KONICA MINOLTA BizHub 163, 211, 220 Theory of Operation Service Manual

SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
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 corresponding 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 Date
1.0 Service manual Ver.
Revision mark
Issue of the first edition Descriptions of revision
Theory of Operation Ver. 1.0 Apr. 2007

bizhub 163/211/220
CONTENTS bizhub 163/211/220 main body Outline

1. 2. 2.1 3. 4. 5. System configuration............................................................................................... 1 Product specification ............................................................................................... 3 Fax kit (FK-506): (Option) ..................................................................................... 6 Cross sectional view................................................................................................ 7 Paper path............................................................................................................... 8 Copy process .......................................................................................................... 9
Composition/Operation
6. 6.1 6.2 7. 7.1 7.2 7.3 Overall configuration ............................................................................................. 11 Timing Chart at Power ON.................................................................................. 11 Control Block Diagram ........................................................................................ 12 Scanner (IR) .......................................................................................................... 13 Composition........................................................................................................ 13 Drive ................................................................................................................... 14 Operation ............................................................................................................ 15 Scanner Moving Mechanism/Control .......................................................... 15 Original Size Detection ............................................................................... 16 Determination of Original Size .................................................................... 17 For Metric, China and Latin America (Metric) areas ................................... 20
7.3.1 7.3.2 7.3.3 7.3.4 8. 8.1 8.2 9. 9.1 9.2 10.
PH (Writing section) .............................................................................................. 21 Composition........................................................................................................ 21 Drive ................................................................................................................... 22 Imaging unit........................................................................................................... 23 Construction ....................................................................................................... 23 Operation ............................................................................................................ 24 PC Drum ............................................................................................................... 25
10.1 Composition........................................................................................................ 25 10.2 Drive ................................................................................................................... 25 10.3 Operation ............................................................................................................ 26 10.3.1 11. Grounding of the PC Drum ......................................................................... 27 PC Drum charging................................................................................................. 28
11.1 Composition........................................................................................................ 28 11.2 Operation ............................................................................................................ 28 12. Developing ............................................................................................................ 29
Outline

bizhub 163/211/220
12.1 Composition ....................................................................................................... 29 12.2 Drive ................................................................................................................... 29 12.3 Operation............................................................................................................ 30 12.3.1 12.3.2 12.3.3 12.3.4 13. Developing Roller........................................................................................ 30 Developing Bias .......................................................................................... 30 TCR Sensor ................................................................................................ 31 TCR Sensor Automatic Adjustment ............................................................ 31
Toner replenishing................................................................................................. 32
Outline
13.1 Composition ....................................................................................................... 32 13.2 Drive ................................................................................................................... 32 13.3 Operation............................................................................................................ 33 13.3.1 13.4.1 13.4.2 14. Toner Replenishing Mechanism.................................................................. 33 T/C Recovery Mode.................................................................................... 35 Toner Bottle Home Position Detection ........................................................ 36 13.4 Toner Replenishing Control ................................................................................ 34
Image transfer and paper separation section........................................................ 37
14.1 Composition ....................................................................................................... 37 14.2 Drive ................................................................................................................... 37 14.3 Operation............................................................................................................ 38 14.3.1 14.3.2 15. Image Transfer Section ............................................................................... 38 Paper Separation Section ........................................................................... 38
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 16.3.2 16.3.3 16.3.4 16.3.5 16.3.6 16.3.7 16.3.8 17. Paper Separating Mechanism..................................................................... 43 Drawer in Position Detection....................................................................... 43 Paper Empty Detection Mechanism............................................................ 44 Paper Lifting Plate....................................................................................... 44 Universal Tray Paper Size Detection Mechanism ....................................... 45 ON/OFF Positions of Paper Size Detecting Switches and Corresponding Paper Size Detected .......................................................... 46 Paper feed Control...................................................................................... 47 Paper feed Retry Control ............................................................................ 47
Manual bypass section.......................................................................................... 48
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bizhub 163/211/220 Composition/Operation Outline
17.1 Composition........................................................................................................ 48 17.2 Drive ................................................................................................................... 48 17.3 Operation ............................................................................................................ 49 17.3.1 17.3.2 18. Paper Detection Mechanism ....................................................................... 49 Manual Feed Take Up Control..................................................................... 50
Registration roller section...................................................................................... 51
18.1 Composition........................................................................................................ 51 18.2 Drive ................................................................................................................... 51 18.3 Operation ............................................................................................................ 52 18.3.1 19. Paper Dust Remover................................................................................... 52 Fusing unit section ................................................................................................ 53
19.1 Composition (for bizhub 163).............................................................................. 53 19.2 Composition (for bizhub 211/220)....................................................................... 54 19.3 Drive ................................................................................................................... 55 19.4 Operation ............................................................................................................ 55 19.4.1 19.4.2 19.4.3 19.4.4 20. Fusing Roller Pressure Mechanism ............................................................ 55 Fusing Temperature Control (for bizhub 163) ............................................. 56 Fusing Temperature Control (for bizhub 211/220) ...................................... 57 PPM Control (bizhub 163 Only) .................................................................. 58
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. 23. Image stabilization system .................................................................................... 61 Others ................................................................................................................... 62 23.1.1 23.1.2 Composition ................................................................................................ 62 Operation .................................................................................................... 63 22.1 Composition........................................................................................................ 61 23.1 Fan Control ......................................................................................................... 62
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bizhub 163/211/220 Composition/Operation Outline
Blank Page
iv
1. System configuration
bizhub 163/211/220 [8] [9]
A08EE501AA
Outline
[2] [3] [4]
1/2 System front view
[12] [6] [1] [13] [7]
[14] [11]
[10]
[1] [2] [3] [4] [5] [6]
bizhub 163/211/220 *1 Original cover (OC-504) *2 Automatic document feeder (DF-502) Reverse automatic document feeder (DF-605) *3 Shift tray (SF-501) Automatic duplex unit (AD-504) *3 *5
[8] [9] [10] [11] [12] [13]
Paper feed unit (PF-502) Desk (DK-703) Desk (DK-702) Desk (DK-701) Job separator (JS-503) Key counter mount kit 1 (previous models for minolta.) Key counter mount kit 2 (previous models for konica) Mechanical counter (MC-503)
[7]
Multi bypass tray (MB-501) *4
[14]
*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)
Outline
[5]
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2/2 System rear view
[4]
[3]
[1]
[2]
Outline
A08EE502AA
[1] [2]
Expanded memory unit (EM-103) Fax kit (FK-506)
[3] [4]
Image controller (IC-206) * Network interface card (NC-503) *
* It is not possible to mount these units at the same time.
2. Product specification
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x 1.00 x 0.250, x 0.500. x 0.700, x 0.810 x 1.150, x 1.410, x 2.000, x 4.000 x 1.00 x 0.250, x 0.500, x 0.640, x 0.780 x 1.210, x 1.290, x 2.000, x 4.000
2.
Type Platen
Product specification
Console/desktop type Stationary CCD line sensor Organic photoconductor Electrostatic dry powdered image transfer to plain paper with a laser 600 600 dpi
A. Copier
Original scanning system Photoconductor Copying system Resolution Paper feeding system Exposure system Developing system Charging system Image transfer system Paper separating system Fusing system Paper discharging system
Mirror scanning HMT system Comb electrode DC negative corona with scorotron system Roller image transfer Paper separator fingers and charge neutralizing plate Heat roller Charge neutralizing brush
B. Functions
Types of original Max. original size Multiple copies Sheets, books, and three-dimensional objects A3 or 11 17 1 to 99 15 sec. or less: bizhub 211/bizhub 220 30 sec. or less: bizhub 163 (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), Rear edge: 4 mm (1/4 inch), front edge: 4 mm (1/4 inch) Scan through glass: 7 sec. or less ADF scan: 11 sec. or less (Values in conditions of paper fed from tray 1 at a room temperature of 23C and with a rated power source) 93 mm/s 21 cpm or more (bizhub 211: metric areas) Copying speed for multi-copy cycle (A4, 8-1/2 x 11) 22 cpm or more (bizhub 220) 20 cpm or more (bizhub 211: inch areas) 16 cpm or more (bizhub 163) Full size Fixed zoom ratios (Europe, china) Fixed zoom ratios (Latin america areas for inch) Reduction Enlargement Full size Reduction Enlargement
Warming-up time
Image loss
First copy time (A4, full size) Processing speed
Outline
Max. six-way system
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Full size Fixed zoom ratios (Latin america area for Reduction metric) Enlargement Variable zoom ratios Paper size used 0.250 to 4.000 Tray 1 Manual bypass Plain paper/recycled paper Paper capacity (Tray 1)

