit Rollers
Composition/Operation

4688C508AA

8
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Theory of Operation Ver. 1.0 Apr. 2007 2. Automatic Document Feeder (DF-502)

2.3.5 Document Size Detection Mechanism


The document size is determined by means of two different systems of document width

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.

B. Document Length Detection


The length of the original is detected by the Paper Length Sensor when the document is
loaded in the unit.
The Paper Length Sensor is located at the Document Loading Tray.

2.3.6 Raised/Lowered Position Detection Mechanism


There is a magnet installed in the ADF body to allow the copier to know that the ADF is
raised or lowered.
This magnet actuates the Original cover set switch on the copier.

Composition/Operation
Magnet

Original cover set switch (S6)

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specifications

Outline
1. Product specifications

AD-504
A. Type

Name Automatic duplex unit


Type Sheet duplex paper take-up section
Installation Installed to the right side door
Power requirements DC24 V (supplied from the copier)
DC5 V

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

Max. power consumption 9 W or less


Dimensions 412 mm (W) x 215 mm (D) x 88 mm (H)
16.25 inch (W) x 8.5 inch (D) x 3.5 inch (H)
Mass 2.5 kg (Duplex unit + Manual bypass assy
Operating environment Conforms to that of the copier

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

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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

Transport motor (M1)

AD drive board (ADDB)

Transport sensor (PS2)

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

2. Immediately before the first sheet of


paper leaves the Paper Exit Roller,
the direction of rotation of the Paper
Exit Roller is reversed and the first
sheet of paper is transported toward
and into the Duplex Unit.

Composition/Operation
4532C506AA

3. The paper moving through the


Duplex Unit is directly subjected to
the second print cycle without being
stopped.

4532C507AA

4. The image of page 1 of the original is


printed on the other side of the first
sheet of paper.

4532C508AA

5. While the first sheet of paper is being


fed out of the copier, the image of
page 4 of the original is printed on
one side of the second sheet of
paper.

4532C509AA

6. Steps 2 through 5 are repeated.

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

1. The first sheet of paper is taken up


and the image of page 2 of the origi-
nal is printed.

4532C505AA

2. Immediately before the first sheet of


paper leaves the Paper Exit Roller,
the direction of rotation of the Paper
Exit Roller is reversed and the first
sheet of paper is transported toward
and into the Duplex Unit.
Composition/Operation

3. At the same time, the second sheet


4532C510AA
of paper is taken up and fed in.

4. The image of page 4 of the original is


printed on one side of the second
sheet of paper.
5. At the same time, the first sheet of
paper is transported through the
Duplex Unit.

4532C511AA

6. The image of page 1 of the original is


printed on the other side of the first
sheet of paper that has been fed into
the copier again.
7. At the same time, the second sheet
of paper is subjected to a switchback
sequence at the exit section.
4532C512AA
8. It is then fed through the Duplex Unit
without.

9. While the first sheet of paper is being


fed out of the copier, the image of
page 4 of the original is printed on
one side of the second sheet of
paper.

4532C513AA

6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Duplex Unit (AD-504)

10. While the second sheet of paper is


being fed out of the copier, the third
sheet of paper is taken up and the

AD-504
image of page 6 of the original is
printed.

4532C514AA

11. Steps 2 through 10 are repeated.

Composition/Operation

7
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2. Duplex Unit (AD-504) Theory of Operation Ver. 1.0 Apr. 2007
AD-504
Composition/Operation

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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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification

Outline
1. Product specification

PF-502
A. Type

Name Add-on paper feed unit


Installation Installed on the underside of the copier

B. Paper

Plain paper (60 to 90 g/m2)


Type 250 sheets

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

Paper alignment Center


Capacity 250 sheets
Power requirements DC24 V, DC5 V (supplied from the copier)
Power consumption 9 W or less
590 mm (W) x 558 mm (D) x 108 mm (H)
Dimensions
23.25 inch (W) x 22 inch (D) x 4.25 inch (H)
Weight 5.5 kg (12.25 lb)

D. Operating environment
Conforms to the operating environment of the main body.

NOTE
These specifications are subject to change without notice.

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1. Product specification Theory of Operation Ver. 1.0 Apr. 2007
PF-502
Outline

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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

Trailing Edge Stop

Side Door

Edge Guide Paper Lifting Plate

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

nism for the Paper Feed Unit.

Vertical Transport Roller

Paper Feed Drive


Mechanism
Feed Roller
Composition/Operation

4686C503AA

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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.

Trailing Edge Stop Edge Guide

Composition/Operation
4686C504AA

2.3.2 Paper Lifting Plate


The Paper Lifting Plate is locked into position when it is pressed down. It is unlocked
when the tray is slid into the unit.
The Paper Lifting Plate is pushed upward by the Paper Lifting Springs at all times.

Paper Lifting Spring

Paper Lifting Plate

4686C505AA

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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007

2.3.3 Tray-in-Position Detection


When a tray is slid into the cabinet, the Tray Set Sensor is blocked and the copier deter-
mines that the tray has been slid in position.
PF-502

Light Blocking Plate


Composition/Operation

Tray set sensor (PS3)


4686C506AA

2.3.4 Paper Empty Detection


The Paper Empty Sensor detects a paper-empty condition in the tray.

Paper empty sensor (PS1)


4686C507AA

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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)

2.3.5 Paper Size Detecting Mechanism


Both the width (in the crosswise direction) and length (in the feeding direction) of the

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.