x 1.00 x 0.250, x 0.500, x 0.700, x 0.780 x 1.150, x 1.410, x 2.000, x 4.000 in 0.001 increments A3 to A5S, Letter, LedgerS, 11 x 14, LegalS, Invoice, 8K, 16K, FLS 250 sheets 20 sheets 10 sheets 1 sheets
Special paper (thick paper, overhead projector transparencies, postcards, label sheets) Envelopes
Outline
Paper capacity (Manual bypass)
Plain paper/recycled paper/special paper
C. Paper
Tray1 Plain paper (60 to 90 g/m2) Transparencies Type Thick Paper (91 to 157 g/m2) Postcards Labels Envelopes Size Width Length Paper feed unit Manual bypass *1 *1 *1 *1 *1 *1
(250 sheets) (20 sheets) (20 sheets) (20 sheets) (20 sheets) (10 sheets) 140 to 432 mm *2
90 to 297 mm *2 182 to 297 mm *2 90 to 297 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 (bizhub 211/bizhub 220) 240,000 prints or 5 years, whichever is earlier (bizhub 163)
Machine durability
Theory of Operation Ver. 1.0 Apr. 2007 E. Machine specifications

Power requirements Voltage Frequency
bizhub 163/211/220
AC100 V, AC120V, AC220-240V 50/60 Hz 100/110/120 area 1000 W 10% or less 1050 W 10% or less 940 W 10% or less 1100 W 10% or less 1200 W 10% or less 1350 W 10% or less 1250 W 10% or less
bizhub 163 Max power consumption bizhub 211/220
127/230 area 220 area 240 area 110/120/220 area 127/240 area 230 area
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) Space requirements Mass 998 (W) x 665 (D) mm (bizhub 211/220) 998 (W) x 620 (D) mm (bizhub 161) 89 kg (when fully equipped)
*1: Including the original cover *2: Including MB-501 and original cover F. Operating environment
Temperature Humidity 10 to 30C (with a fluctuation of 10C or less per hour) 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 Interface Printer language Font Complying OS Shared with the copier USB revision 2.0 compatible GDI Windows Windows XP (SP2 or later), Windows 2000 (SP4 or later), Windows ME, Windows 98 SE
Outline
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2.1
Fax kit (FK-506): (Option)

G3 General subscriber telephone line, NCC each line Direct connection (using a modular jack) 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) 3 seconds *1 8 dots/mm x 3.85/7.7/15.4 lines/mm, 16 dots/mm x 15.4 lines/mm *2 Maximum A3 (Ledger), banner documents (maximum 1000 mm (39-1/4 inches)) possible 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) With built in memory (5 MB): 280 pages With expanded memory (64 MB): 1,024 pages *With standard A4-size documents MH / MR / MMR / JBIG
Transmission mode Compatible wiring Connection method Transmission speed Transmission time Scanning density
Outline
Document size Print paper size Scanning storage
Compression encoding format
*1: This is the speed for transmitting an A4-size, or Letter-size document containing approximately 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.
3. Cross sectional view

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2 3 4 5 6 7 8
4034G502BA
3.
Cross sectional view

1
12
11
10
[1] [2] [3] [4] [5] [6]
Automatic document feeder DF-502 (Option) Scanner Job separator JS-503 (Option) Fusing unit Image transfer section Multiple bypass MB-501 (Option)
[7] [8] [9] [10] [11] [12]
Paper feed unit PF-502 (Option) Copy table DK-703 (Option) Paper feed tray/1 PH unit Imaging unit Exit section
Outline
4. Paper path
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4.
Paper path
Outline
4034G503BA
5. Copy process
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[13] Fusing [11] Cleaning [10] Paper Separation [9] Image Transfer [8] Paper Feed
A08EE568AA
5.
Copy process
[1] Photoelectric Conversion [2] IR Image [14] Paper Exit
Processing
[3] PH Image
Processing
[6] Laser Exposure
[5] Drum Charging [7] Developing
[1]
Photoelectric Conversion
A CCD sensor is used to convert the image data represented by light reflected off the original to a corresponding electric signal which, in turn, is output to the IR image processing section. The analog electric signal is converted to an 8-bit digital image
IR Image [2] Processing
signal (A/D conversion) which, in turn, goes through appropriate corrections before being output to the PH image processing section.
After going through corrections, the digital image signal is con-
[3]
PH Image Processing
verted to a corresponding electric signal (D/A conversion), with which the laser is turned ON or OFF as necessary.
Made up of an aluminum pipe coated with a photoconductive
[4] PC Drum [5] Drum Charging [6] Laser Exposure
layer, on which an electrostatic latent image is formed.

A uniform negative DC charge is deposited across the entire
surface of the PC Drum.

The laser beam strikes the surface of the PC Drum, forming an
electrostatic latent image. Toner negatively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image. 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.
Paper is supplied from the paper feed tray. A DC positive charge is applied to the Image Transfer Roller to
[7] Developing
[8] Paper Feed [9] Image Transfer
transfer the visible image on the surface of the PC Drum onto the paper.
Outline
[12] Main Erase
[4] PC Drum
5. Copy process
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The PC Drum Paper Separator Fingers remove paper from the surface of the PC Drum. [10] Paper Separation The Charge Neutralizing Plate neutralizes any charge left on the paper.
[11] Cleaning [12] Main Erase [13] Fusing
Residual toner on the surface of the PC Drum is scraped off.

The toner is then recycled back to the Developing Unit. The surface of the PC Drum is irradiated with light and any sur-
face potential remaining there after cleaning is neutralized.

The developed image is permanently fused to the paper by the
combination of heat and pressure applied by the Fusing Roller. The paper is fed out onto the Exit Tray. The optional Job Separator (JS-503), when mounted on the copier, allows a specific tray, in which paper is fed, to be selected according to the operating mode.
Outline
[14] Paper Exit
10
6. Overall configuration
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A08EE569AA
6.
6.1
Overall configuration
Timing Chart at Power ON
Power unit cooling fan motor (FM2)
11
Fusing cooling fan motor (FM1)
6. Overall configuration
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6.2
Control Block Diagram
Operation Panel
IR
CCD
MFP board (MFPB) EM-103
Document related option
FAXB NC-503 or IC-206
NCUB
Paper Exit Source Option PH High voltage unit Paper Source Option Printer control board (PRCB) PU
Process (Motor, Sensor, DC Power) Control System Line Image Bus Line
A08EC506AA
12
7. Scanner (IR)
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A08EC579AA
7.
7.1
Scanner (IR)
Composition
A08EC508AA
Original size sensor 1 (PS101) Original cover sensor (PS8) Scanner home position sensor (PS100) Original cover set switch (S6) Scanner motor (M5) CCD board (CCDB)
Scanner Assy
Exposure Lamp 2nd/3rd Mirrors Carriage

A08EC514AA
13
7. Scanner (IR)
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7.2
Drive
A08EC515AA
14
7. Scanner (IR)
bizhub 163/211/220 Composition/Operation
A08EE572AA
7.3
7.3.1
Operation
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>
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 original 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 lowered, 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.
15
7. Scanner (IR)
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<Making copiers using DF-502>
A08EE578AA
1. When the original is loaded and the Start key pressed, the Scanner performs shading. 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
16
Theory of Operation Ver. 1.0 Apr. 2007 7.3.3 Determination of Original Size
7. Scanner (IR)
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 Sensor PS101 *PS102 OFF ON Invoice S Legal S Letter S Legal S Letter 1117 S ~144.7 mm ~220.9 mm ~221.0 mm
Pattern 2
Original Size Sensor PS101 *PS102 OFF ON OFF ON OFF OFF ON ON Invoice S FLS S A5 S FLS S B5 S FLS S A4 S FLS S Letter S FLS S B5 FLS S B4 S B4 S B5 B4 S B4 S B4 S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 mm ~153.0 mm ~187.0 mm ~213.0 mm ~220.9 mm ~225.0 mm ~262.0 mm ~284.4 mm 284.5 mm~
Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S
*: PS102 is an option.
17
7. Scanner (IR)
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<For Metric, China and Latin America (Metric) areas> Pattern 1

Original Size Sensor PS101 OFF ON *PS102 A5 S FLS S B5 S FLS S 16K S FLS S A4 S FLS S B5 FLS S B5 B4 S 16K 8K S A4 A3 ~153.0 mm ~187.0 mm ~200.0 mm ~215.0 mm ~225.0 mm ~262.0 mm ~275.0 mm 275.1 mm~
Pattern 2
Original Size Sensor PS 101 *PS 102 Invoice S A5 S B5 S 16K S A4 S Letter S B5 B5 B4 S B4 S B4 S 16K 8K S 8K S 8K S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5 mm mm mm mm mm mm mm mm mm mm mm~
OFF OFF ON OFF ON
OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S ON ON Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S B4 S B4 S
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Theory of Operation Ver. 1.0 Apr. 2007 (2) Size Detection (When FLS/LEGAL Change is selected) For Inch and Latin America (Inch) areas Pattern 1
Original Size Sensor PS101 *PS102 OFF ON Invoice S FLS S Letter S FLS S Letter 1117 S ~144.7 mm ~220.9 mm ~221.0 mm
7. Scanner (IR)
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~262.0 mm ~284.4 mm 284.5 mm~ B4 S B4 S B4 S 1117 S 1117 S 1117 S A3 A3 A3
Pattern 2
Original Size Sensor PS101 *PS102 ~143.9 mm Invoice S FLS S ~153.0 mm ~187.0 mm ~213.0 mm ~220.9 mm ~225.0 mm
ON OFF ON
OFF ON ON
FLS S
FLS S
FLS S
FLS S
FLS S B4 S B4 S
Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S
*: UN3 is an option.
19
OFF
OFF
A5 S
B5 S
A4 S
Letter S
B5
B5
Letter
A4
7. Scanner (IR)
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7.3.4 Pattern 1
For Metric, China and Latin America (Metric) areas
Original Size Sensor PS101 OFF ON *PS102 A5 S B5 S 16K S A4 S B5 B5 B4 S 16K 8K S A4 A3 ~153.0 mm ~187.0 mm ~200.0 mm ~215.0 mm ~225.0 mm ~262.0 mm ~275.0 mm 275.1 mm~
Legal S Legal S Legal S Legal S Legal S
Pattern 2
Original Size Sensor PS 101 *PS 102 Invoice S A5 S B5 S 16K S A4 S Letter S B5 B5 B4 S B4 S B4 S 16K 8K S 8K S 8K S Letter 1117 S 1117 S 1117 S A4 A3 A3 A3 ~143.9 ~153.0 ~187.0 ~200.0 ~213.0 ~220.9 ~225.0 ~262.0 ~274.7 ~284.4 284.5 mm mm mm mm mm mm mm mm mm mm mm~
OFF OFF ON OFF ON
OFF FLS S FLS S FLS S FLS S FLS S FLS S FLS S ON ON Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S Legal S B4 S B4 S
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8. PH (Writing section)
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A08EC580AA
8.
8.1
PH (Writing section)
Composition
A08EC508AA
Polygon Motor
f Lens
LD Board
SOS Sensor
A08EC516AA
21
8. PH (Writing section)
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8.2
Drive
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
LD Board
SOS Sensor
A08EC526AA
22
9. Imaging unit
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A08EC581AA
9.
9.1
Imaging unit
Construction
A08EC509AA
Cleaning Blade
PC Drum Paper Separator Fingers
PC Drum Charge Corona
PC Drum
Developing Roller
3rd Toner Conveying Roller
1st Toner Conveying Roller 2nd Toner Conveying Roller
A08EC517AA
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9. Imaging unit
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9.2
Operation
The Main Motor provides drive for the PC Drum, Developing Roller, and other mechanical components.
Main motor (M1)
Recycled Toner Conveying Screw
Developing Roller Recycled Toner Recycling Coil 2nd Toner Conveying Roller
A08EC562AA
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10. PC Drum
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10. PC Drum
10.1 Composition
A08EC509AA
10.2 Drive
A08EC563AA
25
A08EC582AA
10. PC Drum
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10.3 Operation
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
A08EC527AA
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Theory of Operation Ver. 1.0 Apr. 2007 10.3.1 Grounding of the PC Drum
10. PC Drum
The ground contact (Ground Plate) of the PC Drum is located on the inside on its lefthand 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
Frame
Ground Plate
A08EC528AA
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11. PC Drum charging

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11. PC Drum charging

11.1 Composition
A08EC583AA
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 uniform 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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12. Developing
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A08EC584AA
12. Developing
12.1 Composition
A08EC509AA
12.2 Drive
A08EC518AA
29
12. Developing
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12.3 Operation
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 Carrier
2nd Toner Conveying Roller
Developing Roller
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 difference 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
30
Theory of Operation Ver. 1.0 Apr. 2007 12.3.3 TCR Sensor
12. Developing
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
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 The voltage input to the TCR Sensor from the Master Board at this time is fixed as the reference voltage. NO The voltage input to the TCR Sensor from the Master Board is varied. 2.37 V or more: Decrease the voltage. 2.29 V or less: Increase the voltage.
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13. Toner replenishing

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13.1 Composition
A08EC585AA
A08EC510AA
13.2 Drive
A08EC564AA
32

A08ET2C522AA
13.3 Operation
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 Bottle. 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
Metering Chamber
Toner replenishing motor (M2)
Toner Conveying Screw
Developer Mixing Chamber
A08EC561AA
33