Paper size detect board (PSDTB)

SW4 SW3 SW2 SW1

Composition/Operation
Paper size detect switch (SW1)

4686C508AA
Trailing Edge Stop Edge Guide

Paper size detect board (PSDTB)


Paper Size Paper size detect switch (SW1)
SW4 SW3 SW2 SW1
A3 ON ON
B4
A4 S ON ON ON
A4 ON ON ON
B5 S ON ON ON ON
B5 ON ON
A5 ON

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2. Paper Feed Unit (PF-502) Theory of Operation Ver. 1.0 Apr. 2007

2.3.6 Paper Separating Mechanism


A loop is formed in the paper between the Separator Fingers and the Feed Roller. The
turning force of the Feed Roller overcomes the block of the Separator Fingers, causing
PF-502

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

Friction Plate 4686C509AA

Paper Lifting Plate

2.3.7 Paper Feed Control


The operation of the Paper feed solenoid is controlled by the signal output from PJ3A-1
and 2 of the Control Board.
<For the 2nd Tray>

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Theory of Operation Ver. 1.0 Apr. 2007 2. Paper Feed Unit (PF-502)

2.3.8 Paper Feed Retry Control


To minimize the occurrence of paper misfeed, the Paper feed solenoid is energized a

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.

<For the 2nd Tray>

No. of Paper Feed Retry Sequences


Paper Feed Retry 1

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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Theory of Operation Ver. 1.0 Apr. 2007
MB-501
Outline
Composition/Operation

Blank Page

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Theory of Operation Ver. 1.0 Apr. 2007 1. Product specification

Outline
1. Product specification

MB-501
A. Type

Name Multiple bypass tray


Installation Screwed to the copier

B. Paper

Plain paper (60 to 90 g/m2) 100 sheets

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.

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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)

Paper empty sensor (PS1)


4687C501AA

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

The drive is transmitted through the Paper feed Solenoid.

Main motor (M1)

Feed Roller
Composition/Operation

Paper feed solenoid


(SD1)

Paper empty sensor (PS1)


4687C503AA

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.

Paper feed solenoid (SD1)


Drive from Main Motor

Feed Roller

Composition/Operation
Cam
4687C504AA

<Ascent/Descent Motion>
Main Motor (M1) is energized.
Feed Roller is turned.
Feed Roller
Paper

Paper feed solenoid (SD1): Energized Cam

Cam: Rotates

Tray: Raised

Paper feed solenoid (SD1): Deenergized

Paper take-up

Paper feed solenoid (SD1): Energized

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

2.3.2 Paper Empty Detection Mechanism


The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass.
MB-501

<When Paper is Present> <When Paper is not Present>

Paper feed solenoid (SD1)

Paper

4687C506AA
Composition/Operation

2.3.3 Paper Feed Control

4687E507AA

6
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Theory of Operation Ver. 1.0 Apr. 2007 2. Multiple Bypass (MB-501)

2.3.4 Paper Feed Retry Control


To minimize the occurrence of a paper misfeed, the paper feed sequence is temporarily

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.

No. of Paper Feed Retry Sequences


Paper Feed Retry 2

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

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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

Type Add-on drawer


Installation Built into the exit section of the copier
Paper storage system Moving drawer system

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

Power requirements DC24 V, DC5 V (supplied from the copier)


Power consumption 24 W or less

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

Paper empty sensor (PS4) Paper full sensor (PS3)

JS drive board (JSDB)

Job Tray
Paper detecting
board (PSDB)

Bin switching motor


(M1)
Lower home position
sensor (PS2) 4688C510AA
Upper home position
sensor (PS1)

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

Paper detecting board (M1)

Job Tray
Composition/Operation

4689C502AA

4
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Theory of Operation Ver. 1.0 Apr. 2007 2. Job Separator (JS-503)

2.2.1 Tray Selecting Mechanism


The paper is fed out into either the Exit Tray of the copier or the Job Tray. The active tray

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.

<When feeding paper into the Exit Tray: Copier>

Upper home position sensor (PS1): Activated


Bin switching motor (M1)

Composition/Operation
4021M046AB
Paper 4689C503AA

(M1: Backward Rotation)

<When feeding paper into the Job Tray: fax/printer>

Lower Home position sensor (PS2): Activated

Paper

Job Tray
4689C504AA

5
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2. Job Separator (JS-503) Theory of Operation Ver. 1.0 Apr. 2007

2.2.2 Tray-Full Detecting Mechanism


Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the low-
ered position).
JS-503

A tray-full condition is detected when the sensor is blocked for a continuous given period
of time (approx. 20 sec.).

Paper full sensor (PS3)


Paper

Job Tray

Exit Roller
Composition/Operation

4689C505AA

2.2.3 Job Tray Paper Detecting Mechanism


If paper is fed into the Job Tray when the machine is in a mode in which paper is fed into
the Exit Tray (Job Tray in the raise position), the indicator lamp on the Paper Detecting
Board lights to warn the user that there is paper in the Job Tray.
A sensor is provided for detecting paper in the Job Tray.

<When Paper is Present>


Paper empty sensor (PS4)
Paper

Paper detecting board


(PSDB)

Job Tray

<When Paper is not Present>

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.

2007/04 1.0 Issue of the first edition


Date Service manual Ver. Revision mark Descriptions of revision

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Theory of Operation Ver. 1.0 Apr. 2007

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

SF drive board (SFDB)


Home sensor (PS1)

Shift motor (M1)

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.

Shift motor (M1) Paper

Home sensor (PS1)

Exit Roller

4690C504AA

4
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2007.04 Ver.1.0

2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.


Printed in Japan
Use of this manual should be strictly supervised to
DDA09A-M-TE1
avoid disclosure of confidential information.

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