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13.4 Toner Replenishing Control

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 (%) More than 14 13.5 to 14 13 to 13.5 12.5 to 13 12 to 12.5 10 to 12 Less than 7 B/W ratio More than 2000 More than 1000 More than 500 More than 500 More than 0 toner replenishing not supplied supplied supplied supplied supplied supplied
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 original).
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Theory of Operation Ver. 1.0 Apr. 2007 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.
T/C is recovered by 2 % or more, or is 12 % or more.
T/C is not recovered by 2 % or more, or T/C is less than 12 %.
Toner is replenished for 30 sec. to complete the T/C recovery mode.
A toner-empty condition is detected.
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 condition 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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13.4.2
Toner Bottle Home Position Detection
The toner supply port is on the upper side whenever the toner bottle is at its home position. The toner bottle home position sensor (PS6) detects the toner bottle at its home position.
Toner Supply Port
Toner bottle home position sensor (PS6)
A08EC530AA
36
14. Image transfer and paper separation section

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A08EC565AA

14.1 Composition
A08EC511AA
14.2 Drive
37
A08EC591AA

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14.3 Operation
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 conditions 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 misfeed 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. 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 transfer, 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
38
15. Toner recovery

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A08EC585AA
15. Toner recovery

15.1 Composition
A08EC509AA
15.2 Drive
A08EC567AA
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15. Toner recovery

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15.3 Operation
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 backward (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 Approx. 330 sec. PC Drum Backward Rotation Time 50 ms
PC Drum
Spent Toner Conveying Screw 1
Spent Toner Conveying Screw 2
Spent Toner Recycling Coil
Spent Toner Recycling Duct
Cleaning Blade
Developer Mixing Chamber

A08EC532AA
40
16. Paper feed

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16. Paper feed

16.1 Composition
A08EC557AA
Paper empty sensor/1 (PS4) Feed Roller/1
Paper size detect board (PSDTB) Paper size sensor (S5)
Separation Roller/1
Paper Lifting Plate
A08EC533AA
41
A08EC587AA
16. Paper feed

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16.2 Drive
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
A08EC534AA
42
16. Paper feed

16.3 Operation
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 backside 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 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

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16.3.3
Paper Empty Detection Mechanism
The Paper Empty Sensor detects a paper-empty condition in the drawer.
Paper empty sensor/1 (PS4)
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
44
Theory of Operation Ver. 1.0 Apr. 2007 16.3.5 Universal Tray Paper Size Detection Mechanism
16. Paper feed

A08EC539AA
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 combination 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)
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16. Paper feed

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16.3.6
ON/OFF Positions of Paper Size Detecting Switches and Corresponding Paper Size Detected
<For Metric>
Paper Size Detect Board (PSDTB) SW1 ON ON SW2 ON ON ON ON ON SW3 ON ON ON ON ON ON SW4 ON ON ON ON ON ON ON Paper size sensor (S5) Activated Activated Activated Paper Size B4 A3 A5 S A4 A5, postcards A5 S A4 B5 A4 S B5 S
ON
<For Inch>
Paper Size Detect Board (PSDTB) SW1 SW2 SW3 SW4 Paper size sensor (S5) Activated Activated Activated Activated Paper Size B4, Legal B4, 1114 B5 S, Invoice S A3, 1117 A5 S, Invoice S A4, Letter A5, Invoice A5 S, Invoice S A4, Letter B5, Invoice A4 S, Letter S B5 S, Letter S
ON ON ON
ON ON ON ON ON
ON ON ON ON ON ON
ON ON ON ON ON ON ON
46
Theory of Operation Ver. 1.0 Apr. 2007 16.3.7 Paper feed Control
16. Paper feed

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A08EE588AA
16.3.8
Paper feed Retry Control

To minimize the occurrence of a paper misfeed, the paper take-up sequence is temporarily 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
47
17. Manual bypass section

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17.1 Composition
A08EC590AA
A08EC512AA
17.2 Drive
Main motor (M1)
Paper set sensor/bypass (PS2)
Paper feed solenoid/bypass (SD2)
A08EC566AA
48

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A08EC542AA A08EC543AA
17.3 Operation
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)
Paper feed solenoid/bypass (SD2)
17.3.1
Paper Detection Mechanism
The Sensor detects a sheet of paper on the Manual Bypass.

<When Paper is Present> Paper set sensor/bypass (PS2) <When Paper is not Present>
Paper
49

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17.3.2
Manual Feed Take Up Control
A08EE573AA
50
18. Registration roller section

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A08EC586AA

18.1 Composition
A08EC558AA
18.2 Drive
Registration roller clutch (CL1) Registration roller
Registration sensor (PS1)
Paper Dust Remover

A08EC545AA
51

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18.3 Operation
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)
A08EC546AA
18.3.1
Paper Dust Remover
The Paper Dust Remover collects paper dust on the paper.
Paper Dust Remover
A08EC547AA
52
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.
A08EC592AA
A08EC559AA
Heater Lamp
Fusing Roller/rt Fusing Roller
Thermistor (TH1)
Pressure Lever
A08EC548AA
Thermostat
53

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19.2 Composition (for bizhub 211/220)

Sub Heater Lamp) Heater Lamp
Fusing Roller/rt
Fusing Roller
Thermostat
Pressure Lever
A08EE571AA
Thermistor (TH1) Thermistor (TH2)
54

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Fusing Roller/Rt
A08EC549AA
19.3 Drive
The main motor (M1) provides the drive for the fusing unit.
Main motor (M1)
Fusing roller
19.4 Operation
19.4.1 Fusing Roller Pressure Mechanism To provide a nip width between the rollers, a Pressure Spring is used functioning to press the Fusing Roller/Rt up against the Fusing Roller.
Fusing Roller/Rt
Pressure Lever
Fusing Roller
Pressure Spring
A08EC550AA
55

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19.4.2
Fusing Temperature Control (for bizhub 163)
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
A08EE574AA
Machine Condition or Paper Type Standby Plain paper (width: 250 mm or more; length: less than 360 mm) Plain paper (width: less than 250 mm) Thick paper (width: 250 mm or more) Thick paper (width: less than 250 mm) OHP film (width: 250 mm or more) OHP film (width: less than 250 mm)
Mode 1 180 C 190 C 180C 210 C 200 C 180 C 155 C
Mode 2 180 C 170 C 190 C 170 C 180 C 165 C 210 C 190 C 200 C 190 C 180 C 165 C 155 C
Mode 3 170 C 170 C 165 C 190 C 190 C 165 C 155 C
56
Theory of Operation Ver. 1.0 Apr. 2007 19.4.3 Fusing Temperature Control (for bizhub 211/220)

A08EE576AA
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
Machine Condition or Paper Type Standby Plain paper (width: 221 mm or more) Plain paper (width: 220 mm or less) Thick paper (width: 201 mm or more) Thick paper (width: 200 mm or less) OHP film (width: 201 mm or more) OHP film (width: 200 mm or less)
Mode 1 180 C 180 C 180 C 200 C 200 C 165 C 165 C
Mode 2 180 C 165 C 180 C 180 C 200 C 200 C 165 C 165 C
Mode 3 165 C 180 C 180 C 200 C 200 C 165 C 165 C
57

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19.4.4
PPM Control (bizhub 163 Only)
If paper of a small size (width of 250 mm or less) or thick paper is used to run a multicopy cycle, the temperature on the edges of the Fusing Rollers tends to run high, meaning 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.
58
20. Paper exit (for bizhub 163)

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A08EC593AA
20. Paper exit (for bizhub 163)

20.1 Composition
A08EC560AA
20.2 Drive
The main motor (M1) provides the drive for the exit section.
Exit Roller Main motor (M1)
A08EC553AA
59
21. Paper exit (for bizhub 210/220)

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21. Paper exit (for bizhub 210/220)

21.1 Construction
A08EC593AA
A08EC560AA
21.2 Operation
The exit rollers are driven by the switchback motor (M3).
Exit Roller
Switchback motor (M3)

A08EE575AA
60
22. Image stabilization system

22. Image stabilization system

22.1 Composition
The following image stabilization controls are provided to ensure stabilized copy image.
Purpose Means Control
To stabilize image density.
The Vg/Vb control voltage is varied to bring Vg/Vb to an appropriate level according to the following settings. Grid voltage (Vg) and devel- Tech. Rep. Choice: ID Adjustment 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 according to the following conditions. Paper type Paper width B/W ratio of image
To stabilize image transfer.
Image transfer output control
A08EE577AA
61
23. Others
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23. Others
23.1 Fan Control
23.1.1 Composition
Power unit cooling fan motor (FM2)

A08EC555AA
Ozone Filter
A08EC556AA
62
Theory of Operation Ver. 1.0 Apr. 2007 23.1.2 Operation
23. Others
A. Function
Motor Name Control Conditions
A fan motor draws air from the area around the Fusing Unit to the outside to prevent the machine interior temperature from running high. In addition, the fan motor pulls paper being transported up through suction force to help stabilize paper transport. Ozone produced from the PC Drum Charge Corona is absorbed by 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 running high. Power unit cooling fan motor (FM2) The cooling fan motor is turned at full speed when the Main Motor 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) Fusing cooling fan motor (FM1) Half speed rotation after the lapse of a given period of time after the end of the print cycle Half speed Half speed rotation at any timing other than the full speed and stop control Stop When a malfunction occurs When the right door is open
Full speed When power is turned ON or Sleep is canceled Power unit cooling fan motor (FM2) Stop Half speed rotation if the main motor (M1) is deenergized after the lapse of a given period of time after the full speed rotation
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23. Others
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Blank Page
64
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
DF-605/MK-501 Outline
1. 2. 2.1 2.2 Product specifications ............................................................................................. 1 Paper Feed Path ..................................................................................................... 4 In 1-sided mode .................................................................................................... 4 In 2-sided mode .................................................................................................... 4
3. 4. 5. 5.1 5.2 5.3 Composition ............................................................................................................ 5 Operation ................................................................................................................ 7 Document pick-up mechanism ............................................................................. 7 Pick-up operation .......................................................................................... 7 Document feed/transport mechanism................................................................... 8 Raised/lowered position detecting mechanism................................................... 12 Document size detection............................................................................. 12 Raised/lowered position detection .............................................................. 12 5.1.1
Drive ........................................................................................................................ 6
5.3.1 5.3.2
Outline
DF-605/MK-501
CONTENTS
Outline
DF-605/MK-501
Blank Page
ii
1. Product specifications
1.
Name
Product specifications
Reverse automatic document feeder Paper feed Paper feed from top of stack Switch back system Straight exit system
A. Type
Type
Turnover Paper exit
Installation Document alignment Document loading
Screw cramp to the main unit Center Left image side up
B. Functions
Modes 1-sided mode / 2-sided mode
C. Paper
1-Sided mode 35 to 128 g/m2 (9.25 to 34 lb) 2-Sided mode 50 to 128 g/m2 (13.25 to 34 lb) 1-Sided / 2-Sided Mode 50 to 128 g/m2 (13.25 to 34 lb) 1-Sided mode 35 to 128 g/m2 (9.25 to 34 lb) 2-Sided mode 50 to 128 g/m2 (13.25 to 34 lb)
Standard mode Plain paper Mixed original detection mode Plain paper FAX mode Plain paper
Type of document
Detectable document size*1 Capacity
Metric area B6S to A3 Inch area 5 1/2 8 1/2S / 5 1/2 8 1/2 to 11 17 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.
Outline
DF-605/MK-501
Outline
1. Product specifications D. Paper feed prohibited originals If fed, trouble occurrence will be highly possible.
Type of original Original that is stapled or clipped. Book original Original weighing less than 35g/m2 or 129g/m2 or more Torn original
DF-605/MK-501
Possible trouble Feed failure, damage to the original, or drive failure due to clip clogging Feed failure, damage to the original, or drive failure Feed failure Feed failure, damaged sheet Original misfeed due to dog-ear or skew Feed failure Feed failure Feed failure Damaged sheet Patched part folded or torn sheet, Sheets misfed
Outline
Highly curled original (15 mm or more) OHP transparencies Label Sheet Offset master Sheets clipped or notched Sheets patched
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 Sheets lightly curled (Curled amount: 10 - 15 mm) Heat sensitive paper Coated paper (Ink Jet paper) Translucent paper Paper immediately after paper exit from the main unit Possible trouble Dog-eared, exit failure Edge folded, exit failure, transport failure Take-up failure, transport failure Take-up failure, transport failure 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 Sheets two-folded or Z-folded Sheets with rough surface (e.g., letterhead) Sheets folded Transport failure Transport failure, image deformation Take-up failure Image deformation, multi-page feed, take-up failure
Theory of Operation Ver. 1.0 Apr. 2007 F. Mixed original feed chart For Metric
Max. original size Mixed original size 297 mm A3 A4 B4 B5 A4S A5 B5S A5S B6S 297 mm A3 OK OK OK OK OK* NG NG NG NG A4 OK OK OK OK OK* NG NG NG NG 257 mm B4 OK OK OK OK OK* NG NG B5 OK OK OK OK OK* NG NG
210 mm A4S OK OK OK NG NG A5 OK OK OK NG NG
182 mm 148 mm B5S OK OK NG A5S -
257 mm
210 mm 182 mm 148 mm 128 mm
OK OK
For Inch
Max. original size Mixed original size 11 11 x 17 8.5 x 11 8.5 x 14 8.5 x 11S 8.5 x 5.5 8.5 x 5.5S 11 x 17 OK OK OK* OK* NG NG 11 8.5 x 11 OK OK OK* OK* NG NG 8.5 x 14 OK OK OK NG 8.5 8.5 x 11S OK OK OK NG 5.5 x 8.5 OK OK OK NG 5.5 8.5 x 5.5S OK
8.5
5.5
OK NG *
Mixed original feed available (Tilted with in 1.5% or less) 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 Consumption Dimensions Weight 48 W or less 582 (W) x 558 (D) x 145 (H) mm 23 inch (W) x 20.5 inch (D) x 5.75 inch (H) 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.
Outline
DF-605/MK-501
2. Paper Feed Path
DF-605/MK-501
2.
2.1
Paper Feed Path

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
3. Composition
3.
Composition
Document feed section
Conveyance section
Switchback section
Document exit section

4344T2C501AA
DF-605/MK-501
4. Drive
DF-605/MK-501
4.
Drive
Paper feed motor (M1-ADF)
Transport motor (M2-ADF)
4344T2C502AA
5. Operation
5.1
Document pick-up mechanism
The Document Pick-Up Section consists of the Pick-Up Rollers, Feed Roller and Separation 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 lowered position during feeding.
Paper feed motor (M1-ADF) Pick-Up Roller
Feed Roller
Separation Roller
4344T2C503AA
DF-605/MK-501
5.
Operation
5. Operation
5.2
DF-605/MK-501
Document feed/transport mechanism
When the document reaches the Registration Sensor, the Feed Roller starts turning forward 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.
Parts Direction of Rotation Backward rotation Forward rotation Backward rotation Forward rotation Details The Pickup Rollers lower and start turning and the Feed Roller turns. The Registration Roller turns. The Transport Roller and Exit/Turnover Roller turn in the direction to turn over the original. The Transport Roller and Exit/Turnover Roller turn in the direction to feed the original out.
Paper Feed Motor (M1-ADF)
Transport Motor (M2-ADF)
Transport motor (M2-DF)
Paper feed motor (M1-DF)
Exit/Turnover Roller
Registration Roller Transport Roller
4344T2C504AA
Theory of Operation Ver. 1.0 Apr. 2007 A. Operation flow in the 1-sided mode
5. Operation
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. 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 original. 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.
DF-605/MK-501
5. Operation
B. Operation flow in the 2-sided mode 1. When the Start key is pressed, the Paper Feed Motor starts turning backward, 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/Turnover Sensor.
Original Detection Sensor
DF-605/MK-501
Stop
Scanning the 1st side
Exit/Turnover Sensor
4344T2C506AA
2. The Transport Motor is turned backward to turn over the original. After the Registration 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 Retraction Solenoid is energized so that the Exit/Turnover Roller is retracted.
Turnover Stop
Scanning the 2nd side

4344T2C505AA
10
5. Operation
Turnover Exit
Scanning the 2nd side

4344T2C505AA
11
DF-605/MK-501
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.
5. Operation
5.3
DF-605/MK-501
Raised/lowered position detecting mechanism

Document size detection
5.3.1
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 Actuator 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 actuates the Original cover set switch on the main unit to perform this operation.
Original cover set switch (S6)
4344T2C508AA
12
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS DF-502 Outline

1. Product specification ............................................................................................... 1
DF-502
2. 2.1 2.2 2.3 Automatic Document Feeder (DF-502) ................................................................... 3 Composition.......................................................................................................... 3 Drive ..................................................................................................................... 4 Operation .............................................................................................................. 5 Document Transport...................................................................................... 6 Document Separating Mechanism ................................................................ 7 Document Exit Mechanism ........................................................................... 8 Document Size Detection Mechanism .......................................................... 9 Raised/Lowered Position Detection Mechanism ........................................... 9
Composition/Operation Outline
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6
Document Pick-Up and Feed ........................................................................ 5
Outline
DF-502
Blank Page
ii
Outline
A. Type
Name Installation Modes Document loading Automatic document feeder Inserted in top portion of the copier Standard = 1-sided original Mixed original = 1-sided original Left-hand side, face up
B. Paper
Standard Type Sizes Plain paper (50 to 110 g/m2) A3, A4S, A4, A5S, B4, B5S, B5, 11 x 17, 11 x 14, Legal, LetterS, Letter, InvoiceS, and Invoice Mixed original Plain paper (60 to 90 g/m2) A3 and A4, B4 and B5, 11 x 17 and Letter, Legal and LetterS, Legal and Invoice, LetterS and Invoice
C. Paper feed prohibited originals

Type of original Sheets stapled or clipped together Sheets glued together Sheets folded, torn, or wrinkled Sheets severely curled Possible problems Take-up failure, damaged sheet, defective drive mechanism due to jammed staples or clips Take-up failure, damaged sheet Take-up failure, damaged sheet Sheet misfed due to its being dog-eared or fed in askew
D. Machine specifications
Document alignment Capacity Power requirements Power consumption Dimensions Mass Center 50 sheets max. (80 g/m2) DC24 V, DC5 V (supplied from the copier) 36 W or less 598 mm (W) x 483 mm (D) x 102 mm (H) 6.3 kg
E. Operating environment Conforms to the operating environment of the main unit. NOTE These specifications are subject to change without notice.
Outline
DF-502
1.
Outline
DF-502
Blank Page
2. Automatic Document Feeder (DF-502)
2.1 Composition
DF-502
4688C512AA
2.
Automatic Document Feeder (DF-502)
4688C502AA
Main Motor Feed Clutch Pick-Up Roller Exit Rollers
Feed Roller
Registration Rollers
4688C501AA
2.2
DF-502
Drive
4688C503AA
2.3
2.3.1
Operation
DF-502 Composition/Operation
4688C504AA
Document Pick-Up and Feed
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 connected to the raising and lowering of the Pick-Up Roller.
Paper feed clutch (CL1) Main motor (M1)
Pick-Up Roller
Paper empty sensor (PS2)
Feed Roller Document Stoppers
2. Automatic Document Feeder (DF-502) 2.3.2

DF-502
Document Transport
The document taken up is transported to the document scanning position of the copier 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)
Registration Rollers
4688C506AA
Theory of Operation Ver. 1.0 Apr. 2007 2.3.3 Document Separating Mechanism
When one sheet of paper is taken up
Since the friction coefficient on the top side of the paper is equal to that on the underside of the paper, the Separation Roller is turned by the 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.
Feed Roller Separation Roller

4688C507AA
DF-502
The coefficient of friction between the Feed Roller and Separation Roller is effectively used to prevent double feed of paper.
2. Automatic Document Feeder (DF-502) 2.3.4

DF-502
Document Exit Mechanism
The document is fed out of the ADF by the Exit Roller. The Exit Roller is driven by gears and a belt which are driven by the Main Motor.
Main motor (M1)
Exit Rollers
4688C508AA
Theory of Operation Ver. 1.0 Apr. 2007 2.3.5
Document Size Detection Mechanism

DF-502 Composition/Operation
The document size is determined by means of two different systems of document width 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.
Magnet
Original cover set switch (S6)
4688C509AA
DF-502
Blank Page
10
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS AD-504 Outline

1. Product specifications ............................................................................................. 1
AD-504
2. 2.1 2.2 2.3 Duplex Unit (AD-504) .............................................................................................. 3 Composition.......................................................................................................... 3 Drive ..................................................................................................................... 4 Operation .............................................................................................................. 4 2-sided Copying with a Single Sheet of Paper Resident in the Unit.............. 5 2-sided Copying with Two Sheets of Paper Resident in the Unit .................. 6
2.3.1 2.3.2 2.3.3
Switchback Operation ................................................................................... 4
Outline
AD-504
Blank Page
ii
Outline
A. Type
Name Type Installation Power requirements Automatic duplex unit Sheet duplex paper take-up section Installed to the right side door DC24 V (supplied from the copier) DC5 V
B. Paper
Size Type Document alignment A3, A4S/A4, A5S/A5, B4, B5S/B5, FLS, Ledger, Legal, Letter, InvoiceS/ Invoice Plain paper (60 to 90 g/m2), recycled paper (60 to 90 g/m2) Center
C. Machine specifications
Max. power consumption Dimensions Mass Operating environment 9 W or less 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) 2.5 kg (Duplex unit + Manual bypass assy 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.
Outline
AD-504
1.
Outline
AD-504
Blank Page
2. Duplex Unit (AD-504)
2.1 Composition
AD-504
4532C516AA
2.
Duplex Unit (AD-504)
4532C515AA
Transport motor (M1)
AD drive board (ADDB)
Transport sensor (PS2)

4532C503AA
2.2
AD-504
Drive
The Duplex Unit Transport Motor provides the drive for the Duplex Unit.
Transport Roller 1
Transport Roll 1
Transport Roller 2
Transport Roll 2
4532C502AA
2.3
2.3.1
Operation
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
Theory of Operation Ver. 1.0 Apr. 2007 2.3.2
2-sided Copying with a Single Sheet of Paper Resident in the Unit 1. The first sheet of paper is taken up and the image of page 2 of the original is printed.
AD-504 Composition/Operation
A. Operation
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.
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.
2. Duplex Unit (AD-504) 2.3.3

AD-504
2-sided Copying with Two Sheets of Paper Resident in the Unit 1. The first sheet of paper is taken up and the image of page 2 of the original is printed.
A. Operation
4532C505AA
4532C510AA
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. 3. At the same time, the second sheet 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
4532C512AA
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. 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
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 image of page 6 of the original is printed.
4532C514AA
11. Steps 2 through 10 are repeated.
AD-504
AD-504
Blank Page
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS PF-502 Outline

PF-502
2. 2.1 2.2 2.3 Paper Feed Unit (PF-502) ....................................................................................... 3 Composition.......................................................................................................... 3 Drive ..................................................................................................................... 4 Operation .............................................................................................................. 5 Paper Lifting Plate......................................................................................... 5 Tray-in-Position Detection ............................................................................. 6 Paper Empty Detection ................................................................................. 6 Paper Size Detecting Mechanism ................................................................. 7 Paper Separating Mechanism....................................................................... 8 Paper Feed Control ....................................................................................... 8 Paper Feed Retry Control ............................................................................. 9
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8
Edge Guide and Trailing Edge Stop .............................................................. 5
Outline
PF-502
Blank Page
ii
Outline
A. Type
Name Installation Add-on paper feed unit Installed on the underside of the copier
B. Paper
Outline
Type Plain paper (60 to 90 g/m2) Recycled paper (60 to 90 g/m2) 250 sheets
Sizes
Metric areas: A3, A4S, A4, A5, B4, B5S, and B5 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)
Paper alignment Capacity Power requirements Power consumption Dimensions Weight Center 250 sheets DC24 V, DC5 V (supplied from the copier) 9 W or less 590 mm (W) x 558 mm (D) x 108 mm (H) 23.25 inch (W) x 22 inch (D) x 4.25 inch (H) 5.5 kg (12.25 lb)
PF-502
1.
Outline
PF-502
Blank Page
2. Paper Feed Unit (PF-502)
2.1 Composition
PF-502
4686C512AA
2.
Paper Feed Unit (PF-502)
4686C502AA
Trailing Edge Stop
Side Door
Edge Guide
Paper Lifting Plate

4686C501AA
2.2
PF-502
Drive
Drive from the Main Motor (M1) is transmitted via a gear train to the paper feed mechanism for the Paper Feed Unit.
Vertical Transport Roller
Paper Feed Drive Mechanism
Feed Roller
4686C503AA
2.3
2.3.1
Operation
PF-502
4686C504AA 4686C505AA
Edge Guide and Trailing Edge Stop
The Edge Guide and Trailing Edge Stop can be slid into any desired position.
Trailing Edge Stop
Edge Guide
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
2. Paper Feed Unit (PF-502) 2.3.3

PF-502
Tray-in-Position Detection
When a tray is slid into the cabinet, the Tray Set Sensor is blocked and the copier determines that the tray has been slid in position.
Light Blocking Plate
Tray set sensor (PS3)

4686C506AA
2.3.4
Paper Empty Detection
The Paper Empty Sensor detects a paper-empty condition in the tray.

4686C507AA
Theory of Operation Ver. 1.0 Apr. 2007 2.3.5 Paper Size Detecting Mechanism
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 combination 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
Paper size detect switch (SW1)
4686C508AA
Trailing Edge Stop
Edge Guide
Paper Size A3 B4 A4 S A4 B5 S B5 A5
Paper size detect board (PSDTB) SW4 ON ON ON ON SW3 ON ON ON SW2 ON ON ON SW1 ON ON ON
Paper size detect switch (SW1) ON ON
PF-502
2. Paper Feed Unit (PF-502) 2.3.6

PF-502
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 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 Lifting 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
Separator Finger Roll
Friction Plate Paper Lifting Plate
4686C509AA
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>
Theory of Operation Ver. 1.0 Apr. 2007 2.3.8 Paper Feed Retry Control
To minimize the occurrence of paper misfeed, the Paper feed solenoid is energized a 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>
4686C511AA
PF-502
PF-502
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10
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS MB-501 Outline

MB-501
2. 2.1 2.2 2.3 Multiple Bypass (MB-501) ....................................................................................... 3 Composition.......................................................................................................... 3 Drive ..................................................................................................................... 4 Operation .............................................................................................................. 5 Paper Empty Detection Mechanism.............................................................. 6 Paper Feed Control ....................................................................................... 6 Paper Feed Retry Control ............................................................................. 7
2.3.1 2.3.2 2.3.3 2.3.4
Paper Feed Mechanism ................................................................................ 5
Outline
MB-501
Blank Page
ii
Outline
A. Type
Name Installation Multiple bypass tray Screwed to the copier
B. Paper
Plain paper (60 to 90 g/m2) OHP film Type Thick paper (91 to 157 g/m2) Postcards and labels Envelopes Recycled paper (60 to 90 g/m2) Size Sizes Width Length 10 sheets 100 sheets 90 X 297 mm 140 X 432 mm 20 sheets 100 sheets
A3, A4S, A4, A5, A5S, B4, B5S, B5, FLS, Ledger, 11 x 14, Legal, LetterS, Letter, InvoiceS, Invoice, 8K, 16KS, and 16K
Registration Capacity Power requirements Power consumption Dimensions Mass Center 100 sheets (80 g/m2) DC24 V, DC5 V (supplied from the copier) 9 W or less 439 mm (W) x 435 mm (D) x 137 mm (H) 17.25 inch (W) x 17.25 inch (D) x 5.5 inch (H) 3.1 kg (6.75 lb)
Outline
MB-501
1.
Outline
MB-501
Blank Page
2. Multiple Bypass (MB-501)
2.1 Composition
MB-501
4687C509AA
2.
Multiple Bypass (MB-501)
4687C502AA
Feed Roller
Paper feed solenoid (SD1)

4687C501AA
2.2
MB-501
Drive
Drive for bypass paper feed is provided by the Main Motor (M1). The drive is transmitted through the Paper feed Solenoid.
Main motor (M1)
Feed Roller
Paper feed solenoid (SD1)

4687C503AA
2.3
2.3.1
Operation
MB-501 Composition/Operation
4687C504AA
Paper Feed Mechanism
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.
Drive from Main Motor Paper feed solenoid (SD1)
Feed Roller
Cam
<Ascent/Descent Motion> Main Motor (M1) is energized. Feed Roller is turned. Paper feed solenoid (SD1): Energized Cam: Rotates Tray: Raised Paper feed solenoid (SD1): Deenergized Paper take-up Paper feed solenoid (SD1): Energized Cam: Rotates Tray: Lowered Paper feed solenoid (SD1): Deenergized
4687C505AA
Feed Roller Paper Cam
2. Multiple Bypass (MB-501) 2.3.2

MB-501
Paper Empty Detection Mechanism
The Paper Empty Sensor detects a sheet of paper on the Multiple Bypass.
<When Paper is Present> Paper feed solenoid (SD1) <When Paper is not Present>
Paper
4687C506AA
2.3.3
Paper Feed Control
4687E507AA
Theory of Operation Ver. 1.0 Apr. 2007 2.3.4 Paper Feed Retry Control
To minimize the occurrence of a paper misfeed, the paper feed sequence is temporarily 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.
MB-501
MB-501
Blank Page
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS JS-503 Outline

JS-503
2. 2.1 2.2 Job Separator (JS-503) ........................................................................................... 3 Construction ......................................................................................................... 3 Operation .............................................................................................................. 4 Tray Selecting Mechanism ............................................................................ 5
2.2.1 2.2.2 2.2.3
Tray-Full Detecting Mechanism..................................................................... 6 Job Tray Paper Detecting Mechanism........................................................... 6
Outline
JS-503
Blank Page
ii
Outline
A. Type
Type Installation Paper storage system Add-on drawer Built into the exit section of the copier Moving drawer system
B. Paper
Upper drawer Plain paper (60 to 90 g/m2) OHP film Thick paper (91 to 157 g/m2) Postcards, labels, and envelopes 100 sheets (A4S), Recycled paper (60 to 90 g/m2) 50 sheets (other than A4S) Load height up to 22 mm 150 sheets (A4S), 75 sheets (other than A4S) 10 sheets 20 sheets 100 sheets (A4S), 50 sheets (other than A4S) Load height up to 22 mm Lower drawer 150 sheets (A4S), 75 sheets (other than A4S)
Power requirements Power consumption DC24 V, DC5 V (supplied from the copier) 24 W or less
Outline
JS-503
1.
Outline
JS-503
Blank Page
2. Job Separator (JS-503)
2.1 Construction
JS-503
4689C507AA
2.
Job Separator (JS-503)
4689C501AA
Paper empty sensor (PS4) JS drive board (JSDB) Job Tray
Paper full sensor (PS3)
Paper detecting board (PSDB)
Bin switching motor (M1) Lower home position sensor (PS2) Upper home position sensor (PS1)
4688C510AA
2.2
JS-503
Operation
The Main Motor (M1) provides drive for the Job Separator.
Paper detecting board (M1) Job Tray
4689C502AA
Theory of Operation Ver. 1.0 Apr. 2007 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 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)
Paper
4021M046AB
4689C503AA
(M1: Backward Rotation)
<When feeding paper into the Job Tray: fax/printer> Lower Home position sensor (PS2): Activated
Paper
Job Tray
4689C504AA
JS-503
2. Job Separator (JS-503) 2.2.2

JS-503
Tray-Full Detecting Mechanism
Tray-full detection is valid only when paper is fed into the Job Tray (Job Tray in the lowered position). 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
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
SERVICE MANUAL
THEORY OF OPERATION
2007.04 Ver. 1.0
Revision history
2007/04 Date
Revision mark
CONTENTS SF-501 Outline

1. Product specifications ............................................................................................. 1
SF-501
2. 2.1 2.2 SHIFTING UNIT (SF-501) ....................................................................................... 3 Composition.......................................................................................................... 3 Operation .............................................................................................................. 4 Exit Position Shifting Mechanism .................................................................. 4
2.2.1
Outline
SF-501
Blank Page
ii
Outline
A. Machine specifications
Shifting amount Paper capacity Power consumption 28 mm 250 sheets Less than 63 W
NOTE These specifications are subject to change without notice.
Outline
B. Operating environment Conforms to the operating environment of the main body.
SF-501
1.
Outline
SF-501
Blank Page
2. SHIFTING UNIT (SF-501)
2.1 Composition
SF-501
4690C505AA
2.
SHIFTING UNIT (SF-501)
4690C502AA
SF drive board (SFDB)
Home sensor (PS1)
Shift motor (M1)
4690C501AA
2. SHIFTING UNIT (SF-501)
2.2
SF-501
Operation
Exit Position Shifting Mechanism
2.2.1
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
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
2007 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Use of this manual should be strictly supervised to avoid disclosure of confidential information. Printed in Japan DDA09A-M-TE1

KONICA MINOLTA BizHub 163, 211, 220 Theory of Operation Service Manual

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KONICA MINOLTA BizHub 163, 211, 220 Theory of Operation Service Manual

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SERVICE MANUAL

2007.04 Ver. 1.0

1.0 Service manual Ver.

Issue of the first edition Descriptions of revision

Theory of Operation Ver. 1.0 Apr. 2007

CONTENTS bizhub 163/211/220 main body Outline

7.3.1 7.3.2 7.3.3 7.3.4 8. 8.1 8.2 9. 9.1 9.2 10.

Theory of Operation Ver. 1.0 Apr. 2007

Image transfer and paper separation section........................................................ 37

Toner recovery ...................................................................................................... 39

Manual bypass section.......................................................................................... 48

Theory of Operation Ver. 1.0 Apr. 2007

Registration roller section...................................................................................... 51

Paper exit (for bizhub 163) .................................................................................... 59

Theory of Operation Ver. 1.0 Apr. 2007

Theory of Operation Ver. 1.0 Apr. 2007

1/2 System front view

[12] [6] [1] [13] [7]

[1] [2] [3] [4] [5] [6]

[8] [9] [10] [11] [12] [13]

Multi bypass tray (MB-501) *4

Theory of Operation Ver. 1.0 Apr. 2007

2/2 System rear view

Expanded memory unit (EM-103) Fax kit (FK-506)

Image controller (IC-206) * Network interface card (NC-503) *

* It is not possible to mount these units at the same time.

Theory of Operation Ver. 1.0 Apr. 2007

First copy time (A4, full size) Processing speed

Max. six-way system

Theory of Operation Ver. 1.0 Apr. 2007

Paper capacity (Manual bypass)

Plain paper/recycled paper/special paper

90 to 297 mm *2 182 to 297 mm *2 90 to 297 mm *2

Theory of Operation Ver. 1.0 Apr. 2007 E. Machine specifications

bizhub 163 Max power consumption bizhub 211/220

Theory of Operation Ver. 1.0 Apr. 2007

Fax kit (FK-506): (Option)

Document size Print paper size Scanning storage

Compression encoding format

Theory of Operation Ver. 1.0 Apr. 2007

3. Cross sectional view

Cross sectional view

[1] [2] [3] [4] [5] [6]

[7] [8] [9] [10] [11] [12]

Theory of Operation Ver. 1.0 Apr. 2007

Theory of Operation Ver. 1.0 Apr. 2007

[5] Drum Charging [7] Developing

IR Image [2] Processing

[4] PC Drum [5] Drum Charging [6] Laser Exposure

layer, on which an electrostatic latent image is formed.

surface of the PC Drum.

[8] Paper Feed [9] Image Transfer

[12] Main Erase

Theory of Operation Ver. 1.0 Apr. 2007

Residual toner on the surface of the PC Drum is scraped off.

face potential remaining there after cleaning is neutralized.

[14] Paper Exit

Theory of Operation Ver. 1.0 Apr. 2007

Power unit cooling fan motor (FM2)

Fusing cooling fan motor (FM1)

Theory of Operation Ver. 1.0 Apr. 2007

Control Block Diagram

MFP board (MFPB) EM-103

90 to 297 mm 2 182 to 297 mm 2 90 to 297 mm *2